ECU CHEVROLET CAMARO 1967 1.G Chassis Workshop Manual

SECTION 11

CHASSIS SHEET METAL

CONTENTS OF THIS SECTION

Chevrolet and Chevelle 11-1

Chevy II . . 11.-11

Camaro 11-19

Corvette (See Section IB)

Special Tools 11-25

CHEVROLET AND CHEVELLE

INDEX

Page

General Description 11-1

Maintenance and Adjustments •. il-1

Hood Adjustment 11-1

Hinges 11-1

Bumpers 11-1

Catch Assembly and Lock 11-1

Fenders 11-4

Sheet Metal 11-4

Component Part Replacement 11-4

Battery Tray 11-4
Page

Radiator Support 11-4

Fender Assembly . . 11-4

Skirt 11-4

Trim 11-5

Hood Assembly 11-6

Lock and Catch 11-7

Trim and Insulation 11-7

Cowl Vent Grille 11-7

Rear Wheel Cover 11-7

Simulated Wood Grain Moulding . . . . 11-7

GENERAL DESCRIPTION

The new front end appearance of the 1967 Chevrolet

and Chevelle passenger cars affects the servicing and

replacement of the chassis sheet metal. Refer to Section

13 for Radiator and Grille service procedures, Section
14 for Bumpers, and Section 1A for Air Conditioning

components. Figures 1 and 2 illustrate the Chevrolet

and Chevelle sheet metal components.

MAINTENANCE AND ADJUSTMENTS

HOOD ADJUSTMENT

The alignment of the hood is controlled by the position

of the hood hinges and the height of the two bumpers lo-

cated one at each side of the radiator support. The ad-

justment at the hood lock must be made after the hinges

and bumpers are properly adjusted. To align the hood

and lock proceed as follows:

HOOD HINGE (Fig. 3)

NOTE:
The body mounted portion of the hood

hinges are slotted to provide up and down move-

ment. The hood mounted end is slotted to pro-

vide forward and rearward movement.

1.
Scribe a line around the entire hinge plate to be re-

positioned.
2.
Loosen the appropriate screws and shift the position

of the hood into correct alignment using the scribe

marks to check amount of movement. Check align-

ment by tightening screws and closing the hood.

HOOD BUMPERS

Adjust hood bumpers so that hood top surface is flush

with the fender and grille top surfaces. Refer to Fig-

ures 4 and 5 for correct sheet metal adjustment dimen-

sions.

HOOD CATCH AND LOCK

The hood catch assembly (fig. 6) mounting holes are

slotted to provide adjustment for the hood lock bolt. Ad-

just the hood lock bolt until hood engages securely when

closed and hood bumpers are slightly compressed.

CHEVROLET CHASSIS SERVICE MANUAL

CHASSIS SHEET METAL 11-4

FENDERS

Fenders are adjustable with shims at the cowl and

rocker panel. To add or remove shims, loosen bolts at

shim locations (fig. 7) and carefully apply force with pry

bar to provide clearance for shim removal or installa-

tion.
SHEET METAL ADJUSTMENTS

For proper operation of doors and hood, and for pre-

sentable appearance, adjust front sheet metal to the tol-

erances shown in Figures
4-
and 5.

COMPONENT PART REPLACEMENT

NOTE: When replacing sheet metal compo-

nents on Chevrolet or Chevelle, note position and

attachment of all seals and dust shielding and

replace as necessary.

BATTERY TRAY

Removal

1.
Disconnect battery cables.

2.
Remove screw retaining battery hold down clamp and

remove battery from vehicle.

3.
Remove screws retaining battery tray to fender skirt

and radiator support.

4.
On Chevrolet, remove headlamp bezel and remove

screw retaining tray to radiator support.

5.
Remove battery tray from vehicle.

Installation

Reverse removal procedure.

RADIATOR SUPPORT

Removal

1.
Remove front bumper (Section 14).

Fig.
3 - Hood Hinge - Chevrolet
2.
Remove grille and related components (Section 13).

3.
Remove battery tray as outlined above.

4.
Remove all electrical connections from radiator

support.

5.
Remove windshield washer bottle from bracket on

radiator support.

6. Remove shroud and radiator (Section 13).

7.
Remove screws and bolts securing support to skirts,

fenders, and frame horns (figs. 8 and 9).

