Page 1 REPAIR & TUNE-UP GUIDE CORVETTE 1963 to 1983 All U.S. and Canadian 305 « 327 • 350 • 396 * 427 • 454 models; including fuel injection President, Chilton Enterprises David S. Loewith Senior Vice President Ronald A. Hoxter Publisher and Editor-in-Chief Kerry A. Freeman, S.A.E. Managing Editors Peter M.
Page 2 L5A 3P2. Before substituting any tool for the one recommended, read the SAFETY NOTICE at the top of this page. ACKNOWLEDGMENTS The Chilton Book Company expresses its appreciation to the Chevrolet Motor Division, General Mo- tors Corporation for their generous assistance. Information has been selected from Chevrolet shop manuals, owners manuals, service bulletins, and technical training manuals.
Page 3: Table Of Contents
CONTENTS General Information and Maintenance 1 How to Use this Book 2 Tools and Equipment 14 Routine Maintenance and Lubrication Drive Train 226 Driveshaft and U-Joints 2 2 7 Rear Axle Suspension Tune-Up and and Steering Performance 230 Front Maintenance 3 9 Tune-Up Suspension 242 Rear Procedures...
Page 4 Specifications Vehicle Fill in this chart with the most commonly used specifications for your vehicle. Specifications can be found in Chapters 1 through 3 or on the tune-up decal under the hood of the vehicle. Firing Order _______________________ ' _______________________________ , _______________ Spark Plugs: Type ----------------------------------------- , --------------------------------------------------------- : --------- ' Gap (in.) ___________________________________________________________________...
Page 5: General Information
General Information and Maintenance HOW TO USE THIS BOOK All chapters contain adjustments, mainte- nance, removal and installation procedures, Chilton's Repair & Tune-Up Guide for the and repair or overhaul procedures. When re- pair is not considered practical, we tell you Corvette is intended to help you learn more about the inner workings of your vehicle and how to remove the part and then how to in-...
Page 6: Tools And Equipment
GENERAL INFORMATION AND MAINTENANCE you don't force it or resist a change in angle. proper position. (We will supply exploded Don't put a wrench on the part until it's been view whenever possible). When making ad- turned a couple of turns by hand. If you sud- justments, especially tune-up adjustments, do denly encounter resistance, and the part has them in order;...
Page 7 GENERAL INFORMATION AND MAINTENANCE COMPRESSION GAUGE FROM TOP: BATTERY TERMINAL TOOL; FEELER GAUGES; OIL SPOUT; FILTER WRENCH ALLEN WRENCHES BEAM-TYPE TORQUE WRENCH VACUUM GAUGE DWELL TACHOMETER DWELL/TACHOMETER TIMING LIGHT You need only a basic assortment of hand tools and test instruments for most maintenance and repair Jobs...
Page 8 While the tools involved here are slightly can be purchased from your car dealer. more sophisticated, they need not be outra- NOTE: Chevrolet special tools referred to in geously expensive. There are several inex- this guide are available through the Service...
Page 9 GENERAL INFORMATION AND MAINTENANCE of water and baking soda and get medical at- • Don't work around moving parts while tention immediately. wearing a necktie or other loose clothing. • Do use safety stands for any undercar Short sleeves are much safer than long, loose service.
Page 10 GENERAL INFORMATION AND MAINTENANCE headlights, rotated by two electric motors, required for carburetor clearance. Cars were also a new feature for the Corvette. equipped with the 396 received a larger front The frame is a ladder type with five cross- stabilizer bar and the addition of a rear sta- members.
Page 11 GENERAL INFORMATION AND MAINTENANCE performance usage. Engines remained the of the small block was deleted from the op- same, except for the addition of the air-injec- tion list. tion reactor pump to control exhaust emis- 1972 saw very few changes made to the sions.
Page 12 (TBI) was introduced. The twin TBI system, SERIAL NUMBER referred to as "Cross-fire Injection" by the IDENTIFICATION Chevrolet marketing force, is said to improve both throttle response and fuel economy as Vehicle compared to the previous 4-bbl. carburetion The 1963 through 1967 Corvette vehicle se- system.
Page 13 GENERAL INFORMATION AND MAINTENANCE and paint combination is located on the in- INTERPRETING THE SERIAL NUMBER strument panel reinforcing member directly A typical vehicle serial number tag yields under the glove compartment. The vehicle manufacturer's identity, vehicle type, model serial number plate is located on the top left year, engine type, assembly plant and pro- of the instrument panel (1968—76) and on the duction unit number when broken down as...
Page 14 Year Plant Type Model Type" Number 400.001 Manufacturers identity number assigned to all Chevrolet built passenger cars A—Non-passive restraint with manual seat belts Y—Corvette "87—Two door hardtop coupe Engine code : 6(1981), 8(1982-84) Manufacturers use only B—1981, C—1982, E—1984, etc.
Page 15 GENERAL INFORMATION AND MAINTENANCE Engine Identification (cont.) Engine Identification (cont.) 1967 327 cubic 427 cubic inch engine Inch engine Triple carburetion, special high performance, A.I.R. and Powerglide heavy duty clutch Heavy duty and Turbo Special high performance and A.I.R. Hydra-Matic Triple carburetion, special high Powerglide performance, Turbo Hydra-Matic Special high performance...
Page 16 GENERAL INFORMATION AND MAINTENANCE Engine Identification (cont.) Engine Identification (cont.) 1978 350 cubic 454 cubic Inch engine inch engine 185 hp AT. (Fed.) 185hpM.T. 225 hp M.T. 270 hp with 4-speed 225hpA.T. 270 hp with Turbo Hydra-Matic 270 hp CSR.C 1979 1973 350 cubic 195 hp (Calif.)
Page 17 GENERAL INFORMATION AND MAINTENANCE 1979 and later 3-speed automatic transmis- Rear Axle Ratio Identification sions are coded either on the right side of the Axle Ratio and Type Year Prefix case above the front of the oil pan or on the 3.36 with 3-speed 1963-64 case above the left rear of the oil pan.
Page 18 GENERAL INFORMATION AND MAINTENANCE Rear Axle Ratio Identification Rear Axle Ratio Identification (cont.) (cont.) Year Prefix Axl e Rati o and Type Year Prefix Axl e Rati o and Type 3.70 Positraction with 3.36 Positraction 1972-75 AX, LR 427 engine 4.11 Positraction AC AB 4.1 1 Positraction with...
Page 19 GENERAL INFORMATION AND MAINTENANCE Unscrew the wing nut and remove the cover 1. Air cleaner assembly 7. Manifold vacuum hose 2. Gasket 8. Air filter element 3. Hose clamp 9. Hood seal Remove and discard the old filter 4. Heat stove adapter 10.
Page 20 GENERAL INFORMATION AND MAINTENANCE is located in the hose or in the rocker cover BATTERY TOP BATTERY TOP BATTERY TOP on later models. Replace the PCV valve and if so equipped the PCV filter, located in the air cleaner, every 12,000 miles (1963-71), every 24,000 miles (1972-74), every 30,000 miles (1975-84).
Page 21 GENERAL INFORMATION AND MAINTENANCE Heat Riser LOCATING SLOT =. A/C COMPRESSOR „,-.„ The heat riser is a thermostatically or vacuum BRACKET LOCATING TAB operated valve in the exhaust manifold. Not TENSIONER all engines have one. It closes when the en- gine is warming up, to direct hot exhaust gases to the intake manifold, in order to preheat BRACKET...
Page 22 GENERAL INFORMATION AND MAINTENANCE HOW TO SPOT WORN V-BELTS V-Belts are vital to efficient engine operation—they drive the fan, water pump and other acces- sories. They require little maintenance (occasional tightening) but they will not last forever. Slipping or failure of the V-belt will lead to overheating. If your V-belt looks like any of these, it should be replaced.
Page 23 GENERAL INFORMATION AND MAINTENANCE HOW TO SPOT BAD HOSES Both the upper and lower radiator hoses are called upon to perform difficult jobs in an inhospi- table environment. They are subject to nearly 18 psi at under hood temperatures often over 280°F., and must circulate nearly 7500 gallons of coolant an hour—3 good reasons to have good hoses.
Page 24 GENERAL INFORMATION AND MAINTENANCE use. Use a good quality antifreeze with water pump or other areas, indicate possible leak- pump lubricants, rust inhibitors and other age, which must be corrected before filling corrosion inhibitors along with acid neutral- die system with fresh coolant. izers.
Page 25 GENERAL INFORMATION AND MAINTENANCE or tighten any fittings or perform any work other than that outlined here. CHECKING FOR OIL LEAKS Refrigerant leaks show up as oily areas on the various components because the compressor oil is transported around the entire system along with the refrigerant.
Page 26 GENERAL INFORMATION AND MAINTENANCE 4. If the line that leads from the re downward out of the groove in the arm to free the refill. The new refill will lock into place ceiver/drier to the condenser is a lot colder automatically as it is installed.
Page 27 GENERAL INFORMATION AND MAINTENANCE AUTOMATIC TRANSMISSION FLUID neck, or the line on expansion tank-equipped models. Run the engine until it reaches normal oper- CAUTION: Allow the engine to cool con- ating temperature. Park the car on a level siderably and then add water while the en- surface.
Page 28 GENERAL INFORMATION AND MAINTENANCE Capacities & Pressure Transmission Pts to Refill after Draining Engine Manual Fuel Cooling Coolant Crankcase Tank System Pressure Model (cu Add 101 for (gai) (qts) (psi) Year In.) © New Filter Automatic Differential (pts) 3-spd 4-spd 1963 327 (hyd.
Page 30 GENERAL INFORMATION AND MAINTENANCE Capacities & Pressure (cont.) Transmission Pis to Refill after Draining Engine Manual Fuel Coolant Crankcase Cooling Model Tank Pressure Add 1 at far System Year (cuin.)© New Filler Automatic Differential (pts) (gal) (qts) (psl) 3-spd 4-spd 1974 —...
Page 31 GENERAL INFORMATION AND MAINTENANCE tread remains. The appearance of tread wear indicators means that the tires should be re- placed. In feet, many states have laws prohib- iting the use of tires with less than Vie" tread. You can check your own tread depth with an inexpensive gauge or by using a Lincoln head penny.
Page 32 GENERAL INFORMATION AND MAINTENANCE TIRE STORAGE Store the tires at proper inflation pressures if they are mounted on wheels. All tires should be kept in a cool, dry place. If they are stored in the garage or basement, do not let them stand on a concrete floor;...
Page 33 GENERAL INFORMATION AND MAINTENANCE rolet recommends doing this for vehicles which see severe usage (racing, etc.), it is also a wise move for street-driven vehicles. The small, carburetor mounted filter clogs more easily than a large in-line filter. The clogged filter can cause a drastic drop in fuel pressure which will generally cause the engine to run leaner;...
Page 34 Maintenance Intervals Maintenance 1963-67 1968-71 1972-74 1975-79 1980-84 Air Cleaner (Check and Clean) Oil 12,000 mi 1 2,000 mi 30,000 mi (replace) bath Paper elem ent © (replace) 12,000 mi (replace) 24,000 mi (replace) 30,000 mi (replace) PCV Valve (Replace) 12 mo/1 2,000 mi 12 mo/1 2,000 mi 12 mo/1 2,000 mi...
Page 35 GENERAL INFORMATION AND MAINTENANCE g>0) 0) § •5 "5 to CO " c (fl § ,§• O C CO m Cu (A - c 1 0 _g 'cr...
Page 37 SF rated oil an ANY Corvette. In addi- and unleaded premium in a 1:3 proportion (1 tion, Chevrolet recommends the use of an part regular leaded to 3 parts unleaded pre- SF/Energy Conserving oil. Oils labeled "En- mium).
Page 38 10. Refill the engine with the correct Chevrolet recommends changing both the amount of fresh oil. See the "Capacities" oil and filter during the first oil change and chart.
Page 39 GENERAL INFORMATION AND MAINTENANCE 15. Add either Dexron or Dexron II trans ally check that you can gain access to all of mission fluid through the filler tube. See the the transmission pan bolts. If you can, pro- Capacities Chart to determine the proper ceed to step 8;...
Page 40 GENERAL INFORMATION AND MAINTENANCE GL-MULTI-PURPOSE OR LUBRICATE EVERY 6,000 MILES CL-CHASSIS LUBRICANT UNIVERSAL GEAR S AT-DEXRON AUTOMATIC LUBRICANT* TRANSMISSION FLUID REPLACE EVERY 24,000 MILES BF-BRAKE FLUID WB-WHEEL BEARING LUBRICANT LUBRICATE EVERY 34,000 MILES * REFILL POSITRACTION REAR AXLE WITH SPECIAL LUBRICANT ONLY Lubrication points—1963-74 PUSHING AND TOWING grease gun.
Page 41 GENERAL INFORMATION AND MAINTENANCE GL-MULTI-PURPOSE OR CL-CHASSIS LUBRICANT LUBRICATE EVERY7.500MILES UNIVERSAL GEAR AT-DEXRON-H® AUTOMATIC TRANSMISSION FLUID LUBSICATE FIRST 12,000 MILES LUBRICANT' REPLACE EVERY 30,000«ILtS BF-BRAKE FLUID SG-STEERING WB-WHEEL BEARING LUBRICANT CHECK FOR GREASE LEAKAGE GEAR LUBRICANT EVERY 30,000 MILES REFILL POSITRACTION REAR AXLE WITH SPECIAL LUBRICANT ONLY 1.
Page 42 GENERAL INFORMATION AND MAINTENANCE bumpers, only on the spindle struts at the rear 4. Attach one end of the remaining cable and the frame crossmember or lower control to the negative (—) terminal of the booster arm at the front. battery and the other end to the alternator bracket.
Page 43 GENERAL INFORMATION AND MAINTENANCE tions, always be sure that it is adequately Heavy wooden blocks or adjustable jack- supported, preferably by jackstands at the stands should be used to support the vehicle proper points. Always block the wheels when while it is being worked on. Drive-on tres- changing tires.
Page 44: Tune-Up And
Tune-Up and Performance Maintenance TUNE-UP PROCEDURES die fartiier it extends into die engine), die hotter the plug will operate; the shorter the insulator die cooler it will operate. A plug tiiat This section gives specific procedures on how absorbs littie heat and remains too cool will to tune-up your Corvette.
Page 46 TUNE-UP AND PERFORMANCE MAINTENANCE •4 - - - - •^ © s © © § o in § © © © © © © • . < • © 1 © © § © © © © © © © © ©...
Page 47: 0 Tune-Up Specifications
Tune-Up Specifications (cont.) Spark Plugs Distributor Valves Normal llrtake Clearance (In.) Point Point Basic Ignition Idle Fuel Dwell Timing (deg Speed Pressure BTDC) (rpm) Year Model Type (In.) (deg) (In.) Intake Exhaust (deg BTDC) (psl) 1971 270 hp R44TS 0.035 28-32 0.019 4®...
Page 48 1980 180hp® R45TS 0.045 Electronic ® /a-9 ® (305 eng.) 190 hp (350 R45TS 0.045 Electronic 6© ® 600® /z-9 eng.) 230 hp (350 R45TS 0.045 Electronic 7Va-9 ® eng.) 1981 190 hp® R45TS 0.045 Electronic 700® /2-9 ® 1982 200 hp R45TS 0.045...
Page 49 TUNE-UP AND PERFORMANCE MAINTENANCE casion to change their plugs from the factory- size socket. ( /ie in. through 1971, % in. 1972 recommended heat range. and later.) Turn the socket counterclockwise to remove the plug. If the engine has alumi- REPLACING SPARK PLUGS num cylinder heads, be extremely careful when removing the plugs.
Page 50 TUNE-UP AND PERFORMANCE MAINTENANCE the wire firmly into the tower on the distrib- utor cap, then seat the boot over the tower. Repeat the process for each cable. NOTE: Always replace the points and con- denser together. Uniset@ points are avail- able which combine the point set and con- denser, greatly simplifying installation.
Page 51 TUNE-UP AND PERFORMANCE MAINTENANCE INSPECTION OF DISTRIBUTOR CAP CLEANING 1 INSPECTION OF CLEANING & INSPECTION OF I INSIDE OF DISTRIBUTOR C AP TOWERS OUTSIDE OF DISTRIBUTOR CAP REPLACING DISTRIBUTOR _______ INSUFFICIENT TOR TIP ROTOR CONTACT SPRING TENSION INSPECTION OF CAIBON I CORROD ROTOR INSPECTION aOTOa BUTTON...
