| 1962 Corvette Restoration: Reinstalling the Engine and Engine-Accessories |
From "Classic Car Restoration"
episode DCR-207 |
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In this segment, the refurbished and detailed Chevy V-8 engine is reinstalled in the engine bay of the Corvette, and work begins on installing and connecting related components including the starter motor (figure A), sparkplugs, speedometer cable, drive-shaft connection, etc.
Note: This is a summary of steps included in the automotive restoration procedures shown in this episode of Classic Car Restoration. These are general guidelines for restoration procedures on this particular make and model of vehicle, and for the level of restoration selected for this project. There may be variations in procedures depending on model, condition of vehicle, level of restoration undertaken and the types of replacement parts or upgrade kits selected. Always follow proper safety precautions, and read and follow manufacturer's guidelines, diagrams and safety notices that come with any replacement parts or kit that you select.
Safety Alert: Installing -- or "dropping" -- an engine into a vehicle requires the proper equipment and at least two people. Engine hoists, tilt-bars and heavy-duty chains specially designed for this job are available at most rental centers. Read and follow any safety precautions that the manufacturer or rental company provides regarding the equipment.
Materials:
Engine hoist, tilt-bar, chain
Standard automotive tools (socket-wrenches, screwdrivers, nut-drivers, etc.)
Channel-lock pliers
Starter motor
Fuel pump
Spark-plugs; plug-gapping tool
Oil filter
Motor oil
Speedometer cable
Power wrench Steps:
- Before installing the engine in the vehicle, several components need to be pre-installed onto the engine. When rebuilding an engine, it's typically advisable to install a new or refurbished starter motor and generator. In our case, the starter motor only needed a new solenoid and bendix drive.
- To install the starter motor onto the engine, oil the mounting-bolts and slide them into place on the starter motor. Place the starter motor into position in the bell-housing (figure B) and hand-tighten the bolts while supporting the back of the motor. Once the bolts are all threaded, use a socket wrench to tighten the bolts down.
- The next step is to install the new sparkplugs on the engine. Use a gapping tool to gap the plugs according to spec (figure C). For our Corvette, we gapped the plugs to .035.
- Apply a small amount of oil onto the sparkplug threads and hand-tighten them in position (figure D), using caution not to cross-thread the plugs in their openings. Also use new sealing washers when installing new plugs.
- With all of the plugs in place, use a hand-wrench to tighten the plugs down ( figure E) just far enough to begin crushing the washers, using about 15 pounds of torque.
- Next, install the new oil-filter on the engine.
Important: The most vulnerable time in the life of a newly refurbished engine is the first start-up If a new engine is started "dry," without proper oil, serious problems could ensue.
- Add fresh oil to the oil filter before installing it (figure F), and use your finger to wipe a film of oil around the filter gasket to ensure a good seal, and to help ensure easy removal of the filter at the next oil change. (Note : Both of these techniques are advisable even during regular oil/filter changes.)
- With fresh oil added, install the oil-filter in position, tightening as much as you can easily tighten using one hand (figure G).
- With the starter motor, plugs and new oil-filter installed, the engine is ready for re-installation in the vehicle. Using the engine hoist and tilt-bar to keep the engine and transmission suspended, one person should control the hoist while a second person carefully guides the engine and transmission into place in the engine bay. Carefully maneuver the engine, and adjust the angle and orientation as needed using the tilt bar. In this installation, the engine needs to be angle sharply to fit the transmission tail under the bulkhead (figure H). The rear transmission mount had to be removed in order to clear the rear cross-member during installation.
- At this point, re-install the motor mounts (figure I) while the engine is still suspended.
Safety Alert: Keep your hands away from beneath the engine while working to install the motor mounts.
- The motor-mount pad supports the weight of the engine and acts as a buffer to absorb vibration of the engine, and reducing the amount of vibration that reaches the chassis. Carefully align the engine and lower it onto the motor mounts (figure J). Secure the engine to the motor-mounts with bolts using the appropriate socket.
- With the refurbished engine re-installed in the vehicle, we have reached an important milestone in the "rolling restoration" of the vehicle. Work can now begin beneath the car reconnecting the exhaust system, driveshaft, etc.
- With the vehicle back up on the lift, reconnect the fuel-pump by sliding the fuel hose into place and securing it with the hose clamps (figure K).
- Re-connect the exhaust system following the same steps that were used earlier when the old exhaust system was replaced with the new one. For each side, position the header-pipe gasket and attach the header pipe to the manifold. Hand-tighten the three-flange bolts (figure L), then go back and tighten them securely with a socket wrench.
- Reinstall the speedometer cable by inserting the end of the cable into the drive flange (figure M). A cable ring threads into place to hold the connection. Tighten the ring using channel-lock pliers.
- Next, re-connect the rear of the driveshaft. Apply grease into grease-cups, and place the cup into position on the yoke-flange. Install the second cup on the opposing side, making sure that the cups are installed behind the ears of the flange (figure N).
- Slide both of the U-bolts into the flange (figure O) and secure them with their washers and nuts. Tighten each nut down to the flange, just finger-tight initially.
