Chevrolet 1963 Corvette Repair & Tune-Up Manual Download | Manualshive

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TROUBLESHOOTING 295

Condition

Possible Cause

Engine cranks, but does not
start

1.  Improper starting procedure
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.  Throttle linkage not making full travel
9.  Stuck needle or float

10. Leaking float needle or seat
11. Improper float adjustment

Engine stalls

1. Improperly adjusted idle speed or mixture

Engine hot

2.  Improperly adjusted dashpot
3.  Defective or improperly adjusted solenoid
4.  Incorrect fuel level in fuel bowl
5.  Fuel pump pressure too high
6.  Leaking float needle seat
7.  Secondary throttle valve stuck open
8.  Air or fuel leaks
9.  Idle air bleeds plugged or missing

10. Idle passages plugged

Engine Cold

11.  Incorrectly adjusted choke
12.  Improperly adjusted fast idle speed
13.  Air leaks
14.  Plugged idle or idle air passages
15.  Stuck choke valve or binding linkage
16.  Stuck secondary throttle valves
17.  Engine flooding—high fuel level
18.  Leaking or misaligned float

Engine hesitates on
acceleration

1.  Clogged fuel filter
2.  Leaking fuel pump diaphragm
3.  Low fuel pump pressure
4.  Secondary throttle valves stuck, bent or misadjusted
5.  Sticking or binding air valve
6.  Defective accelerator pump
7.  Vacuum leaks
8.  Clogged air filter
9.  Incorrect choke adjustment (engine cold)

Engine feels sluggish or flat
on acceleration

1.  Improperly adjusted idle speed or mixture
2.  Clogged fuel filter
3.  Defective accelerator pump
4.  Dirty, plugged or incorrect main metering jets
5.  Bent or sticking main metering rods
6.  Sticking throttle valves
7.  Stuck heat riser
8.  Binding or stuck air valve
9.  Dirty, plugged or incorrect secondary jets

10.  Bent or sticking secondary metering rods.
11.  Throttle body or manifold heat passages plugged
12.  Improperly adjusted choke or choke vacuum break.

Carburetor floods

1.  Defective fuel pump. Pressure too high.
2.  Stuck choke valve
3.  Dirty, worn or damaged float or needle valve/seat
4.  Incorrect float/fuel level
5.  Leaking float bowl

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Summary of Contents for 1963 Corvette

Page 1: ...in Chief Kerry A Freeman S A E Managing Editors Peter M Conti Jr a W Calvin Settle Jr S A E Assistant Managing Editor Nick D Andrea Senior Editors Debra Gaffney a Ken Grabowski A S E S A E Michael L...

Page 2: ...blication the possibility exists that the manufacturer made later changes which could not be included here While striving for total accuracy Chilton Book Company cannot assume responsibility for any e...

Page 3: ...Electrical System 88 Engine Service and Specifications Brakes 262 Brake System 269 Drum Brakes 271 Disc Brakes 274 Parking Brake E4 134 Emission Control System and Service 147 Fuel System Service 279...

Page 4: ...__ Ignition Timing ______________________________________________________________ Vacuum Connected Disconnected ________________________________ __________ Valve Clearance in Intake __________________...

Page 5: ...peration should be ap proached logically and all procedures thor oughly understood before attempting any work All chapters contain adjustments mainte nance removal and installation procedures and repa...

Page 6: ...rt and start over again at a different angle until it can be in serted and turned several turns without much effort Keep in mind that many parts espe cially spark plugs use tapered threads so that gen...

Page 7: ...GHT You need only a basic assortment of hand tools and test instruments for most maintenance and repair Jobs FROM TOP BATTERY TERMINAL TOOL FEELER GAUGES OIL SPOUT FILTER WRENCH ALLEN WRENCHES BEAM TY...

Page 8: ...st light volt ohm meter 4 An induction meter This is used for de termining whether or not there is current in a wire These are handy for use if a wire is broken somewhere in a wiring harness As a fina...

Page 9: ...ourself Always use power vents windows fans or open the garage doors Don t work around moving parts while wearing a necktie or other loose clothing Short sleeves are much safer than long loose sleeves...

Page 10: ...raulic cam option In mid year a 396 cubic inch 425 horsepower engine was made available in the Corvette 396 Cor vettes were distinguished by the domed hood required for carburetor clearance Cars equip...

Page 11: ...peed transmission and Positraction rear axle were made standard equipment Horsepower was decreased in 1971 through an across the board compression reduction The 350 horsepower hydraulic cam version of...

Page 12: ...hevrolet marketing force is said to improve both throttle response and fuel economy as compared to the previous 4 bbl carburetion system Also a new 4 speed automatic over drive transmission with a loc...

Page 13: ...unit number when broken down as shown in the following charts Engine All Corvette engine identification numbers are stamped on a pad of the engine block which is located at the lower front edge of th...

Page 14: ...ansmission special high perfor RR mance A C Manual transmission and transistor ignition RT Fuel injection and transistor ignition RX Manual transmission transistor ignition A C RU Powerglide and A C S...

Page 15: ...L88 LO Aluminum heads LP Triple carburetion and high performance LQ Triple carburetion and special high perfor LR mance Engine Identification cont 427 cubic inch engine Triple carburetion special high...

Page 16: ...CLR CLS CKW CKX CLS CHC CHR CKC 1977 350 cubic inch engine 180 hp 210 hp CKZ CLA CLB CLC CHD CKD CLD CLF 1978 350 cubic inch engine 185 hp Calif 185 hp high altitude 1978 350 cubic inch engine 185 hp...

Page 17: ...with 4 speed 3 70 with 4 speed 1965 AK 3 36 AL 3 08 Positraction AM 3 36 Positraction AN 3 55 Positraction AO 3 70 Positraction AP 4 11 Positraction AQ 4 56 Positraction AR 3 08 AS AT 3 70 with 4 spee...

Page 18: ...3 36 Positraction Year Prefix AxleRatioandType 1972 75 AX LR AC AB AA AW AV 3 36 Positraction 4 11 Positraction 3 70 Positraction 3 55 Positraction 3 08 Positraction 2 73 Positraction 1976 77 OA LR O...

Page 19: ...ir cleaner cover 5 Heat stove 11 Knurl nuts 6 Heat stove tube Air cleaner assembly 1984 TBI shown Positive Crankcase Ventilation PCV The PCV valve is screwed into the carburetor or located in the vent...

Page 20: ...a maintenance free bat tery check the electrolyte level in the bat tery see Battery under Fluid Level Checks in this chapter Be sure that the vent holes in the caps and the vent tubes are not blocked...

Page 21: ...ingle ser pentine belt is used to drive all accessories formerly driven with V belts Belt tension is maintained by a spring loaded tensioner which has the ability to maintain belt tension over a broad...

Page 22: ...m the reinforcing cords that hold the belt together The belt will first slip then finally fail altogether Softening grease and oil Glazing is caused by a belt that is slipping A slipping belt can caus...

Page 23: ...This hose could burst at any time when hot or under pressure Swollen hose Cracked hoses can usually be seen but feel the hoses to be sure they have not hardened a prime cause of cracking This hose ha...

Page 24: ...her corrosion inhibitors along with acid neutral izers 1 Drain the existing antifreeze and cool ant Open the radiator and engine drain pet cocks or disconnect die bottom radiator hose at the radiator...

Page 25: ...conditioner is working properly you ll be able to see a continuous flow of clear refrigerant through the sight glass with perhaps an oc casional bubble at very high temperatures Air conditioning sigh...

Page 26: ...the tabs will click into place and lock the refill The fourth type of refill is termed the poly carbonate type The refill of this type is held into place by a locking lever which is pushed downward ou...

Page 27: ...con siderably and then add water while the en gine is running STANDARD REAR AXLE The rear axle oil level should be checked when the chassis is lubricated Remove the plug from the side of the housing...

Page 28: ...2 5 18 3 7 20 17 13 327 300 hp 4 3 3 0 18 3 7 20 19 15 327 HP 350 hp 5 3 0 3 7 20 19 15 1966 427 5 3 0 3 7 20 22 15 327 300 hp 4 3 3 0 19 3 7 20 19 15 327 HP 350 hp 5 3 0 3 7 20 19 15 427 5 3 0 19 3 7...

Page 29: ...3 0 1973 3 0 15 18 Is 454 8 18 24 15 4 0...

Page 30: ...d the gauge on the service station air hose is notoriously in accurate The tire pressures recommended for your car are usually found on the glove box door or in the owner s manual Ideally inflation pr...

Page 31: ...u can see the top of the Lincoln memorial it s time to replace the snow tires TIRE ROTATION Tire wear can be equalized by switching the position of the tires about every 6000 miles Including a convent...

Page 32: ...er from the wheel hub Select a socket of suitable size that will Removing adapter pin slip over the adapter pin Position the socket over the back of the pin and clamp the entire assembly in a vise so...

Page 33: ...sively lean fuel mixture Another negative view of a carburetor mounted filter is that if a fuel pressure problem is encountered a clogged carburetor mounted filter would not show a pressure loss durin...

Page 34: ...r Replace 12 000 mi 12 000 mi 12 000 mi 15 000 mi 15 000 mi Powerglide Transmission Fluid Check Replace 6 000 mi 24 000 mi 6 000 mi 24 000 mi Turbo Hydra Matic Fluid Filter Check fluid Change fluid Re...

