Chevrolet 40 Series 1972 User manual

Type
User manual

This manual is also suitable for

40-60 SERIES TRUCK
SUPPLEMENT
SERVICE MANUAL
1 9 7 2
CHASSIS SERVICE MANUAL
SECTION INDEX
SECTION
NAME
0
LUBRICATION
SUPPLEMENT
3
FRONT SUSPENSION
c o v e rin g
4
REAR SUSPENSION
SERIES 40-60
CHEVROLET TRUCKS
5
BRAKES
6A
GASOLINE ENGINES
FOREW ORD
6D
ENGINE MOUNTINGS
6K
ENGINE COOLING
SYSTEM
This manual is a supplement to the 1971 Series 40-60
Truck Service Manual. It includes procedures for main
tenance and adjustments, minor service operations, and
removal and installation for components of Chevrolet Series
40 through 60 Trucks. Procedures involving disassembly
and assembly of major components for these vehicles are
contained in the 1972 Chevrolet Passenger Car and Series
10-30 Truck Overhaul Manual or the 1972 Series 40-60
Truck Overhaul Manual Supplement.
This manual should be kept in a handy place for ready
6M
ENGINE FUEL SYSTEM
6T
AIR COMPRESSOR
AND GOVERNOR
6Y
ENGINE ELECTRICAL
reference. If properly used, it will enable the technician to
better serve the owners of Chevrolet built vehicles.
All information, illustrations and specifications con
tained in this literature are based on the latest product
information available at the time of publication approval.
The right is reserved to make changes at any time without
notice.
7
TRANSMISSIONS
AND CLUTCHES
9
STEERING SYSTEM
10
WHEELS & TIRES
11
SHEET METAL
CHEVROLET MOTOR DIVISION
General Motors Corporation
DETROIT, MICHIGAN
12
CHASSIS ELECTRICAL
AND INSTRUMENTS
ALPHABETICAL INDEX
© 1972 General Motors Corporation
Printed in U.S.A.
Sec. 0
Page 1
SECTION 0
J luh nica tio -n
All information contained in Service Manual ST-331-71 under
LUBRICATION (SEC. 0, Page 1 through 12) will apply to vehicles cov
ered by this publication. The following information will also apply:
TRANSMISSION CAPACITY CHART
Manual Transmission
U.S.
IMP.
SM465
8
6%
NP435
7
5%
NP540 9
U
NP542 10
8%
CL282 12
10
CL285
12
10
CL325
14
11%
CL327
14
11%
SP5652
13
10%
SP5752 15
m
SP5756 15
12%
Automatic Transmission
MT40
18*
15
MT41
18* 15
AT475 10*
8l4
AT540
22*
18%
* Filter Change Only.
Auxiliary Transmission
SP6041
8 6%
SP7041 11
9%
ENGINE OIL
(SYMBOL E” ON CHARTS)
ENGINE OIL
It is recommended that new engines should
have the first oil change at 3,000 m iles, thereafter
at 3 months or 4,000 mile intervals. This drain
interval may be increased or decreased depending
upon the severity of service and experience with
specific oils or the recommendations and used oil
* analysis as furnished by the supplier. Such a pro
cedure would be helpful in establishing the most
practical oil change period for the particular
service. Refer to Service Manual ST-331-71.
Contaminated engine oil can cause a malfunc
tion of valve lifters or the PCV valve. A sticking
valve lifter can cause leakage of unburned gases
through the valve. A plugged or sticking PCV valve
will affect carburetor mixture and will prevent
proper crankcase ventilation.
ENGINE OIL FILTER
Oil filter should be replaced at the first oil
change and each oil change thereafter to filter
sm all particles which could affect valve lifters or
PCV valve action.
RECOMMENDATIONS
The oil industry markets various types of en
gine oil under certain service designations and
specification numbers.
The selection of a reliable supplier, with close
attention to his oil and filter element change rec
ommendations can provide satisfactory lubrication
and longer life for engine.
Gasoline and D iesel Engines
Use only high quality oils which are intended
for Service Designations "MS” and "DM (SE/CC
New A.P.I. Designation) see NOTE.
The following additive limitations, which re
quire emphasis, have been placed on the recom
mended MIL-L-2104B (now superseded by MIL-L-
46152) and Supplement 1 oils:
1. Sufficient zinc dithiophosphate to produce
a minimum of 0.07 and a maximum of 0.10 per
cent by weight.
2. Sulfated ash (ASTM D-874) of 1.00 per cent
maximum by weight, except lubricants that contain
only barium detergent-dispersants where 1.50 per
cent by weight is allowed.
NOTE: Supplement 1 engine oils (based upon
now obsoleted MIL-L-2104A) have been superseded
by MIL-L-2104B engine oils. However, Supplement
1 engine oils MS-DM (SE/CC New A.P.I. D esig
nation), with a history of satisfactory performance
are available, and may be used.
The use of proper engine oils and oil change
intervals are your best assurance of continued re
liability and performance from your engine.
IMPORTANT: Non-detergent and other lower
quality engine oils are specifically not recom
mended.
POWER STEERING FLUID
(SYMBOL "S32)
GM Approved Hydraulic Power Steering Fluid
is available through wholesale warehouses and truck
Sec. 0
Page 2
LUBRICATION
centers. Check fluid level every 6,000 m iles or 4
months, whichever occurs first. Fill pump reser
voir to proper level. If GM Power Steering Fluid is
not available, DEXRON® Automatic Transmission
Fluid (Symbol SI9) may be used.