Page 52 TUNE-UP AND PERFORMANCE MAINTENANCE When hooking up a remote starter switch, disconnect the "BAIT" terminal. Ignition Timing Adjustment 1963-80 Except 1980 California 1. Warm the engine to normal operating temperature and check the idle speed. Ad just the idle speed to specifications, if neces sary.
Page 53 TUNE-UP AND PERFORMANCE MAINTENANCE 1982 EST BYPASS wire connector location. On these models, this connector must be separated prior to setting the ignition timing—see text the "before" (advance] sice of the zero, or NOT use a timing light which requires pierc- ing of the spark plug lead.
Page 54 TUNE-UP AND PERFORMANCE MAINTENANCE CHECK ENGINE lamp location. This lamp will be illuminated while the EST BYPASS wire is disconnected the distributor housing which join at a com- Valve Lash mon multi-connector, close to the distribu- ADJUSTMENT tor. Follow the tan wire with a black stripe (EST BYPASS wire) from the multi-connec- Engines equipped with hydraulic lifters tor.
Page 55 TUNE-UP AND PERFORMANCE MAINTENANCE part of the clip while holding the lower sec- tion. If the clip must be removed, press the lowermost arms of the clips together with needle nose pliers and push upward. If the vehicle uses a PCV valve pressed into the valve cover grommet, pull the valve from the grommet and remove the valve from the hose.
Page 56 TUNE-UP AND PERFORMANCE MAINTENANCE important that all tune-up instructions be gauge to the engine, then set the parking carefully followed to ensure satisfactory en- brake and shift the manual transmission into gine performance and minimum exhaust pol- Neutral, automatic into Drive. lution.
Page 57 TUNE-UP AND PERFORMANCE MAINTENANCE 3. With engine running, adjust the idle speed screw. Adjust the carburetor idle speed screw to obtain the specified idle speed. screw to obtain 400 rpm. 5. Adjust the mixture screw in to "lean roll" 4. Adjust the idle mixture screw(s) in to "lean roll"...
Page 58 TUNE-UP AND PERFORMANCE MAINTENANCE they are lightly seated, then back them out 4 IDLE MIXTURE turns. 3. With automatic transmission in Drive, adjust the carburetor idle speed screw to ob tain 630 rpm. Adjust the idle mixture screws in equally to obtain 600 rpm. 4.
Page 59 TUNE-UP AND PERFORMANCE MAINTENANCE conditioner off) or 550 rpm (automatic trans- NOTE: If no lower figure is given, adjust the idle to 450 rpm. mission in Drive with the air conditioner on). 8. Reconnect all of the wires and hoses 350 and 454 (4-BBL Holley) Engines which were disconnected in order to perform 1.
Page 60 TUNE-UP AND PERFORMANCE MAINTENANCE Position the fast idle cam follower on the top 5. Turn the solenoid screw to higher of the step of the cam and adjust the fast idle to 1300 two idle speeds specified on the underhood rpm on manual;...
Page 61 TUNE-UP AND PERFORMANCE MAINTENANCE a time until the maximum idle speed is ob- Without A/C tained. Then set the idle speed screw to: 1. Turn the idle speed screw to achieve the Standard engine (180 hp) M.T.-800 rpm, rpm specified on the underhood specifica- A.T.-550 rpm;...
Page 62: Engine And Engine Rebuilding
Engine and Engine Rebuilding UNDERSTANDING THE ENGINE good condition and the operating conditions are normal, the power removed from the bat- ELECTRICAL SYSTEM tery will be replaced by the generator (or al- ternator) which will force electrons back The engine electrical system can be broken down into three separate and distinct sys- through the battery, reversing the normal flow, and restoring the battery to its original...
Page 63 ENGINE AND ENGINE REBUILDING The vehicle's generator is driven mechan- switch, and the wiring necessary to connect ically, through V belts, by the engine crank- these with the starter solenoid or relay. shaft. It consists of two coils of fine wire, one A pinion, which is a small gear, is mounted stationary (the "stator"), and one movable (the to a one-way drive clutch.
Page 64 The distributor is geared to the camshaft of the engine, and in the case of a Chevrolet V- SAFETY PRECAUTIONS 8, is also used to drive the engine oil pump Observing these precautions will ensure safe in addition to its usual "spark sorting"...
Page 65 ENGINE AND ENGINE REBUILDING economy. As engine load increases, engine wire) is through the primary (low voltage) vacuum drops, which allows the ignition tim- windings of the coil, to the breaker point set. ing to retard, thereby preventing detonation When the points are closed (grounded), a due to over-advanced timing.
Page 66: Engine Electrical
ENGINE AND ENGINE REBUILDING nition coil (though the ignition coils DO NOT wires. When replacing them, make sure you interchange), but is controlled by the timer get the correct wires, since conventional wires core, pole piece, and module; instead of the won't carry the voltage.
Page 67 ENGINE AND ENGINE REBUILDING CONDENSER CONTACT POINT ASSEMBLY RETAINING RING ROTOR BREAKER PLATE VACUUM ADVANCE UNIT RADIO FREQUENCY FELT WASHER 0---------------------- INTERFERENCE SHIELD PLASTIC SEAL WEIGHT SPRINGS HOUSING MAINSHAFT ADVANCE WEIGHTS TANGED WASHER CAM WEIGHT BASE ASSEMBLY SHIM WASHER DRIVE GEAR DRIVE PIN Exploded view of the V8 points-type...
Page 68 Distributor Specifications NOTE: The following specifications are given in degrees advance at crankshaft speed. Half degrees for distributor machine testing. Centrifugal Advance Vacuum Advance Intermediate Start Start Degrees Degrees Distributor Degrees @ Degrees Degrees @ Year Model Part Number @rpm @rpm In.
Page 69 > Distributor Specifications (cont.) are given in degrees advance at crankshaft speed. Half degrees for distributor machine NOTE: The following specifications testing. Centrifugal Advance Vacuum Advance Start Intermediate Start Distributor Degrees Degrees Degrees Degrees @ Degrees @ Year Model Part Number @rpm @rpm in.
Page 70 ENGINE AND ENGINE REBUILDING : in oo o f in • * © o © o © o •sf • * • * © © © © o o to •& O O CO CM ^* •* © CM • O - ©...
Page 71 ENGINE AND ENGINE REBUILDING full revolution and again align the timing marks. Recheck the position of the rotor. 6. Disconnect the vacuum line from the distributor vacuum advance unit, if so equipped. 7. Follow steps 5, 7, 8, and 10-12 of the previous procedure, in that order to com plete distributor removal.
Page 72 ENGINE AND ENGINE REBUILDING CIRCLIP COVER POLE PIECE LEAD WIRE AMPLIFIER MODULE CAPACITOR VACUUM CONTROL UNIT HOUSING ADVANCE SPRING GASKET CONNECTOR GEAR' WASHER Exploded view of the HEI distributor. Engines with the computer emissions system do not have the vacuum advance unit.
Page 73 ENGINE AND ENGINE REBUILDING 6. Install the distributor hold-down bolt FIRING ORDER and plate. Snug down the retaining bolt. To avoid confusion, replace spark plug wires 7. Connect the vacuum advance hose, tach one at a time. drive cable, and injection drive cable, on ve hicles equipped with these items.
Page 74 ENGINE AND ENGINE REBUILDING 2. Disconnect the hose from the vacuum SEAL advance unit. 3. Remove the two vacuum advance unit retaining screws and pull the unit outward. 4. Rotate the unit to disengage the oper ating rod from the distributor. 5.
Page 75 ENGINE AND ENGINE REBUILDING distributor housing. If the compound is not Transistorized Systems used, the module will overheat, causing fail- 1. Remove the distributor cap and the ure of the ignition system. rotor. NOTE: Silicone compounds are available 2. Remove the centrifugal advance strictly for this purpose—DO NOT use a springs and weights.
Page 76 ENGINE AND ENGINE REBUILDING Alternator sembly). If the internal teeth of the pickup are not fully exposed; remove the magnetic The alternating current generator (alternator) shield from the pickup assembly (three at- supplies a continuous amount of electrical taching screws). Remove the pickup assem- energy at all engine speeds to keep the bat- bly retaining ring and remove the pickup tery fully charged.
Page 77 ENGINE AND ENGINE REBUILDING "BATT" ROTOR PUUEV GREASE RESERVOIR S1A10R afitu. WINDING • -" FIELD RELAY TERMINAL Externally regulated, "perforated case" Delcotron Both the internally and externally regu- externally regulated Delcotron (except the lated Delcotrons use positive and negative "perforated case" models), the negative diodes diodes.
Page 78 ENGINE AND ENGINE REBUILDING contains the positive. InternaDy regulated sidered before making any electrical connec- Delcotrons use a different type of diode ar- tions within the system. rangement. In these models, the negative 10. Never operate the alternator on an diodes are permanently mounted in a rec- open circuit.
Page 79 ENGINE AND ENGINE REBUILDING BAT terminals, and noting the lowest range speed and adjust the carbon pile to obtain on the ohmmeter scale. It should indicate maximum alternator output as indicated on very low resistance. Reversing the connec- the ammeter. If output is within 10% of rated tions should result in an infinitely high resis- output as stamped on the alternator frame, tance indication.
Page 80 ENGINE AND ENGINE REBUILDING ground), start the engine and run at 1,500- prevent it from turning. Unbolt the retaining 2,000 rpm with all lights and electrical acces- nut and slide it off the pulley. Disconnect the sories turned on. If the voltmeter reads 12.8 battery ground strap to prevent diode dam- volts or greater, the alternator is good and no age and remove the generator.
Page 81 ENGINE AND ENGINE REBUILDING with the alternator to avoid overstressing Internally Reglated Type the lead wire. 1. Place alternator in a vise, clamped by 5. Scribe alignment marks to indicate the the mounting flange only. relationships between the end frames and the 2.
Page 82 ENGINE AND ENGINE REBUILDING 3. Inspect rotor slip rings for scoring. They TESTING STATOR (CHECK FOR OPENS) may be cleaned with 400 grit sandpaper (not emery), rotating the rotor to make the rings concentric. Maximum out-of-true is 0.001 in. If slip rings are deeply scored, the entire ro tor must be replaced as a unit.
Page 83 OHMMETER OHMMETER Stator testing—"perforated case" models...
Page 84 ENGINE AND ENGINE REBUILDING Diode Rectifier Bridge all other tests fail to locate the problem, it is more than likely a short in the stator. Refer to the accompanying illustration for component identification. Use a self-pow- ered ohmmeter set on its lowest reading scale. Separately Mounted Diodes (Pressed-in CAUTION: DO NOT use a 110 volt test Type)
Page 85 ENGINE AND ENGINE REBUILDING END FRAME VIEW REPAIRS INSULATING RESISTOR i ______ Pressed-in Diode Replacement WASHERS ^ij^^^^^^^^s: (USED ON SOME MODE LSI Despite rumors to the contrary, diodes of this type may be replaced. It is not necessary to replace me entire generator assembly as some unscrupulous garage owners convinced their unwary customers in the introductory days of the AC generator.
Page 86 ENGINE AND ENGINE REBUILDING BRUS Brush holder—Externally regulated Delcotron, ex- cept "perforated case" models CONDENSER LEAD Brush holder wiring—"perforated case" Delcotron placement of the internal voltage regula- tor. 1. Remove two brush holder screws and stator lead to strap nut and washer, brush holder screws and one of the diode trio lead strap attaching screws.
Page 87 ENGINE AND ENGINE REBUILDING properly grounded and do not overtighten the mounting screws, as this will cancel the cush- ioning effect of the rubber grommets. Type Three 1. Remove the alternator from the vehicle FIELD RELAY as previously outlined. 2. Scribe a line on the alternator case from front-to-rear which will aid in attaining the "LATCH"...
Page 88 ENGINE AND ENGINE REBUILDING REGULATOR VOLTMETER Schematic for testing the regulator voltage setting junction block, as shown in the accompany- the regulator connector, install the cover and ing illustration. reconnect the regulator connector. 2. Install a voltmeter as shown in the ac 9.
Page 89 ENGINE AND ENGINE REBUILDING the alternator (refer to the illustration under 3. Connect regulator and test light as Alternator Tests.) Insert a screwdriver into the shown, observing battery polarity. test hole about %" to depress the field 4. The test light should be on when con grounding tab.
Page 90 m > 3D m co Alternator and Regulator Specifications Alternator Regulator Field Relay Regulator Output @ Generator RPM Point Field Current Point Draw Volts to Volts at Year Model @12V (in.) (in.) Close (in.) (in.) 125° 2000 5000 Model 1963- 64 1100628 1 .9-2.3 1119512...
Page 91 ENGINE AND ENGINE REBUILDING «? > » CO 00 CO CO 0 CO • c i c T— T— i — o CM CM < in in < 1 a S <a "i " i £ • • > • •...
Page 92 ENGINE AND ENGINE REBUILDING 5. Loosen the two main starter mounting bolts, support the starter and remove the bolts. Lower the starter front end first and remove the starter. 6. Reverse the previous steps to install the starter. Torque the two main starter mount ing bolts to 25-35 ft.
Page 93 ENGINE AND ENGINE REBUILDING 7. To reassemble, lubricate the drive end with silicone lubricant. Install the armature of the armature shaft with silicone lubricant and clutch assembly into the drive housing, and slide the starter drive onto the shaft with engaging the solenoid shift lever with the the pinion gear facing away from the arma clutch, and positioning the front end of the...
Page 94: System
09 OB General Engine Specifications Engine Displace- Fuel Pressure ment ( Delivery Horsepower Torque @ rpm Bore and Compres- @2000 in.) System (ffirpmn Stroke (in.) sion Ratio Year (ft. lbs.)« 1963- 64 4bbl 250 @ 4400 350 @ 2800 4.00 x 3.25 10.5:1 >...
Page 95 ENGINE AND ENGINE REBUILDING •* CO X CO X CO X CO X •* X CO X CO X CO X CO X o p • < * in CM •^ § •sf © © © in 5 in in cj in in &...
Page 96 General Engine Specifications (cont.) Engine Displace- Fuel Pressure Horsepower ment (cu Delivery Bore and Compres- @2000 Torque @ rpm Year In.) System @rpmB (fl. lbs.)e Stroke (in.) sion Ratio 1979 4bbl 195 @ 4000 285 @ 3200 4.000 x 3.480 8.2:1 4bbl 225 @ 5200...
Page 97 Valve Specifications Engine Stem to Guide Stem Diameter Displace- Seal Face Spring Test Spring Clearance (in.) (In.) ment (cu Angle Angle Pressure (Ibs. Installed Year In.) (deg) (deg) @ in.) Height (in.) Intake Intake Exhaust Exft3EISt 1963-64 175 @ 1.26 1.66 0.0010-0.0027 0.0016-0.0033...
Page 99 ENGINE AND ENGINE REBUILDING •* 03 Ej en in in cn co co •a 8 8 8 c\i I •as f— cvi § CD" o cvi CD O cvi cvi cvi cvi cvi < — 4 Q.-S in in C/) .3 V—...
Page 100 Crankshaft and Connecting Rod Specifications (cont.) All measurements are given in inches Crankshaft Connecting Rod Journal Side Main Big Main Big Oil Shaft Tlmist Year Engine Diameter Clearance Journal Dia Clearance End-Play on No. Clearance 454 (425 hp) 2.7481 -2.7490® 0.0013 -0.0025®...
Page 101 ENGINE AND ENGINE REBUILDING Piston Clearance Specifications Ring Gap Specifications All measurements are given in inches pistoiMo-Dore Engine Advertised Clearance Displacement Year Displace- Horsepower (In.)® (cu. in) ment (cu Bottom Year In.) Compression Compression Control SMALL-BLOCK ENGINES 0.0005- 0 . 0 1 3- 0 .