Page 35: ...30 GENERAL INFORMATION AND MAINTENANCE 1 g 0 0 5 5 E 1 to CO c fl E 0 8 0 i E O C CO m E 8 O to Cu A c 1 0 s S P C3 E1 _g cr 1 E E B...

Page 36: ...GENERAL INFORMATION AND MAINTENANCE 31 CM E 8 in 1 o s 1 O 1 8 o o o o CD o o o CO E o o o co JD in fCD I ts...

Page 37: ...ting capabili ties cold and hot and general all weather performance As far as octane rating is con cerned refer to the General Engine Speci fications chart in Chapter 3 to find your en gine and its co...

Page 38: ...ot oil 1963 67 Corvettes use a cartridge type oil filter On these models loosen the center bolt on the filter housing and remove the housing along with the filter If possible replace the housing to bl...

Page 39: ...00 s NOTE If the transmission uses a filter having a fully exposed screen it may be cleaned and re used 14 Install the pan using a new gasket Tighten the bolts to 12 14 ft Ibs in a criss cross pattern...

Page 40: ...installation Improp erly adjusted wheel bearings can cause steer ing instability front end shimmy and wan der and increased tire wear For complete adjustment procedures see the Wheel Bearing section i...

Page 41: ...OR UNIVERSAL GEAR LUBRICANT WB WHEEL BEARING LUBRICANT CL CHASSIS LUBRICANT AT DEXRON H AUTOMATIC TRANSMISSION FLUID BF BRAKE FLUID SG STEERING GEAR LUBRICANT 1 Front suspension 2 Steering linkage 3...

Page 42: ...inal of the discharged bat tery 4 Attach one end of the remaining cable to the negative terminal of the booster battery and the other end to the alternator bracket Do not attach to the negative ter mi...

Page 43: ...but these items are seldom found in the home garage However small hydraulic screw or scissors jacks are satis factory for raising the vehicle Heavy wooden blocks or adjustable jack stands should be u...

Page 44: ...s distributed through die spark plug wires to die spark plugs The current passes along die center electrode and jumps die gap to die side electrode and in so doing ig nites die air fuel mixture in die...

Page 45: ...40 TUNE UP AND PERFORMANCE MAINTENANCE Is tO CD B ll s s Mil COCO 0 0 0 3 q d CO o 0 1 0 a I SP ZJ4 ill q d CDq d CMCO 1 sd 8 5 5 3 1 g in s...

Page 46: ...e n en CD r o O e n e n e n e n o O o o O o o o o o o o o o o 0 o 0 o 0 o 0 o o o d d d O o o o 0 o 0 o o o o o o o o o o o o O r d to O vj c 1co CM 7 CM 7 CO CM 1 7 CM CM CO A 7 CM CM CO CO A 7 I 7 7...

Page 47: ...1972 270 hp R44T 0 035 28 30 0 019 8 56 750 7Vz 9 190hp R44T 0 035 29 31 0 019 12 26 900 7 1 2 9 250 HP R44T 0 035 29 31 0 019 8 40 900 7V2 9 1973 270 hp R44T 0 035 29 31 0 019 10 56 900 7V2 9 195hp R...

Page 48: ...mission and A I R 700 W automatic transmission and A I R 750 W automatic transmission 600 W automatic transmission 4 BTDC W automatic transmission 8 BTDC W automatic transmission 550 W automatic trans...

Page 49: ...etrating lubricant Liquid Wrench WD 40 etc around the plug threads and turn the plug back in Wait a couple of minutes for the oil to work its way through the threads and then nurse the plug out about...

Page 50: ...will not interfere with the cap weight base or breaker advance plate Install the half of the R F I shield which covers the points first 9 Have an assistant tap the ignition key to turn the engine unti...

Page 51: ...eck with the manufacturer if there is any doubt CAUTION The TACH terminal should never be connected to ground get the car started but a finer adjustment should be made A dwell meter is needed to check...

Page 52: ...peed Ad just the idle speed to specifications if neces sary 2 If so equipped disconnect and plug the vacuum advance hose from the distributor 3 Connect a timing light according to the timing light man...

Page 53: ...ing and tools are clear of the fan and belts Start the engine and al low it to idle Aim die timing light at the marks and note where the vibration damper mark aligns with die timing tab NOTE The O mar...

Page 54: ...e tard Some engines will also have a magnetic timing probe hole for use with electronic tim ing equipment Consult the manufacturer s instructions for the use of this equipment Valve Lash ADJUSTMENT En...

Page 55: ...just the valves Then adjust the valves on the other side after the first cover has been reinstalled 4 Start the engine and allow it to idle 5 HYDRAULIC LIFTER ENGINES Slowly loosen the rocker arm nut...

Page 56: ...nd vacuum gauge to the engine then set the parking brake and shift the manual transmission into Neutral automatic into Drive 2 Turn the idle mixture screw s in until lightly seated then back out IVz t...

Page 57: ...Adjust the mixture screw in to lean roll position then back out rich turn 6 Repeat Steps 3 4 and 5 for the other idle mixture screw 7 Readjust the idle speed screw to obtain final specified rpm if nec...

Page 58: ...t and the limiter caps in stalled at the factory in order to meet emis sion control standards Do not remove these limiter caps unless all other possible causes of poor idle condition have been thor ou...

Page 59: ...the lower of the two figures given in the specifications Use the normal idle speed adjusting screw NOTE If no lower figure is given adjust the idle to 450 rpm 8 Reconnect all of the wires and hoses w...

Page 60: ...er hood tune up decal 2 Turn the A C system on 3 Disconnect the A C compressor lead at the compressor 4 Open the throttle slightly to allow the solenoid plunger to fully extend 5 Turn the solenoid scr...

Page 61: ...lace the manual transmission is Neutral and the auto matic transmission in Drive NOTE Make sure the parking brake is on and the drive wheels are safely blocked before the transmission is placed in Dri...

Page 62: ...good condition and the operating conditions are normal the power removed from the bat tery will be replaced by the generator or al ternator which will force electrons back through the battery reversi...

Page 63: ...ery and the battery is returned to its fully charged state The vehicle s generator is driven mechan ically through V belts by the engine crank shaft It consists of two coils of fine wire one stationar...

Page 64: ...to regulator wires have been disconnected the generator must be repolarized To do this with an ex ternally grounded light duty generator mo mentarily place a jumper wire between the battery terminal a...

Page 65: ...the ignition system to aid in starting the engine Voltage flow after the resistor or bypass wire is through the primary low voltage windings of the coil to the breaker point set When the points are cl...

Page 66: ...with HEI Timing lights which connect between the spark plug and the spark plug wire occasion ally not always give false readings Spark Plug Wires The plug wires used with H E I systems are of a differ...

Page 67: ...or from the engine Note the rotation of the rotor as the distributor is pulled upward caused by the angled distributor drive teeth CAUTION Do not rotate the engine while the distributor is removed 12...

Page 68: ...2 Special performance w transistor ign 1111060 0 800 NA 26 2500 0 4 1 6 5 8 2 1965 F I w transistor ign 1111064 0 800 NA 26 2500 0 4 1 6 5 8 2 300 hp 1111194 0 900 15 1500 30 5100 0 6 15 12 350 hp 11...

Page 69: ...0 hp 1111493 0 1150 10 1700 26 5000 0 8 19 17 370 hp 1111491 0 1000 NA 26 5000 0 8 15 15 5 390 hp 1111464 0 1085 17 21 00 22 3200 0 7 12 12 1970 460 hp 1112026 0 1000 NA 21 2300 0 7 12 12 270 hp 11120...

Page 70: ...o oo o oo o 8 oo o CO o sf o o o o o CM 00 8 o o CM O o CM O O O CO t S 8 o o to 8 Si Si a 8 co 8 CO 8 CO CM CM 8 O 8 CO o o O 8 o o O O 8 o 8 o 8 8 a i 00 8 CM 8 8 CO 8 8 8 co CO o s in 00 CM 8 S a Q...

Page 71: ...istributor housing mark re member the rotor will turn slightly during installation 3 Engage the distributor to the engine by moving it downward The rotor should turn to its proper alignment position I...

Page 72: ...n assistant Position the gauge dial so that it may be viewed while cranking the engine Turn the engine over until the gauge needle reading increases indicating compression Stop cranking the engine whe...

Page 73: ...iming as previously outlined 9 Install the ignition shielding H E S COMPONENT REPLACEMENT Distributor Cap 1 Disconnect the feed module and ta chometer wiring from the drivers side of the distributor c...

Page 74: ...usly outlined 2 Disconnect the hose from the vacuum 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...

Page 75: ...move the point set condenser and the condenser mounting bracket from the breaker pkte Remove the washer and seal from beneath the breaker plate Transistorized Systems 1 Remove the distributor cap and...

Page 76: ...or supplies a continuous amount of electrical energy at all engine speeds to keep the bat tery fully charged The Corvette as all other GM vehicles uses a Delcotron alternator Delcotron is a trade name...

Page 77: ...which can be used by the 12VDC system In the externally regulated Delcotron except the perforated case models the negative diodes 3 are pressed into die slip ring end frame the positive diodes 3 are...