8.. Spread fenders apart enough to allow support move-

ment and remove support from front of vehicle.

Installation

1.
Position the radiator support in vehicle", aligning

mounting screw and bolt holes with drift punch.

2.
install screws and bolts loosely until all are started.

3.
Replace all parts removed following removal proce-

dure in reverse order.

4.
Refer to torque specifications in rear of manual for

correct torque values.
•

5.
Aim headlamps as outlined in Section 12.

FENDER ASSEMBLY

Removal

1.
Remove hood with hinges from vehicle as outlined in

this section.

2.
On Chevrolet models, remove headlamp bezels and

headlamps; on Chevelle models, remove grille ex-

tension panels (fig. 1 or 2 as applicable).

3.
Disconnect wiring harness clips from fender to be

removed.

4.
If applicable, remove horn assembly from fender.

5.
If applicable, remove radio antenna.

6. Remove fender brace (fig. 1 or 2 as applicable).

7.
Remove screws retaining fender to radiator support,

skirt, cowl, filler panel, tie bar, and rocker panel.

Note number and location of shims removed from

locations shown in Figure 7.

8. Remove fender from vehicle.

Installation

Refer to disassembly procedure for location of screws

and install screws loosely. Install the shimmed screws

at rocker panel and cowl and adjust fender (figs. 4 and 5)

before tightening other screws. Always start adjustment

with original amount of shims, then add or remove shims

as required.

FENDER SKIRT

Removal

CAUTION: Chevelle air conditioned models

have condenser hoses routed through the right

front fender skirt. Cut skirt and bend as neces-

sary to move hoses clear of skirt. If necessary,

refer to Section 1A for air conditioning compo-

nents and procedures.

CHEVROLET CHASSIS SERVICE MANUAL

CHASSIS SHEET METAL 11-5

GRILLE TO BE FLUSH

TO +.06 TO W/SHIELD

MOLDING

±.06 GRILLE TO FENDER

.06 -.05 FENDER TO

W/SHIELD MOLDING

GRILLE"
& FENDER; ~ ~

FLUSH ± .06

FENDER FLUSH TO .06 INBOARD

OF DOOR SURFACE. FULL LENGTH

OF VERTICAL OPENING.
12±.O6 HOOD

TO GRILLE

.12 -.04

TO FENDER
FLUSH ± .06

HOOD TO GRILLE

FLUSH ± .06

HOOD TO FENDER

.12/.17 (REF.)

AT RAD. SUPPORT

.18 ± .06 FENDER

TO DOOR

FLUSH ± .06

HOOD TO FENDER

09 zfc .06 FENDER

TO ROCKER

.75 (REF.) AT

TOP FLANGE

1.08 EXC. WAG

URFACE

TYPICAL ON SURFACE

FLUSH CONDITION

DESIRED

.75 REF.

Fig.
4
- Sheet Metal Adjustments - Chevrolet

1.
Remove fender as outlined above.

2.
Jack up front end of vehicle and remove wjheel.

3.
Remove all wires, hoses, cruise control, etc. at-

tached to skirt; also remove bolt attaching battery

tray bracket to skirt. Remove battery, j

Remove battery tray from vehicle. \

5.
On Chevrolet, remove screws securing bj:ace (fig. 1)

to skirt and dash panel and remove brace.;

Remove skirt attaching screws and remove skirt

from vehicle.. !
4.

6.

Installation
j

Install skirt and fender following the removal proce-

dure in reverse order. Refer to torque specifications in

rear of manual for correct torque values. !
FENDER TRIM

On Chevelle, to gain access to spear molding and em-

blem retaining nuts, remove skirt to fender flange screws

top center rearward and pry skirt forward several inches.

Wedge skirt in this position with a wood block and re-

move nuts from inside fender retaining molding to fender.

Emblem attaching hardware is accessible from inside

engine compartment. t

On Chevrolet, open front door and rear inside door

hinge pillar for access to trim retaining nuts. Remain-

ing trim retaining nuts, and emblem retaining nuts are

accessible from inside engine compartment.

CHEVROLET CHASSIS SERVICE MANUAL

CHASSIS SHEET METAL 11-7

Fig.
6 - Hood Catch and Lock Plate - Chevelle Shown

HOOD CATCH AND LOCK {Fig. 6)

Removal

1.
Remove catch plate assembly by removing screws

retaining catch to radiator support, center support,

and tie bar.

