Complete removal and replacement of the 327ci V8 long block assembly, including disconnection of all systems, removal of engine from vehicle, installation of new long block, and reconnection of all components.

Warnings

Tools required

Parts

• 327ci V8 Long Block Assembly × 1 — Use OEM specification or remanufactured equivalent
• Engine oil filter × 1 — AC PF-25 or equivalent
• Radiator hoses (upper and lower) × 1 — Use OEM specification
• Heater hoses × 1 — Use OEM specification
• Thermostat and gasket × 1 — 180°F or 195°F as original
• Water pump gasket × 1 — Use OEM specification
• Intake manifold gasket set × 1 — Fel-Pro MS-90014 or equivalent
• Exhaust manifold gaskets × 2 — Fel-Pro 1405 or equivalent
• Valve cover gaskets × 2 — Cork or rubber as original
• Oil pan gasket × 1 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Fuel pump gasket × 1 — Use OEM specification
• Engine mount hardware × 1 — Grade 8 bolts as original
• Antifreeze/coolant × 1 — DEX-COOL Extended Life

Fluids

• 5W-30 Conventional Engine Oil — 5 qt
• DEX-COOL Extended Life Coolant (Orange) — 10 qt
• 75W-90 GL-5 Gear Oil (for rear differential if drained) — 2 qt

Preparation

1. Park vehicle on level concrete surface with adequate overhead clearance for engine hoist operation
2. Disconnect negative battery cable and secure away from battery terminal
3. Remove hood by unbolting at hinges with assistant support (save hardware for reinstallation)
4. Drain engine oil into suitable container by removing drain plug from oil pan
5. Drain coolant from radiator petcock and engine block drain plugs into suitable container
6. Remove air cleaner assembly and disconnect all vacuum lines from carburetor and intake manifold (label each connection)
7. Place protective fender covers over front fenders to prevent damage during engine removal

Procedure

1. 1

   Disconnect fuel system and throttle linkage
   Disconnect fuel line from fuel pump at engine. Use two wrenches to prevent twisting the fuel pump fitting. Disconnect throttle linkage from carburetor including throttle cable, kickdown linkage (if automatic), and return spring. Cap or plug fuel line to prevent spillage.
2. 2

   Remove radiator and cooling system components
   Disconnect upper and lower radiator hoses from engine. Disconnect heater hoses at firewall connections. Remove radiator support shroud if equipped. Unbolt and remove radiator assembly (4 bolts at radiator support). Disconnect transmission cooler lines if equipped with automatic transmission. Remove fan belt(s), fan, and fan assembly (4 bolts through fan to water pump pulley, standard right-hand thread). Remove water pump pulley.
3. 3

   Disconnect electrical system
   Disconnect spark plug wires from distributor cap (label cylinder positions). Remove distributor cap. Disconnect primary ignition wire from coil. Disconnect alternator wiring harness (main charging wire and field connector). Disconnect temperature sender wire at cylinder head. Disconnect oil pressure sender wire at block. Disconnect starter motor wiring (main power cable and trigger wire). Label all connections for reinstallation.
4. 4

   Remove exhaust system connections
   Working from underneath vehicle on jack stands, disconnect exhaust pipes from exhaust manifolds. Remove 4 bolts per side securing exhaust flange to manifold. Support exhaust system with wire or blocks to prevent strain on hangers. If exhaust manifolds are remaining with old engine, remove 5 bolts per manifold and remove manifolds from cylinder heads.
5. 5

   Disconnect power steering and accessories
   If equipped with power steering, remove drive belt and unbolt power steering pump from brackets (leave hoses connected). Secure pump to frame rail with wire to prevent hose strain. Remove alternator mounting bolts and position alternator aside (2 bolts: one pivot bolt at bottom, one adjustment bolt at top). Remove air conditioning compressor if equipped (4 mounting bolts) and secure to frame without disconnecting refrigerant lines.
6. 6

   Separate bell housing from engine block
   Remove bell housing inspection cover from bottom of bell housing (2 bolts). For automatic transmission, rotate engine by hand using socket on crankshaft pulley bolt to access each of the 3 torque converter bolts through inspection opening. Remove all 3 converter-to-flexplate bolts. Remove upper and lower bell housing bolts connecting transmission to engine block (typically 6 bolts total: 4 on sides, 2 on top). Leave transmission supported on transmission jack or crossmember.
7. 7

   Disconnect remaining engine connections and motor mounts
   Disconnect clutch linkage (if manual transmission) from bell housing and frame. Remove any remaining ground straps from engine block to frame. Unbolt engine motor mounts from frame brackets (2 bolts through each mount, 4 total). Verify all hoses, wires, cables, and lines are disconnected from engine before proceeding to lift.
8. 8

   Attach engine hoist and remove engine
   Position engine hoist over engine compartment. Attach lifting chains to intake manifold bolts (use two outside bolts on each side of intake manifold, 4 attachment points total). Connect chains to engine leveler on hoist. Carefully raise hoist until chains are taut and slight tension is applied to engine. Verify all connections are disconnected. Slowly lift engine while simultaneously tilting forward to clear bell housing input shaft or torque converter. Continue lifting and guide engine forward and up out of engine compartment. Once clear, position engine over engine stand and secure to engine stand mounting plate using 4 bolts through bell housing mounting holes.
9. 9