Page 78: ...oss or ground any of the terminals on the AC generator 9 The polarity of the battery generator and regulator must be matched and con sidered before making any electrical connec tions within the system...

Page 79: ...d a 10 ohm 6 watt resistor into the charging circuit Do not connect the carbon pile to the battery posts at this time 2 Increase alternator speed and observe the voltmeter if the voltage is uncontroll...

Page 80: ...from turning Unbolt the retaining nut and slide it off the pulley Disconnect the battery ground strap to prevent diode dam age and remove the generator On the 6 2 in perforated case generator remove...

Page 81: ...ush into the holder and retain with a straightened paper clip during in stallation Remove the clip after the holder is installed Internally Reglated Type 1 Place alternator in a vise clamped by the mo...

Page 82: ...er read ing is high Connect a 12 volt battery and an ammeter in series with the slip rings to check for shorts The windings are shorted if the reading ex ceeds 1 5 amps An ohmmeter may be sub stituted...

Page 83: ...OHMMETER OHMMETER Stator testing perforated case models...

Page 84: ...s the diode is bad Diode Rectifier Bridge Refer to the accompanying illustration for component identification Use a self pow ered ohmmeter set on its lowest reading scale CAUTION DO NOT use a 110 volt...

Page 85: ...ess select a suitable removal spacer and press the diode from the frame Use the same method to install a replacement diode To replace heat sink diodes which in cludes all of the diodes of perforated c...

Page 86: ...ng washers must be re placed in the same position on reassembly 2 Remove brush holder and brushes The voltage regulator may also be removed at this time if desired 3 Brushes and brush springs must be...

Page 87: ...to the rectifier bridge which is attached within the rear end frame 5 Disconnect the three stator wire termi nals at the rectifier bridge connections 6 Remove the stator from the slip ring end frame I...

Page 88: ...internal temperature of the regulator Type One only 10 Again cycle the regulator by discon necting and reconnecting the regulator con nector 11 Recheck the voltmeter reading If it is between 13 5 and...

Page 89: ...test requires the use of a fast charger 1 Remove the voltage regulator from the alternator 2 Connect voltmeter and fast charger to battery as shown 3 Connect regulator and test light as shown observi...

Page 90: ...7A 1119515 0 015 0 030 2 3 3 7 0 067 0 014 13 5 14 4 1100794 2 2 2 6 27A 37A 1119515 0 015 0 030 2 3 3 7 0 067 0 014 13 5 14 4 1968 1100696 2 2 2 6 29A 42A 1119515 0 015 0 030 2 3 3 7 0 067 0 014 13 5...

Page 91: ...I g g I I I 1 d o d d i 1 5 2 1 j 2 i 1 i 5 i i i 1 i 5 1 1 i 5 Integrate d O S c c i 1 i i 1 1 i Integrate d Integrate d i in y o E o O 3 d d o E in en in c 1 in in H c en o j iE 3 Q 5 C C 4 4 r 4 4...

Page 92: ...e tainer Carefully tap the socket or pipe to wards the armature to drive the retainer off of the snap ring 5 Remove the snap ring from the arma ture shaft Be careful as the snap ring will Use a piece...

Page 93: ...brushes over the ar mature commutator Continue to push the field frame until the frame mates to the drive housing Work slowly and carefully to pre vent brush damage 13 Lubricate the bushing in the co...

Page 94: ...00 x 3 25 11 0 1 45 327 4bbl 375 6200 350 4000 4 00 x 3 25 11 0 1 45 327 Fuel Inj 365 6200 350 4600 4 00 x 3 25 11 0 1 45 1965 396 4bbl 425 6400 41 5 4000 4 094 x 3 76 11 0 1 45 327 4bbl 300 5000 360...

Page 95: ...GINE REBUILDING 89 9 in CM ci in in in in CO in CO X in CM CO X 8 CO X o o CO X o p X in CM CO X o p X CO X o o p CO X CO X o o o 8 8 8 O co 8 I o o o sf in 5 8 o CM in CD co 8 in in cj in in CM o 8 s...

Page 96: ...1 350 4bbl 1 90 4200 280 1600 4 000 x 3 480 8 2 1 45 1982 350 TBI 200 4200 285 2800 4 000 x 3 480 9 0 1 45 1984 350 TBI 205 4300 290 2800 4 000 x 3 480 9 0 1 45 Beginning 1972 horsepower and torque ar...

Page 97: ...50 hp 46 45 200 1 25 1 32 0 0010 0 0027 0 0015 0 0032 0 3410 0 3417 0 3410 0 3417 427 390 400 hp 46 45 NA NA 0 0010 0 0027 0 0015 0 0032 0 3715 0 3722 0 3713 0 3720 1967 427 435 hp 46 45 315 1 38 17 8...

Page 98: ...92 ENGINE AND ENGINE REBUILDING co ii 1 8 0 o o s 0 0 SB If 8 6 0 8 8 d I 8 g TSS as S o wSH S S Sf ro S 8 CO in O 1 I ill o co r...

Page 99: ...CO o o o o O So C v I d 002 0 006 0 CO 8 I o 1 8 o co o o d s o d 8 o o d o d d 8 o Q d o o d d d d d d d d d d d iaft and Conn Crankshaft Main Brg Oil Clearance 0 0008 0 0034 0 0008 0 0034 in 8 co o...

Page 100: ...0 021 350 2 4502 0 0013 0 0025 0 002 0 006 5 2 0990 2 1000 0 0013 0 0035 0 008 0 014 1973 74 454 2 7504 0 0007 0 0019 0 006 0 010 5 2 1990 2 2000 0 009 0 0025 0 015 0 021 1975 76 350 2 4502 0 0013 0...

Page 101: ...y in the housing Remove the solenoid 4 To reinstall the unit pkce the return spring on the plunger and pkce the solenoid body on the drive housing Push the solenoid inward and turn counterclockwise to...

Page 102: ...t the cylinder bore is a smaller 3 736 The 305 327 and 350 engines are collectively referred to as the small block Corvette engines The 327 engine was derived from the ear lier 265 and 283 Corvette en...

Page 103: ...en the radiator drain petcock and allow the coolant to drain from the radiator 7 Remove the radiator hoses and the heater hoses 8 Remove the radiator fan shroud radia tor engine cooling fan s and fan...

Page 104: ...aratus to the cylinder heads and secure with the cylinder head bolts CAUTION Be absolutely sure that the chain which you are using has a weight rating greater than the weight of the engine If possible...

Page 105: ...ts jobber or tool supply house specializing in automotive work Occasionally the use of special tools is called for See the information on Special Tools and the Safety Notice in the front of this book...

Page 106: ...reamer tap section Most manufacturers also supply blister packed thread repair inserts separately in addition to a master kit contain ing a variety of taps and inserts plus installa tion tools Before...

Page 107: ...Vi 13 20 39 5 4 41 5 7 52 8 55 6 75 10 4 85 11 7 101 7 115 2 85 11 75 115 2 9 16 12 18 51 7 0 55 7 6 69 2 74 5 110 15 2 120 16 6 149 1 162 7 120 16 6 162 7 11 18 83 11 5 95 13 1 112 5 128 8 150 20 7...

Page 108: ...es of cranks and record the high est of these readings Repeat this procedure for each of the engine s cylinders Compare the highest reading of each cylinder to the compression pressure specifications...

Page 109: ...e drain plugs located on the en gine block above the top of the oil pan 3 Remove the intake manifold as de scribed Remove the alternator lower mount ing bolt and lay the unit aside 4 Remove the exhaus...

Page 110: ...er arms out of the way so that the pushrods can be removed Identify the push rods so that they can be reinstalled in then original locations 6 Remove the cylinder head bolts and cylinder heads 7 Insta...

Page 111: ...arm 6 Valve spring retainer 7 Valve spring 8 Exhaust valve 9 Intake valve 10 Gasket 11 Exhaust manifold 12 Spark plug shield 13 Bolt 14 Washer 15 Head gasket 16 Spark plug 17 Cylinder head 18 Pushrod...

Page 112: ...r damaged valves 4 Clean all carbon from combustion chambers and valve ports using 2 wire brush 5 Thoroughly clean the valve guides us ing a suitable wire bore brush 6 Clean all carbon and sludge from...

Page 113: ...nt from the intake manifold flange 15 Insert a valve in the proper port 16 Assemble the valve spring and related parts as follows a Set the valve spring shim valve spring damper assembly oil shedder a...

Page 114: ...reputation for precision work Whether you have a small or big block en gine valve guides are most accurately re paired using the bronze wall rebuilding method In this operation threads are cut into t...

Page 115: ...Valve lapping can also be done by fastening a suction cup to a piece of drill rod in a hand eggbeater type drill Pro ceed as above using the drill as a lapping tool Due to the higher speeds involved w...

Page 116: ...type valve seal placement Note the optional seal types are shown as dotted lines INSTALLATION 1 If a rubber umbrella type seal is used big block only install the seal over the valve stem and seat it...

Page 117: ...ct them carefully If any parts are damaged or worn the entire lifter assembly should be replaced If the lifter body wall is scuffed or worn inspect the cylinder block lifter bore If the bottom of the...

