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400
TECHNICAL SECTION
MUFFLER ATTACHING – This diagram roughly shows how most Corvair mufflers attach.
NOTE: GM did not intend for the strap to fit all the way around the muffler. The bolt takes up the gap.
The hanger is also attached to the motor by the coil stud. If you cannot remove the stud, then you need
to remove the engine sheet metal as the hanger installs over the stud and behind the sheet metal.
MUFFLER SHIELD INSTALLATION – RIGHT SIDE = #1 This end attaches to the muffler hanger with 2 small bolts.
#2 This end attaches to two small bolts on the front end of the head
.
LEFT SIDE – 140 DUAL EXHAUSTS
#3 = This end attaches to the muffler hanger with 2 small bolts.
#4 = This end is held to the muffler with a muffler strap that attaches to the shield,
wraps around the muffler and then bolts to the other edge of the shield.
Loosen Manifolds – It is normal to have to loosen the manifold clamps to allow the manifolds to move slightly while installing crossover pipes.
Brass Nuts TOO GOOD! – The brass nuts and stainless studs that we sell have proved to be too good in some cases.
(They don’t rust and the nuts loosen.) If yours do this, just get extra brass nuts to use as a jam nut.
NON-ASBESTOS REPORT – As most people are aware there is a definite attempt being made to remove asbestos from our every-
day world. Replacement materials generally have a common trait – higher prices.
ACCELERATOR PUMP CUPS – These are very difficult to install. We recommend complete accelerator pump
(page 55, #9 – C2762) for easiest installation.
CIean Your Fuel System! If we get a rebuilt carburetor returned, we find that 90% of the time it is full of "junk" and smelly old gas. The
fuel filter stones are fine for "larger" particles but do not seem to be that good for stopping 20 years of sediment in a gas tank forced in under pressure.
If you don't know when (if ever!) your gas tank has been out, we highly suggest you get new hoses, clamps, filter, gasket, gas tank sealer and clean that
tank before you bother working on the carbs!
GAS TANK FILTER – Car run a few miles and stop? It will idle but won't rev above 1500 RPM? Just can't get fuel to fuel pump? Drain the gas tank
and check the filter and fuel outlet. We had one so clogged we couldn't even drain the tank!
Parking Your Corvair for Storage?
Do not set the emergency brake.
TURBO – HOW EASY SHOULD IT SPIN?
f
More Turbo info – see page 397
There are usually (3) things that keep a Turbo from spinning.
1. Carbon build up behind the turbine.
2. The large clamp not tight enough or exhaust housing so worn that it can't press hard enough against the heat shield to push it away from
the turbine (SEE SHIM, PAGE 44).
3. Turbine bearing not shimmed correctly.
Assuming all of these are okay (and the exhaust housing is in place), the turbine WILL NOT spin like a pin wheel. In fact, if you spin it as hard as you can
with your finger, it probably will not do more than 1-1½ revolutions. As long as it doesn't seem to bind, it’s normal.
Turbo Exhaust Housing Shims: We are finding that due to rust and repeated sand and glass beading, the "ledge" on the
exhaust housing that "pushes in" on the heat shield behind the impeller is eroding back.
Rebuilt your Turbo and still no boost?
It often is bad enough so it does not even push the shield away from the backside of the impeller.
We suggest 1 or 2 of our C5705 shims as part of any rebuild (page 44).
1961 CHOKE CABLE – If you pull out choke and at the same time push down on the accelerator pedal, the choke will pull out easily. If you do
not do this you can hardly pull out the choke. It is usually worse when the weather is really cold.
MAXIMUM HEAT – If you need maximum heat from your Corvair you may want to try the following: 1960-64 Cars & Vans – Maximum heat, maximum fan,
NO AIR. We have found the air tends to "dilute" the heat. 1965-69 Cars – You may want to try blocking the "fresh air hose" for the winter.