2.
Remove lock plate by removing screws retaining lock

plate to hood and remove lock plate.

Installation

1.
Install lock and catch plate following the removal

procedure in reverse order. Refer to torque speci-

fications in rear of manual for correct torque values.

2.
Adjust lock and catch plate as outlined under adjust^

ment procedure in this section.

FENDER

ASSEMBLY

ROCKER

PANEL

BODY HINGE

PILLAR

VIEW B

Fig.
7 - Fender to Cowl and Rocker Panel Shimming
HOOD TRIM AND INSULATION (Figs. 13 and 14)

Figure 13 shows the installation details of both the

hood ornamentation and insulating pads. The hood em-

blem and molding retaining nuts may be reached from the

underside of the hood panel.

COWL VENT GRILLE (Figs. 1 and 2)

Removal

1.
Raise hood.

2.
Remove windshield wiper arms and disconnect

washer hoses from tubes. Remove screws securing

washer tubes to cowl vent grille. Pull tubes out

from under rubber molding and remove.

3.
Remove cowl vent grille retaining screws.

4.
Leaving rubber molding in place, remove cowl vent

grille from vehicle.

Installation

Install cowl vent grille following removal procedure in

reverse order. Refer to Figure 4 and 5 for correct

sheet metal adjustments.

REAR WHEEL COVER (CAPRICE, AND OPTIONAL

ON OTHER CHEVROLET MODELS EXCEPT

STATION WAGONS)

Removal and Installation

Lift the skirt (fig. 15) retaining lever (at the bottom

inside skirt flange) over the lip of the flange and pull it

downward. Pull the skirt downward and out of the open-

*
ing. To install the skirt: position it inside the opening,

insert the rod into the slot, lift the skirt and attach the

hook to the wheel opening flange. Hold the skirt from

below and behind to assure proper hook attachment then

lift the retaining lever up and into the skirt lip. Check

to insure cover is firmly engaged to fender.

SIMULATED WOOD GRAIN MOULDING

(STATION WAGONS ONLY)

The wood grain transfer film is a vinyl material with

a pressure sensitive adhesive backing. The transfers

are serviced in pre-cut panels. The shelf life of this

material is 90 days at a maximum temperature of
105°
F.

Removal

Remove the mouldings from the affected panel. Re-

move the transfer film by lifting an edge and peeling the

material from the painted surface. Exercise care so as

not to damage the paint.

NOTE: Application of heat to the transfer and

panel with a heat gun or heat lamp will aid in the

removal.

Installation

Preparation of the surface to which the transfer will

be applied is very important. In cases where body metal

repair has been made it is necessary to prime and color

coat these areas to blend with the undamaged surface.

Apply the transfer film to color coated panels only, never

to bare metal or primer. The surface must be free of

any imperfections that may high-light through the film.

Remove dirt nibs and other foreign material in the paint

by light sanding with 600 grit sandpaper.

CHEVROLET CHASSIS SERVICE MANUAL

CHASSIS SHEET METAL 11-12

GENERAL DESCRIPTION

The sturdy front end structure is formed by three

welded assemblies, the left and right hand fender skirts

and the radiator support panel. These units are bolted

together and to the dash panel (fig.
16).

Fender skirts, containing spring towers and support

brackets for control arms, are welded to the reinforced

"closed hat section" side rails. The skirts and rails

are fastened at top and bottom to reinforced areas of the

dash panel. Each skirt and rail assembly is securely

mated ta the body with three bolts at the top, and at the

stub fr|.me butt plates with a four bolt series. Heavy

gauge, formed, reinforcing plates receive the top of the

fender skirt and provide a shimming surface for precise

alignment of front end and body when assembled.
The one-piece radiator support panel completes a box

section when welded to the front crossmember. The

panel is formed to add structural strength and rigidity.

This strong combination is bolted along the full length of

each forward vertical edge of the fender skirts and at

the stub frame ends. Additional strength is obtained from

rigid diagonal corner braces. These open hat section

braces, bolted to side rails and front crossmember,

provide mountings for the suspension tension struts.

Conventional front fenders, grille, bumper and brack-

ets all bolt on to the unit front end structure. The hood

is connected to the front end with hinges that are attached

to the fender skirts.