Page 118: ...gh performance small block engines use screw in studs and pushrod guide plates NOTE If engine is equipped with the A I R exhaust emission control system the interfering components of the system must b...

Page 119: ...fold instead of the cylinder head 12 Mark and disconnect any remaining vacuum lines which will interfere with the removal of the intake manifold and carbu retor assembly 13 Remove the distributor as p...

Page 120: ...Before starting the engine make sure that the throttle return springs are con nected properly and the linkage does not bind in any way f If disturbed during manifold re moval adjust the drive belt s t...

Page 121: ...engine block 3 Apply a W bead of RTV sealer to the oil pan to engine block front junctions where the excess gasket was previously removed 4 Coat the new timing cover to oil pan seal and lightly coat...

Page 122: ...ing the seal into place Timing Chain REMOVAL AND INSTALLATION 1 Set the engine to top dead center with the number one cylinder on its compression stroke both valves closed 2 Remove the timing cover as...

Page 123: ...ters in order so that they can be returned to their original posi tions Remove the grille timing chain and camshaft sprocket Loosen the engine side mount through bolts and jack up the front of the eng...

Page 124: ...ons by 0 001 in Two compression rings and an oil ring as sembly are used on Corvette pistons The compression rings are marked on their top side and should always be assembled to the piston with this m...

Page 125: ...Wear ridge must be removed before piston removal...

Page 126: ...is Fabricate rod bolt guides out of rubber hose to pre vent damage to crankshaft journals when remov ing or Installing pistons Stamped number matchmarks on connecting rod and cap Scribe a matchmark o...

Page 127: ...on rings without damaging them any other method screwdriver blades pliers etc usually results in the rings being bent scratched or distorted or the piston itself being damaged When the rings are re mo...

Page 128: ...n some cases clean up honing can be done with the cylinder block in the car but most exces sive honing and all cylinder boring must be done with the block stripped and removed from the car CHECKING RI...

Page 129: ...in position the ends extend slightly beyond the rod and cap surfaces so that when the rod bolts are torqued the shells will be clamped tightly in place to insure positive seating and to prevent turn...

Page 130: ...ithin the specified limits when checked for clearance with Plas tigage Each undersize shell has its size stamped on it 7 When the proper size shell is found clean off the Plastigage oil the bearing th...

Page 131: ...ally makes or breaks any engine especially a high performance one such as the Corvette The most critical maintenance operation is the replacement of the crankshaft main bear ings These bearings are of...

Page 132: ...ps also mil have the paint on each side of the undersized journal Generally the lower half of the bearing shell except No 1 bearing shows greater wear and fatigue If the lower half only shows the ef f...

Page 133: ...check all clearances after installing new bearings 8 Replace the rest of the bearings in the same manner After all bearings have been checked rotate the crankshaft to make sure there is no excessive d...

Page 134: ...bolts finger tight To align the thrust bearing pry the crankshaft the extent of its axial travel several times holding the last movement toward the front of the engine Add thrust washers if required f...

Page 135: ...il pan and oil pump 2 Remove the rear main bearing cap and pry the seal out from the bottom with a small screwdriver 3 Remove the upper seal with a small hammer and a brass pin punch Tap on one Before...

Page 136: ...RHAUL 1 Remove the pump cover attaching screws and the pump cover 2 Mark gear teeth so they may be reas sembled with the same teeth indexing Re move the idler gear and the drive gear and shaft from th...

Page 137: ...main bearing cap and block until the shaft mates into the distributor drive gear 3 Install the pump onto the rear main bearing cap and install the attaching bolts Torque the bolts to specifications 4...

Page 138: ...nd check for leaks 1969 74 1 Drain the radiator 2 Raise the hood and insert a bolt in the hole of the hood support Remove the hood 3 Remove the radiator inlet and outlet hoses and if applicable the tr...

Page 139: ...and sup port it with jack stands 5 Disconnect the fan shroud from the ra diator support bracket 6 If so equipped disconnect the auto matic transmission cooler lines from the ra diator 7 Remove the ra...

Page 140: ...pipe at intake and power steering reservoir bracket 17 Remove power steering reservoir bracket including top alternator bolt 18 Remove lower AIR bracket on water pump 19 Remove lower radiator and heat...

Page 141: ...les 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 fasteners remove thev fan and...

Page 142: ...idle will tend to be rough due to the excessively rich mixture Maintenance is covered in Chapter 1 Air Injection Reactor AIR Two different systems of air injection have been used on the Corvette The...

Page 143: ...ad of using a diverter valve this 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 com...

Page 144: ...air cleaner The intake vacuum then pulls hot air generated by the exhaust manifold through the hot air duct and into the air cleaner This heated air supply helps to more effectively vaporize the fuel...

Page 145: ...M will either energize or de energize the solenoid When the solenoid is energized vacuum is not available to draw fuel vapors from the canister when de ener gized vacuum draws the canister vapors into...

Page 146: ...ns The switch deenergizes the solenoid in high gear the plunger extends and uncovers the vacuum port and the distributor receives full vacuum The temperature switch overrides the system when engine te...

Page 147: ...he CEC solenoid is controlled by a temperature switch a transmission switch and a 20 second time delay relay This system also contain a re versing relay which energizes the solenoid when the transmiss...

Page 148: ...o prevent the engine from running on Two throttle settings are necessary one for curb idle and one for emis sion control on coast Both settings are de scribed in the Tune Up chapter 1972 74 A vacuum a...

Page 149: ...op eration of the distributor vacuum advance unit When the engine temperature is below 93 F or above 232 F the temperature switch contacts are closed and the vacuum solenoid is energized This moves th...

Page 150: ...ed is closed and the EGR valve responds to an unmodified vacuum sig nal At wide open throttle the EGR flow is reduced in proportion to the amount of vac uum signal available 1979 and later models have...

Page 151: ...system consists of a vacuum controlled heat valve assembly EFE valve and a thermostatic vacuum switch TVS installed in the coolant thermostat housing of the engine The TVS controls the action of the...

Page 152: ...of the pre vious steps If gaskets are used at the pipe or valve connections replace the gaskets 6 Check for proper operation of the EFE valve Catalytic Converter All 1975 and later models are equipped...

Page 153: ...ensor flag on the in strument panel indicates when the oxygen sensor must be replaced NOTE To reset the Emission flag on the speedometer face remove the instrument cluster lens Insert a long pointed i...

Page 154: ...m are greatly ex tended compared to the C 4 system through the use of additional sensors and increased control capacities of the ECM and PROM units In addition to the functions of the C 4 sys tem the...

Page 155: ...inder block in front of the starter The purpose of the sensor is to tell the ECM when the engine begins to ping allowing the ECM to signal the distributor module to retard the spark timing just enough...

Page 156: ...to route the hot fuel and fuel vapor from the pump back to the fuel tank which considerably reduces the chance of vapor lock For all intents and purposes the fuel pump is not rebuildable Some 60s Corv...

Page 157: ...e fuel tank as part of the fuel gauge sending unit The pump can be replaced independently of the sending unit TIGHTEN TO 5 N m 45 IN IBS REMOVAL AND INSTALLATION 1 Disconnect the battery cables at the...

Page 158: ...float hinge pin for wear and the floats for distortion or dents Repkce the float ifjfiikhas leaked into it 3 necK he throttle and choke shaft bores for out of round Damage or wear to the throttle arm...

Page 159: ...n 1963 1965 Corvettes Functionally it is two dual carburetors mounted in a single housing and is comprised of four basic components choke housing top cover main body and throttle flange The metering r...

Page 160: ...gauge The measurement between the top of the choke valve and the air horn divider should be 0 096 in Adjustment is made by bending the intermediate choke rod FLOAT ADJUSTMENT To make the float adjustm...

Page 161: ...14 Vacuum piston 15 Vacuum piston spring 16 Pump plunger assembly 17 Pump plunger return spring 18 Primary float...

Page 162: ...adjusting screw until the throttle valves are fully seated then loosen the screw in the metering arm Depress the metering rod arm upward until it just touches the hanger Se cure the arm with the set s...

Page 163: ...retor Re move the secondary main jets but do not mix them as their orifices are not the same size Check the low speed jets to see that they are angled slightly on installation The antiper colator plug...

Page 164: ...float measures in INTERMEDIATE CHOKE ROD ADJUSTMENT The intermediate choke rod adjustment be gins with the removal of the choke coil hous ing assembly gasket and baffle plate Posi tion a 0 026 in wire...

Page 165: ...rom the vacuum opening in the mounting boss Remove the choke piston levers pump clus ter and gasket and pump discharge needle Remove the venturi cluster The venturi as semblies are dissimilar and cann...

Page 166: ...bi metallic strip next to the valve Measure the distance between the top of the choke valve wall and the top of the pump stem Bend to adjust FLOAT LEVEL ADJUSTMENT Remove the top cover and gasket and...

Page 167: ...CHILTON S Tune up Spark Plug Diagnosis Emission Controls Fuel System Cooling System Tires and Wheels CONOMY UP TIPS General Maintenance...

Page 168: ...r of spark plugs sur conduct heaf away from the flring end It must conduct the heat away jri an even pattern to avoid becoming spiirce of pre ignition yet it must also operate hot ejiough to burn off...