   Transfer external components to new long block
   Transfer the following components from old engine to new long block: intake manifold and carburetor assembly, exhaust manifolds, water pump, fuel pump, distributor, starter motor, alternator brackets, power steering pump brackets, motor mount brackets, oil dipstick tube, clutch assembly and flywheel (or flexplate for automatic), timing cover and harmonic balancer, oil pan (if not included with long block), valve covers, and all temperature/pressure sending units. Use new gaskets for all component installations. Verify new long block includes camshaft, lifters, timing chain, and oil pump as specified by supplier.
10. 10

    Install new long block into vehicle
    With new long block prepared and mounted on hoist using same lifting points, carefully lower engine into engine compartment. Angle engine to clear firewall and align with transmission bell housing. Guide engine rearward ensuring transmission input shaft or torque converter pilot enters crankshaft properly. Lower engine until motor mount brackets align with frame mount pads. Thread motor mount bolts by hand and snug (do not fully tighten yet). Install upper bell housing bolts first, then lower bolts, tightening in cross pattern to ensure even seating (final torque specifications needed).
11. 11

    Connect torque converter and complete transmission attachment
    For automatic transmission, rotate torque converter to align bolt holes with flexplate. Install 3 torque converter bolts through bell housing inspection opening, tightening in sequence (torque specification needed). Install bell housing inspection cover. For manual transmission, verify clutch fork and throwout bearing are properly positioned. Final torque all bell housing bolts and motor mount bolts to specification.
12. 12

    Reconnect exhaust system
    Install exhaust manifolds to cylinder heads using new gaskets if not previously installed (5 bolts per side). Position exhaust pipes to manifold flanges using new gaskets and install 4 bolts per flange. Tighten exhaust manifold bolts working from center outward. Tighten exhaust flange bolts evenly to prevent gasket distortion.
13. 13

    Reinstall accessories and drive belts
    Install alternator to mounting brackets and adjust tension using adjustment bolt. Install power steering pump to brackets and reconnect to engine (if equipped). Install air conditioning compressor to brackets (if equipped). Install all drive belts with proper tension (approximately 1/2 inch deflection under moderate thumb pressure at belt midpoint). Install fan, and fan pulley assembly to water pump using standard right-hand thread bolts.
14. 14

    Reconnect electrical system
    Reconnect all electrical connections using labels from disassembly: starter motor wiring, alternator harness, distributor primary wire to coil, temperature sender, oil pressure sender. Install distributor cap and reconnect spark plug wires to correct distributor terminals according to firing order (1-8-4-3-6-5-7-2 for Chevrolet small block). Verify distributor rotor position corresponds to number 1 cylinder firing position.
15. 15

    Reconnect cooling system and fuel system
    Install radiator assembly and secure with 4 mounting bolts. Reconnect transmission cooler lines if equipped. Connect upper and lower radiator hoses with hose clamps positioned away from hose seams. Connect heater hoses at firewall. Install radiator shroud if equipped. Reconnect fuel line to fuel pump using two wrenches to prevent fitting damage. Reconnect throttle linkage, throttle cable, kickdown linkage (automatic), and return spring. Verify throttle operates smoothly through full range.
16. 16

    Fill fluids and perform initial start
    Install new oil filter. Fill engine with 5 quarts of 10W-30 high-ZDDP (zinc) conventional oil suitable for flat-tappet camshafts. Fill cooling system with conventional green ethylene glycol (IAT) coolant mixed 50/50 with distilled water, approximately 16-18 quarts total system capacity. Check transmission fluid level and add Dexron-compatible ATF (Dexron III or VI, backward compatible) as needed. Reconnect negative battery cable. Prime fuel system by cranking engine for 5 second intervals until fuel pump delivers fuel to carburetor. Set initial ignition timing per the factory specification for this specific 327 engine option (typically in the range of 4-12 degrees BTDC depending on variant) before start, then verify with timing light after break-in. Start engine and verify oil pressure within 10 seconds. Allow engine to reach operating temperature while checking for leaks. Verify cooling fan operation and thermostat opening. Bleed cooling system by removing radiator cap after engine cools and topping off coolant level.

Reassembly

1. Install hood with assistant support, aligning hinge bolts to original positions for proper fit
2. Verify all fluid levels after initial run: engine oil, coolant, transmission fluid, power steering fluid
3. Install air cleaner assembly and reconnect all vacuum lines according to labels
4. Remove fender covers and clean any spilled fluids from engine bay

Verification

• Start engine and verify stable idle and oil pressure above 10 psi within 10 seconds of start
• Check for any fluid leaks from oil pan, valve covers, intake manifold, water pump, and all hose connections
• Verify cooling system maintains proper temperature and thermostat opens (upper radiator hose becomes hot)
• Test drive vehicle to verify proper engine performance, smooth acceleration, and no unusual noises or vibrations
• Recheck all fluid levels after test drive and top off as necessary
• Verify exhaust system is sealed with no leaks at manifold connections
• Check belt tension and adjust if necessary after initial run-in period
• Retorque cylinder head bolts and intake manifold bolts after 500 miles of operation per manufacturer recommendation

More procedures for this vehicle