Page 102 ENGINE AND ENGINE REBUILDING Torque Specifications All readings are given in ft. Ibs. Manifold Engine Crankshaft Displace- Main Flywtieel-To- ment (cu Cylinder Connecting Bearing Balancer Crankshaft Year in.) Head Bolls Rod Cap Bolts Cap Bolts Bolts Bolts Exhaust Intake 1963- 67 6 0 - 7 0 60®...
Page 103 ENGINE AND ENGINE REBUILDING ranged in a vee configuration. The cylinders 8. Remove the radiator fan shroud, radia are numbered front to rear with cylinders 1, tor, engine cooling fan(s) and fan clutch (if so 3, 5, and 7 on the left bank and 2, 4, 6, and 8 equipped).
Page 104 ENGINE AND ENGINE REBUILDING 13. Disconnect the cruise control chain or Ibs. Avoid using chains with a lesser rating; serious injury could result if you use an in- cable from the engine, if so equipped. ferior chain. 14. Disconnect the exhaust pipes from the 24.
Page 105 ENGINE AND ENGINE REBUILDING ENGINE OVERHAUL • Plastigage® • engine stand Use of most of these tools is illustrated in Most engine overhaul procedures are fairly this chapter. Many can be rented for a one- standard. In addition to specific parts re- time use from a local parts jobber or tool placement procedures and complete spec- supply house specializing in automotive...
Page 106 ENGINE AND ENGINE REBUILDING Repairing Damaged Threads Before effecting a repair to a threaded hole, remove any snapped, broken or dam- Several methods of repairing damaged aged bolts or studs. Penetrating oil can be threads are available. Heli-Coil® (shown used to free frozen threads; the offending here), Keenserts®...
Page 107 ENGINE AND ENGINE REBUILDING Standard Torque Specifications and Fastener Markings In the absence of specific torques, the following chart can be used as a guide to the maximum safe torque of a particular size/grade of fastener. • There is no torque difference for fine or coarse threads.
Page 108 ENGINE AND ENGINE REBUILDING 7. Read the compression gauge at the end CHECKING ENGINE of each series of cranks, and record the high COMPRESSION est of these readings. Repeat this procedure for each of the engine's cylinders. Compare A noticeable lack of engine power, excessive the highest reading of each cylinder to the oil consumption and/or poor fuel mileage mea- compression pressure specifications in the...
Page 109 ENGINE AND ENGINE REBUILDING 16. Exhaust manifold after just 5 minutes of running time, and ad- 17. Bc-lts ditional belt stretch will usually occur. 18. Spark plug and gasket 9. ALWAYS check for coolant, fiiel, and 19. Intake valve oil leaks after the engine is started. If there is 20.
Page 110 position it out of the way. Do not disconnect original locations. the refrigerant lines. 6. Remove the cylinder head bolts and 5. Back off the rocker arm nuts and pivot cylinder heads. the rocker arms out of the way so that the 7.
Page 111 ENGINE AND ENGINE REBUILDING 1. Valve cover 8. Exhaust valve 15. Head gasket 2. Screw reinforcements 9. Intake valve 16. Spark plug 3. Gasket 17. Cylinder head 10. Gasket 4. Adjusting nut 18. Pushrod 11. Exhaust manifold 5. Rocker arm 19.
Page 112 ENGINE AND ENGINE REBUILDING ket mating surface Be careful not to score the machined gasket surface while cleaning. 9. Inspect the cylinder head for cracks in I® the exhaust ports, combustion chambers, or external cracks to the water chamber. 10. Inspect the valves for burned heads, cracked faces or damaged stems.
Page 113 ENGINE AND ENGINE REBUILDING mounting position is altered, and must be ment of the valve stem from side to side corrected by machining a proportionate (crosswise to the head) will cause a direct amount from the intake manifold flange. movement of the indicator stem. The in- 15.
Page 114 Aluminum big-block cylinder heads use hardened steel valve seat inserts pressed into the cylinder heads. As in the case with big- block valve guides, Chevrolet does not sell replacement valve seats nor have they pub- 1/32" MINIMUM THIS LINE...
Page 115 ENGINE AND ENGINE REBUILDING Lapping the valve and seat by hand—typical Checking valve seat concentricity with run-out gauge smooth, polished seat is evident (you may have to add a bit more compound after some lap- LAPPING THE VALVES ping is done). When valve faces and seats have been re-faced 5.
Page 116 ENGINE AND ENGINE REBUILDING same design and arrangement as the small- block type. REMOVAL NOTE: The following Removal and Instal- lation procedures apply to cylinder heads installed on the vehicle. Access to an air compressor and the purchase of certain special tools is required.
Page 117 ENGINE AND ENGINE REBUILDING 1. Lifter Body 2. Push Rod Seat 3. Metering Valve 4. Check Ball 5. Check Ball Retainer 6. Push Rod Seat Retainer 7. Plunger 8. Check Ball Spring 9. Plunger Spring Installing ball check valve into lifter body Typical hydraulic valve lifter showing internal com- ponents 2.
Page 118 ENGINE AND ENGINE REBUILDING tempt to force or pump the plunger. At this A.I.R. exhaust emission control system, the point, oil holes in the lifter body and plunger interfering components of the system must assembly will be aligned. be removed. Disconnect the lines at the air 10.
Page 119 ENGINE AND ENGINE REBUILDING TORQUE SEQUENCE 1982 and later TBI plate installation tioning compressor mounting brackets are mounted to the intake manifold, remove the brackets. 15. Disconnect the heater hose(s) at die manifold and the upper radiator hose at the thermostat housing.
Page 120 ENGINE AND ENGINE REBUILDING f 13 20. Disconnect the fuel return line at the moval, adjust the drive belt(s) to recom- rear TBI unit. mended tension. 21. Remove the power brake booster line. g. After the engine is started, check for 22.
Page 121 ENGINE AND ENGINE REBUILDING Removing the vibration damper using a puller 2. Remove the radiator and fan shroud as outlined in the Engine Cooling section. 3. Remove the drive belts, cooling fan (en Apply sealer to the front pads at the area shown gine-mounted only), and fan pulley.
Page 122 ENGINE AND ENGINE REBUILDING system, adjust the tension of the drive belts, Timing Chain and check for leaks after the engine is started. REMOVAL AND INSTALLATION 1. Set the engine to top dead center with the number one cylinder on its compression stroke (both valves closed).
Page 123 Completely clean the camshaft with solvent, lon-toothed sprocket with the hardened-iron paying special attention to cleaning the oil sprocket available through Chevrolet deal- holes. Visually inspect the cam lobes and ers. Make sure that you explain your inten- bearing journals for excessive wear. If a lobe...
Page 124 ENGINE AND ENGINE REBUILDING as to pull the bearings towards the center of VALVE CLEARANCE DEPRESSION TO CENTER OF CYLINDER BLOCK the block. Leave the tool in this position, pilot the new front and rear bearings on the in- staller, and pull them into position. 4.
Page 125 Wear ridge must be removed before piston removal...
Page 126 ENGINE AND ENGINE REBUILDING rag, and remove the cuttings that remain on the piston with a magnet and a rag soaked in clean oil. NOTE: Make sure the piston top and cyl- inder bore are absolutely clean before moving the piston. 4.
Page 127 ENGINE AND ENGINE REBUILDING bly. The chamfered comers of the bearing caps should face toward the front of the left bank and toward the rear of the right bank, and the boss on the connecting rod should face to- ward the front of the engine for die right bank and to the rear of the engine on the left bank.
Page 128 ENGINE AND ENGINE REBUILDING the cylinder to size. Generally, if the cylin- -CENTERLINE OF ENGINE- der bore is tapered .005 in. or more or is out- of-round .003 in. or more, it is advisable to rebore for the smallest possible oversize pis- ton and rings.
Page 129 ENGINE AND ENGINE REBUILDING trated; spacing of the various piston ring gaps is crucial to proper oil retention and even PISTON RING cylinder wear. When installing new rings, refer to the installation diagram furnished with FEELER GAUGE the new parts. Connecting Rod Bearings Conecting rod bearings for the engines cov- ered in this guide consist of two halves or shells...
Page 130 ENGINE AND ENGINE REBUILDING chapter for the desired clearance. It is advis- able to install a new bearing if clearance ex- ceeds .003 in.; however, if the bearing is in good condition and is not being checked be- cause of bearing noise, bearing replacement is not necessary.
Page 131 ENGINE AND ENGINE REBUILDING crankshaft must be welded and reground, or replaced. 7. Replace the oil pump, if removed, and the oil pan. 8. Install the cylinder head(s) and intake manifold, as previously described. Crankshaft Servicing Crankshaft servicing literally makes or breaks any engine;...
Page 132 ENGINE AND ENGINE REBUILDING spot of light green paint; the bearing caps 5. Note overlap of adjacent rods also mil have the paint on each side of the 6. Rubber bands undersized journal. Generally, the lower half of the bearing shell (except No.
Page 133 ENGINE AND ENGINE REBUILDING MAIN BEARING REPLACEMENT Engine Out of Car 1. Remove and inspect the crankshaft. 2. Remove the main bearings from the bearing saddles in the cylinder block and main bearing caps. 3. Coat the bearing surfaces of the new, correct size main bearings with clean engine oil and install them in the bearing saddles in the block and in the main bearing caps.
Page 134 ENGINE AND ENGINE REBUILDING Fabricate a roll-out pin as illustrated, if necessary the main bearing cap. Install the main bear- ing cap, making sure it is positioned in proper direction with the matchmarks in alignment. 6. Torque the main bearing cap bolts to Measure crankshaft end play with a dial indicator specification.
Page 135 ENGINE AND ENGINE REBUILDING 2. Raise the car and support the front on stands. Drain the engine oil. 3. Remove the starter and flywheel shield. 4. Disconnect the steering idler arm and lower it out of the way. 5. Remove the oil pan and discard the side gaskets and end seals.
Page 136 ENGINE AND ENGINE REBUILDING REMOVAL OVERHAUL 1. Drain and remove the oil pan. 1. Remove the pump cover attaching 2. Remove the oil pump-to-rear main screws and the pump cover. bearing cap bolt. Remove the pump and the 2. Mark gear teeth so they may be reas extension shaft.
Page 137 ENGINE AND ENGINE REBUILDING extension to the drive shaft, the end of the extension nearest the washers must be in- serted into the drive shaft. 2. Insert the drive shaft extension through the opening in the main bearing cap and block until the shaft mates into the distributor drive gear.
Page 138 ENGINE AND ENGINE REBUILDING sure should be taken with replacdment drain hoses and, if applicable, the transmission coolant hoses. cocks. A Vs in. cast iron plug may be substi- 4. If applicable, remove the supply tank tuted only for an extremely short period of hose at the radiator connection.
Page 139 ENGINE AND ENGINE REBUILDING 11. Shim 6. Upper cushion 1. Bracket 12. Bracket 7. Radiator 2. Screw 8. Cushion 13. Screw 3. Support 14. Shim 9. Bolt 4. Washer 10. Washer 5. Bolt Standard duty small block radiator mounting—typical 8. Disconnect the two radiator hoses and ing the radiator cap make sure die arrows line the overflow hose.
Page 140 ENGINE AND ENGINE REBUILDING NOTE: If installing new water pump, 7. Remove transmission cooler line. transfer heater hose fitting from old unit. 8. Remove fen wires from fen and shroud. 9. Remove fan to gain access to lower cooler line. Thermostat 10.
Page 141 ENGINE AND ENGINE REBUILDING REMOVAL AND INSTALLATION 1. Disconnect the battery cables at the battery. 2. Remove the fresh air scoop. 3. Remove the engine-mounted cooling fan. 4. Remove the upper radiator shroud screws. 5. Remove the three fen bracket-to-shroud TEMPERATURE SWITCH fasteners, remove the...
Page 142: Emission Controls And Fuel System
Emission Controls and Fuel System EMISSION CONTROLS the engine idle will tend to be rough due to the excessively rich mixture. Maintenance is covered in Chapter 1. Positive Crankcase Ventilation (PCV) Air Injection Reactor (AIR) In this system, crankcase vapors are drawn into the intake manifold to be burned in the Two different systems of air injection have combustion chambers;...
Page 143 EMISSION CONTROLS AND FUEL SYSTEM uses both an air control valve and an air switching valve. Both the control and switch- ing valves are controlled by the Electronic Control Module (ECM) of the computer con- trolled emissions system. When the engine is cold, the ECM energizes an air control sole- noid, which allows air to flow to the air switching valve.
Page 144 EMISSION CONTROLS AND FUEL SYSTEM TIGHTEN TO 10 N-m (88 IN. IBS.) TIGHTEN TO 10 N-m (88 IN. IBS.) AIR SWITCHING AIR PUMP VALVE AIR CONTROL VALVE TIGHTEN TO 3 N'm (25 IN. IBS.) Mounting of the AIR control and switching valves that it is mounted to a bracket on the A/C introduction of cold, outside air to the air compressor.
Page 145 EMISSION CONTROLS AND FUEL SYSTEM REMOVAL AND INSTALLATION emission. The canister filter should be re- placed every 12 months or 12,000 miles on Vacuum Motor Models 1970-74, on Models 1975-81 the in- 1. Remove the air cleaner. terval was extended to 24 months or 30,000 2.
Page 146 EMISSION CONTROLS AND FUEL SYSTEM FUEL TANK CARBURETOR VACUUM SIGNAL BOWL VENT OFF IDLE PURGE PORT IDLE PURGE LINE IDLE PURGE PORT (CONSTANT) PRESSURE-VACUUM RELIEF GAS CAP VAPOR STORAGE CANISTER PURGE AIR Schematic of the evaporative emissions system (open)—1980; most models similar Transmission Controlled Spark two-way transmission switch is activated by (TCS)
Page 147 EMISSION CONTROLS AND FUEL SYSTEM HIGH GEAR IDLE POSITION, DECELERATION POSITION CLEAN AIR FILTER • TH^OTTLE MANIFOLD IDLE VACUUM H O T ( I LIGHT COLD I I © G.M. Corp. WATER TEMP. SWITCH ACCESSORY j »,.^ j j BATTERY IGN.
Page 148 plete the CEC circuit when coolant temper- ature reaches 232°. The time delay relay al- lows vacuum advance (and raised idle speed) for 20 seconds after the ignition key is turned to the "on" position. Models with an auto- matic transmission and air conditioning also have a solid state timing device which en- gages the air conditioning compressor for three seconds after the ignition key is turned...
Page 149 EMISSION CONTROLS AND FUEL SYSTEM This relay closes to complete the TCS circuit BATTERY SWITCH and open the TCS solenoid, allowing vacuum advance, for 20 seconds after the key is turned to the "on" position. The operating tempera- ture of the temperature override switch has been raised to 93°, and the switch that was used to engage the A/C compressor when the key was turned "off' has been eliminated.
Page 150 EMISSION CONTROLS AND FUEL SYSTEM lower the combustion temperature. At full- DIAPHRAGM IS SEATED WHEN ENGINE IS NOT RUNNING throttle the valve closes again. Some California engines are equipped with a dual diaphragm EGR valve. This valve fur- VACUUM SIGNAL TUBE ther limits the exhaust gas opening (com- pared to the single diaphragm EGR valve) during high intake manifold vacuum periods,...
Page 151 Throttle Body (fuel) Injection system. VERIER VALVE EGR valve and solenoid used with most computer emissions systems—1982 shown (© Chevrolet Motor Division) TVS SWITCH REMOVAL AND INSTALLATION 1. Drain the radiator. 1. Disconnect the vacuum lines from the switch, noting their locations.