Page 169: ...ur vehicle s operating and performance characteristics If your vehicle suddenly de velops performance or fuel economy problems it could be due to one or more of the following 5 v i Ai f ii 8 Check the...

Page 170: ...etween ihe towers of affepted cylinders i 5 RECOMMpNiDATldNrAfternhe prbblerrys por rected tfies plugs can be 1 stalled it not worn severely Oil Deposits v APPEARANCE Trie firing end of the plug is co...

Page 171: ...os Courtesy Champion Sp rk Plug Co High Speed Glazing APPEARANCE Glazing appears asHshiny coat ing on the plug either yellow or tan In color CAUSE During hard fast acceleration plug temperatures rise...

Page 172: ...e fuel filter at least as often as recommended Extremely clogged filters should be discarded and replaced with a new one 20 Set the idle speed and carburetor mixture to specifications 21 Check the aut...

Page 173: ...ot on the insides indicates an overly rich mixture 27 Check the fuel pump pressure The fuel pump may be supplying more fuel than the en gine needs 28 Use the proper grade of gasoline for your engine D...

Page 174: ...Be sure the battery is fully charged for fast starts A slow starting engine wastes fuel 48 Be sure battery terminals are clean and tight 49 Check the battery electrolyte level and add distilled water...

Page 175: ...ment BEND CHOKE ROD AT THIS POINT TO ADJUST SEE INSET LOOSEN THREE RETAINING SCREWS AND REMOVE THE THERMOSTATIC COVER AND COIL ASSEMBLY FROM CHOKE HOUSING Quadrajet choke coil lever adjustment PLACE 0...

Page 176: ...ve spring re WITH LOCK SCREW LOOSENED AND WITH AIR VALVE CLOSED TURN ADJUSTING SCREW HALF TURN AFTER SPRING CONTACTS PIN TIGHTEN IOCK 5CBEW_ SPRING Quadrajet air valve spring adjustment FIGURE 1 SEAT...

Page 177: ...he air horn 5 Remove the air horn gasket from the float bowl Use care to withdraw the gasket from beneath the primary metering rod hanger Remove tie accelerator pump plunger from the pump well 6 Remov...

Page 178: ...e rod into the throttle linkage and align the lever pivot hole with the pivot pin Push die pin through by carefully prying it widi a screwdriver between the pin and die choke plate wall C E C VALVE MA...

Page 179: ...in the specified initial idle speed then make equal adjustments to the mixture screws until the required carbon monoxide level is reached in the exhaust gas Adjust the idle speed screw until the final...

Page 180: ...ast idle lever against the top step of the fast idle cam Bend the fast idle lever so that the specified opening of the throttle plate on the idle transfer slot of the carburetor is achieved FLOAT LEVE...

Page 181: ...throttle lever and separate the housing from the carburetor body 2 Remove the throttle body attaching screws and separate the throttle body from the main body Remove die fuel inlet baffle hinge screws...

Page 182: ...open the throttle and push down the pump lever Clearance between the pump lever arm and the spring adjusting nut should be 0 015 in minimum Turn the screw or nut to adjust this clear ance SECONDARY TH...

Page 183: ...there are minor differences from model to model The following is a generalized disas sembly and assembly procedure for all Cor vette four barrel Holley carburetors 1 Remove the primary and secondary f...

Page 184: ...vers a constandy regulated air fuel flow regardless of the en gine requirements and eliminates carbure tion difliculties caused by cornering or brak ing While the fuel injection system is more complex...

Page 185: ...speed Fuel pressures span a range of near zero to 200 psi according to engine speed Fuel not used by the engine reenters the fuel meter through a fuel control system The 1965 fuel meter contains a ve...

Page 186: ...rgized when the igni tion switch is held in the start position and the accelerator pedal is depressed less than Vs of its travel Depressing the accelerator pedal further trips a micro switch on die di...

Page 187: ...old engine operation Release the cold enrichment valve warm the engine and adjust the fast idle screw to ob tain 2200 rpm Make the cold enrichment ad justment by setting the cold enrichment cover to 3...

Page 188: ...er stop Do not prolong this operation or spark plug fouling will result Increase the engine rpm until a 0 5 in sig nal is reached on die water manometer and check and record die mercury manometer read...

Page 189: ...ifold outer mounting hole to allow the unit to be placed upright on a workbench without damaging the nozzles 6 Reverse the above procedure to install DISASSEMBLY AND ASSEMBLY 1 The first step in disas...

Page 190: ...m the fuel meter scribe reassembly marks on the pump housing 11 Remove the cover attaching screws and the cover Hand pressure is sufficient to pull the drive shaft from the pump drive gear and housing...

Page 191: ...Spill plunger assemblies are basically the same for all fuel injection units After re moving the assembly from the fuel meter lu bricate with fuel and check the valve action Clean or replace the assem...

Page 192: ...the top cover Float level should be 29 32 in while float drop should be 227 32 in Bend to adjust Twin Throttle Body Injection TBI System Marketed as Cross Fire Injection The TBI system introduced as s...

Page 193: ...TBI unit noting the connection points Dur ing installation refer to the underhood emis sion control information decal for vacuum line routing information 5 Disconnect the transmission detent ca ble fr...

Page 194: ...lectrical connection 2 IAC motor electrical connection 3 Fuel inlet line 4 Fuel balance line Electrical and fuel line connections at the front TBI unit 1 Fuel injector 2 IAC motor 3 Throttle position...

Page 195: ...as sembled DO NOT mix parts between either unit 1 Remove the fuel meter cover assembly five screws Remove the gaskets after the cover has been removed The fuel meter cover assembly is serviced only as...

Page 196: ...screw 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 instruction...

Page 197: ...he TPS 1982 84 THROTTLE BODY INJECTION Minimum die and Throttle Valve Synchronizing The throttle position of each throttle body must be balanced so that the throttle plates are synchronized and open s...

Page 198: ...er is not blocked before the throttle synchronizing screw is re moved the screw may be damaged and reinstallation will be done only with great difficulty Block throttle lever movement as shown d Remov...

Page 199: ...ove the spare tire compartment if applicable spare tire and spare tire carrier 5 Loosen the U clamps and separate the exhaust systems at the transmission cross member Disconnect the muffler support br...

Page 200: ...same features should be used Failure to use the correct cap can result in a serious malfunction of the system Allow the fuel level to fall be low 4 tank for this procedure The fuel tank consists of a...

Page 201: ...attempt any re pair on tank or filler neck where heat or flame is required 1 Disconnect the negative battery cable if not already done 2 Remove in line fuel filter and inspect for dirt rust or contam...

Page 202: ...old Enrichment Setting Index 3 notches lean 3 notches lean Index Maximum vacuum to apply Cranking signal valve in Hg 1 1 Vacuum to apply Main signal diaphragm in H2O 1 2 Va Vfe 1 2 Part No 701 7375 R...

Page 203: ...casting or choke plate A I R Air Injector Reactor System Prim 170 Sec 300 Hold the choke valve closed and push downward on the coil rod to the end of travel The top of the rod should be even with the...

Page 204: ...186 EMISSION CONTROLS AND FUEL SYSTEM evf CM e T CM CM CM CM CM CM CM S o r 8 8 8 8 8 8 8 8 8 8 8 8 too 8 8 8 8 IS OT 8 t 1 111 u o tc e CM CM I 1 s CO...

Page 205: ...EMISSION CONTROLS AND FUEL SYSTEM 187 8 CO 8 8 8 8 inCM CO 8 CM I I I IS N ino 1...

Page 206: ...ed rpm 185 17058202 15 32 a 179 2NL 314 277 185 17058502 15 32 a 187 2NL 314 277 220 17058211 15 32 a 203 2NL 314 277 1978 220 17058210 1S 32 a 203 2NL 314 277 195 17059203 1 2 1 4 157 2NL 243 195 170...

Page 207: ...ever Bend the rod to adjust California HI Hold the choke valve open Pull downward on the coil rod to the end of travel The bottom of the rod end which slides into the hole in the choke lever should S...

Page 208: ...oling tube 3 Remove the three sill plate molding screws and pry it out to gain access to the right splash shield retaining bolts 4 Remove the splash shield retaining bolts and remove the splash shield...

Page 209: ...s senger side carpet 7 Remove the two control cables from the instrument panel 8 Disconnect the wire leads from the lower switch and the resistor 9 Carefully remove the heater assembly from under the...

Page 210: ...rom the selector and remove it from the car 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 s...

Page 211: ...bracket attaching screws 12 Cut the heater hose at the heater core inlet and outlet connection The heater hoses should be replaced when installing the core 13 Remove the heater core Be careful of any...

Page 212: ...tal horseshoe brace remove the nuts from the studs on the lower edge of the console cluster 6 Remove the remaining console attach ing screws and disconnect the radio electrical connectors antenna wire...

Page 213: ...e the steering column escutch eon screws and the nuts from the column support U bolt 5 Loosen the lower column clamp at the firewall 6 Loosen the lower spring stop clamp and slide the stop and spring...

Page 214: ...he screws attaching the lens to the bezel and remove the lens 4 Remove the cluster attaching screws and pull the cluster slightly forward 5 Disconnect the speedometer cable and lamp connectors as nece...

Page 215: ...e air inlet leaf screen 3 Turn the ignition ON and activate the wiper switch Allow the motor to rotate the crank arm to a position between 4 and 5 o clock as viewed from the passenger compartment Turn...

