Chevrolet gasoline Big-block W-series (Mark I) 409 CID (6.7 L) High Torque 215 hp (1963) engine DIY maintenance and service manual

General Information

Chevrolet gasoline Big-block W-series (Mark I) 409 CID (6.7 L) High Torque 215 hp (1963) is an 409 in³ (6.7 L) internal combustion reciprocating V8 engine. It has bore/stroke ratio of 4.3125 in × 3.5 in (10.9538 cm × 8.89 cm), and uses 7.75:1 compression. This engine was rated 215 hp (160.33 kW) at 4000 rpm and 352 lbf⋅ft (477.25 N⋅m) of torque at 2400 rpm. It was used in Chevrolet and GMC cars.

Truck version.

Equipped with 4 barrel carburetor.

Forged Crank: bell shaped flywheel bolt flange

Connecting rod length: 6.00 inches

Connecting rod weight: 25.025 ounces

Crankshaft mains: 2.4977 inches

Push rod length: exhaust 9.140 inches, intake 8.772 inches

Fuel pump push rod length: 5.75 inches

Dipstick: on passenger side

Rocker arm ratio: 1.75:1

Internally balanced

Engine Performance Rating

SAE J1349 (SAE Net)

Chevrolet gasoline Big-block W-series (Mark I) 409 CID (6.7 L) High Torque 215 hp (1963) engine performance rating according to SAE J1349 (SAE Net) standard.
Parameter	Output
Power Rating	215 hp (160.33 kW) at 4000 RPM
Torque Rating	477.25 N⋅m352 lbf⋅ft352 lbf⋅ft at 2400 RPM

SAE J1995 (SAE Gross)

Chevrolet gasoline Big-block W-series (Mark I) 409 CID (6.7 L) High Torque 215 hp (1963) engine performance rating according to SAE J1995 (SAE Gross) standard.
Parameter	Output
Power Rating	252 hp (187.92 kW) at 4000 RPM
Torque Rating	528.77 N⋅m390 lbf⋅ft390 lbf⋅ft at 2400 RPM

Specifications

General

Chevrolet gasoline Big-block W-series (Mark I) 409 CID (6.7 L) High Torque 215 hp (1963) engine general specifications.
Parameter	Value
Type	Internal Combustion Reciprocating
Fuel Type	Gasoline
Cylinder Configuration	V8
Engine Displacement	6.7 L409 in³409 in³
Bore	10.9538 cm4.3125 in4.3125 in
Stroke	8.89 cm3.5 in3.5 in
Compression Ratio	7.75:1
Firing Order	1-8-4-3-6-5-7-2
Curb Weight	370.58 kg817 lb817 lb
Curb Idle Speed	475 RPMs

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Block, crankshaft and pistons

Chevrolet gasoline Big-block W-series (Mark I) 409 CID (6.7 L) High Torque 215 hp (1963) engine block, crankshaft and pistons specifications.
Parameter	Value
Block Material	Cast alloy iron
Crankshaft Material	Forged steel, induction hardened journals
Piston Material	Cast alloy aluminum with cast-in steel ring; angular head; tin plated; cam ground; 3 ring grooves above piston pin
Piston Pin Material	Tubular, hardened chrome alloy steel
Connecting Rod Material	Forged carbon steel; I-beam section

Spark Plugs and Wires

Chevrolet gasoline Big-block W-series (Mark I) 409 CID (6.7 L) High Torque 215 hp (1963) spark plugs and wires specifications.
Parameter	Value
Spark Plugs	AC Delco C42-1
Spark Plug Size	0.55 in0.55 in14 mm
Spark Plug Gap	889 μm0.035 in0.035 in

Engine head and valvetrain

Chevrolet gasoline Big-block W-series (Mark I) 409 CID (6.7 L) High Torque 215 hp (1963) engine head and valvetrain specifications.
Parameter	Value
Head Material	Cast alloy iron
Valvetrain Type	OHV
Valves per Cylinder	2
Camshaft Material	Cast alloy iron

Air Intake

Chevrolet gasoline Big-block W-series (Mark I) 409 CID (6.7 L) High Torque 215 hp (1963) air intake specifications.
Parameter	Value
Air Intake Method	Naturally Aspirated

Fuel Injection

Chevrolet gasoline Big-block W-series (Mark I) 409 CID (6.7 L) High Torque 215 hp (1963) fuel injection specifications.
Parameter	Value
Injection Type	Carburetor
Injection Info	4-barrel Rochester downdraft type with manual choke control

Valve Timings

Chevrolet gasoline Big-block W-series (Mark I) 409 CID (6.7 L) High Torque 215 hp (1963) valve timings.
Parameter	Value
Intake Opens	12.5° B.T.D.C.
Intake Closes	57.5° A.B.D.C.
Intake Duration	250°
Exhaust Opens	54.5° B.B.D.C.
Exhaust Closes	15.5° A.T.D.C.
Exhaust Duration	250°
Valves Overlap	140°
Ignition Timing	8° B.T.C.

Chevrolet gasoline Big-block W-series (Mark I) 409 CID (6.7 L) High Torque 215 hp (1963) valve timing diagram.

Oil Pump

Chevrolet gasoline Big-block W-series (Mark I) 409 CID (6.7 L) High Torque 215 hp (1963) oil pump specifications.
Parameter	Value
Oil Pump	Spur-gear type driven by distributor shaft
Oil Pump Pressure	2.04 atm.30 Psi30 Psi at 1200 RPM
Oil Pump Capacity	15.52 lpm3.41 UK gpm4.1 US gpm at 1200 RPM

Water Pump

Chevrolet gasoline Big-block W-series (Mark I) 409 CID (6.7 L) High Torque 215 hp (1963) water pump specifications.
Parameter	Value
Water Pump	Centrifugal type driven by fan belt
Water Pump Capacity	168.43 lpm37.05 UK gpm44.5 US gpm at 4000 RPM