MAINTENANCE AND ADJUSTMENTS

" TO •/•"

Fig.
17 - Sheet Metd Adjustment - Chevy II

CHEVROLET CHASSIS SERVICE MANUAL

CHASSIS SHEET METAL 11-18

b.
Check and adjust front wheel alignment as out-

lined in Section 3.

c. Check and adjust headlamp aiming as outlined in

Section 12.

HOOD ASSEMBLY

Hood may be removed either with or without hinges.

To shorten aligning time, hood hinge plates may be lo-

cated by scribing a mark on hood and/or body which

outlines entire plate. See Maintenance and Adjustments -

Hood Hinge for hood adjustment procedure. Hood hinge

springs may be easily and safely removed and installed.

through the use of Tool J-9559 as follows:

1.
With hood opened only far enough to allow passage of

mechanic's arm between hood and fender, insert ends

of J-9559 (through bolt removed) between coils of

spring until barrel of tool contacts outer diameter

of spring.

2.
Open hood fully while still holding spring (with tool

installed) in hand; when hood is near fully opened

position, spring may be removed as shown in Figure

28.

3.
As soon as spring is removed, insert long bolt sup-

plied with J-9559 through holes in end of tool, pass-

ing it through spring, and install nut on bolt.

Spring may be removed from J-9559 or J-9559 may be

installed in a new spring by the following method:

1.
Place a closed 6 or 8 inch "C" clamp in a vise or

fasten it to a heavy bench top (bench should be fas-

tened to floor).

2.
Hook one end of spring in clamp and the other end

in hook of a hoist as shown in Figure 29.

3.
Stretch the spring enough to allow insertion of

J-9559. Install through bolt if spring is not to be

installed on hinge at once.

HOOD CATCH AMD LOCK (Fig. 19)

Removal

1.
Remove catch assembly as follows:

a. Remove screws retaining catch assembly to radi-

ator support.

b.
Remove screws retaining catch assembly to catch

support assembly.

c* Remove screws retaining catch assembly to grille

upper bar.

2.
Before removing hood lock plate from hood, locate

position on hood by scribing around base of lock

plate. Remove screws retaining lock plate to hood

and remove lock plate from vehicle.

Installation

1.
Install both catch and lock assemblies in reverse

order of removal procedure.

2.
Align as outlined under Maintenance and Adjust-

ments - Hood Catch.

HOOD TRIM

Crown Molding

Hood crown molding is retained by clips installed on

underside of hood. Clips may be removed by carefully

pressing them off molding mounting studs with screw

driver.
When installing a new molding, force clips onto mount-

ing studs as far as possible and then clench clips with

long-nosed pliers to eliminate gap between molding and

hood, as shown in Figure 30.

Emblem

The hood emblem is retained by four nuts which are

accessible from under the hood.

COWL VENT GRILLE

The cowl vent grille replacement procedure for Chevy

U is the same as for Chevrolet and Chevelle. Refer to

Chevrolet and Chevelle Cowl Vent Grille replacement

procedure and see Figure 16.

FRONT END ASSEMBLY

The Chevy n front end body design allows for removal

of the entire front end of the vehicle without disassembly

of front suspension of sheet metal. One man may remove

and transport the front end assembly using only a floor

jack placed under the crossmember and the vehicle front

wheels. Figure 31 illustrates the assembly in process

of removal with jack stand in position under rocker panel.

Proceed with removal
as.
follows:

Removal

1.
Remove hood assembly as outlined in this section.

2.
Remove engine assembly as outlined in Section 6.

On 4 cylinder models, replace crossmember.

3.
Raise car from floor and install jack stands as

shown in Figure 31.

4.
Remove pitman arm from steering gear as outlined

in Section 9.

5.
Remove steering gear mounting bolts from skirt

assembly.

6. Remove 4 bolts securing each skirt assembly to

lower dash brace.

7.
Remove fender-to-rocker extension mounting screws

and record shimming.

8. Remove brake hydraulic line and fuel line from right

hand skirt.

9. Position floor jack or equivalent under front cross-

member.

10.
Remove hydraulic line from main cylinder.

11.
Remove fender-to-cowl mounting screws and record

shimming.

12.
Remove upper skirt-to-dash mounting screws and

record shimming.

13.
Remove front end from vehicle as shown in Figure

31.