Page 216: ...ct the ground cable from the battery 2 Remove the cylinder by placing it in the lock position and inserting a stiff wire in a small hole to depress the plunger Turn the cylinder counter clockwise unti...

Page 217: ...NOTE This type of reel locks up when the car decelerates rapidly as during a crash The lap belts use the same ratchet type re tractors that the 1972 73 models use The switches for the interlock system...

Page 218: ...he right headlight clockwise and the left headlight counterclockwise to release it from the aim ing pins 5 When installing the sealed beam unit make sure the number which is moulded into the lens is a...

Page 219: ...Flashers Fuses are located in the junction box below the instrument panel to the left of the steer ing column The turn signal flasher and haz ard warning flasher also plug into the fuse 1 Horn relay...

Page 220: ...ctedCircuit Type of Protection 1963 66 Headlamp circuit Headlamp motors and power windows Instrument clock and radio lamps Taillights Radio Heater Stop license courtesy and dome lamps Parking brake al...

Page 221: ...circuit breaker 10 amp fuse 25 amp fuse 20 amp fuse 25 amp fuse 20 amp fuse 5 amp fuse 10 amp fuse 25 amp fuse 25 amp fuse 20 amp fuse 30 amp fuse in line 14 gauge fusible link 16 gauge fusible link...

Page 222: ...turn signals Clock lighter courtesy anti theft alarm glove box dome spare tire lamp horn Electronic control module anti theft alarm Gauges telltale lamps seat belt buzzer lamp power win dow relay crui...

Page 223: ...window defogger switch center information cluster 10 amp fuse canister purge seat belt chime auto trans converter clutch brake TCC EGR control air switch air control dome lamp timer E cell Gauges Tur...

Page 224: ...ard A push rod is connected to the slave cylinder and rides in the pocket of the clutch fork As the slave cyl inder piston moves rearward the push rod forces the clutch fork and release bearing to dis...

Page 225: ...ALLATION 1 Remove the transmission from the car as outlined in this chapter 2 Disconnect the clutch fork push rod and spring On 1984 models remove the slave cylinder attaching bolts 3 Remove the bell...

Page 226: ...17 Install the transmission as previously outlined 18 Connect the fork push rod and spring 19 Adjust the free pedal play and check the clutch release position Lubricate all link age pivot points NOTE...

Page 227: ...1974 Corvette 1 lVz in 1975 81 NOTE No manual transmission was avail able in 1982 1 Disconnect the return spring between the floor and the cross shaft 2 Push the clutch lever and shaft assem bly until...

Page 228: ...ct hydraulic line at master cyl inder 8 Connect push rod at clutch pedal Lu bricate pivot point 9 Install hush panel 10 Fill master cylinder with new hy draulic fluid conforming to Dot 3 or Dot 4 spec...

Page 229: ...lave cylinder at clutch housing RETAINING SEAL CLIP Exploded view of slave cylinder 5 Remove the push rod and slave cylin der from the vehicle Overhaul if necessary as described later 5 Install the hy...

Page 230: ...e Speed and 1963 Borg Warner T 10 Four Speed 1 Jack the car high enough to provide working clearance 2 Disconnect the speedometer cable from the transmission Support with jack stands 3 Disconnect the...

Page 231: ...r shaft O ring 28 Thrust washer 28a Thrust bearing 28b Thrust bearing washer 29 Reverse idler gear 30 Reverse idler shaft pin 31 Reverse idler shaft 32 Countershaft 33 Countergear and roller thrust wa...

Page 232: ...e sliding gear 10 Second speed gear 11 Thrust washer 12 Case extension 13 Mainshaft rear bearing 15 Mainshaft 18 Front pilot bearing rollers 19 Thrust washer 20 Thrust washer 21 Rear pilot bearing rol...

Page 233: ...e clutch Lower the front end of the transmission and remove it from the car 16 Perform the above steps in reverse or der to install the transmission 1984 4 Speed Overdrive 1 Disconnect the negative ba...

Page 234: ...ft rod to the shift lever adjust the clevis as done with the other shift rod and secure it to the selector lever 6 Tighten the locknuts on both shift rod clevis fittings and check the shift pattern fo...

Page 235: ...ft rod to the lever Hold the lever against the gauge block and adjust the threaded swivel on the shift rod until the clevis pin freely enters the clevis hold and hole in selector lever Secure the lock...

Page 236: ...rop erly align the levers It may be necessary to move the shift lever s to install the locating gauge completely 6 Loosen the locknuts of the 3 4 shift rod swivel front of transmission side cover and...

Page 237: ...ET ASM 4 ALIGN AND FIRMLY SEAT PIN INTO T SLOT OF KNOB AND SLOT OF LEVER AND BRACKET ASM 6 ALIGN AND ASSEMBLE BUTTON INTO GROOVE OF KNOB THEN FIRMLY SEAT BUTTON IN PLACE AS SHOWN Shifter knob removal...

Page 238: ...r was introduced to improve fuel economy All 1981 82 models have this feature In 1982 the TH700R 4 four speed automatic transmission is the only transmission available in the Corvette The TH700R 4 is...

Page 239: ...lts to 12 14 ft Ibs in a criss cross pattern Recheck the bolt torque after all of die bolts have been tightened once 15 Add either Dexron or Dexron II trans mission Suid through the filler tube See th...

Page 240: ...cable to the lever retaining pin 1978 81 Turbo Hydra Matic 350 1 Loosen the screw from the swivel so the rod moves within the swivel 2 Put the transmission control lever in drive D and loosen the nub...

Page 241: ...he lever fails to open fully repeat the adjustment LEVER Powerglide transmission throttle linkage THROTTLE VALVE T V CABLE ADJUSTMENT 1976 80 Turbo Hydra Malic 350 1 Remove the air cleaner to gain acc...

Page 242: ...trim plate to get at the switch Proceed as described in the first paragraph above then place the contact support drive slot over the drive tang Tighten the switch mounting screws then remove the pin R...

Page 243: ...ear ance 5 Loosen the adjusting screw V turn and hold with a wrench 6 Using an in Ibs torque wrench adjust the band to 70 in Ib and back off exactly four turns for a band in use over 6 000 miles and t...

Page 244: ...dels from the carrier support bracket Loosen but do not remove the rear thru bolt and swivel the bracket down and away 5 Mark the driveshaft so that it may be reinstalled in its original position Remo...

Page 245: ...tside end of the driveshaft into the spindle drive flange Install the locks and bolts Torque the bolts to 70 90 ft Ibs and bend the locktabs up 1963 79 axle driveshaft installation 9 Realign the cambe...

Page 246: ...tion 3 55 ratio 396 AZ Positraction 3 70 ratio 396 FA Positraction 4 1 1 ratio 396 FB Positraction 4 56 ratio 396 FC 1967 3 36 ratio AK Positraction 3 08 ratio AL Positraction 3 36 ratio AM Type 1967...

Page 247: ...rear If one corner bounces longer than the other it should be inspected for damage and possibly be replaced REMOVAL AND INSTALLATION 1 To remove raise the vehicle and hold the upper stem of the shock...

Page 248: ...aining components in a re verse order Transverse Leaf Spring REMOVAL AND INSTALLATION 1 Raise the vehicle and support it safely 2 Remove the wheel and tire assem blies 3 Remove both spring protectors...

Page 249: ...t coil springs A stabilizer bar connects the lower control arms to the front frame rails Tapered roller bearing are used in the front wheels On 1984 models the front suspension uses aluminum for all i...

Page 250: ...tion 3 36 ratio Positraction 3 55 ratio Positraction 3 70 ratio 1979 1980 OM OH OJ 1972 75 Positraction 3 07 ratio DANA Posifracfion 3 36 ratfo Positraction 3 36 ratio Posifraction 4 11 ratio Posnraet...

Page 251: ...fy gas shocks on 1984 and later models Shock absorber attachments Ball Joints Erratic front suspension behavior or align ment difficulties suggest possible excessive ball joint wear To check raise the...

Page 252: ...lation OEM rivets must be drilled and replaced with bolts supplied with re placement part 1984 shown NEVER LOOSEN NUT TO ALIGN KOTTER PIN j Lower ball joint installation typical joint Now position the...

Page 253: ...t the lower ball joint from the steering knuckle and lift the knuckle and wheel hub out of the way NOTE Removal of the spring is not nec essary so long as the lower control arm is adequately supported...

Page 254: ...ss into place 8 Repeat the procedure for the other end then install the collar and lockwasher but loosely thread in the bolts 9 Reverse the removal procedure to in stall the spring and lower control a...

Page 255: ...r mounting 6 Raise the car and tighten all connec tions with a wrench Wheel Hub REMOVAL AND INSTALLATION 1 To remove the wheel hub snap off the wheel covers and loosen the lug nuts then raise and secu...

Page 256: ...unting bracket 1984 and later MUST BE INSTALLED IN DIRECTION SHOWN Stabilizer shaft linkage 1984 and later SHOCK ABSORBER MOUNTING BRACKET 40 NTTI 30 FT LBS LOWER CONTROL ARM 48 N m 35 FT LBS MUST BE...

Page 257: ...y 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...