Page 152 EMISSION CONTROLS AND FUEL SYSTEM the position of the control rod changes (valve 6. Check for proper operation of the EFE closes). If the valve did not close, disconnect valve. the vacuum line from the EFE valve. If vac- uum is felt at this line, either the EFE valve Catalytic Converter is defective or the linkage is binding.
Page 153 EMISSION CONTROLS AND FUEL SYSTEM SIGNAL NOTE: All COMPONENTS SHOWN NOT ON ALL ENGINES. C-4 system schematic gine/transmission combination was available content as a rich mixture. The data from the in Corvettes sold in California. In later years, oxygen sensor is processed by the ECM, many different PROM units are used for the causing the ECM to vary other system func- same model, according to vehicle weight,...
Page 154 EMISSION CONTROLS AND FUEL SYSTEM tended (compared to the C-4 system) through Throttle Position Sensor (IPS)—Monitors the the use of additional sensors and increased degree of throttle opening, allowing the ECM control capacities of the ECM and PROM to alter the air/fuel mixture according to en- units.
Page 155 EMISSION CONTROLS AND FUEL SYSTEM AIR SWITCHING REAR INJECTOR OIL PRESSURE SWITCH SOLENOID MAP SENSOR HOOD LOUVRE RELAY THROTTLE POSITION SENSOR CONTROL SOLENOID FRONTINJECTOR COOLANT TEMPERATURE SWITCH FUEL VAPOR SOLENOID Typical CCC system component locations—left side view (1982 shown) The purpose of the sensor is to "tell" the ECM specific engine operating conditions, as sensed by the various monitoring devices of when the engine begins to "ping,"...
Page 156 EMISSION CONTROLS AND FUEL SYSTEM detonation sensor, the entire computer emis- FITTING sions system should be professionally tested. Because both types of EST systems are di- rectly tied into the computer emissions sys- tem, service, testing, and repair should be performed by a qualified, professional tech- nician.
Page 157 EMISSION CONTROLS AND FUEL SYSTEM buretor. While this line is disconnected, REMOVAL AND INSTALLATION check the fuel filter. 1. Disconnect the battery cables at the 2. Run a piece of fuel-resistant rubber hose battery. from the line to a graduated container. 2.
Page 158 EMISSION CONTROLS AND FUEL SYSTEM sure on the gauge. Fuel pressure should be parts require close tolerances and an air leak 9-13 psi. Turn the engine OFF. Replace the here can cause poor starting and idling. fuel pump if the pressure is not within this 4.
Page 159 EMISSION CONTROLS AND FUEL SYSTEM or uneven jetting will result. Always use new enough to freely enter the rear secondary gaskets and adjust the float. throttle hole. Connect the rod. Adjust the forward secondary rod so that it barely enters the throttle lever hole.
Page 160 EMISSION CONTROLS AND FUEL SYSTEM 1. Bowl cover 6. Choke shaft lever 13. Choke valve screw 2. Metering rod arm 7. Vent arm screw 14. Inlet fitting nut 3. Vent arm 8. Metering rod discs 15. Filter gaskets 4. Pump operating arm 9.
Page 161 14. Vacuum piston 15. Vacuum piston spring 16. Pump plunger assembly 17. Pump plunger return spring 18. Primary float...
Page 162 EMISSION CONTROLS AND FUEL SYSTEM the notched portion of the gauge fits over the METERING ROD ADJUSTMENT edge of the casting. Bend the floats until their To adjust the metering rods, back off the idle- sides just clear the vertical uprights of the speed adjusting screw until the throttle valves gauge.
Page 163 EMISSION CONTROLS AND FUEL SYSTEM primary throttle valves open, the secondary colator plugs and bushings and main dis- throttle-to-bore angle will be SVz . There charge nozzles are a press fit and should not should be 0.017 in.-0.022 in. clearance be- be removed.
Page 164 EMISSION CONTROLS AND FUEL SYSTEM 1. Bowl cover assembly 8. Pump lever 15. Cover gasket 2. Screw 9. Pump lever pivot screw 16. Pump plunger assembly 3. Piston cover plate 17. Float needle seat 10. Screw 4. Power piston 18. Float needle 11.
Page 165 EMISSION CONTROLS AND FUEL SYSTEM 5. Remove the choke housing cover, gas PUMP INTAKE PRIMARY ket, and baffle. Remove the O-ring seal from CHECK BAU VENTURI CLUSTER the vacuum opening in the mounting boss. Remove the choke piston, levers, pump clus ter and gasket, and pump discharge needle.
Page 166 EMISSION CONTROLS AND FUEL SYSTEM IDLE VENT ADJUSTMENT GAUGE FROM TOP OF CHOKE VALVE WALl, NEXT TO VENT Remove the idle vent valve cover from the STACK. TO TOP OF PUMP STEM air horn, if so equipped. Close the vent valve BEND PUMP LEVER ,TO and open the primary throttle until the vent ADJUST...
Page 167 CONOMY UP TIPS CHILTON'S Tune-up • Spark Plug Diagnosis * Emission Controls Fuel System « Cooling System * Tires and Wheels General Maintenance...
Page 168 CHILTON'S FUEL ECONOMY & TUNE-UP TIPS Fuel economy is important to everyone, no delivery, electronic engine controls and alterna- matter what kind of vehicle you drive. The tive engines for use in smaller and lighter vehi- maintenance-minded motorist can save both cles, among other alternatives to meet the money and fuel using these tips and the peri- federally mandated Corporate Average Fuel...
Page 169 veyed over 6,000 cars nationwide, they found that a tune-up, on cars that needed one, in- creased fuel economy over 11%. Replacing worn plugs alone, accounted for a 3% increase. The same test also revealed that 8 out of every 10 vehicles will have some maintenance defi- ciency that will directly affect fuel economy, emissions or performance.
Page 170 SPARK PLUG DIAGNOSIS Normal ' - , V ' ? , , , " -,\ V Oil Deposits ^ \ ' ^ ,'v , APPEARANCE: Trie firing end of;the/plug\is APPEARANCE: This plug is typical of one'oper- ,, ating normally.' The insulator nose varies froraa > .covered with a-wet,oijy*cbating., ^' '^' j.')"...
Page 171 High Speed Glazing APPEARANCE:; Spark plugs fouled, by <MMT APPEARANCE: Glazing appears as shiny<coat" ing on the plug, either yellow 'or tan In color."; (Methycyclppentadlenyl JMaganeseTrlcarbonyl) ^kve reddish, rusty appearance on the insulator CAUSE: During hard, fast- acceleration, -plug temperatures rise suddenly. Deposits from nor ...and'sidefelectrode, "...
Page 172: Fuel System Service
EMISSION CONTROLS .or brittle conditions. Something as simple as a 13. Be aware of the general condition of the leaking vacuum hose can cause poor perform- emission control system: It contributes to re duced pollution and should be serviced regu ance and loss of economy.
Page 173 lines as recommended. omy by tampering with emission controls is 17. Besure that all vacuum lines and hoses more likely to worsen fuel economy than im- are reconnected properly after working under prove it. Emission control-changes oh modern the hood. An unconnected or misrouted vacuum engines are not readily reversible.
Page 174 GENERAL MAINTENANCE Check the fluid levels (particularly engine oil) on a A vacuum gauge is another excellent indicator of regular basis. Be sure to check the oil for grit, water internal engine condition and can also be Installed in or other contamination. the dash as a mileage indicator.
Page 175 EMISSION CONTROLS AND FUEL SYSTEM Position the cam follower on the second CHOKE VALVE step of the fast-idle cam, touching the high step. Close the choke valve and gauge the clearance between the lower edge of the valve and the body. Bend choke rod to obtain the specified clearance.
Page 176 EMISSION CONTROLS AND FUEL SYSTEM ©PUSH UP LIGHTLY ON GAUGE BETWEEN AIR HORN WALL VACUUM BREAK LEVER BEND ROD AND LOWER EDGE OF CHOKE VALVE '» GAUGE BETWEEN AIR HORN TO ADJUST TO CLOSE CHOKE (HOLD OPEN PRIMARY WALL AND LOWER EDGE OF IN POSITION WITH THROTTLE VALVES "CHOKE VALVE...
Page 177 EMISSION CONTROLS AND FUEL SYSTEM quires a hex wrench on 1977 and later from beneath the primary metering rod model carburetors. hanger. Remove tie accelerator pump Remove all spring tension by loosening the plunger from the pump well. 6. Remove the power piston and meter locking screw and backing out the adjusting ing rods by pushing downward on the piston screw.
Page 178 EMISSION CONTROLS AND FUEL SYSTEM Quadrajet® air horn screw torque sequence Installing the lower choke rod lever—Quadrajet® d. When installing the air horn assem typical bly, be sure to follow the accompanying Assembly is the reverse of the previous torque sequence diagram for the air horn steps.
Page 179 EMISSION CONTROLS AND FUEL SYSTEM TO VACUUM ADVANCE ON DISTRIBUTOR Quadrajet CEC valve screws until the required carbon monoxide changes. Of primary importance is the re- level is reached in the exhaust gas. Adjust the vised procedure for removing the power pis- idle-speed screw until the final idle setting is ton.
Page 180 EMISSION CONTROLS AND FUEL SYSTEM CONNECTION TO -PRIMARY <CARBURETOR Holley 2300 secondary carburetor the 427 engine from 1967 through 1969. This ACCELERATOR PUMP ADJUSTMENT- configuration uses one 2300C as the primary PRIMARY CARB carburetor and two 2300 models as the two Secure the throttle plate fully open and de- secondary units.
Page 181 EMISSION CONTROLS AND FUEL SYSTEM 6. Remove the choke vacuum break, choke Gasket—inlet lever and fast-idle cam. Remove the acceler lockscrew ator pump discharge nozzle and its check Screw—inlet lock Float assembly valve. Screw—float hinge 7. Reverse the above procedure to assem Fuel lever sight plug ble.
Page 182 EMISSION CONTROLS AND FUEL SYSTEM Holley float level adjustment Holley accelerator pump adjustment check to see that die fuel level reaches the ACCELERATOR PUMP ADJUSTMENT bottom threads of the sight plug port. A plus or minus tolerance of Vs2 in. is acceptable. Turn off the engine.
Page 183 EMISSION CONTROLS AND FUEL SYSTEM MAIN BODY <fi> Exploded view of Holley 4150 3. Remove the float hinge pin retainer C.E.C. VALVE ADJUSTMENT and remove the float and spring from the 1971 4150 Holley bowl. If so equipped, remove the inlet baffle. This adjustment is made only when it has 4.
Page 184 EMISSION CONTROLS AND FUEL SYSTEM freely. Replace the bowl assembly if ball to the nozzles where it is injected into the movement is restricted or if either the ball or engine. passage are damaged. 7. To disassemble the metering body (all DESCRIPTION AND OPERATION except 4160 secondary): remove the main Air Meter...
Page 185 EMISSION CONTROLS AND FUEL SYSTEM was modified to the extent that a choke pis- Fuel Control System ton was added and the choke valve stop was A fuel control system regulates fuel pressure relocated in the diiuser cone. This allows an (flow) from the fuel pump to the nozzles.
Page 186 EMISSION CONTROLS AND FUEL SYSTEM dirotde linkage and stops fuel delivery to the upward and permits the spill ports to by-pass fuel into the reservoir, thus fuel flow to the by-pass circuit. nozzles is reduced. Idle System The diaphragm vacuum-to-fuel pressure ratio, and subsequent fuel/air ratio, is regu- Correct injector operation at idle speed is lated by the position of the ratio lever.
Page 187 EMISSION CONTROLS AND FUEL SYSTEM Hot Starting/Unloading speed screw until 800-850 rpm is obtained. Adjust the idle-fuel screw until the smooth- Rich mixtures must be prevented during hot est engine idle is attained. Should the two starting/unloading situations. Depressing the idle-adjusting screws become completely out accelerator pedal to fully open the throttle of phase, purge the system or stop the engine...
Page 188 EMISSION CONTROLS AND FUEL SYSTEM check to see that the unit is operating on the economy stop. Some injectors may be diffi- cult to start with the cranking-signal valve line disconnected. The line may be reconnected during die initial starting procedure. Increase engine rpm until arO.5 in.
Page 189 EMISSION CONTROLS AND FUEL SYSTEM main control diaphragm vent tube at both ends. Invert the injector and drain the fuel reservoir through the cover vent, then dis- connect the fuel pressure lines. Remove the lower retaining screws, the single upper bolt, and the short vent tube.
Page 190 EMISSION CONTROLS AND FUEL SYSTEM O-ring at the fuel meter end of the fuel line. Remove the fuel meter from the injector unit. Nozzle Code Part Number 4. Disassemble the air meter by remov W 1 7 o r 1 8 7017323 ing the air cleaner adapter, fast-idle cam pi X 1 8 o r 1 9...
Page 191 EMISSION CONTROLS AND FUEL SYSTEM Checking spray pattern 14. A fuel nozzle spray-pattern check should be made whenever a complete nozzle cleaning is made. Drive the gear pump with an electric drill while applying oral vacuum at the main control diaphragm. The latter en sures that all fuel is routed through the noz zle circuit.
Page 192 EMISSION CONTROLS AND FUEL SYSTEM NORMAL FUEL LEVEL FUEL INLET CONTROL DIAPHRAGM ENRICHMENT TOWER/LEVER ELEC. SWITCH IDLE MIXTURE SCREW VENTURI SIGNAL EXHAUST STOVE COLD ENRICHMENT HOUSING THERMOSTAT Fuel injection system diagram time, check for throttle shaft binding. If such Twin Throttle Body Injection a condition exists, attempt to remedy by (TBI) System (Marketed as soaking in solvent.
Page 193 EMISSION CONTROLS AND FUEL SYSTEM cedures to remove the TBI unites) and replace FUEL PRESSURE REGULATOR FUEL the defective components). INJECTOR FUEL RETURN LINE REMOVAL AND INSTALLATION TO FUEL TANK Front TBI Unit 1. Disconnect the battery cables at the battery.
Page 194 EMISSION CONTROLS AND FUEL SYSTEM 1. Fuel injector electrical connection 3. Fuel inlet line 2. IAC motor electrical connection 4. Fuel balance line Electrical and fuel line connections at the front TBI unit 1. Fuel injector 2. IAC motor 3. Throttle position sensor (IPS) Electrical connections at the rear TBI unit...
Page 195 EMISSION CONTROLS AND FUEL SYSTEM Rear TBI Unit FUEL PRESSURE REGULATOR OR 1. Disconnect the battery cables at the COMPENSATOR ATTACHING SCREWS ASSEMBLY DO NOT REMOVE battery. 2. Remove the air cleaner assembly, not FUEL METER COVER GASKET ing the connection points of the vacuum lines. 3.
Page 196 EMISSION CONTROLS AND FUEL SYSTEM aligning the flats of the lever and the shaft. FUEL METER BODY ATTACHING Install and tighten the retaining screw. SCREWS 3. Install the fuel meter body on the throttle body, using a new gasket. Also, ap ply thread locking compound to the three fuel meter body screws according to the chemical manufacturers instructions.
Page 197 EMISSION CONTROLS AND FUEL SYSTEM installed alongside the fuel injector (one screw 1982-84 THROTTLE BODY INJECTION each side). Minimum (die and Throttle Valve 13. For the rear TBI unit only: With the Synchronizing throttle valve in the closed (idle) position, in The throttle position of each throttle body stall the TPS but do not tighten the attaching must be balanced so that the throttle plates...
Page 198 EMISSION CONTROLS AND FUEL SYSTEM BLOCK LEVERS HERE j^ \ Block throttle lever movement as shown d. Remove the screw and collar and dis card the collar. Plug the idle air passages of each throttle body as shown e. Reinstall the throttle synchronizing screw, using thread locking compound.
Page 199 EMISSION CONTROLS AND FUEL SYSTEM 20 GALLON TANK Fuel tank assembly—1963-67 (20 gal.), 1966-67 (optional 36 gal.) or use any type of drop tight in the service exhaust systems at the transmission cross- area. member. Disconnect the muffler support NOTE: It is best to run the tank as low on brackets and slide the exhaust system rear- fuel as possible prior to removing the tank.
