Chevrolet 1977 light duty truck, Service Manual

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5. Disconnect ra d ia to r and heater hoses and
rem ove ra d ia to r and fan shroud.
6. Disconnect wires at:
• Starter Solenoid
• Delcotron
• T e m p e ra tu re switch
• Oil Pressure Switch
• Coil
7. Disconnect:
• Accelerator linkage at inlet manifold.
• Fuel line, from tank, at fuel pump.
• Hoses at fuel v a p o r storage canister (if
applicable).
• Vacuum line to power brake unit at manifold,
if so equipped.
8. Remove power steering p u m p and lay aside, if
so equipped.
9. Raise vehicle on hoist.
10. D ra in crankcase.
1 1. Disconnect exhaust pipe at manifold and. if so
e quipped, converter bracket at transmission rear mount.
12. Remove starter.
13. Remove flywheel splash shield or converter
housing cover as applicable.
14. On vehicles with autom atic transmissions,
rem ove converter to flywheel attaching bolt.
15. Remove m ount " th r o u g h " bolts.
16. Remove bell housing bolts.
17. Lower vehicle on hoist.
18. Raise transm ission using floor jack.
19. Attach engine lifting devices, raise engine.
20. Remove m otor m ount to engine brackets.
21. Remove engine assembly.
Installation
1. Position engine assembly in vheicle.
2. Attach m otor m ount to engine brackets and
lower engine in place.
3. Remove engine lifting device.
4. Remove transmission floor jack.
5. Raise vehicle on hoist.
6. Install m ount " t h r o u g h " bolts. Torque to
specification.
7. Install bell h o u sin g bolts. T o rq u e to
specifications.
8. On vehicles with autom atic transmissions, install
c o n v e rte r to flywheel a tta c h in g bolts. T o rq u e to
specification.
9. Install flywheel splash shield or converter
housing cover as applicable. Torque attaching bolts to
specifications.
10. Install starter.
11. C o n n e c t ex h a u st p ip e at m a n ifo ld and
converter bracket at transmission re a r mount.
12. Lower vehicle on hoist.
13. Reinstall power steering pum p, if so equipped.
14. Connect:
• Accelerator linkage at inlet manifold.
• Fuel line, from tank, at fuel pump.
• Hoses at fuel vapor storage canister.
• Vacuum line to power brake unit at m anifold,
if equipped.
15 Connect wires at:
• Starter Solenoid
•
Delcotron
• T em p eratu re Switch
• Oil Pressure Switch
• Coil
16. Install ra d ia to r and fan shroud and reconnect
rad iato r and heater hoses.
17. Fill cooling system.
18. Fill crankcase with oil. See ow n er’s m anual for
specifications.
19. Install air cleaner.
20. Install hood.
21. Connect battery cables.
N O TE: To avoid possible arcing o f battery,
connect positive battery cable first.
22. Start engine, check for leaks and check timing.
C R A N K S H A F T
Removal
1. Remove engine as previously outlined. Remove
clutch, if applicable, and flywheel and m ount engine on
stand.
2. Remove the oil dipstick and oil dipstick tube.
3. Remove the spark plugs.
4. Rem ove c r a n k s h a f t pulley an d torsional
dam per.
5. Remove oil p a n and oil pum p.
6. Remove crankcase front cover.
7. Check the connecting rod caps for cylinder
n u m b e r identification. If necessary, mark them.
8. Remove the connecting rod caps and push the
pistons to the top o f bores.
9. Remove m a in bearing caps and lift cran k sah ft
out of cylinder block.
10. Remove r e a r main bearing oil seal and main
bearings from cylinder block and m ain bearing caps.
Cleaning and Inspection
1. Wash cran k sh aft in solvent and dry with
compressed air.
2. Measure dim ensions o f main bearing journals
and crankpins with a m icrom eter for out-of-round, taper
or undersize. (See Specifications.)
3. Check cran k sh aft for run-out o f supporting at
the front and re a r m a in bearings jo u rn als in " V " blocks
and check at the fro n t and rear interm ediate journals
with a dial indicator. (See Specifications.)
4. Replace or recondition the crankshaft if out o f
specifications.
Gear Replacement
Remove cra n k sh a ft gear using Tool J-8105 and
install using Tool J-5590 (fig. 6A-71).
Installation
1. Install rear m ain bearing oil seal in cylinder