Page 258: ...lts Camber and caster adjustment may be made at the same time A Vs2 in shim will effect a Ve0 change in camber Adjust to spec ifications TOE IN ADJUSTMENT Toe in is the measurement in inches of the in...

Page 259: ...NDARD SCREEN INDICATES TOE PER WHEEL IN INCHES INDICATES TOE PER WHEEL IN DEGREES TENTHS 5C 0 5C INDICATES TOE PER WHEEL IN DEGREES TWELFTHS I 1 o 91 Jf J n 121212 1212 INDICATES TOE PER WHEEL IN DEGR...

Page 260: ...ccentric cam on the inner end The uni versal jointed axle driveshafts double as the upper locating links Shock absorbers attach Wheel Alignment Specifications All measurements stated in degrees unless...

Page 261: ...er thus all brake torque and braking tractive forces are transmitted through the arms The lateral links transmit side forces to the fixed differential and through the rub ber bushings in the cover bea...

Page 262: ...Rr Whi Spindle 11 SHIELD Rr Whi Inr Brg 12 BOLT Rr Spring 13 SEAL Rr Inr Brg 14 BOLT 24x2 15 BEARING Rr WhL Inr 16 SHIM Rr Whi 17 ARM Torque Control 18 BOLT 16x1 19 WASHER 5 ie x19 32 20 BOLT 5 i6 18x...

Page 263: ...1W 75 HOUSING ASM Brake Caliper 76 DISC Rr WhI Brake 77 SPINDLE Rr WhI 78 SEAL Rr WhI Otr Brg 79 BEARING ASM Rr WhI Otr 80 SPACER Brg link bolt and then remove the link bolt nut cushions and retainers...

Page 264: ...Shaft U JoInt 5 428 35 16 REPAIR KIT U Joint 36 17 PIN RrWhl Spindle 37 18 NUT Hex Slot 20 38 19 WASHER 7 32 39 20 FLANGE Rr Whl Spindle 40 DEFLECTOR RrWhl Spindle SHIELD Rr Whl Inr Bearing SEAL Rr In...

Page 265: ...24 72 WASHER 73 HOUSING ASM Brake Caliper 74 NUT Whl 7 ie 20 75 WHEEL ASM 76 DISC Rr Whl Brake 77 SPINDLE Rr Whl 78 SEAL Rr Whl Otr Brg 79 BEARING ASM Rr Whl Otr 80 SPACER Bearing 81 SOCKET Adj Screw...

Page 266: ...ck absorber eye on the strut rod shaft Install the outer grommet washer lockwasher and nut 7 Torque the upper nut to 40 60 ft Ibs and the lower nut to 50 60 ft Ibs DISPOSAL OF PRESSURIZED SHOCK ABSORB...

Page 267: ...he shock absorber lower eye on the strut rod shaft Torque the nut to 50 60ft Ibs 14 Lower the car and then tighten the camber cam nut to 55 77 ft Ibs Tighten the strut rod shaft nut to 80 ft Ibs and i...

Page 268: ...cotter pin and retaining nut from tie rod end at knuckle Discard the cot ter pin 3 Loosen jam nut on tie rod end 4 Using tool J 24319 01 or equivalent press tie rod end out of the knuckle 5 Remove tie...

Page 269: ...r shaft 6 Remove the driveline beam by prying transmission to the driver side of vehicle Re move support beam from the vehicle NOTE Do not use excessive force when prying transmission housing Torque S...

Page 270: ...hing and seal and result in fluid leakage Inadequate fluid level can damage the transmission Apply sealant to the mating surfaces of the transmission extension housing differential carrier and beam Ad...

Page 271: ...outside gap until solidarity is reached between the pivot bush ing and the frame walls Insert the bolt torque the nut to 50 ft Ibs and install a cot ter pin On 1984 and later models rear toe in is adj...

Page 272: ...lease the brake and remove the brake drum or caliper and disc as described in Chapter 9 6 Remove the spindle flange then rein stall the nut until it is flush with the end of the spindle Use a puller t...

Page 273: ...3 Position the replacement seal on the spindle before installing the bearing assem bly 4 Pack the replacement bearing with a high melting point grease and place it on the spindle large end facing the...

Page 274: ...g Wheel REMOVAL AND INSTALLATION 1963 67 Standard Wheel 1 Disconnect the battery ground cable 2 Pry off the horn cap with a small screw driver 3 Remove the steering shaft nut and washer 4 Install a wh...

Page 275: ...ining screws and install the horn contact to the spacer and the steering wheel with three screws 10 Install the horn cap 1968 76 Telescoping Wheel 1 Disconnect the battery ground cable 2 Remove the ho...

Page 276: ...ock wise to remove the hub assembly 5 When installing make sure the turn signal is in the neutral position then install the hub on the steering shaft and secure it with the nut Torque the nut to 30 ft...

Page 277: ...d the switch from the mast jacket Pull each wire separately through the mast jacket slot to prevent damaging the harness 5 Transfer the wiring harness to the re placement switch and install the compon...

Page 278: ...preload spring NOTE 1969 Corvette assembly order is horn control carrier lockplate and upper bearing preload spring 7 Pull the switch connector out of the mast jacket and tape die upper part to facili...

Page 279: ...ends are self adjusting and with die exception of periodic lubrication require no servicing ADJUSTMENTS 1963 82 Relay Arm Ball Joint 1 Remove the cotter pin and adjust the end plug slot clockwise unti...

Page 280: ...air must be bled from the system With wheels turned all the way to the left add power steering fluid to level indicated on reservoir 4 Start engine and running at fast idle recheck fluid level Add fl...

Page 281: ...bracket retaining nuts and remove the drive belt 4 Withdraw the bracket to pump bolts and remove the pump from the car On large block Corvettes the alternator drive belt must be removed first 5 Place...

Page 282: ...brake parts do not create dust by grinding or sanding brake linings or by cleaning wheel brake parts with a dry brush or with com pressed air A water dampened cloth should be used Many wheel brake par...

Page 283: ...gasoline or kerosene are removed Gasoline will cause premature deterioration of the cyl inder s rubber parts 4 Carefully inspect the washed metal parts and the cylinder bore A corroded cyl inder must...

Page 284: ...die inner seal face die piston compen sating holes 13 Slip die primary seal and its protector over die secondary seals The flat side of diis seal should face die piston s compensating hole flange 14 R...

Page 285: ...brake fluid 2 Secure the master cylinder in a suit able holding fixture like a piece of steel plate with holes drilled to accommodate the mounting bolts and piston bore clamped in a vise Clamping the...

Page 286: ...d secondary seal 4 19 Install the secondary spring and spring locator in the secondary piston 20 Lubricate the master cylinder bore with clean brake fluid and install the secondary piston spring assem...

Page 287: ...warning lamp on the instrument panel if either the front or rear hydraulic system fails The brake warning light will come on only when the brakes are applied It will not remain on when the brakes are...

Page 288: ...r hose to a rear brake bleed screw and immerse the other end of the hose in a container partially filled with clean brake fluid Make sure the master cyl inder reservoirs are filled 3 Turn the ignition...

Page 289: ...to start it off the studs 4 If extreme resistance to removal is en countered it will be necessary to retract the adjusting screw Knock out the access hole in the brake drum and turn the adjuster to re...

Page 290: ...tandard brakes Do not substitute these lin ings in standard drums unless they have been honed to a 20 micro inch finish and equipped with the special heat resistant springs The oversize metallic linin...

Page 291: ...correctly adjusted remove the idler return spring and loosen the locknut on the convex side of the rear brake cable equalizer Next tighten the adjustment nut against the concave side of the equalizer...

Page 292: ...orce the caliper pistons into their bores and insert the replacement pads 6 Replace the retaining pins and secure them with new 3 az in x in plated cotter pins On 1984 and later models install new sel...

Page 293: ...h those in the brake service kit 8 Inspect the piston bores for damage or corrosion Polish corroded bores with crocus cloth and if this is not enough replace the caliper Replace all self locking bolts...

Page 294: ...he parking brake is a conventional drum brake located in the rear wheel disc Adjust ments are similar to those for a regular drum brake 1 Block the front wheels Jack the rear wheels off the ground and...

Page 295: ...rom the axle hub 4 Insert a screwdriver into the adjusting hole and turn the screw several times to ex pand the shoes 5 Push the brake shoes forward until the front shoe hold down spring can be seen t...

Page 296: ...tep 6 depress the spring and twist the pin 90 16 Repeat the above step on the rear shoe Another pair of needle nosed pliers will have to be utilized to hold the pin in position as head of this pin is...

Page 297: ...ormat will locate problems within a given system but because many automotive sys tems are interrelated the solution to your particular problem may be found in a number of systems on the car or truck U...

Page 298: ...engine very slowly Starter turns engine normally Starter turns engine very quickly Engine fires intermittently Engine fires consistently Engine Runs Poorly Hard starting Rough idle Stalling Engine die...

Page 299: ...and Indications Proceed to If case is cracked replace battery If the case is intact remove corrosion with a solution of baking soda and water CAUTION do not get the solution into the battery and fill...

Page 300: ...charge the battery NOTE no obvious reason exists for the low state of charge i e battery age prolonged storage proceed to 1 4 Specific Gravity 80 F ADD THIS NUMBER TO THE HYDROMETER READING TO OBTAIN...