Page 200 EMISSION CONTROLS AND FUEL SYSTEM Fuel tank mounting—1978-82 2. Remove the gas cap and siphon the re maining fuel from the tank. 3. Remove the filler neck seal and the drain tube. 4. Disconnect the fuel lines and electrical connectors from the inlet and meter assem bly.
Page 201 EMISSION CONTROLS AND FUEL SYSTEM 8. Raise vehicle and support it safely. 1. Disconnect the negative battery cable, 9. Remove spare tire and tire carrier. if not already done. 10. Disconnect oxygen sensor electrical 2. Remove in-line fuel filter and inspect connector, located in the exhaust manifold.
Page 202 EMISSION CONTROLS AND FUEL SYSTEM hose clamps over replacement part and push moved. If more than a 6 in. length of pipe is the hose an equal amount onto each portion removed, use a combination of steel pipe and of fuel pipe. Tighten clamps on each side of hose so that hose lengths will not be more repair, but do not overtighten.
Page 203 EMISSION CONTROLS AND FUEL SYSTEM Holley 4150 and 4160 Specifications Accelerator Float Pump Level Lever Choke Choke Choke (Dry) Adjustment Unloader Vacuum Identifi- Engine Fast Idle Setting (in.) (In.) cation Horse- Clearance On Car Break (in.) Year No.® power (in.) (ipm) (in.) 1966...
Page 206 § Rochester Quadrajet® Carburetor Specifications (cont.) Float Idle Vacuum Choke Fast Idle Engine Level Pump Carburetor Vent Break Choke Choke Unloader Speed Horse- Air Valve Year (in.) Rod (in.) power Identification® Spring (in.) (in.) Setting Rod (in.) (in.) (rpm) 1978 185®...
Page 207 190® 17080207 — — .243® © y.® — .157 © 190® 17080204 y«® — .157 — — .243© © 17080228 ® — .179 — — .243© ©The carburetor identification number is stamped on the float bowl, near the secondary throttl e lever. ®...
Page 208 HEATER screws and pry it out to gain access to the right splash shield retaining bolts. 4. Remove the splash shield retaining bolts Blower Motor and remove the splash shield. REMOVAL AND INSTALLATION 5. Remove the motor to case mounting 1963-1967 With or Without A/C screws and lower the motor through the splash shield opening.
Page 209: Chassis Electrical
CHASSIS ELECTRICAL 1. Blower motor location ery jar must be removed to gain access to the motor 2. On air conditioned models, the coolant recov- Typical blower motor location 7. Installation is the reverse of removal. 9. Carefully remove the heater assembly Make sure all electrical connections are clean from under the dashboard.
Page 210 CHASSIS ELECTRICAL Heater and blower assembly-wo/Ac—typical RESISTOR door 10. Remove the temperature plate from the selector duct. 11. Remove the heater core and housing from the selector. 12. Reverse the removal procedure to in stall. 1981-82 All Models Heater and distributor assembly—1968-79 wo/AC 1.
Page 211 CHASSIS ELECTRICAL taining screws and pull the panel rearward to release the upper retaining clip. 15. Remove the following ducts: a. Right side vent b. Main vent distribution c. Lower heater deflector d. Heater-defroster distribution duct assembly (Disconnect the vacuum line). 16.
Page 212 CHASSIS ELECTRICAL to gain access to switch connector and re- move connector and trim plate from cluster assembly. 5. Unclip and remove right and left con sole forward trim pads and remove forward- most screw on right and left side of console. 6.
Page 213 CHASSIS ELECTRICAL 1984 and Later SOCKET ,BULB There are several different types of radio .INSTRUMENT CLUSTER and/or cassette sound system available in the 1984 Corvette. By removing the trim plate covering the radio, access can be gained to the mounting screws securing the assembly to the instrument panel.
Page 214 CHASSIS ELECTRICAL 15. Remove the ignition switch from the 1984 and Later instrument cluster and remove all wiring 1. Disconnect the negative battery cable. connectors. Unsnap the two locking tangs 2. Remove the spring-loaded light switch with a screwdriver and unplug the ignition knob and the light switch nut.
Page 215 CHASSIS ELECTRICAL 5. Remove the ignition shielding and dis tributor cap. 6. Remove the three, motor retaining screws or nuts and remove the motor. 7. Check gaskets and replace if necessary. Ensure that the motor is in Park position. 8. Reverse removal steps to install. 1984 and Later 1.
Page 216 CHASSIS ELECTRICAL 3. Remove the rubber plug from the front of the wiper door actuator, insert a screw driver and push the internal piston rearward to actuate the wiper door open. 4. Remove the wiper arm and blade as semblies from the transmission. 5.
Page 217 2. Remove die headlight bezel retaining As required by law, all 1974 and some 1975 screws and remove the bezel. Chevrolet passenger cars cannot be started 3. Disengage die spring from die retain until the front seat occupants are seated and ing ring and remove die two attaching screws.
Page 218 CHASSIS ELECTRICAL Location of horizontal (1) and vertical (2) adjust- ment screws Headlamp assembly—1968-82 5. When installing the sealed beam unit make sure the number which is moulded into 4. Remove the retaining ring and discon- the lens is at the top. The number 1 inboard nect the sealed beam unit at the wiring con- unit takes a double connector plug and the nector.
Page 219 4. Hazard flasher 5. Turn signal flasher FUSIBLE LINK AFTER SHORT CIRCUIT 1. Horn relay 2. Warning buzzer Fusible link (© Chevrolet Motor Division) 3. Electric choke relay Convenience center and components—typical FUSIBLE LINK 1 THOROUGHLY TAPE ALL EXPOSED WIRES...
Page 220 CHASSIS ELECTRICAL enclosed in a plastic housing. There are three block. Each fuse recepticle is marked as to spade-type electrical terminals which plug the circuit it protects and the correct amper- age of the fuse. In line fuses are also used. into an in-line connection at the wiring har- Refer to the Fuse Chart at the end of the ness to the air conditioning compressor.
Page 221 CHASSIS ELECTRICAL Circuit Protection Chart (cont.) Type ot Protection Model Year Protected Circuit 1968-69 Horn relay 16 gauge fusible link Voltage regulator No. 3 terminal 20 gauge fusible link Ammeter circuit (both sides of meter) 20 gauge fusible link 1970 Headlamp circuit 15 amp circuit breaker Power window circuit...
Page 222 CHASSIS ELECTRICAL Circuit Protection Chart (cont.) Model Year Protected Circuit Type of Protection 1 9 7 8 Headlamp circuit "Power window circuit Back-up lamp circuit breaker 30 amp and turn signals Heater/air conditioner Radio, rear circuit breaker 20 amp defogger Instrument lamps Tail lamps (side marker and AGO fuse 25 amp parking lamps), underhood 3AG fuse 20 amp...
Page 223 CHASSIS ELECTRICAL Circuit Protection Chart (cont.) Model Year Protected Circuit Type of Protection 1984 Rear window defogger switch (Defog) 30 amp fuse L.C.D. speedometer cluster (L.C.D.) 5 amp fuse Hatch release relay (Rr Hatch) 20 amp fuse Center information cluster, under hood lamps, horn relay, 15 amp fuse courtesy lamps, map lamps—door, power door lock switches, radio clock, key warning &...
Page 224: Clutch And Transmission
A" long. DO NOT re- place either of these bearings with the 17s" turn pressure of the clutch. Fluid returns to unit which is popular in other Chevrolet the master cylinder and the final movement models. of the plunger lifts the valve seal off the seat,...
Page 225 CLUTCH AND TRANSMISSION CLUTCH FORK CLUTCH HOUSING FLYWHEEL DRIVEN PLATE ASM PRESSURE PLATE AND COVER ASM CLUTCH HOUSING CLUTCH RELEASE BEARING COVER CLUTCH FORK Typical clutch assembly BALL STUD effort, gear clash and grinding or transmis- 2. Disconnect the clutch-fork push rod and sion blockout.
Page 226 CLUTCH AND TRANSMISSION 1. Flywheel 6. Diaphragm spring 2. Dowel hole 7. Cover 3. Pilot bushing 8. Throwout bearing 4. Driven disc 9. Fork 5. Pressure plate 10. Retracting spring Cutaway of single disc clutch down evenly and gradually. Install the re- 17.
Page 227 CLUTCH AND TRANSMISSION CLUTCH ADJUSTMENT 1963-74 1. Disconnect the spring between the clutch push rod and cross shaft lever. 2. While holding the clutch pedal against the stop, loosen the two locknuts enough to allow the adjusting rod to move against the clutch fork until the throwout bearing lightly touches the pressure plate springs.
Page 228 CLUTCH AND TRANSMISSION stances, use fluid which has been bled from 7. Connect hydraulic line at master cyl a system to fill the reservoir as it may be inder. aerated, have too much moisture content 8. Connect push rod at clutch pedal. Lu and possibly be contaminated.
Page 229: Manual Transmission
CLUTCH AND TRANSMISSION 9. Fit the plunger seal to the plunger. BLEEDSCREW 10. Fit the valve seal, smallest diameter DUST COVER leading to the valve head. 11. Position the spring washer on the valve stem so that it flares away from the valve stem shoulder and follow with valve spacer, legs first, and spring.
Page 230 CLUTCH AND TRANSMISSION shift rods on the transmission. Remove'the naw 3-speed, Muncie 4-speed, and the War- ner 4-speed. Identification is determined by shift lever assembly and linkage. the side cover design and linkage. The 3-speed 4. Remove the driveshaft as described in Muncie side cover has two bolts on the side the driveshaft section of Chapter 7.
Page 231 CLUTCH AND TRANSMISSION 37. Shifter interlock retainer stud 1. Clutch gear bearing retainer 21. Snap-ring nut lock 2. Bearing retainer gasket 22. Speedometer drive gear 38. Shifter interlock retainer 3. Bearing nut and oil slinger 23. Case extension gasket 39. Second and Third shifter fork 4.
Page 232 > 1. Clutch gear bearing retainer 22. Synchronizer ring 11. Thrust washer 2. Clutch gear bearing 36. Snap-ring 12. Case extension 3. Clutch gear 37. Countershaft 13. Mainshaft rear bearing 4. Energizing spring 38. Thrust washer 15. Mainshaft 39. Roller bearing 6.
Page 233 CLUTCH AND TRANSMISSION return spring and "T" handle, and remove the 1ST GEAR OVERDRIVE anti-rattle bushings. On 1968 and later cars, \SWITCH remove the console trim plate. CONN BACK-UP 3. Jack the car high enough to provide SWITCH working clearance. Support with jackstands. CONN 4.
Page 234 CLUTCH AND TRANSMISSION mission rearward to disengage the input shaft vates the first and reverse lever, but still re- from the clutch. Remove the transmission from mains in Neutral. the vehicle. 5. Attach the first/reverse shift rod to the 17. Inspect the clutch components for signs shift lever, adjust the clevis as done with the of wear or heat damage.
Page 235 CLUTCH AND TRANSMISSION clevis pin freely enters the holes in the clevis and the selector levers. 3. Secure the pins and lock the clevis se- curing nuts. Remove the gauge block and check the shift pattern. Minor adjustment of the rods may be necessary to remove all traces of shifting roughness.
Page 236 CLUTCH AND TRANSMISSION NEUTRAL LEVER C LEVER & BRKT ASM NOTCH LEVER F RODN .05x45° MAXIMUM .040 LEVER 0 APPROXIMATELY 35°' BEND TO CLEAR RETAINER G _______FLOOR PAN Shift linkage adjustment—1978-81. The locating gauge Is shown on the left. 3. Set transmission shift levers in neutral the transmission lever with the retaining clip positions.
Page 237 CLUTCH AND TRANSMISSION ROD-3RD & 4TH 20-32 N-m (15-23 FT. IBS.) GAGE PIN ROD-3RD & 4TH ROD-1ST&2ND ROD-REVERSE 27-40 N-m (20-30 FT. IBS.) Linkage adjustments—1984 4-speed overdrive transmission levers. Hand tighten the forward and rear ad- 11. Reinstall the components removed by reversing Steps 1 through 7.
Page 238: Automatic Transmission
CLUTCH AND TRANSMISSION oil pan, remove oil pan attaching bolts from front and side of pan. FRONT 3. Loosen rear pan attaching bolts approx imately four turns. 4. Carefully pry oil pan loose, allowing fluid to drain. 5. Remove remaining bolts and remove oil pan.
Page 239 CLUTCH AND TRANSMISSION position, holding the brakes. Return the le- just enough to take the weight of the trans- ver to PARK, and check the fluid level with mission off of the crossmmember. the engine idling. The level should be be- 6.
Page 240 CLUTCH AND TRANSMISSION 7. Working under the dash, remove the two nuts at the steering column-to-dash bracket. PLACE SELECTOR 8. Turn the lock tube lever counterclock wise (when viewed from the front of the col umn) to remove any freeplay from the col umn.
Page 241 CLUTCH AND TRANSMISSION 4. Check the alignment of the control ca ble hole against the transmission lever stud. If the cable hole aligns with the stud, attach SNAP the cable with the washer and retaining pin; LOCK the adjustment is okay. If the stud and hole do not align, loosen the stud mounting nut and slide the stud as necessary to align it with the cable hole.
Page 242 CLUTCH AND TRANSMISSION THROTTLE BODY LEVER ADJUST LOCK TAB FITTING SLIDER DETENT CABLE 1981 Throttle valve (T.V.) cable adjustment— 1981 and later The shift control lever must be THROTTLE LEVER disconnected from the control rod and the PADDLE shift control knob removed. Then remove the trim plate to get at the switch.
Page 243 CLUTCH AND TRANSMISSION LOW BAND ADJUSTMENT 1963-67 Powerglide Low band adjustment should be performed at 12,000 mile intervals, or if slipping is en- countered. 1. Place the selector lever in Neutral. 2. Jack the car up to the required working height and support with jackstands.
Page 244 Drive Train DRIVELBNE The Stingray driveline consists of the drive- shaft, differential carrier, and axle drive- shafts. The driveshaft is of conventional tu- bular design with a universal joint at each end. The differential is mounted directly to a sus- pension crossmember.
Page 245 DRIVE TRAIN CAP SNAP BEARINGS RING SEAL SPIDER Typical universal joint assembly 1963-79 axle driveshaft installation joints are removed from the car, they should 9. Realign the camber adjusting cam and be checked and regreased. bracket. Torque the nut to 15-22 ft. Ibs. 1.
Page 246 DRIVE TRAIN Rear Axle Identification Rear Axle Identification (cont.) NOTE: Axle identification is stamped on the NOTE: Axle identification is stamped on the differential carrier along urith the date of differential carrier along with the date of manufacture. manufacture. Plant Plant Identification Identifi -...
Page 247 SUSPENSION AND STEERING BOUNCE TEST REMOVAL AND INSTALLATION Each shock absorber can be tested by bounc- 1. To remove, raise the vehicle and hold ing the corner of the vehicle until maximum the upper stem of the shock absorber with an up and down movement is obtained.
Page 248 SUSPENSION AND STEERING The displacement contributes to the direc- Transverse Leaf Spring tional sense. Combined with +3° caster, REMOVAL AND INSTALLATION spindle offset gives an effect similar to higher caster without the poor responsiveness. 1. Raise the vehicle and support it safely. 2.
Page 249 Suspension and Steering FRONT SUSPENSION front coil springs. A stabilizer bar connects the lower control arms to the front frame rails. The Corvette Stingray front suspension is an Tapered roller bearing are used in the front unequal length arm, independent design. wheels.
Page 250 DRIVE TRAIN Rear Axle Identification (cont.) Rear Axle Identification (cont) NOTE: Axle identification is stamped on the NOTE: Axle identification is stamped on the differential carrier along with the date of differential carrier along uMh the date of manufacture. manufacture. Plant Identifi- cation Identifi-...