CAUTION: DO NOT use GM Power
Steering Fluid in automatic transmissions.
AUTOMATIC TRANSMISSION FLUID
(SYMBOL SI 9 ON CHARTS)
(Refer to Service Manual ST-331-71)
Oil level in the automatic transmission must
be checked at each engine oil change. Under normal
driving conditions the transm ission fluid should be
changed every 24,000 m iles. Under unusual condi
tions such as off-road (construction) or constant
stop and go driving (pickup and delivery) fluid
should be changed at 12,000-mile intervals. It is
important that transmission fluid level be main
tained at the full mark and NOT OVERFILLED.
ENGINE AND ACCESSORY
LUBRICATION
The following additional information applies to
Lubrication Chart (fig. 4) on page 7 of ST-331-71
Service Manual.
CARBURETOR AIR CLEANER
ELEMENT
Air cleaner should be inspected and serviced
at intervals specified in Emission Control System
booklet, or more often under severe dust conditions,
also, whenever dirt is visible in element or oil.
POWER STEERING RESERVOIR
Fluid level should be checked every 6,000
m iles and filled with S32 Power Steering Fluid, or
if not available with S19 Automatic Transmission
Fluid.
Sec. 3
Page 3
SECTION 3
S u d s K t & n d A X U l
SECTION 3A
f y n x w U A U < f * u n e + t t
All information and alignment instructions in Service Manual
ST-331-71 "FRONT END ALIGNMENT (SEC. 3A) are applicable
to models covered by this supplement.
SECTION 3B
A xle .
All front axle information in Service Manual ST-331-71 "FRONT
AXLE (SEC. 3B) is applicable to models covered by this supplement.
All front axle information for the F-120 axle is also applicable to the
F-110 axle. Illustrations and specifications have been updated.
1 Steering Knuckle
9 Axle Center
Spindle
10 Stop Bolt and Lock
2 Kingpin Bushing
Nut
(Upper)
11 Draw Key
3 Kingpin
12 Thrust Bearing
4 Cap Screw
13 Tie Rod End Assy.
5 Kingpin Bearing Cap
14 Kingpin Bearing Cap
(Upper)
(Lower)
6 Gasket
15 Gasket
7 Lube Fitting
16 Kingpin Bushing
8 Shim (Lower) t-8793
1 Steering Knuckle
Spindle
2 Steering Knuckle
Bushing
3 Kingpin Bushing
(Upper)
4 Kingpin
5 Dust Cap
6 Kingpin Nut
7 Cotter Pin
8 Gasket
9 Lube Fitting
10 Washers or Shims
11 Axle Center
12 Stop Bolt and Lock
Nut
13 Thrust Bearing
14 Tie Rod Assembly
15 Plug Retainer
16 Ejqpansion Plug
17 Kingpin Bushing
(Lower) t-8794
Figure 1Steering Knuckle (F070 Axle)
Figure 2 —Steering Knuckle (F090 Axle)
T r o n t axle
Sec. 3
Page 4
___________
T-8795
1 Steering Knuckle
Spindle
2 Steering Knuckle
Bushing
3 Kingpin Bushing
(Upper)
4 Kingpin
5 Cap Screw
6 Dust Cap
7 Kingpin Nut
8 Cotter Pin
9 Gasket
10 Lube Fitting
11 Spacers or Shims
12 Axle Center
13 Stop Bolt & Lock Nut
14 Thrust Bearing
15 Tie Rod End Assy.
16 Plug Retainer
17 Expansion Plug
18 Kingpin Bushing
(Lower)
Figure 3— Steering Knuckle (FI 10 and F I20 Axles)
AXLE SPECIFICATIONS
AXLE MODEL
F050-F055
F070
F090 F110FI 20
KING PIN
Length
.................
6.3594
7.8906
8.750
8.750
Diameter
At Top
...............
1.1090 1.1094
1.2492”— 1.2496 1.1855”— 1.1865” 1.1855 1.1865
At Bottom
...........
1.1090”— 1.1094
1.2492”— 1.2496
1.14330”— 1.14340
1.4330 1.4340”
KING PIN BUSHING
Length
.................
1.9063 1.9063”
Diameter
Outer
................
1.4330”— 1.4340 1.4330”— 1.4340
Inn er
.................
1.1870”— 1.1880 1.1870”— 1.1880”
STEERING KNUCKLE BUSHING*
Length
.................
Upper
................
1.3438 1.875
1.709”— 1.729 1.760”
Lower
................
1.3438
1.875
1.990”— 2.010
2.150
I.D. When Installed ....
1.1094 1.1124
1.2496 1.2526
*1.4365 1.4375
1.434 1.437
STEERING KNUCKLE TO AXLE
CENTER CLEARANCE
0.005
0.005
.004”— .012
.004”— .012
.114”— .116 White
.114”— .116 White
SPACING WASHERS AVAILABLE
.121”— .123 Yellow .121”— .123 Yellow
.128”— .130” Blue .128”— .130 Blue
SPACING SHIMS AVAILABLE..
0.005
0.005
0.005
_
0.010
TORQUE SPECIFICATIONS
King Pin Nut
...........
_
_
250 Ft. Lbs. then
250 Ft. Lbs. then
Advance to Next
Advance to Next
Cotter Pin Hole.
Cotter Pin Hole.
King Pin Bearing Cap, Cap
Screw
................
4 -5 Ft. Lbs. 5 -6 Ft. Lbs.
