How to Rebuild Pontiac V-8s - Updated Edition. Rocky Rotella

Source Guide

DEDICATION

      I wish to dedicate this book to my mother, Carmen Rotella. She was excited for me when she learned that I was to author this book. She passed away mid-project, however, and wasn’t able to see the completed book down here. Hopefully she’s reading it from up there. Mom, this one’s for you!

ACKNOWLEDGMENTS

      Many people assisted in the compilation of information for this book. I couldn’t have completed the project without their assistance. I extend thanks to the following:

      Dave Anderson, Ken Anderson, Kevin Beal, Rich Benolken, Dave Bisschop, Ken Brewer, Armin Brown, David Butler, Brian Carson, Chris Casperson, Wade Congdon, Ken Crocie, Paul Delfield, Tom DeMauro, Alan Fanning, Bob Florine, Bart Foreman, Eric Gardner, Kevin Gertgen, Dick Glady, Rick Gonser, Jim Hairston, Dave Hall, Jim Hall, Floyd Hand, Jim Hand, Joe Hand, Tom Hand, Jon Hardgrove, Jill Hepp, Mike Hicks, John Glasgo, Dan Jensen, Paul Johnson, Terry Johnson, Jeff Kauffman, Don Keefe, Ken Keefer, Shawn Kniesly, John Kryta, Jim Lehart, Robert Loftis, Robert Martin, Jim Mattison, Jim Mazzei, Pete McCarthy, Skip McCully, Malcolm “Mac” McKellar, Bill McKnight, Robert McMackin, Chase Milner, Fred Mittan, Randy Moore, Hailey Naylor, Kerry Novak, Joe Oldham, Scott Parkhurst, Christopher Phillip, Mike Randal, Chris Ritter, Nunzi Romano, Tony Romano, Jim Rotella, Cliff Ruggles, John Sawruk, Steve Schappaugh, Fred Simmonds, Ann Skrycki-Mohler, Smitty Smith, Paul Spotts, Kevin Studaker, Scott Sulprizio, Kevin Swaney, Scott Tiemann, Joe Tonietto, Jim Wangers, Mike Wasson, Mark Weymouth, Chuck Willard, Jeff Williams, and George Zapora.

      I extend special thanks to my dad, Jim Rotella. He is the reason behind my passion toward the Pontiac hobby. Because of his profound love for Pontiacs, we always drove Pontiacs while I was growing up. And because of him, I learned my way around the Pontiac V-8 at an early age. He was very willing to lend a helping hand many times on this project.

      I extend special thanks to my wonderful wife, Jennifer, for the confidence and support to write a book and for being so understanding while my head was buried in a camera viewfinder or a computer keyboard so often during the past year.

      FOREWORD

      There are few objects in this world as beautiful to behold as a trimmed-out Pontiac V-8. With its light-blue paint, chrome valve covers and 4-barrel, or even better, three 2-barrel Rochester 2GC carbs sitting under three small chrome pots, it is truly a stunning sight—in my opinion, the best-looking car engine of all time.

      Even more exciting than looking at a Pontiac V-8 is stomping on the throttle of one. I have had that pleasure many times over the years in the course of road-testing Pontiacs for various magazines, and in owning some. I’d had a few clunkers before, but my first real car was a 1959 Pontiac Bonneville convertible—Tri-Power, Royal Bobcat kit, and 4.55:1 gears. Later I bought a 1968 GTO—400 H.O., 4-speed, and 3.90:1 gears. I still own a 1976 Trans Am.

      I can say with certainty that there is something unique about the wail of a Pontiac V-8 under full throttle. It starts out as a low moan. As the revs climb and the secondaries fully open, the sound changes to a banshee-like wail that promises to suck up and spit out any nearby competitor. It’s absolute music to an enthusiast’s ear.

      Pontiac engines also possess inner beauty. For one thing, they’re relatively easy to work on. All the components are pretty much straightforward and easily bolt on and off. There are no tricks involved.

      For another thing, they’re responsive. Want to build a Poncho that screams? That’s easy. Pontiac V-8s respond, and quite well, to just about any modification or improvement you wish to bestow upon them. All the usual stuff makes any Pontiac run better—increased carburetion, a hotter cam, headers, headwork, etc. You can hardly make a mistake if you’re working with a Pontiac.

      Finally, there is the interchangeability. Just about any component from any year—heads, intake manifolds, camshafts, etc.—fits to just about any other year block. So, if you want to put a 1966 389 Tri-Power intake manifold on a 1970 400 block and use a number-068 H.O. cam from a 1968, go right ahead. It all works—and well. Thank you, Pontiac engine design engineers, wherever you are.

      In this book, renowned Pontiac tech expert Rocky Rotella takes you through the ubiquitous 400 Pontiac V-8, from a stock rebuild with mild modifications that increases horsepower to nearly 400. But what he shows and tells you applies to your Pontiac engine too, be it a 1958 347 or a 1976 455. Rocky’s tech articles appear regularly in Pontiac publications such as High Performance Pontiac magazine and the Pontiac-Oakland Club International’s official mag, Smoke Signals. He knows Pontiacs. He knows his stuff. You’re in good hands with Rocky.

      —Joe Oldham, author of Muscle Car Confidential

WHAT IS A WORKBENCH® BOOK?

      This Workbench^® Series book is the only book of its kind on the market. No other book offers the same combination of detailed hands-on information and revealing color photographs to illustrate engine rebuilding and modifying. Rest assured, you have purchased an indispensable companion that will expertly guide you, one step at a time, through each important stage of the rebuilding process. This book is packed with real-world techniques and practical tips for expertly performing rebuild procedures, not vague instructions or unnecessary processes. At-home mechanics or enthusiast builders strive for professional results, and the instruction in our Workbench^® Series books help you realize pro-caliber results. Hundreds of photos guide you through the entire process from start to finish, with informative captions containing comprehensive instructions for every step of the process.

      The step-by-step photo procedures also contain many additional photos that show how to install high-performance components, modify stock components for special applications, or even call attention to assembly steps that are critical to proper operation or safety. These are labeled with unique icons. These symbols represent an idea, and photos marked with the icons contain important, specialized information.

      Here are some of the icons found in Workbench^® books:

       Important! Calls special attention to a step or procedure, so that the procedure is correctly performed. This prevents damage to a vehicle, system, or component.

       Save Money Illustrates a method or alternate method of performing a rebuild step that will save money but still give acceptable results.

       Torque Fasteners Illustrates a fastener that must be properly tightened with a torque wrench at this point in the rebuild. The torque specs are usually provided in the step.

       Special Tool Illustrates the use of a special tool that may be required or can make the job easier (caption with photo explains further).

       Performance Tip Indicates a procedure or modification that can improve performance. The step most often applies to high-performance or racing engines.

       Critical Inspection Indicates that a component must be inspected to ensure proper operation of the engine.

       Precision Measurement Illustrates a precision measurement or adjustment that is required at this point in the rebuild.

       Professional Mechanic Tip Illustrates