Page 251 SUSPENSION AND STEERING 3. Reverse the procedure to install the re- placement shock absorbers. DISPOSAL OF PRESSURIZED SHOCK ABSORBERS 1984 and Later Models Due to the high pressure of gas it is advised that, upon scrapping or disposal of these shock absorbers, the pressure be released.
Page 252 SUSPENSION AND STEERING WORN WEAR SURFACES RUBBER PRESSURE RING WEAR 1.27mm (.050") INDICATOR WHEN BALL JOINT WEAR CAUSES THIS (OUT WHEN SHOULDER TO RETREAT BELOW THE NEW) SURFACE, REPLACEMENT IS REQUIRED. Typical ball joint inspection, showing how to check wear indicator 25 N«m (19 FT.
Page 253 SUSPENSION AND STEERING wheel and tire. Be sure that the lift is posi- NOTE: Removal of the spring is not nec- essary so long as the lower control arm is tioned so that the front suspension will hang adequately supported. 9. The lower ball freely.
Page 254 SUSPENSION AND STEERING Steering Knuckle 6. Torque the upper stud nut to 50 ft. Ibs., and the lower stud nut to 90 ft. Ibs. Upper and Lower Control Arms Removing the upper control arm shaft SHAFT REMOVAL AND INSTALLATION 1. To remove the lower, control arm shaft, 7.
Page 255 SUSPENSION AND STEERING SHIMS SPECIAL THICK WASHER IS LOCATED AT REAR INBOARD POSITION UPPER CONTROL 85 N-m (63 FT. LBS.) Upper control arm chassis mounting on 1984 and later models 65 N-m (48 FT. LBS.) 130 N-m (96 ft. Ibs. KNUCKLE ASSEMBLY Lower control arm assembly on 1984 and later...
Page 256 SUSPENSION AND STEERING SHOCK ABSORBER MOUNTING BRACKET (30 FT. LBS.) NTTI LOWER CONTROL »40 N-m (30 FT. LBS.) Shock absorber mounting bracket—1984 and later MUST BE INSTALLED IN 48 N-m (35 FT. LBS.) MUST BE INSTALLED IN DIRECTION SHOWN 30 N-m (22 FT. LBS.) 48 N-m (35 FT.
Page 257 SUSPENSION AND STEERING ing or chattering is felt while turning, the bearing assembly should be replaced with a new unit. 9. Pack each bearing by pkcing a "ball" of grease on your palm and pushing die larger side of the bearing into the grease with your other hand, forcing the grease into the cage and rollers and out of the narrow side of the Front wheel hub assembly...
Page 258 SUSPENSION AND STEERING bolts. Camber and caster adjustment may be made at the same time. A Vs2 in. shim will effect a Ve change in camber. Adjust to spec- ifications. TOE-IN ADJUSTMENT Toe-in is the measurement in inches of the inward departure of the front of the wheels from a line drawn through the horizontal cen- ter of the wheel, parallel to the centerline of...
Page 259 SUSPENSION AND STEERING v— v— TOE IN « » STANDARD SCREEN INDICATES TOE PER WHEEL IN INCHES. INDICATES TOE PER WHEEL IN DEGREES & TENTHS. • • 1 o 91 Jf J! 121212 1212 INDICATES TOE PER WHEEL IN DEGREES &...
Page 260: Suspension
SUSPENSION AND STEERING (OP VEHICLE ouna AMOK CASTB ANOU ttONT VffiW SIM VIEW WMBLTOMN TOP VIEW Caster, camber, toe-In If a tram gauge is available, position the REAR SUSPENSION front wheels straight-ahead. Loosen the tie- rod clamp on one end and adjust the one rod The Stingray rear suspension is a three-link independent system.
Page 261 SUSPENSION AND STEERING braking tractive forces are transmitted through to the frame at the top and attach to the spin- the arms. The lateral links transmit side forces dle/camber rod strut at the bottom. Spring- to the fixed differential, and through the rub- ing is provided by a multi-leaf transverse ber bushings in the cover beam to the frame.
Page 262 SUSPENSION AND STEERING 1. MEMBER, Rr. Susp. Mtg. Cross 15. BEARING, Rr. WhL Inr 2. BOLT ( /ie"-14 x 1W) 16. SHIM, Rr. Whi 3. WASHER ( 17. ARM, Torque Control 4. BUMPER, Rr. Spring 18. BOLT(%"-16x1%") 5. NUT (%"-16) 19.
Page 263 SUSPENSION AND STEERING link bolt, and then remove the link bolt nut, Spring cushions, and retainers. REMOVAL AND INSTALLATION 4. Raise the spring again and remove the 1. Jack the rear of the car up high enough chain and C-clamp. to provide working clearance and support with 5.
Page 264 SUSPENSION AND STEERING 1981 W/3SPD. exc. FE7 DEFLECTOR, RrWhl Spindle 1. BUSHING, Rr Stab Shaft SHIELD, Rr Whl Inr Bearing 2. SHAFT, Rr Stab SEAL, Rr Inr Bearing 3. BRACKET, Rr Stab Shaft BEARING, RrWhl Inr 4. SCREW, Rr Stab Shaft Brkt SHIM, Rr Wheel 5.
Page 265 SUSPENSION AND STEERING DIFFERENTIAL DIFFERENTIAL CARRIER CARRIER ASM Rear leaf spring mounting assembly—1984 and later Spindle support rod assembly—1984 and later mounting bolts. Tighten the bolts to 55-75 bottom carrier mounting pad with the center ft. Ibs. bolt aligned with the hole in the mounting 11.
Page 266 SUSPENSION AND STEERING 7. Torque the upper nut to 40-60 ft. Ibs. and the lower nut to 50-60 ft. Ibs. DISPOSAL OF PRESSURIZED SHOCK ABSORBERS 1984 and Later Due to the high pressure of gas it is advised that, upon scrapping or disposal of these shock absorbers, the pressure be released.
Page 267 SUSPENSION AND STEERING CAUTION: The strut rod shaft is often very REAR SIDE MEMBER hard to remove; take care not to distort UPPER SPINDLE either the shaft or the spindle support in CONTROL ROD the removal process. 4. Scribe the camber adjusting cam-to- bracket relationship for correct relocation.
Page 268 SUSPENSION AND STEERING 12. Remove cam bolt and separate spindle sleeve. Note the number of turns during re- support rod from the mounting bracket, moval and install the same number during 13. Remove the trunnion straps at the side reassembly. gear yoke shaft.
Page 269 Torque Sp Bolt Location Cover beam to body Supp earner Support beam to tr Truunion straps at side ge straps at spindle yoke Spi bearing Hub and bearing t CARRIER TO SUPPORT BEAM shield to backing plate Sh to knuckle Shock absorbe Driveline beam attachments—1984 and later absorber to knuckle Contr Control arms to knuckle Jo...
Page 270 INSTALLATION Installation is the reverse of removal. Align driveline components. To insure proper alignment of the driveline, a clearance of 45mm±6 (1.77±.250 in.) must be main- tained between the top of the beam to the underbody and a clearance of 28mm ±6 (1.1 ±...
Page 271 Wheel Bearings ADJUSTMENT The spindle bearings ar design and require an e to 0.008 in. To measure wheels clear of the groun axle driveshaft from the sufficient clearance to shaft when the rear sus adjusted so the strut ro must be loosened and ro rod forces the trailing ar Toe-in adjustment shim location hicle centerline and perm...
Page 272 Checking spindle bearing play ceeds the 0.001 in. to 0.008 in. tolerances, the bearings must be adjusted. 4. Set the handbrake and remove the drive spindle nut. 5. Release the brake and remove the brake drum or caliper and disc as described in Chapter 9.
Page 273: Steering
SUSPENSION AND STEERING the inner bearing race, roller assembly, shim, connects the steering gear to the relay rod by and bearing spacer from the spindle support. way of a pivoted joint. The opposite end of 8. Check the size of the old shim and, if this transverse relay rod attaches to a frame- mounted idler arm by way of another pivot- the dial indicator reading exceeded 0.008 in.,...
Page 274 SUSPENSION AND STEERING switch and ignition lock system. This system 4. Install a wheel puller in the two prevents the removal of the ignition key un- threaded holes provided. Remove the steer less the automatic transmission is in Park or ing wheel.
Page 275 SUSPENSION AND STEERING Tilt and telescoping wheel—1965-66 1968-76 Telescoping Wheel 6. Install the spacer on the steering wheel and position the lock knob. 1. Disconnect the battery ground cable. 7. The lock screw installs through the lock 2. Remove the horn cap and upper horn knob, is turned into the shaft, and adjusted contact.
Page 276 SUSPENSION AND STEERING UPPER HORN EMBLEM CONTACTv RETAINER INSULATOR EYELET SNAP RING C O L U M N EXTENSION _>> ^S>\ SPRING SPACER " " " ^ STRG WHEEL ASM WHEEL STRG COLUMN ASM H O W E R H O R N Standard steering wheel—1977-79 CONTACT 4.
Page 277 SUSPENSION AND STEERING Pull each wire separately through the mast remove the four screws securing the exten- sion to the steering wheel then separate. jacket slot to prevent damaging the harness. 7. To assemble the steering wheel, posi 5. Transfer the wiring harness to the re- tion the extension to the steering wheel and placement switch and install the components install the attaching screws.
Page 278 SUSPENSION AND STEERING turn signal and shifter housing in Low posi- tion and remove the harness cover. 8. Remove the three switch mounting screws. Remove the switch by pulling it straight up while guiding the wiring harness cover through the column. 9.
Page 279 SUSPENSION AND STEERING Positioning the ignition switch "Off-Unlocked" position when it is in the next to the uppermost detent. 3. Remove the two switch screws and re move the switch assembly. 4. Before installing, place the new switch in "Lock" or "Off-Unlocked" position and make sure the lock cylinder and actuating rod are in "Lock"...
Page 280 SUSPENSION AND STEERING STEERING GEAR Power rack and pinion assembly on 1984 and later models 6. Remove the mounting bolt, drivers all the way to the left, add power steering fluid to level indicated on reservoir. side. 4. Start engine, and running at fast idle, 7.
Page 281 SUSPENSION AND STEERING (7.5 ft. Ibs.) Power steering pump, reservoir and mounting brackets on engines with serpentine drive belt block Corvettes, alternator drive belt must removed first. 5. Place 24 N-m (18 ft. Ibs.) the pump on the bracket and in stall the attaching pieces hand-tight.
Page 282: Brakes
Brakes BRAKE SYSTEM Adjustment DRUM BRAKES 1963-64 Corvettes are equipped with four- wheel drum brakes. These are hydraulically Rotate the star wheel adjuster until a slight operated, self-adjusting, and feature double- drag is felt between the shoes and drum, then piston wheel cylinders.
Page 283 BRAKES tort and fail to provide a check valve seal, 1. Thumbscrew which will result in a reduction of brake 2. Vent cover 3. Flat washer pedal travel and a corresponding loss of ac- 4. Reservoir cover tual braking. 5. Gasket 7.
Page 284 BRAKES replaced when overhauling the dual master seal should face die piston's compensating cylinder. The displacement capability of the hole flange. master cylinder is dependent upon the length 14. Replace die primary piston assembly of the secondary piston. widi die assembled component found in the overhaul kit.
Page 285 BRAKES 1. Body and reservoir assemblies 11. Secondary seal 2. Stop bolt 12. Primary spring 3. Diaphragm 13. Primary piston 4. Cap 14. Retaining ring 5. Spring locator 15. Warning switch 6. Secondary spring 16. Combination piston 7. Seal retainer 17.
Page 286 BRAKES 4. Remove the brass rod or dowel and primary piston. 5. Lightly tap the open end of the master cylinder body on a block of wood to dislodge the secondary piston. 6. Remove the primary piston spring. 7. Remove the seal retainer with a small screwdriver and discard the retainer.
Page 287 BRAKES the seals and rubber components in the brake system. Use brake fluid that meets or exceeds DOT 3 specifications, such as Delco Supreme #11 or equivalent. Pressure Regulating Valve (Rear Metering) 7965-68 WITH H.D. BRAKES The pressure regulating valve is mounted in the rear brake line just below the main cyl- inder.
Page 288 BRAKES to the pedal. This will apply hydraulic pres- REMOVAL AND INSTALLATION sure to the switch which will recenter it. 1. Disconnect the hydraulic lines at the 5. Repeat Step 4 for the front bleed screw. combination valve. Plug the lines to prevent 6.
Page 289: Drum Brakes
BRAKES essary to gently tap the rear edges of the drum Pressure Bleeding to start it off the studs. 1. Clean the top of the master cylinder, 4. If extreme resistance to removal is en remove the cover, and attach the pressure countered, it will be necessary to retract the bleeding adapter.
Page 290 BRAKES Brake Shoes should be nearest the secondary shoe when properly installed. INSPECTION 9. Reverse the procedure for reassembly. Remove the drum and inspect the lining When completed, make an initial adjustment thickness on both brake shoes. A front brake as described under adjustments.
Page 291: Disc Brakes
BRAKES manner as for the master cylinder. Cleaning and honing procedures are the same. To reassemble, moisten the pistons and cups with clean brake fluid and position the spring in the center of the cylinder. Install the rubber cups—flat side Out—followed by the pistons—flat side in.
Page 292 BRAKES Exploded view of Girlock caliper assembly on 1984 and later models 1. Housing 10. Guide pin 2. Mounting bracket 11. Bleeder screw 3. Guide pin boot 12. Cap 4. Self-locking bolt 5. Piston seal 6. Piston 7. Piston boot 8.
Page 293 BRAKES cloth and, if this is not enough, replace the Calipers caliper. Replace all self-locking bolts. REMOVAL AND OVERHAUL 9. Maintain the proper tolerances by re- 1. With the vehicle securely raised and ferring to the following chart. its wheels removed, disconnect the front cal- iper's brake hose at its support bracket and Caliper Piston-to-Bore die rear unit's line from the inside caliper.
Page 294: Parking Brake
BRAKES ceed 0.005 in. total. Discs should not be re- must be drilled out. The replacement disc finished to a thickness of less than 1.215 in. does not have to be riveted to the hub as the /64 in. on 1982 and later) lug nuts adequately secure both.
Page 295 BRAKES fter Installation, rotate clip so that open end UNDERBODY BRACKET- FRAME Spring pin to be flush to recessed by .040. SECTOR faces downward. Disc brake parking brake cable assembly ously outlined. Do not disconnect the brake line, but remove the line clip from the con- trol arm and hang the caliper above the disc with wire.
Page 296 BRAKES contact surfaces, anchor pin, and adjusting to be utilized to hold the pin in position, as screw threads. head of this pin is not accessible. 11. Install the return spring on the re 17. Turn the adjuster screw to retract the placement shoes and position the shoes on the shoes.
Page 297 Troubleshooting This section is designed to aid in the quick, format will locate problems within a given system, but, because many automotive sys- accurate diagnosis of automotive problems. While automotive repairs can be made by tems are interrelated, the solution to your particular problem may be found in a many people, accurate troubleshooting is a rare skill for the amateur and professional...
Page 298 TROUBLESHOOTING Troubleshooting Engine Problems See Chapters 2, 3, 4 for more information and service procedures. Index to Systems -' ' . ; • • : • ' System •.:•';':.: -' -w ' y ; .•;• U>iV^ To>esr ;'.C ;:"•;;' ;;;.-% Group -;•.
Page 299 TROUBLESHOOTING Specific Diagnosis This section is arranged so that following each test, instructions are given to proceed to another, until a problem is diagnosed. Section 1—Battery Proceed Results and Indications Test and Procedure If case is cracked, replace battery: 1.1—Inspect the battery visually for case condition (corrosion, cracks) If the case is intact, remove corrosion with a and water level.