3 - 5 Ft. Lbs. 3 - 5 Ft. Lbs.
* Ream after Installation
SECTION 3C
f y n & n t S f J S U w a A .
All information on Front Springs contained in Service Manual
ST-331-71 FRONT SPRINGS" (SEC. 3C) is applicable to models
covered by this supplement. The following “ Torque Specifications
chart has been updated.
TORQUE SPECIFICATIONS
C-M-S
Models
(Ft.-Lbs.)
T
Models
(Ft.-Lbs.)
Spring U-Bolt (N u t).................................................
. . 105 - 130 190 - 210
Spring U-Bolt (N u t)................................................. . . *175 - 250
-
Spring Hanger to Frame Bolt (N ut)
..................
60-85
35 - 45
Spring Bumper to Frame Bolt (Nut)
...............
14-22 35 - 45
Spring Bumper to Frame Bolt (Nut)
...............
** 2 - 3
-
Spring Front Eye Bolt (N u t)
..............................
. . 190 - 210 150 - 200
Spring Rear Rebound Pin Retainer (Bolt) . . .
20 - 25
Spring Rear Rebound Bolt (N u t)
........................
75-95
-
Shock Absorber Bracket to Frame Bolt (Nut)
. . 40-50
65 - 95
Shock Absorber Upper and Lower Eye Bolt (Nut) 65 - 95
40 - 50
Shock Absorber Stud to Frame (N ut)................
130 - 190
-
* 9,000 and 11,000 lb. Axles Only.
** 366 and 427 V8 Gas Engines.
SECTION 3D
c J lu b i a n d Q e a s U n G A .
All information in Service Manual ST-331-71 FRONT HUBS AND
BEARINGS” (SEC. 3D) is applicable to models covered by this supple
ment. The following revision will also apply:
CLEANING, INSPECTION, AND REPAIR
REPAIR
Brake Drum Replacement
1. Demountable Type. The demountable type drum may be separ
ated from the hub and removed from the vehicle without disturbing the
hub. The drum is held to the hub by the wheel studs and nuts as shown
in figure 4.
Sec. 3
Page 6
FRONT HUBS AND BEARINGS
T-91 15
Side Ring
Lock Ring
Wheel
Wheel Stud Nut
Wheel Stud
Brake Drum
Hub
Cap Screw & Washer
Bearing Cone and
Roller Assy. (Outer)
Bearing Retainer
Adjusting Nut Washer
Adjusting Nut
Hub Cap
Cotter Pin
Backing Plate
Inner Oil Seal
Bearing Cone and
Roller Assy. (Inner)
Spindle
10
11
12
13
14
15
16
17
18
1
2
3
4
5
6
7
8
9
Figure 4 Front Hub and Bearing with Demountable Wheel and Drum
Sec. 4
Page 7
SECTION 4
( le a / i S u A s n e t t & io s t
All information contained in Service Manual ST-331-71 is ap
plicable to models covered in this supplement. The following informa
tion will also apply:
SECTION 4A
(lean. A xleA. a n d G ottis ioh
IMPORTANT
When parking vehicle equipped with a two- or three-speed axle, the
axle should be shifted into LOW range with engine running. Engage
clutch and transmission to be sure axle has completed shift into LOW
range. Apply parking brake, place transm ission in neutral and shut off
engine. When leaving the vehicle parked or unattended the previous in
structions must be followed:
VACUUM SHIFT SYSTEM
MAINTENANCE
AIR CLEANER
Air cleaner removes dirt particles from at
mosphere which passes into the control valve and
other units. Air cleaner should be removed and
cleaned at regular intervals.
SERVICING AIR CLEANERS
(Refer to Figure 1)
The air cleaner used on Conventional and S50
Models is the metal cup type which uses a hog's
hair type element. This cup is a friction fit on the
air intake pipe and can be removed by pulling
straight off. It can be cleaned by rinsing in a suit
able solvent and reused. Refer to LUBRICATION
(SEC. 0) in this supplement for service intervals.
If cleaner has become so laden with an accumula
tion of dirt, that satisfactory cleaning cannot be
done, replace with a new cleaner.
The air cleaner used on all Tilt-Cab Models
is a plastic encased, synthetic element type filter,
and cleaning is NOT recommended. When cleaner
becomes so laden with dirt, that tapping it against
som e solid surface (such as a work bench) will
not remove foreign matter, then a new cleaner
should be installed.
IMPORTANT: DO NOT OPERATE VEHICLE
WITH AIR CLEANER DISCONNECTED OR RE
MOVED. Figure 1—Air Cleaners
T-9142
HAIR TYPE ELEMENT
PLASTIC HOUSING
SYNTHETIC ELEMENT
)
Sec. 4
Page 8
SECTION 4B
(leal BpAitUfi and Suifiesutiott
HENDRICKSON TANDEM REAR SUSPENSION
Refer to Service Manual ST-331-71 "REAR SPRINGS AND SUS
PENSION (SEC. 4B), pages 4B-7 and 4B-8 for figures 9, 11 and 12.
EQUALIZING BEAM REMOVAL
AND REPAIR
The following procedures cover removal and
installation of either equalizing beam without re
moving any other units of the suspension system .
When removing an axle assembly, accomplish only
steps required to loosen axle at each end of beam.
EQUALIZING BEAM REMOVAL (Fig. 9)
1. Raise and support frame to remove weight
from beams.
2. At axle brackets, remove nuts (5), washers
(7), and bolt (1). Pry adapters (2) from bushings
and brackets.