UPS weight limit is now up to 150 lbs. per box
(We will seldom put over 40-50 lbs. per box)
but it does allow us to ship complete differentials and transmissions
400TECHNICAL SECTIONMUFFLER ATTACHING - This diagram roughly shows how most Corvair mufflers attach.NOTE: GM did not intend for the strap to fit all the way around the muffler. The bolt takes up the gap. The hanger is also attached to the motor by the coil stud. If you cannot remove the stud, then you need to remove the engine sheet metal as the hanger installs over the stud and behind the sheet metal. MUFFLER SHIELD INSTALLATION - RIGHT SIDE = #1 This end attaches to the muffler hanger with 2 small bolts. #2 This end attaches to two small bolts on the front end of the head. LEFT SIDE - 140 DUAL EXHAUSTS #3 = This end attaches to the muffler hanger with 2 small bolts. #4 = This end is held to the muffler with a muffler strap that attaches to the shield, wraps around the muffler and then bolts to the other edge of the shield.Loosen Manifolds - It is normal to have to loosen the manifold clamps to allow the manifolds to move slightly while installing crossover pipes.Brass Nuts TOO GOOD! - The brass nuts and stainless studs that we sell have proved to be too good in some cases. (They don't rust and the nuts loosen.) If yours do this, just get extra brass nuts to use as a jam nut.NON-ASBESTOS REPORT - As most people are aware there is a definite attempt being made to remove asbestos from our every-day world. Replacement materials generally have a common trait - higher prices.ACCELERATOR PUMP CUPS - These are very difficult to install. We recommend complete accelerator pump (page 55, #9 - C2762) for easiest installation.CIean Your Fuel System! If we get a rebuilt carburetor returned, we find that 90% of the time it is full of "junk" and smelly old gas. The fuel filter stones are fine for "larger" particles but do not seem to be that good for stopping 20 years of sediment in a gas tank forced in under pressure. If you don't know when (if ever!) your gas tank has been out, we highly suggest you get new hoses, clamps, filter, gasket, gas tank sealer and clean that tank before you bother working on the carbs!GAS TANK FILTER - Car run a few miles and stop? It will idle but won't rev above 1500 RPM? Just can't get fuel to fuel pump? Drain the gas tank and check the filter and fuel outlet. We had one so clogged we couldn't even drain the tank! Parking Your Corvair for Storage? Do not set the emergency brake.TURBO - HOW EASY SHOULD IT SPIN? f More Turbo info - see page 397There are usually (3) things that keep a Turbo from spinning. 1. Carbon build up behind the turbine. 2. The large clamp not tight enough or exhaust housing so worn that it can't press hard enough against the heat shield to push it away from the turbine (SEE SHIM, PAGE 44). 3. Turbine bearing not shimmed correctly.Assuming all of these are okay (and the exhaust housing is in place), the turbine WILL NOT spin like a pin wheel. In fact, if you spin it as hard as you can with your finger, it probably will not do more than 1-1 1/2 revolutions. As long as it doesn't seem to bind, it's normal.Turbo Exhaust Housing Shims: We are finding that due to rust and repeated sand and glass beading, the "ledge" on the exhaust housing that "pushes in" on the heat shield behind the impeller is eroding back. Rebuilt your Turbo and still no boost? It often is bad enough so it does not even push the shield away from the backside of the impeller. We suggest 1 or 2 of our C5705 shims as part of any rebuild (page 44).1961 CHOKE CABLE - If you pull out choke and at the same time push down on the accelerator pedal, the choke will pull out easily. If you do not do this you can hardly pull out the choke. It is usually worse when the weather is really cold.MAXIMUM HEAT - If you need maximum heat from your Corvair you may want to try the following: 1960-64 Cars & Vans - Maximum heat, maximum fan, NO AIR. We have found the air tends to "dilute" the heat. 1965-69 Cars - You may want to try blocking the "fresh air hose" for the winter.UPS weight limit is now up to 150 lbs. per box(We will seldom put over 40-50 lbs. per box)but it does allow us to ship complete differentials and transmissions
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P.O.Box #NET 400 Mohawk Trail Shelburne Falls, MA 01370 USA All rights reserved.
Main Office Phone: 413.625.9776 Fax: 413.625.8498