Inspection

If car has been involved in a collision, it is advisable

to carefully inspect cowl and dash area for damage. Pay

particular attention to welds, cage nuts, weld nuts and

skirt mounting surfaces. Cage and weld nuts may be

repaired by outright replacement (the best method), or

by the installation of spiral thread inserts. If the spiral

inserts are used, follow the instructions furnished by the

manufacturer. -

Installation

%, position front end assembly at upper dash mounts

and lower dash support, align screw holes with drift

punch and install all mounting screws and bolts

loosely; do not tighten until all screws and bolts are

started. Replace original shimming.

CHEVROLET CHASSIS SERVICE MANUAL

CHASSIS SHEET METAL 11-20

GENERAL DESCRIPTION

The Camaro sheet metal components are much the

same as other Chevrolet passenger models as shown in

Figure 32. The front end design is such that servicing

of the fenders and skirts is most efficiently performed
by removing the fender and skirt as an assembly. Refer

to Section 14 for bumper service procedures, Section 13

for radiator and grille, and Section 1A for air condition-

ing components.

MAINTENANCE AND ADJUSTMENTS

HOOD ADJUSTMENT

The Camaro hood is adjusted in the conventional man-

ner, by adjustment of the hood bumpers and hinges. The

two hood bumpers are located on each side at the top of

the radiator support. Do not attempt hood latch adjust-

ments until the hinges and bumpers are correctly ad-

justed. Latch adjustments are made so that effort re-

quired to open and close the hood is reasonable, and

hood alignment obtained by hinge and bumper adjust-

ment is maintained when the hood is closed. Note that

the hood latch is not designed to correct basic hood mis-

alignment.

HOOD HINGE (Fig. 33)

NOTE: The body mounted portion of the hood

hinges are slotted to provide up and down move-

ment. The hood mounted end is slotted to pro-

vide forward and rearward movement.

1.
Scribe a. line around the entire. hinge plate to be

repositioned.

2.
Loosen the appropriate screws and shift the position

of the hood into correct alignment using the scribe

marks to check amount of movement. Check align-

ment by tightening screws and closing the hood.

HOOD BUMPERS

Adjust hood bumpers so that hood top surface is flush

with fender and header panel top surfaces. See Figure

34 for correct sheet metal adjustment dimensions.

HOOD CATCH AND LOCK (Fig. 35)

Adjust hood lock bolt so that top surface of hood is

flush with top surface'of header panel. The distance that

the lock bolt protrudes out of the lock plate should be

adjusted so that the hood bumpers are slightly com-

pressed by the fully latched hood, and effort required

to release the hood catch is reasonable. Close the hood

and insure catch engages securely.

FENDERS

Fenders are adjustable with shims at the cowl and

rocker panel. To add or remove shims, loosen bolts
Fig. 33 - Hood Hinge - Camaro

at shim locations (fig. 36) and carefully apply force with

pry bar to provide clearance for shim removal or in-

stallation.

SHEET METAL

For proper operation of doors and hood, and for pre-

sentable appearance, adjust front sheet metal to the di-

mensions shown in Figure 34.

COMPONENT PART REPLACEMENT

NOTE: When replacing sheet metal compo-

nents on Camaro, note position and attachment

of all seals and dust shielding and replace if

necessary.

BATTERY TRAY

Removal

1.
Disconnect battery cables and remove battery from

vehicle.

2.
Remove screws securing battery tray to fender skirt

and radiator support.

3.
Remove battery tray from vehicle.
Installation

Install battery tray following removal procedure in

reverse order.

RADIATOR SUPPORT

Removal

1.
Raise hood, disconnect battery cables, and remove

battery.

2.
Remove front bumper (Section 14).

3.
Remove grille and related components (Section 13).

4.
Disconnect horns, horn relay, voltage regulator,

CHEVROLET CHASSIS SERVICE MANUAL

CHASSIS SHEET METAL 11-22

wiring harness, and washer bottle from radiator

support.

5.
Remove screw connecting battery tray to radiator

support.

6. Remove shroud from vehicle if so equipped.

7.
Remove shroud and radiator (Section 13).

8. Remove screws securing support to frame, skirts,

and fenders.

9. Remove radiator support from vehicle.

Installation

Install radiator support following the removal pro-

cedure in reverse order. Refer to torque specifications

in rear of manual for correct torque values for radiator

supportj grille, and bumper.