3. With blocking under beam cross tube (fig.
1) to support weight of beams, remove saddle caps
attached with four nuts and flat washers.
4. Lower the cross tube and beams, then slide
beams from tube ends.
EQUALIZING BEAM INSPECTION
1. Inspect beam end bushings and beam center
bushing for evidence of damage or deterioration of
the rubber. If any damage is evident, replace bush
ings as directed under "Equalizing Beam Bushing
Replacement" later in this section.
2. Inspect cross tube and thrust washers and
replace if bent or worn.
EQUALIZING BEAM BUSHING
REPLACEMENT
Press old bushing out, using a suitable driver
or press to exert force on bushing outer sleeve.
Press new bushing into place, exerting force on
bushing outer sleeve until outer sleeve extends an
equal distance through beam at both sides.
EQUALIZING BEAM INSTALLATION
(Refer to Fig. 9)
1. Position beams, with cross tube and thrust
washers in place at spring saddles and axle brackets.
NOTE: At axle end of beam, install adapters
(2, fig. 9) at each side of bracket and into bushing.
IMPORTANT; The cut-off (flat) side of each
adapter must be located in a vertical position as
shown in figure 11.
2. Install bolt and washer through adapter and
axle bracket at each end of equalizing beam (fig. 11).
NOTE: Install bolt and washer from inner side
with nut located toward wheels (fig. 11). Tighten
nuts or bolts to torque listed in "Specifications" at
end of this section. Figure 12 shows section through
mounting.
3. Install spring saddle caps to attach beam
center bushing to spring saddle. Install saddle cap
stud nuts or cap screws and tighten to torque listed
in "Specifications" at end of this section.
1
Beam Center Bushing
7
Setscrew
2 Spring Saddle 8
Equalizing Beam
3 Spring Assembly
9
Cross Tube
4 Spring Saddle Top Pad
10
Spring Saddle Cap
5 Top Pad to Spring
11 Stud
Saddle Bolts
12
Thrust Washer
6
Lock Nut
13
Bushing
Figure 1— Section Through Spring Saddle and Beam
Sec. 5
Page 9
SECTION 5
lin & k e A ,
All information in this section in Service Manual ST-331-71 also
applies to vehicles covered by this supplement, except as specifically
stated in the following procedures:
SECTION 5A
< M - t^ d n < u c U c B ' l a h e i .
BRAKE SYSTEM MAINTENANCE
CHECKING FLUID LEVEL
A sticker (fig. 1) reading "CHECK BRAKE
FLUID LEVEL EVERY 30 DAYS OR 3000 MILES
is affixed to the cover of each brake master cyl
inder. Figure 2 illustrates a typical cover with the
sticker applied.
Fluid level should be maintained to within V2"
of top of master cylinder reservoir.
VACUUM GAUGE
Two vacuum gauges are used oft some ve
hicles. Two gauges are standard equipment on all
school buses (dual-split-brake system) and optional
on all other vehicles equipped with dual (split)
brake system s. These gauges are mounted on a
special bracket below the center of the dash panel.
One gauge is connected to one vacuum system
of the dual brake system and the other gauge is
connected to the other vacuum system . Vacuum
gauge readings may differ during operation of the
vehicle. However, if the readings differ by ten
inches of mercury or more for an extended period
of vehicle operation the vacuum system s should be
checked immediately to determine causes. If the
vacuum gauge is suspected of being faulty, check
gauge according to instructions in Service Manual
ST-331-71, page 5A-22. Otherwise, check vacuum
system components for leaks or malfunctions.
Figure 1Brake Fluid Sticker
Figure 2Master Cylinder Cover
)
Sec. 5
Page 10
SECTION 5B
A i / i B 'l a k e i
BREATHER AND FILTER
ASSEMBLIES
Figures 1 and 2 illustrate three different
breather and filter assem blies. Figure 1 (left view)
shows the original type breather. Replacement is
covered in Service Manual ST -331-71, page 5D-89.
To remove the intermediate type filter (fig. 1,
right view) or the latest type (fig. 2), remove two
screw s and lift cover and filter off housing. To
install, set filter in place on housing and attach
cover. Filters can be cleaned and reused but
breather cannot. If removed, breather must be
replaced with new parts.
AIR LINE TORQUE
Refer to page 5B-53 of Service Manual ST-
331-71 and change the following torque values:
3/8-inch from 30-50 to 50-75
-inch from 90-115 to 120-150
5/8-inch from 100-125 to 150-200
Also change the statement "retorque to higher
than minimum value" to read: "Retorque to higher
value."
Figure 2 Filter Installed
i
Sec. 6A
Page 11
SECTION 6A
Q a d - a lln e . C n c u n e A ,
The information pertinent to truck models covered by this Supple
ment is the same as given in Service Manual ST-331-71 (pages 6A-1
thru 6A-34) with the following exceptions and/or additions:
ENGINE MAINTENANCE
Inspection, adjustment or replacement of em is
sion control related components must be performed
on a time or mileage basis as indicated. Good
judgment is required in replacement of parts in
those cases where the accumulated mileage is
substantially lower during the specified time period.
SERVICING AIR CLEANER
Air cleaners should be inspected and serviced
every 12,000 miles or more often under severe
dust conditions; also, whenever dirt is visible in
element or oil. Refer to "AIR CLEANERS (SEC.
6M) of this supplement or ST-331-71 Service
Manual.