- Go back and tighten each nut to about 15 to 20 pounds of torque. It's important that all of the nuts be tightened evenly to avoid vibration in the rear of the driveshaft.
In the segment that follows, work proceeds on reinstallation of engine components with the installation of the fuel system and cooling system.
RESOURCES :
Corvette Black Book : 1953-2001
Model: 0933534477
Author: Michael Antonick
Corvette: The American Legend
Model: 0785343741
Author: Consumer Guide Editors
Classic Car Restorer's Handbook: Restoration Tips and Techniques for Owners ...
Model: 1557881944
Author: Jim Richardson
Order this book from Amazon.com
H.P. Books
Classic Car Restoration Guide: The Complete Illustrated Step-By-Step Manual
Model: 1850108900
Author: Lindsay Porter
Order this book from Amazon.com
Haynes Publishing
Special Thanks, Classic Car Restoration: 1962 Corvette (Companies and Products)
Companies and Products
Corvette Central
Full line of Corvette parts and accessories.
Website: www.corvettecentral.com
Dunshee's Corvette Parts
Corvette restoration specialists.
7304 W. Villa Rita Drive
Glendale, AZ 85308
Phone: 602-938-8895
Fax: 602-938-9081
E-mail: 4vetteparts@cox.net
Quanta Restoration and Performance Products
Website: www.quantaproducts.com
Restoration specialists. Quanta Restoration carries (among other specialty items) "correct" fuel tanks for vintage cars.
Lectric Limited
Website: www.lectriclimited.com
Eastwood Company
Unique automotive tools and supplies.
Website: www.eastwoodco.com
Eastwood carries assorted tools, supplies and parts (many hard-to-find) of interest to the auto-restoration hobbyist.
House of Kolor
Automotive paints, primers and painting systems.
Website: www.houseofkolor.com
Strip Technologies of America
A media-blasting facility specializing in coating-removal & coating applications.
4001 Bruhin Road
Knoxville, TN, 37918
Bend-Pak Inc./Ranger Products
Bend-Pak provided the large equipment used throughout the Corvette episodes of DIY's Classic Car Restoration.
NAPA Auto Parts
National Automotive Parts Association.
Customer Support: 877-805-6272
NAPA provided many items that used throughout the Corvette series.
3M Corporation
Products available at retail stores worldwide.
3M provided many general supplies, including all safety equipment, used throughout the Corvette series.
Special Thanks, Classic Car Restoration: 1962 Corvette (Organizations)
Vintage Corvette video and photos provided by General Motors Corporation.
Used with permission, GM Media Archive.
Chevrolet's website: www.chevrolet.com
Corvette Organizations
The National Corvette Museum
Website: www.corvettemuseum.com
The National Corvette Museum is open to the public and offers plant tours and other services and products, including Corvette accessories and memorabilia. The museum also offers library and archive information, build-sheets and a database of information. NCM also sponsors events and gatherings.
For DIY's Classic Car Restoration, the NCM supplied research material and photographs used in episode #201.
National Corvette Restoration Society (NCRS)
Website: www.ncrs.org
The NCRS (National Corvette Restoration Society) is a non-profit organization dedicated to the restoration, preservation, history and enjoyment of Corvettes made from 1953 through 1986. The group offers publications, database information, resources and discussion boards. They also sponsor Corvette events and NCRS Judging programs.
East Tennessee Corvette Club
The East Tennessee Corvette Club is a non-profit organization of Corvette enthusiasts in the East Tennessee area.
Corvette Expo
Website: www.corvetteexpo.com
Corvette Expo is a promoter of Corvette shows, swap meets, and auctions.
Special Thanks, Classic Car Restoration: 1962 Corvette (Books and Publications)
Books and Publications
Classic Auto Manuals
1910 E.S.E. Loop 323 #317, Tyler, TX 75701, 903-566-1939
Classic Auto Manuals offers factory-original shop manuals, service manuals, body manuals, repair manuals and auto-parts manuals on CD format. They provided the 1962 Corvette manual used as reference in the Corvette series for DIY's Classic Car Restoration.
Standard Catalog of Corvette: 1953-2001
ISBN #0-87349-235-8
Krause Publications
Website: www.krause.com
Book and photos featured in #201 (Corvette History).
Classic Corvette: The First 30 years
by Mike Mueller
ISBN #0-7603-1358-X
Motorbooks International (MBI) Publishing Company
Book and photos featured in episode #201 (Corvette History).
Corvette Buyers Guide 1953 - 1967
by Richard Price
ISBN #0-7603-1009-2
MBI Publishing Company
Featured in Classic Car Restoration episode #209.
Corvette: Fifty Years
by Randy Leffingwell
ISBN #0-7603-1180-3
MBI Publishing Company
101 Projects for Your Corvette: 1984 - 1986
ISBN #0-7603-1461-6
MBI Publishing Company
Author Richard Newton featured as guest on episode #209.
Motorbooks (MBI) catalog & information
Website: www.motorbooks.com
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