FENDER AND SKIRT ASSEMBLY

Removal

1.
Remove front bumper (Section 14).

2.
Remove hood and hood.hinges (two men).

3.
Remove bolts securing brace to skirt and dash panel

and remove brace (fig. 32).

4.
Disconnect any components attached to fender and

skirt such as cruise control, hoses, electrical har-

ness etc.

5.
Remove screws securing radiator support to fender

and skirt.

6. Remove headlamp bezel and headlamp.

7.
Remove screws securing fender and skirt assembly

to header panel, headlamp housing and valance panel.

Remove screw securing fender extension to valance

panel.

8. Remove screws securing fender and skirt assembly

to vehicle and remove fender and skirt assembly.

9. If necessary, remove screws attaching fender ex-

tension and bumper bracket to fender and remove

extension and bracket. Replace fender trim if nec-

essary.

Installation

Install fender anci skirt assembly following the removal

procedure in reverse order. Refer to torque specifi-

cations in rear of manual for correct torque values.

HOOD ASSEMBLY

Procedures for hood removal and installation for

Camaro are the same as for Chevrolet and Chevelle.

Refer to Chevrolet and Chevelle hood removal and in-

stallation procedures, Figure 35 for Camaro hood catch,

support, and lock plate, and Figure 37 for Camaro hood

and insulator.

HOOD CATCH AND LOCK (Fig. 35)

Removal

1.
Remove catch plate assembly by removing screws

retaining catch to header panel, center support, and

radiator support.

NOTE: Before removing hood lock plate from

hood, locate position on hood by scribing around

base of lock plate.

2.
Remove lock plate by removing screws retaining lock

plate to hood and remove lock plate.
Fig.
35 - Hood Catch, Support, and Lock Plate - Camaro

Installation

Install lock and catch plate following the removal pro-

cedure in reverse order. Refer to torque specifications

in rear of manual for correct torque values. Adjust lock

and catch plate as outlined under adjustment procedure

in this section.

HOOD TRIM AND INSULATION (Fig. 37}

. Figure 37 shows the installation details of the Camaro

hood ornament and insulation pad. The insulation and

ornament retainers and nuts are accessible from under

the raised hood.

COWL VENT GRILLE

.Procedures'for Camaro cowl vent grille replacement

are the same as for Chevrolet and Chevelle. Refer to

Chevrolet and Chevelle cowl vent grille replacement.

CHEVROLET CHASSIS SERVICE MANUAL

ELECTRICAL-BODY AND CHASSIS 12-2

FJg.
1 - Fuse Panel Assembly

All power window and tailgate circuits require the igni-

tion switch to be "ON" to open or close the windows un-

like past model designs which were operated independ-

ently of the ignition switch.

The windshield wiper and washer switch is new in that

washer button in the center of the knob has been deleted
and its function will be accomplished by pushing the knob.

A set screw is used to retain the knob to the shaft.

In addition to fuses, the wiring harness incorporates

fusible links to protect the wiring. Links are used rather

than a fuse in wiring circuits that are not normally fused,

such as the ignition circuit. Fusible links in the Chevro-

let wiring are four gauge sizes smaller than the cable it

is designed to protect. The links are marked on the

insulation with wire gauge size because of the heavy insu-

lation which makes the link appear a heavier gauge than it

actually is.

Engine compartment wiring harness incorporate sev-

eral fusible links. Each link is identified with its gauge

size.
A fusible link is a length of special wire (normally

four wire gauges smaller than the circuit it is protecting)

used in wiring circuits that are not normally fused, such

as the ignition circuit. The same size wire with a spe-

cial hypalon insulation must be used when replacing a

fusible link.

The links are:

1.
The pigtail lead at the battery positive cable (except

Corvette) is a 14 gauge, brown fusible link protecting

the 10 gange battery charging circuit. This wire is

an integral part of the battery cable assembly and

servicing requires replacing the complete battery

cable assembly. On Corvette models this link is

installed as a molded splice at the solenoid "Bat"

terminal and servicing requires splicing in a new

link.

2.
A 16 gauge black fusible link is located at horn relay

to protect all unfused wiring of 12 gauge or larger.

It is a serviceable piece with an in-line connector

and is not integral with the wiring harness.