IMPORTANT: Vehicle operation under condi
tions such as heavy dust, continuous short trips,
stop and go driving, etc., is not considered normal
use and therefore more frequent maintenance will
be required. Such additional maintenance require
ments are included below where applicable.
Thermostatically Controlled Air Cleaner
The air cleaner should be inspected to make
certain that all hoses and ducts are intact and cor
rectly installed. Operational function should be
checked by inspecting position of valve in air intake.
With engine stopped, valve should be open. At
underhood temperature below 100°F., with engine
running, valve should be partially or fully closed.
As engine underhood temperature rises, the valve
should open.
CHECKING DRIVE BELTS
Fan belt tension on vehicles equipped with
V-belts should be adjusted to 120 - 130 pounds on
new belts using BT-33-73F Belt Tension Gauge.
Used drive V-belts should be adjusted to 80 - 90
pounds. Gauge should be placed at center of the
greatest span.
IMPORTANT: After a belt has been in oper
ation one hour or approximately 50 m iles, it is
considered used. Belt dressing can be used to ex
tend belt life. When V-belts are worn they should
be replaced, as excessive tightening will not pre
vent slippage and can cause damage to bearings.
SPARK PLUGS
Replace spark plugs at 12,000 mile intervals.
Use of leaded fuels results in lead deposits on
spark plugs and can cause misfiring at m ileages
less than 12,000 m iles. Where m isfiring occurs
prior to 12,000 m iles, spark plugs in good condition
can often be cleaned, tested and reinstalled in an
engine with acceptable results.
ENGINE COMPRESSION
Minimum compression recorded in any one
cylinder should not be less than 70% of highest
cylinder. For example, if the highest pressure in
any one cylinder is 150 lbs., the lowest allowable
pressure for any other cylinder would be 105 lbs.
(150 x 70% = 105).
This test should be performed to provide rea
sonable assurance that engine condition is suffic
iently efficient to prevent leakage of unburned
gases. If a problem exists, have corrections made.
DISTRIBUTOR POINTS, CAM LUBRICATOR
Distributor points should be inspected prior to
performance of tune-up adjustments. Burned or
pitted points must be replaced. Points in good con
dition may be reused after readjustment and the
installation of a new cam lubricator. New points
and cam lubricator should be installed at least
every 24,000 miles.
DISTRIBUTOR CAP
The interior and exterior of the distributor
cap should be carefully inspected and cleaned to
prevent misfiring and deterioration.
SPARK PLUG WIRES
Inspect spark plug wires for evidence of check
ing or cracking of exterior insulation and a tight
fit in the distributor cap and at the spark plugs.
Exterior of wires should be cleaned, any evidence
of corrosion on ends removed and wire replaced
if deteriorated.
TIMING, POINTS (DWELL), IDLE SPEED
These adjustments must be performed accur
ately, following the specifications shown on the
label under the hood. Adjustments must be made
with test equipment known to be accurate.
Sec. 6A
Page 12
GASOLINE ENGINES
Figure 1 Flywheel Housing and Adaptor Plate
(350 and 366 V8 Engine)
Proper functioning of the carburetor is par
ticularly essential to control of em issions. Correct
mixtures for em ission compliance and idle quality
have been preset. Plastic idle mixture limiters have
been installed on the idle mixture screws to pre
clude unauthorized adjustment. These idle limiters
are not to be removed unless made necessary by
some major carburetor repair or replacement which
affects the idle screw adjustment.
POSITIVE CRANKCASE VENTILATION VALVE
Replace the PCV valve at 24 months or 24,000
mile intervals (whichever occurs first). PCV valve
hose, when removed for valve replacement, should
be blown out with an air hose to make certain that
it is clean. The PCV valve should be replaced at
12 months or 12,000 miles (whichever occurs first)
when the vehicle is used under the following con-
ditionsi
Driving in dusty conditions.
Extensive idling.
Short trip operation at freezing temper
atures (engine not thoroughly warmed up).
POSITIVE CRANKCASE VENTILATION
SYSTEM - HOSES AND CONNECTIONS
The PCV system should be checked for satis
factory operation at 12-month or 12,000-mile in
tervals using a tester such as the AC Tester CT-3.
POSITIVE CRANKCASE VENTILATION
BREATHER OR FLAME ARRESTER
The breather or flame arrester should be re
moved and cleaned at 12,000 mile intervals. Im
merse in cleaning solvent to remove all deposits
and allow to drain before reinstalling.
MECHANICAL VALVE LIFTERS
Intake and exhaust valves on V6 engines should
be adjusted at 12,000 mile intervals.
MANIFOLD HEAT VALVE
In-Line engines and some V6 and V8 engines
are equipped with a manifold heat valve which should
be checked for free operation. A binding valve may
be freed up with General Motors manifold heat
valve lubricant or equivalent. (NEVER USE ANY
OTHER TYPE LUBRICANT.)
FLYWHEEL HOUSING ADAPTER
PLATE
Figure 1 shows the flywheel housing adapter
plate used with 13-inch clutch on 350 and 366 V8
engines.
Inspect engine front and rear mountings as
part of regular engine maintenance program. Be
sure all bracket attaching bolts are kept tight.
Refer to ENGINE MOUNTINGS (SEC. 6D) for engine
mounting information.
UNDERPAN
FLYWHEEL HOUSING
ADAPTER
EXTENSION COVER
T-9141
Sec. 6A
Page 13
GASOLINE ENGINES
TUNE-UP CHART
(IN-LINE ENGINE)
Except as otherwise indicated, the following specifications apply to both engine models.