Page 301: ...or voltmeter between the starter post of the solenoid or relay and ground Turn the ignition switch to the start position and jiggle the key If the lamp doesn t light or the meter needle doesn t move w...

Page 302: ...s Replace the resistor or resistance wire if the resistance is zero NOTE Some ignition sys tems have no ballast resistor 3 3 CALIBRATED RESISTANCE LEAD Two types of resistors 3 3 On point type ignitio...

Page 303: ...point gap 3 5 On the point type ignition systems check the condenser for short connect an ohmeter across the condenser body and the pigtail lead If any reading other than infinite is noted replace th...

Page 304: ...is good but intermittent test the primary electrical system starting at 3 3 3 3 If the spark is weak or non existent replace the coil high tension lead clean and tighten all connections and retest If...

Page 305: ...nd check resistance with an ohmme ter Replace any cracked or brittle wires If any of the wires are defective replace the entire set Replace any wires with excessive resis tance over 8000 fi per foot f...

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: ...of repairs including holes dents and scratches and fiberglass and offer the advantage of buying the materials you ll need for the job There is little waste or chance of materials going bad from not be...

Page 308: ...ick spots Getting the proper amount of hard ener in the filler is the trickiest part of preparing the filler Use the same amount of hardener in cold or warm weather For contour filler thick coats a be...

Page 309: ...is typical of one that can be pulled out or hammered out from behind Remove the headlight cover headlight assembly and turn signal housing The area should look like this when you re finished grinding...

Page 310: ...ck to shape the metal back to its original contours Get the metal back as close to its original shape as possible Don t depend on body filler to fill dents Let the body filler dry until the sur face c...

Page 311: ...HOIK here are many ways to repair rust holes The fiberglass cloth kit shown here is one of the most cost ef ficient for the owner because it provides a strong repair that resists cracking and moistur...

Page 312: ...a piece about 2 3 larger than the area you have sanded Place the film over the repair and mark the sanded area on the film Avoid any unnecessary wrinkling of the film Place the repair material over t...

Page 313: ...ing Sand the area until the repaired area tapers into the original finish CLEANING Wash the area to be painted thoroughly with water and a clean rag Rinse it thoroughly and wipe the surface dry until...

Page 314: ...fog coat fol lowed by heavier color coats DISTANCE The Ideal spraying dis tance is 8 12 from the gun or can to the surface Shorter distances will pro duce ripples while greater distances will result...

Page 315: ...sign shows that the cylinders fed by the right hand barrel are fouled from overly rich mixture while the cylinders fed by the left hand barrel are normal O O o o If the four rear plugs are overheated...

Page 316: ...Determine that the air filter is functioning efficiently Hold paper elements up to a strong light and attempt to see light through the filter Clean permanent air filters in solvent or manufacturer s...

Page 317: ...ut runs roughly the engine is probably not run enough If the engine won t start 5 9 5 6 Check the needle and seat Tap the carburetor in the area of the needle and seat If flooding stops a gasoline add...

Page 318: ...of fuel into a glass jar Allow to stand and inspect for droplets or a layer of water High humidity extreme tem perature changes For droplets use one or two cans of commercial gas line anti freeze For...

Page 319: ...uretor ad justment or minor in take leak Proceed to 7 2 Incorrect valve timing Gauge reading low 10 15 in Hg but steady Carburetor requires adjustment Gauge reading drifting needle INDICATION ignition...

Page 320: ...amic ignition tim ing Disconnect and plug the vac uum hose s to the distributor if specified start the engine and ob serve the timing marks at the specified engine speed If the timing is not correct a...

Page 321: ...per with zero corresponding to an index mark on the engine Rotate the crankshaft in its direc tion of rotation and observe the opening of the No 1 cylinder in take valve The opening should correspond...

Page 322: ...crankcase If no coolant is present but pressure loss continues 11 4 If coolant is evident in crankcase remove cyl inder head s and check gasket s If gaskets are intact block and cylinder head s should...

Page 323: ...pump Remove the thermostat elbow and the thermostat disconnect the coil high tension lead to prevent start ing and crank the engine mo mentarily If coolant flows replace the thermostat and retest per...

Page 324: ...and retest per 12 1 12 1 If the pump drive and pump appear to be operating normally the engine should be See disassembled to determine where blockage Chapter exists 3 12 6 Purge the engine of ethylen...

Page 325: ...or binding linkage 16 Stuck secondary throttle valves 17 Engine flooding high fuel level 18 Leaking or misaligned float Engine hesitates on acceleration 1 Clogged fuel filter 2 Leaking fuel pump diap...

Page 326: ...ke linkage 4 Stuck heat riser 5 Incorrect idle mixture 6 Defective accelerator pump 7 Air leaks 8 Plugged loose or incorrect main metering jets 9 Improperly adjusted float or fuel level 10 Bent misali...

Page 327: ...s called a short circuit Com mon causes are broken insulation exposing the metal wire to a metal part of the car or truck or a shorted switch Some electrical components which require a large amount of...

Page 328: ...Follow the wire that runs back to the battery The problem is an open circuit between the The test light will show the presence of current when touched to a hot wire and grounded at the other end batt...

Page 329: ...Defective bulb Corrosion in socket Clean contacts Poor ground at socket Turn signal flashes too fast or too slowly Check any bulb on the side flashing too fast A heavy duty bulb is probably installed...

Page 330: ...rs are blinded 1 Lights adjusted too high 2 Rear springs or shocks sagging 3 Rear tires soft Troubleshooting Dash Gauge Problems Most problems can be traced to a defective sending unit or faulty wirin...

Page 331: ...e 3 Defective sending unit Disconnect the wire from the sending unit and ground it Replace the sending unit if the light comes on with the ignition ON 4 Problem in individual system 5 Defective sendin...

Page 332: ...ice procedures Condition Possible Cause Transmission jumps out of gear 1 Misalignment of transmission case or clutch housing 2 Worn pilot bearing in crankshaft 3 Bent transmission shaft 4 Worn high sp...

Page 333: ...prevent small problems from becoming large ones If the problem cannot be traced to loose bolts fluid level misadjusted linkage clogged filters or similar problems you should probably seek professional...

Page 334: ...etermine at what speed the noise is most pronounced then stop in a quiet place With the transmission in Neutral run the engine through speeds corresponding to road speeds where the noise was noticed N...

Page 335: ...ty shocks or springs 7 Loose or bent front end components 8 Play in Pitman arm 9 Steering gear mountings loose 10 Loose wheel bearings 11 Binding Pitman arm 12 Spool valve sticking or improperly adjus...

Page 336: ...ble to see them The most common causes of feathering are incorrect toe in setting or deteriorated bushings in the front suspension When an inner or outer rib wears faster than the rest of the tire the...

Page 337: ...or worn caliper piston seal 2 Scores or corrosion on surface of cylinder bore Grabbing or uneven brake action Brakes pull to one side 1 Causes listed under Brakes Pull 2 Power brake malfunction 3 Low...

Page 338: ...Inferior quality brake shoes or fluid 7 Worn master cylinder piston cups or seals Troubleshooting Drum Brakes Condition Possible Cause Pedal goes to floor 1 Fluid low in reservoir 2 Air in hydraulic...

Page 339: ...brake pedal 12 Defective proportioning valve 13 Insufficient brake shoe lubricant Hard pedal 1 Brake booster inoperative 2 Incorrect brake lining 3 Restricted brake line or hose 4 Frozen brake pedal l...

Page 340: ...n 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 Leak in the hydraulic system 2 Air in the system...

Page 341: ...ospheres Kilopascals 14 7 145 OTHER 1 104 746 1 60 425 Horsepower DIN Horsepower SAE Mph Mpg Horsepower SAE Kilowatts KW Km h Km 1 9861 1 34 625 2 35 Toobtain Tap Drill Sizes National ioarse or U S S...

Page 342: ...djustment 209 Master cylinder 210 Replacement 207 Slave cylinder 211 Condenser 45 Connecting rod and bearings 117 121 Control arm 236 249 Cooling system 17 34 Crankcase ventilation PCV 15 Crankshaft 1...

Page 343: ...Vehicle 8 Engine 9 Transmission 12 211 220 Idle speed and mixture 50 Ignition switch 198 258 Ignition timing 47 Instrument cluster 195 Intake manifold 111 Radiator 130 Radio 193 Rear axle 34 Rear sus...

Page 344: ...259 j Rack and pinion 259 Wheel 254 Valves Strut rod 248 Adjustment 49 Service 107 Specifications 91 J1 Vehicle identification 8 Thermostat 132 A Tie Timing ignition 47 Water pump 132 Tires 23 Wheel...

Page 345: ...ina Tercel Starlet 1970 85 7036 Covers all U S and Canadian models Corona Cretilda Crown Mk ll Camry Van 1970 84 7044 Covers all U S and Canadian models Corvalr 1960 69 6691 Covers all U S and Canadia...

Page 346: ...81 76596065 5907 ______ J197444 Cows al U S and Canadan models Mta MtM Cortto Traoto Stadia 6aUrt19M4J Coven al U S and Canadan models IN 199141 Coven al U S and Canadan models Mtsltae Curt MMtar 1979...

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