3.
The generator warning light and field circuitry (16

gauge wire) is protected by a fusible link (20 gauge

orange wire) used in the "battery feed to voltage

regulator #3 terminal" wire. The link is installed

as a molded splice in the generator and forward lamp

harness and is serviced by splicing in a new 20 gauge

wire as required.

4.
The ammeter circuit on all models is protected by

two orange, 20 gauge wire fusible links installed as

molded splices in the circuit at the junction block or

the solenoid "Bat" terminal (Corvette only) and at the

horn relay. Each link is serviced by splicing in a

new 20 gauge wire as required.

The wiring harnesses use a standarized. color code

common to all Chevrolet vehicles. Under the color code,

the color of the wire designates a particular circuit. The

harness title indicates the type of harness, single of mul-

tiple wire, and also describe the location of the harness.

The body harness is a flat, solid wire assembly and is

routed through the vehicle near the center of the body.

Composite wiring diagrams (figs. 104 thru 124) are in-

cluded at the end of this section.

MAINTENANCE AND ADJUSTMENTS

Maintenance of the lighting units and wiring system

consists of an occasional check to see that all wiring

connections are tight and clean, that the lighting units are

tightly mounted to provide good ground and that the head-

lamps are properly adjusted. Loose or corroded con-

nections may cause a discharged battery, difficult start-

ing, dim lights, and possible damage to generator and

regulator. Wire harnesses must be replaced if insulation

becomes burned, cracked, or deteriorated. Whenever it
is necessary to splice a wire or repair one that is bro-

ken, always use solder to bond the splice. Always use

rosin flux solder on electrical connections. Use insulat-

ing tape to cover all splices or bare wires.

When replacing wires, it is important that the correct

size be used. Never replace a wire with one of a smaller

size.

Each harness and wire must be held securely in place

by clips or other holding devices to prevent chafing or

CHEVROLET CHASSIS SERVICE MANUAL

ELECTRICAL-BODY AND CHASSIS 12-3

Fig.
2 - T-3 Safety Aimer

wearing away the insulation due to vibration.

By referring to the wiring diagrams, circuits may be

tested for continuous circuit or shorts with a conventional

test lamp or low reading volt meter.

HEADLAMP ADJUSTMENT-

T-3 HEADLAMPS

CAUTION: Check and tighten radiator support

grille retaining bolts prior to attempting head-

lamp aiming. Distorted grille or supports in

this area will hinder proper aiming of head-

lamps. On Corvette models make sure head-

lamp panel is adjusted properly - refer to

"Headlamp Panel Travel Adjustment".

When aiming headlamps, vehicle should be filled to ca-

pacity with gas, oil, and water but no load. Tires should

be uniformly inflated to recommended pressure.

the T-3 Safety Aimer-Type B (fig. 2), is used for the

headlamp aiming description that follows. An adapter is

required with the Type B T-3 Aimer when adjusting the 7

inch headlamp used on the Chevy n vehicle.

1.
Drive vehicle onto selected aiming area. Bounce

vehicle several times and allow to settle.

2.
Remove headlamp bezels.

3.
Mount the T-3 Aimers on either the No. 1 or No. 2

pair of headlamps so that "the points of the headlamps

engage the smooth inner ring of the aimers.
HORIZONTAL

AIMING

SCREW

STRING OVER

"2R" ON AIMER ARM

Fig.
4—-Headlamp Horizontal Adjustment

NOTE:
In the dual headlamp installation, the

inboard unit is designated No. 1 and the outboard

unit is designated No. 2.

4.
Secure the aimers to the headlamp units by firmly

pressing knob at center of each aimer (fig. 3). Ro-

tate crossarms inboard to approximate horizontal

position.

NOTE:
Moisten suction cups slightly to obtain

maximum holding force.

5. With both aimers in place, knot both ends of elastic

string and, using slots provided, fasten string across

horizontal crossarms of each aimer.

6. Rotate both aimers so that the string just clears the

points on the crossarms.

HORIZONTAL ADJUSTMENT

7. a. Turn horizontal aiming screw, Figure 4, on left-

VERTICAL ADJUSTMENT SCREW

Fig.
3 - Installing Aimer on Headlamp Unit
Fig.
5 - Headlamp Vertical Adjustment

CHEVROLET CHASSIS SERVICE MANUAL