......................................................
.............15-3-6-2-4
ENGINE TYPE AND NUMBER OF CYLINDERS
..............................
In-Line,
6
-Cyl.
COMPRESSION RATIO
250 Engine ................................................................................ 8.5:1
292 E n g in e ................................................................................ 8.0:1
CYLINDER COMPRESSION (PSI)
At Cranking S p ee d ........................................................................ 130
Max. Variation Between Cylinders
......................................................
20
SPARK PLUG MAKE AND NUMBER
250 Engine .......................................................................... A.C.-R46T
292 Engine .......................................................................... A.C.-R44T
Spark Plug Gap (A ll)..................................................................0.035"
Plug Tightening Torque (Ft.-Lb s.)............................................. 13-17
IGNITION DISTRIBUTOR
Dwell Angle (D egrees).................................................................. 31-34
Point Gap (N ew )........................................................................ 0.019
Point Gap (U sed )
...................................................................... 0.016
Contact Lever Spring Tension (O z.)................................................ 19-23
IGNITION TIM IN G
..............................
Refer to Ign. System Specs. (Sec.
6
Y)
VALVE LA S H .................................................................................. Zero
NOTE: Valve lifters are hydraulic type. Refer to Cylinder Head Bolt
Torque and Rocker Arm Adjustment in this section for instructions.
ENGINE GOVERNOR SETTING . . . .Refer to Governor Charts at end of Gasoline
Engine Fuel Systems (Sec.
6
M) in this manual.
ENGINE IDLE SP EE D
................
Refer to appropriate chart in "Gasoline Engine
Fuel Systems (Sec.
6
M) in this manual.
FUEL PUMP PRESSURE (P S I)............................................................... 4-5
CYLINDER HEAD BOLT TORQUE (FT.-LBS.)
........................................
90-100
TORQUE WRENCH SPECIFICATIONS
(IN-LINE ENGINES)
Torque wrench specifications listed below apply to clean dry threads except as otherwise indicated.
ITEM FT.-LBS. ITEM FT.-LBS.
Push Rod Cover B o lts
...................................................................... 6-8 Main Bearing Cap B o lts ................................................................. 60-70
Cylinder Head B o lts..................................................................... 90-100 Oil Pump B o lts................................................................................9-10
Manifold Clamps (O uter)................................................................ 15-20 Oil Filter (Throw-Away T yp e)................................. (Filter Gasket Oiled 20-25)
Manifold Clamps (Except O uter)...................................................... 25-30 Oil Filter Stud (If U sed)...................................................................45-50
Exhaust-to-lntake Manifold B o lt s..................................................... 25-30 Crankshaft Damper B o lt ................................................................. 40-60
Thermostat Housing B o lts.............................................................. 25-30 Flywheel Bolts
Water Outlet Housing B o lts ........................................................... 15-20 250 Engines............................................................................. 55-70
Water Pump B o lts ........................................................................ 13-17 292 Engines ..................................................................
1 05 41 5
Engine Front Cover B o lts ..................................................................5-7 Flywheel Housing B o lts................................................................... 25-30
Spark Plugs 5 /8 ” Wrench Size Tapered Seat P lu g
...................
13-17 O ilPan Bolts
End B o lts .................................................................................. 8-12
Connecting Rod Bolt Nuts ^ xc- ..........................................................................
®-8
250 En gin es............................................................................. 30-35 Oil Pan Drain Plug B o lts ...........................................................1/2 15-20
292 En gin es............................................................................. 35-45 7 /8 20-25
Sec. 6A
Page 14
GASOLINE ENGINES
TUNE-UP CHART
(V6 ENGINE)
TYPE AND NUMBER OF CYLINDERS...................................60°, V-6 FIRING ORDER 1-6-5-4-3-2
COMPRESSION RATIO IGNITION TIM ING Refer to Ign. System Specs. (Sec. 6Y)
351C Engines ........................................................7:1 VALVE LASH
CYLINDER COMPRESSION (PSD Intake 0.012
At Cranking Speed................................................... 125 Exhaust 0.018
Max. Variation Between Cyl.............................................30 ENGINE GOVERNOR SETTING (No Load RPM)** If Used
SPARK PLUGS* 351C 3900
M ake................................................................. AC
IDLE SPEED
............................. Refer to appropriate chart in
Type and Gap "Gasoline Engine Fuel Systems" (Sec. 6M) in this manual.
35 1C .................................................. CR 43 N, 0.035
Tightening Torque (Ft.-Lbs.)..........................................32 FUEL PUMP PRESSURE ................................................ 5-6V2
IGNITION DISTRIBUTOR CYLINDER HEAD BOLT TORQUE (FT.-LBS.)
...............................
60-65
Dwell Angle (Degrees)............................................. .31-34 *|n extremely cold regions use plugs with higher heat range.
Point Gap (New) .................................................. 0.019
Point Gap (Used)..................................................0.016 **With engine broken in. Full load setting is approximately 300 RPM
Contact Lever Spring Tension (Oz.)
.................................
19-23 less than No Load RPM, and will vary from engine to engine.
TORQUE WRENCH SPECIFICATIONS
(V6 ENGINE)
Torque wrench specifications listed below apply to clean dry threads except as otherwise indicated.
ITEM
Rocker Arm Adjusting Screw
Rocker Arm Shaft Bracket Bolts
Rocker Arm Shaft Cover Bolts
Valve Lifter Cover Bolts
.....