Page 300 If the lights brighten, remove and clean the 1.2—Check the battery clamp and post; coat the post with petroleum cable connections: In- 1.4 1.3 jelly, install and tighten the clamp: sert a screwdriver be- tween the battery post If no improvement is noted: and the cable clamp.
Page 301 TROUBLESHOOTING Section 2—Starting System See Chapter 3 for service procedures Results and 7esf and Procedure Proceed Indications ^ ^ ^ ^ ^ ^ ^ ^ • • • • ^ • ^ ^ ^ ^ • ^ ^ ^ ^ ^ • ^ • ^ • • ^ • • ^ ^ ^ ^ ^ ^ ^ ^ ^ • ^ ^ ^ ^ ^ ^ • ^ ^ ^ ^ • ^ • • • ^ • • • ^ • • • n N M B H H M H H M M B K H B B i ^ H H ^ ^ B H B H H B H H B N H H B H ^ H i Note: Tests in Croup 2 are performed with coil high tension lead disconnected to prevent accidental starting.
Page 302 TROUBLESHOOTING Section 3—Primary Electrical System Proceed Test and Procedure Results and Indications 3.1 —Check the ignition switch "on" po- If the lamp lights: sition: Connect a jumper wire be- If the lamp flickers when the key is jiggled, tween the distributor side of the replace the ignition switch: coil and ground, and a 12V test If the lamp doesn't light, check for loose or...
Page 303 TROUBLESHOOTING Proceed to "•! Results and Indications Test and Procedure On point-type systems, adjust the dwell angle 3.4—On point-type ignition systems, if necessary. NOTE: Increasing the point gap connect a dwell-meter between decreases the dwell angle and vice-versa. 3.6 3.5 the distributor primary lead and ground.
Page 304 TROUBLESHOOTING Section 4—Secondary Electrical System See Chapters 2-3 for service" procedures Proceed Test'and Procedure Results and Indications If no spark is evident: 4.1 —Check for spark: Hold each spark plug wire approximately %" from If spark is good in some cylinders: ground with gloves or a heavy, dry If spark is good in all cylinders: rag.
Page 305 TROUBLESHOOTING Proceed Results and Indications Test and Procedure 4.4—Check the coil secondary resis- The resistance of a satisfactory coil should be tance: On point-type systems con- between 4,000 and 10,000 ohms; If resistance nect an ohmmeter across the dis- is considerably higher (i.e., 40,000 ohms) re- tributor side of the coil and the coil place the coil and retest per 4.1.
Page 306 CHILTON'S Tools and Materials • Step-by-Step Illustrated Procedures How To Repair Dents, Scratches and Rust Holes Spray Painting and Refinishing Tips...
Page 307 ith,a little practice, basic body re the removal of any type of material. pair procedures can be mastered • Wear lung protection (disposable by any do-it-yourself mechanic. The mask or respirator) when grinding, sand- step-by-step repairs shown here can be ing or painting.
Page 308 WORKING WITH : i i FILLER Mixing The Filler leanliness and proper mixing and application are extremely impor- tant. Use a clean piece of plastic or glass or a disposable artist's palette to mix body filler. Mix the body filler and hardener by Allow plenty of time and follow di- wiping across the mixing surface, rections.
Page 309 the metal a little at a time. Get the panel as straight as possible before applying filler. Using an 80-grit grinding disc on an electric drill, grind the paint from the surrounding area down to bare metal. Use a new grinding pad to prevent heat buildup that will warp metal.
Page 310 Tips). Be sure to cover the area com pletely. Mix the body filler (see Body Repair Tips). Spread the body filler evenly over the entire area (see Body Repair Let the body filler dry until the sur- If possible, use a body hammer and face can just be scratched with your block to shape the metal back to its fingernail.
Page 311 Check to be sure that trim pieces that will be installed later will fit ex- actly. Sand the area with 40-grit paper. 4 f% Sand the area with 400 paper and • *• then finish with a scuff pad. The finished repair is ready for priming and painting (see Painting Tips).
Page 312 Grind away all traces of rust with a 24-grit grinding disc. Be sure to grind back 3-4 inches from the edge of the hole down to bare metal and be sure all traces of paint, primer and rust are Lay the release sheet on a flat sur- removed.
Page 313 4 O Block sand the topcoat smooth • with finishing sandpaper (200 grit), and 400 grit. The repair is ready for masking, priming and painting (see Painting Tips). Materials and photos courtesy Marson Corporation, Chelsea, Massachusetts PAINTING TIPS Sand and feather-edge the entire area.
Page 314 THICKNESS — Spray with smooth old piece of'metal to get the right combl;- nation before you begin painting. strokes. In general, the thicker the coat of paint, the longer the drying time. Ap- ply several thin coats about 30 seconds apart.
Page 315 TROUBLESHOOTING Proceed Test and Procedure Results and Indications 4.7—Examine the location of all the The following diagrams illustrate some of the plugs. conditions that the location of plugs will reveal. o o o o Two adjacent plugs are fouled in a The two center plugs in a 6-cylinder engine 6-cylinder engine, 4-cylinder are fouled.
Page 316 TROUBLESHOOTING Proceed: Test and Procedure Results and Indications 4.8—Determine the static ignition tim- The rotor should be pointing toward the No. 1 ing. Using the crankshaft pulley tower in the distributor cap, and, on electronic timing marks as a guide, locate top ignitions, the armature spoke for that cylinder dead center on the compression should be lined up with the stator.
Page 317 TROUBLESHOOTING Proceed Results and Indications Test and Procedure 5.4—Test the fuel pump: Disconnect all If suction is evident, blow out the fuel line to fuel lines from the fuel pump. the. tank with low pressure compressed air Hold a finger over the input fit- until bubbling is heard from the fuel filler ting, crank the engine (with elec- neck.
Page 318 TROUBLESHOOTING Proceed Results and Indications Test and Procedure If the problem is solved: 5.9—Uncommon fuel system malfunc- tions: See below: If the problem remains, remove and recondi- tion the carburetor. Prevailing Weather Condition Indication Test Conditions Remedy Vapor lock Engine will not Cool the components Ensure that the exhaust mani- Hot to very hot...
Page 319 TROUBLESHOOTING Section 7—Engine Vacuum See Chapter 3 for service procedures Proceed Test and Procedure Results and Indications 7.1—Attach a vacuum gauge to the in- See below, take manifold beyond the throttle plate. Start below the engine, and observe the action of the needle over the range of engine speeds.
Page 320 TROUBLESHOOTING Proceed Test and Procedure Results and Indications '•;'•'•-tO •.,'•"•' If the reading improves, replace the indicated 7.2—Attach a vacuum gauge per 7.1, and test for an intake manifold gasket; or seal the indicated fitting or plug: 8.1 7.3 leak. Squirt a small amount of oil If the reading remains low: around the intake manifold gas- kets, carburetor gaskets, plugs and...
Page 321 TROUBLESHOOTING Section 9—Valve Train See Chapter 3 for service procedures Proceed Test and Procedure Results and Indications 9.1—Evaluate the valve train: Remove Sticking valves or erratic valve train motion the valve cover, and ensure that can be observed with the timing light. The Chapter the valves are adjusted to specifi- cylinder head must be disassembled for re-...
Page 322 TROUBLESHOOTING Section 11—Cooling System See Chapter 3 for service procedures Proceed Test and Procedure Results and Indications 11.1—Visually inspect the fan belt for Replace or tighten the fen belt as glazing, cracks, and fraying, and necessary: replace if necessary. Tighten the belt so that the longest span has approximately W play at its mid- point under thumb pressure (see...
Page 323 TROUBLESHOOTING Proceed! Test and Procedure Results and Indications 11.5—Check the radiator pressure cap: If the cap releases within ± 1 psi of the speci- Attach a radiator pressure tester to fied rating, it is operating properly: 11.6 11.6 the radiator cap (wet the seal prior If the cap releases at more than ±...
Page 324 TROUBLESHOOTING Proceed Results and Indications Test and Procedure If the oil pressure improves: 12.3—Inspect the oil pressure relief valve and spring, to ensure that it 12.4 If no improvement is noted: is not sticking or stuck. Remove and thoroughly clean the valve, spring, and the valve body.
Page 325 TROUBLESHOOTING Condition Possible Cause Engine cranks, but does not 1. Improper starting procedure start 2. No fuel in tank 3. Clogged fuel line or filter 4. Defective fuel pump 5. Choke valve not closing properly 6. Engine flooded 7. Choke valve not unloading 8.
Page 326 TROUBLESHOOTING Possible Cause Condition Engine idles roughly and 1. Incorrect idle speed stalls 2. Clogged fuel filter 3. Dirt in fuel system or carburetor 4. Loose carburetor screws or attaching bolts 5. Broken carburetor gaskets 6. Air leaks 7. Dirty carburetor 8.
Page 327 TROUBLESHOOTING TROUBLESHOOTING of the wire in the circuit (gauge size) is also greater. If this large wire were connected from ELECTRICAL PROBLEMS the component to the control switch on the See Chapter 5 for service procedures instrument panel, and then back to the com- For any electrical system to operate, it must ponent, a voltage drop would occur in the make a complete circuit.
Page 328 TROUBLESHOOTING BEFORE SHORT CIRCUIT COVERING BUBBLED AND CHARRED WIRE BURNED OPEN AFTER SHORT CIRCUIT Most fusible .links show a charred, melted Insula- tion when they burn out chassis electrical components, and is the probable cause of trouble when none of the The test light will show the presence of current electrical components function, unless the when touched to a hot wire and grounded at the...
Page 329 TROUBLESHOOTING Troubleshooting Basic Turn Signal and Flasher Problems See Chapter 5 for service procedures Most problems in the tum signals or flasher system can be reduced to defective flashers or bulbs, which are easily replaced. Occasionally, the turn signal switch will prove defective. F = Front R=Rear •...
Page 330 TROUBLESHOOTING Troubleshooting Lighting Problems See Chapter 5 for service procedures Condition Possible Cause One or more lights don't work, but 1. Defective bulb(s) others do 2. Blown fuse(s) 3. Dirty fuse clips or light sockets 4. Poor ground circuit Lights burn out quickly 1.
Page 331 TROUBLESHOOTING Condition Possible Cause OIL PRESSURE GAUGE Gauge does not register or is 1. On mechanical gauge, Bourdon tube may be bent or kinked. inaccurate 2. Low oil pressure. Remove sending unit. Idle the engine briefly. If no oil flows from sending unit hole, problem is in engine. 3.
Page 332 TROUBLESHOOTING Troubleshooting Clutch Problems (cont.) Condition Possible Cause Incomplete clutch release 1. Incorrect pedal or linkage adjustment or linkage or cable bind 2. Incorrect height adjustment on pressure plate release levers 3. Loose, broken facings on driven plate (disc) 4. Bent, dished, warped driven plate caused by overheating Grinding, whirring grating noise 1.
Page 333 TROUBLESHOOTING Condition Possible Cause Gears spinning when shifting into 1. Clutch not releasing fully. gear from neutral 2. In some cases an extremely light lubricant in transmission will cause gears to continue to spin for a short time after clutch is released.
Page 334 TROUBLESHOOTING TROUBLESHOOTING DRIVE but will not alter noise from the rear axle. Noises from the rear axle will normally cease AXLE PROBLEMS at speeds below 30 mph on coast, while tire noise will continue at lower tone as speed is First, determine when the noise is most no- decreased.
Page 335 TROUBLESHOOTING Troubleshooting Steering & Suspension Problems Condition Possible Cause Hard steering (wheel is hard to turn) 1. Improper tire pressure 2. Loose or glazed pump drive belt 3. Low or incorrect fluid 4. Loose, bent or poorly lubricated front end parts 5.
Page 336 TROUBLESHOOTING HOW TO READ TIRE WEAR The way your tires wear is a good indicator of other parts of the suspension. Abnormal wear patterns are often caused by the need for simple tire maintenance, or for front end alignment. Excessive wear at the center of the tread indicates that the air pressure in the tire is consistently too high.
Page 337 TROUBLESHOOTING Troubleshooting Disc Brake Problems Condition Possible Cause Not detrimental to function of disc brakes—no corrective ac- Noise—groan—brake noise emanat- tion required. (This noise may be eliminated by slightly increas- ing when slowly releasing brakes ing or decreasing brake pedal efforts.) (creep-groan) Rattle—brake noise or rattle emanat- 1.
Page 338 TROUBLESHOOTING Troubleshooting Disc Brake Problems (cont.) Possible Cause Condition Brake roughness or chatter (pedal 1. Excessive thickness variation of braking disc. pumping) 2. Excessive lateral runout of braking disc. 3. Rear brake drums out-of-round. 4. Excessive front bearing clearance. Excessive pedal effort 1.
Page 339 TROUBLESHOOTING Condition Possible Cause Squealing brakes 1. Glazed brake lining. 2. Saturated brake lining. 3. Weak or broken brake shoe retaining spring. 4. Broken or weak brake shoe return spring. 5. Incorrect brake lining. 6.- Distorted brake shoes. 7. Bent support plate. 8.
Page 340 TROUBLESHOOTING Troubleshooting Drum Brakes (cont.) Condition Possible Cause Brakes do not self adjust 1. Adjuster screw frozen in thread. 2. Adjuster screw corroded at thrust washer. 3. Adjuster lever does not engage star wheel. 4. Adjuster installed on wrong wheel. Brake light glows 1.
Page 341: Mechanic's Data
Mechanic's Data General Conversion Table Multiply By To Convert To Convert Multiply By L E N G T H A R E A 2.54 Inches Centimeters .3937 Square cms. .155 Square inches Square .645 25.4 Inches Millimeters .03937 yds. Square meters 1.196 .836 30.48...
Page 342: Index
Index Air cleaner, 14 Differential Air conditioning Fluid change, 23 Sight glass inspection, 20 Ratios, 13 Alternator, 71 Automatic Distributor transmission Removal and installation, 61 Adjustment, 220 Breaker points, 45 Filter change, 220 Drive axle, 227 Pan removal, 220 Driveline beam, 250 Axle Driveshaft, 226, 227 Fluid recommendations, 23...
Page 343 INDEX Front wheel bearing, 239 Manual transmission, 33, 211 Fuel injection, 166 Master cylinder, 262 Model Fuel filter, 27 identification, 8 Fuel pump, 147, 148 Fuel system, 147 Fuel tank, 180 Fuses and flashers, 201 Neutral safety switch, 224 Fusible links, 201 Oil and fuel recommendations, 32 Gearshift linkage adjustment Oil change, 32...
Page 344 INDEX Speedometer cable, 196 Tune-up Springs Procedures, 39 Front, 231 Specifications, 40 Rear, 245 Turn signal switch, 257 Stabilizer bar, 236, 250 Starter, 83 Steering *•* Gear, 260 U-joints, 226 Knuckle, 235 Linkage, 259 Rack and pinion, 259 ™ Wheel, 254 Valves Strut rod, 248 Adjustment, 49...
Page 345 Aspen/Volara 1976-80 6637 Corvette 1953-62 6576 Covers all U.S. and Canadian models Covers U.S. Canadian models Audi 1970-73 5902 Corvette 1963-84 6843 Covers all U.S. and Canadian models. Covers U.S. Canadian models Audi 4000/5000 1978-81 7028 Cutlass 1970-85 6933 Covers all U.S. and Canadian models Includ Covers U.S.
Page 346 7571 7346 Coven al U.S. and Canadan models of Coven al front wheel drive U.S. and Canad- DODGE omni, Miser. 024. Charger 2.2; an models of BUICK Century. CHEVROLET PLYMOUTH Horizon. Miser. TC3. TC3 Celebrity. OLDSMOBILE Cuflass Cien and Tourismo; Rampage...