Distributor Clamp B o lt
.......
Cylinder Head Bolts
..........
Intake Manifold Bolts
........
Exhaust Manifold Bo lts
........
Water Outlet Manifold B olts....
Thermostat Housing Bolts ....
Front Cover Bolts
...........
Connecting Rod N u ts
........
Main Bearing Cap Bolts
Main Bearing Cap Bolts (Except W Rear)
...................... 130-140*
Rear
[Vi"
Bolts) ............................................... 90-100*
ITEM FT.-LBS.
Oil Pump Cover Screws ............................................. 10-15
Oil Pump to Block Bolt
.
............................................... 30-35
Oil Filter By-Pass Valve Plug (When Used)............................. 35-40
Fuel Pump Eccentric B o lt........................................... 55-65*
Oil Filter Housing to Cylinder Block Bolts ........................... 26-36
Oil Filter Center Stud (When Used).................................... 45-50
Oil Filter Assy (Filter Gasket Oiled).................................... 20-25
Spark Plugs ......................................................... 30-34
Flywheel Housing Bolts
...............................................
50-60
Flywheel to Crankshaft B o lts
......................................
100-110
Hub-to-Crankshaft Bolt (Without Cone)
............................. 180-200
Damper or Hub-to-Crankshaft Bolt (With Cone)
.......................
240-260
Oil Pan B olts......................................................... 10-15
Oil Pan Drain Plug .................................................. 20-30
*Oiled with S.A.E. No. 10 Engine Oil. (See Text)
FT.-LBS.
.7-17
20-25
3-5
4-5
12-17
60-65*
25-30
15-20
20-25
20-25
22-27
55-65*
Sec. 6A
Page 15
GASOLINE ENGINES
TUNE-UP CHART
(V8 ENGINE)
Except as otherwise indicated, the following specifications apply to all V
-8
Point Opening
engines. New .................................................................................. 0.019
ENGINE M ODELS
........
- ........................................................350,366, 427 Contact Lever Spring Tension (O z .)
...............................................
19-23
NUMBER OF CYLINDERS AND ENG. T Y P E ..................................
8
Cyl., V Type p|R|NG 0RD[R 1-84-3-6-5-7-2
COMPRESSION RATIO ........................................................................ 8:1
...........................
Refer to Ign. System Specs. (Sec.
6
Y)
CYLINDER COMPRESSION (PSD
At Cranking S p ee d ........................................................................ 150 VALVE LASH ................................................................................. ero
Max. Variation Between Cylinders ............................................. 20 Note: Valve Lifters are hydraulic type. Refer to Cylinder Head Bolt
SPARK PLUG MAKE S NUMBER ' X i o n s Rocker A AdiuStment" thiS f0'
427 ..................................................................................... AC-R42T
350 ..................................................................................... AC-R44T ENGINE IDLE SPEED
..................................
Refer to appropriate chart in
366 ..................................................................................... AC-R43T Gasoline Engine Fuel Systems (Sec.
6
M) in this manual.
£ plug list e n in g Torque
(Ft.
-Lbs
.). . . . . . . . . . .
^13-17 « - PUMP PRESSURE (PSD
........................................................ 7 W
CYLINDER HEAD BOLT TORQUE (FT.-LBS.)
350 Eng.................................................................................... 60-70
Dwell Angle (Degrees) .............................................................. 28-32 366 & 427 ............................................................................... 75-85
TORQUE WRENCH SPECIFICATIONS
(V8 ENGINE)
ITEM FT.-LBS. ITEM FT.-LBS.
Rocker Arm Cover B o lt....................................................................3-5 Camshaft Sprocket 15-20
Rocker Arm Stud (366 and 427 Only) ............................................ 45-55 Connecting Rod Caps
Distribute, Clamp Boit..............................................................................20-25 ; ; ;;;;;;;;;;;;;;;;;;;
W * 'H e a d Bolt c , „ Main Bearing Caps (350 Engine)
350 ....................................................................................... 60-70 . D .. 7 n on
366 and 427 Engines............................................................... 75-85 tolfe g ! ^ & 4 Only). .V .V .'.'.'.'.V .. . . . V.'.V. .V .V . '.! ! !! ! !! :60-70
Crankshaft Damper B o lt............................................................... 80-90 ^ ^ Caps ^ s 4?/ Eng|„es)
Manifold Bolts (In let)................................................................... 25-35 |nner
^
100-110
Manifold Bolts (Exhaust) ^uter B o lts 100110
350 Engine ................................................................ 18-22 Oil Pump B o lts 60-70
366 & 427 Engine................................................................... 20-30 Qjl pan
Flywheel Housing and Adapter Bolt (When U sed).............................. 25-35
350
Engines 1/4 B o lts 6-7
5/16 B olts
..............
.
............................................................ 12-15
366 and 427 Engines (1/4 Bolts)................................................. 4-5
Flywheel Bolts
350 Engine............................................................................. 55-65
366 & 427 Engines.................................................................. 60-70 Oil Filter (Filter Gasket Oiled)......................................................... 20-25
Spark Plug 5/8 ” Wrench Size Tapered S ea t........................... 13-17
oil
Pan Drain P lu g ....................................................................... 15-20
Water Pum p............................................................................... 25-35 Flywheel Housing Underpan........................................................ 6-7 1/2
Sec. 6D
Page 16
SECTION 6D
C ' t u j i n e M a u + U i + u j A .