Chevrolet Corvette 1963 Repair & Tune-Up Manual

General Information

And Maintenance

And Steering

Front

Suspension

Brakes

Mechanic's Data

Index

Quick Links

Summary of Contents for Chevrolet Corvette 1963

Page 3: Table Of Contents

Page 5: General Information

Page 6: Tools And Equipment

Page 44: Tune-Up And

Page 47: 0 Tune-Up Specifications

Page 62: Engine And Engine Rebuilding

Page 66: Engine Electrical

Page 94: System

Page 142: Emission Controls And Fuel System

Page 172: Fuel System Service

Page 209: Chassis Electrical

Page 224: Clutch And Transmission

Page 229: Manual Transmission

Page 238: Automatic Transmission

Page 260: Suspension

Page 273: Steering

Page 282: Brakes

Page 289: Drum Brakes

Page 291: Disc Brakes

Page 294: Parking Brake

Page 341: Mechanic's Data

Page 342: Index

This manual is also suitable for:

Chevrolet Corvette 1963 Repair & Tune-Up Manual

General Information

And Maintenance

And Steering

Front

Suspension

Brakes

Mechanic's Data

Index

Quick Links

Related Manuals for Chevrolet Corvette 1963

Summary of Contents for Chevrolet Corvette 1963

This manual is also suitable for:

Table of Contents