All information in ENGINE MOUNTINGS (SEC. 6D) of Service
Manual ST-331-71, pages 6D-1 through 6D-3 applies to vehicles cov
ered by this supplement with the following exceptions or additions:
ENGINE CUSHION BOLT AND NUT TORQUE
Bolt to Alum. Bolt to Casting or Nut
Nut Torque
Size
Torque (Ft.Lbs.) Torque (Ft.-Lbs.) (Ft.-Lbs.)
3/8 16-24
12 - 16
25 - 30
15 - 20
7/16" 14-20 20 - 25
40 - 50 25 - 30
1/2" 13-20 30 - 35
55 - 65
40 - 50
9/16" 12-18
40 - 50 60 - 70 50 - 60
5/8" 11-18
50 - 60 130 - 140 70 - 80
3/4" 10-16
90 - 110 180 - 200 110 - 130 T-9146
MOUNTING BOLTS, BRACKET BOLTS, AND NUT TORQUES
BOLT OR NUT SIZE
1/4" - 20-28 8-10
5/16" -
18-24
20-25
3/8" -
16-24
25-30
7/16" -
14-20
40-50
1/2" -
13-16
55-65
9/16" -
12-18
60-70
5/8" -
11-18
130-140
3/4" -
10-16
180-200
7/8" -
9-14
240-270
1"
8-14
325-380
GM 280-M BOLT
FT.-LBS.
e
BOLT HEAD
IDENTIFICATION
GM 300-M BOLT
FT.-LBS.
10-15
25-30
35-45
70-80
85-105
90-110
170-180
300-320
400-430
700-730
BOLT HEAD
IDENTIFICATION
NUT TORQUE
FT.-LBS.
5-8
8-12
15-20
25-30
40-50
50-60
70-80
110-130
210-230
320-350
* 40 - 50
** 55 - 65
*** 60 - 70
Torque for aluminum casting.
ENGINE FRONT MOUNT WITH AT475
TRANSMISSION (ALL ENGINES)
Figure 1 shows left side front mount used on
In-line 6-cylinder Gas Engine and is typical for V6
and V8 Gas Engines. Refer to page 2 for figure 1.
T-9148
to remove brackets, mounts, spacer, bolts, nuts,
and washers.
NOTE: It will be necessary to bend lock tab
before removing the cushion mount bolt (fig. 1) and
after bolt torque. See next page for figure 1.
Replacement
1. Loosen attaching bolts. Raise engine enough
2. Reverse the procedure to install making sure
to torque bolts or nuts as shown on preceding charts.
Sec. 6D
Page 17
ENGINE MOUNTINGS
WASHER
BOLT
NUT
WASHER
LOCK
> " V
FRONT \ V
BOLT
WASHER NUT
M OU NTING
Figure 1—Engine Front Mount with AT475
Transmission (Typical)
SECTION 6K
S 't K f i n e G o a U r u j , S y d t e m
Information pertinent to truck models covered by this supplement
is the same as explained in Service Manual ST-331-71 ENGINE COOL
ING SYSTEM (SEC. 6K), pages 6K-1 through 6K-9, except as indicated
by the following information which is either new or supplemental in
nature.
Reference should be made to RADIATOR AND SURGE TANK
(SEC. 13) in this supplement for information regarding radiator mount
ing, radiator core and surge tank and cooling system filler cap.
COOLING SYSTEM GENERAL MAINTENANCE
TEST COOLANT LEVEL
Engine coolant should be checked for proper
level regularly (daily if necessary, depending on
severity of service) and every six months for cor
rosion and freeze protection to at least -20 F., or
to the lowest temperature expected during the period
of vehicle operation. Each two years or 24,000
m iles, whichever first occurs, cooling system must
be drained, flushed, and refilled with a new coolant
solution.
RADIATOR CORE EXTERIOR
For proper cooling efficiency, the exterior of
the radiator core and A/C condenser, if so equip
ped, must be kept clean. Light brushing and re
verse air flow is usually a satisfactory cleaning
method. Insects can usually be removed with a
garden hose using light water pressure.
COOLING SYSTEM PRESSURE CHECK
Several types of cooling system pressure
checking devices are available locally and manu
facturer's instructions should be followed for
proper use. A typical tester is illustrated in figure
1 and procedures are given below for testing the
pressure cap and cooling system.
1. Testing Radiator Cap
CAUTION: The radiator cap should
not be removed while the engine is at
normal operating temperature. If it is
necessary to remove the cap while the
engine is hot, first relieve the pressure
in the system by turning the radiator cap
counterclockwise to first stop, using cau
tion not to scald hands. Push down on cap
and turn counterclockwise to remove cap.
a. With radiator filler cap removed, wet the
cap gasket with water and wash off any sediment
from sealing surface, then install cap on tester.
b. Pump up pressure by operating pump plung
er handle. When the pressure stamped on cap is
reached, observe tester dial and note the rate of
decrease in pressure.
c. The indicator hand on gauge dial should re
main within the corresponding pressure segment
of scale for approximately 10 seconds. If pressure
cap does not meet this requirement,it should be
replaced with new cap.
2. Testing Cooling System
a. Tighten all radiator andheater hose clamps.
Also, check other connections for leaks at air com
pressor coolant lines, etc.
GAUGE HOSE AND.TAP
PUMP AND GAUGE
ASSEMBLY
FILLER NECK1
SON RADIATOR
OVERFLOW HOSE
Figure 1 — Use of Cooling System Tester (Typical)
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