headlamp CHEVROLET CAMARO 1967 1.G Chassis User Guide

ELECTRICAL-BODY AND CHASSIS 12-6

\ \

CHEVROLET
CHEVELLE

CHEVY II
CAMARO

Fig.
10 - Headlamp Assemblies (Exc. Corvette)

1.
2.
Remove two bolts retaining housing assembly in Corvette (Fig. 12)

bumper and remove housing.

3.
Remove lens retaining screws, lens and bulb from

housing assembly and transfer to new housing unit.

4.
Connect lamp wiring assembly to harness assembly,

housing and check operation of lamp.

5. Position lamp assembly in place and.install retaining

bolts.

Camaro (Fig. 10)

1.
Raise hood.

2.
Disconnect wiring harness at rear of lamp socket.

3.
Remove attaching nut and disconnect ground wire at

sheet metal connection.

4.
Remove retaining nuts and housing from grille

opening.

5. Transfer lens and bulb to new unit.

6. To install, position lamp housing to grille opening

and install retaining nuts.

7. Connect ground wire to attaching point and install

retaining nut.

8. Connect wiring harness to lamp socket and check

operation of lamp.
Raise hood and disconnect harness connector from

lamp unit skirt-mounted
connector;
then
remove'lamp

unit connector from underside of skirt.

Working at the forward portion of the wheel well, re-

move the two lamp assembly retaining nuts and re-

move the lamp assembly and support from the

vehicle.

Route the lamp assembly lead wires through fender

cutout and position support over lead wires.

Position lamp unit studs through support and install

retaining nuts, making sure that the studs are

horizontal.

Connect harness to lamp unit skirt-mounted connec-

tor and close vehicle hood.

FENDER LAMP SERVICE (Fig. 11)

Chevrolet 16600 Models

1.
Disconnect parking lamp wiring from forward har-

ness connector.

CHEVROLET CHASSIS SERVICE MANUAL

EL«C7RICAL-BODY AND CHASSIS 12-7

PARKING
A

LAMP*
2.
Remove two screws retaining lens housing to the

lamp assembly and remove lens unit.

3.
Replace bulb, lens or housing as required and posi-

tion assembly to fender opening. Make sure wiring

Fig.
11 - Parking and Fender Lamps (Chevrolet)

Fig.
12 - Parking Lamp Installation (Corvette)

Fig.
13 - Headlamp Panel and Motor Details (Corvette)

CHEVROLET CHASSIS SERVICE MANUAL

ELECTRICAL-BODY AND CHASSIS 12-8

is inserted through radiator support opening.

Remove two screws retaining lamp assembly to

lower sheet metal.

Remove three screws retaining lamp assembly to

lender.

To replace lamp assembly, reverse removal proce-

dure and check operation of the unit.
is aligned with flat on pivot shaft. Install stop lock

bolt and torque bolt to 45-60 in, lbs. Make sure that

side-to-side panel alignment is not changed when in-

stalling and tightening the stop.

CAUTION: Do not exceed specified torque

when tightening stop lock bolt.

HEADLAMP PANEL REPLACEMENT-CORVETTE

Refer to Figure 13 for Panel Mounting details.

1.
Remove engine compartment hood as outlined in

Section 1.

2.
Actuate headlamp panel to the open position.

NOTE:
In the event headlamp motor is inop-

erative, manual positioning of the panel can be

accomplished by turning the knurled knob at in-

board end of motor. As an assist in manual

operation of panel, apply light hand pressure to

panel in desired direction of rotation.

3.
Remove positive lead from battery terminal.

4.
Remove headlamp bezel retaining screws and bezel.

5. Remove the sealed beam housing unit as an assem-

bly - disconnect sealed beam leads at harness con-

nector and remove connector from sealed beam

leads;
remove the housing-to-panel retaining screws

and remove housing unit and wiring from panel.

6. Remove motor from panel pivot shaft - see motor

removal procedure. Then remove the panel stop

from panel inboard pivot shaft, and disconnect switch

lead wires from panel, support-mounted motor

switch.

7. Remove the panel retaining bolt access hole plugs

from inside the panel then rotate panel as required

and remove the retaining bolts and slide supports

from ends of panel pivot shaft. Remove bearing, felt

seal, retainer and washer from inboard pivot shaft.

8. Remove panel from its location by alternately disen-

gaging pivots from their retaining slots and with-

drawing unit forward through opening in body (fig.

14).

9. Loosen alien screw in spacer and disassemble parts

from the panel outboard pivot shaft.

10.
Install washer, retainer, felt seal, bearing and

spacer, in that order, to panel outboard pivot shaft.

Do not tighten spacer on shaft at this time.

11.
Position panel in body opening and index panel pivot

shafts in retaining slots; then loosely install support

retaining bolts.

12.
Install washer, retainer, felt seal, bearing and sup-

port, in that order, to panel inboard pivot shaft, and

loosely install support retaining bolts. -

13.
Check side-to-side alignment of panel, making sure

that there is no panel-to-body contact; position

spacer snugly against bearing; then tighten spacer

seat screw to 30-50 in. lbs.

14.
Install stop on panel inboard shaft so that it rests

against bearing, being sure that index mark on stop
15.
Check and align panel to body as follows:

a. Tighten panel pivot support bolts snugly but still

allowing panel to" be moved by applying hand

pressure.

b.
Position panel to the closed position and align

with body so that all surfaces are flush.

c. With the panel in the closed position the outboard

access hole is aligned with the forward bolt head.

Tighten this bolt with the panel in the closed

position - access to bolt head can be obtained by

working through opening between the hood and

body.

d. Rotate panel to obtain access to each bolt head

and torque bolts to 100-140 in. lbs.

e. Connect switch lead wires to support-mounted

limit switch.

16.
Install seaLed beam housing unit and at the same time

position sealed beam lead wires through panel out-

board pivot shaft. Install housing unit retaining

screws and install lead wires in connector, making

sure to match colors between harness and connector.

17.
Install motor assembly - see motor replacement

procedure.

18.
Connect positive lead to battery terminal.

19.
Adjust headlamp panel as outlined under "Headlamp

Panel Travel Adjustment".

20.
Adjust headlamp aiming as outlined under "Headlamp

Adjustment".

21.
Install headlamp bezel and engine compartment

hood - refer to Section 1 for hood installation.

Fig.
14
- Headlamp Panel Removal (Corvette)

CHEVROLET CHASSIS SERVICE MANUAL

ELECTRICAL-BODY AND CHASSIS 12-9

Fig.
15 - Headlamp Panel Actuating Motor Mounting (Corvette)'

HEADLAMP PANEL MOTOR-CORVETTE (Fig. 15)

Removal

1.
Raise hood and as a safety precaution install a bolt

through the hole in the hood support - secure bolt

with a nut.

2.
Remove positive lead from battery terminal.

3.
Disconnect motor lead wire and position it out of the

way.

4.
Turn the knurled knob at inboard end of motor until

the gear seems to turrj freely - turn the knob in one

direction until a definite drag is experienced, then

rotate knob approximately six complete turns in the

opposite direction.

NOTE:
The above step is necessary to produce

a no-load condition on the drive gear and to per-

mit separation of motor from the panel pivot

shaft.

5. Remove the retainer from groove in motor locating

stud then remove the motor-to-support retaining

screw and remove motor assembly from the vehicle.

Installation

1.
Rotate motor and headlamp panel as required to align

slot in motor with headlamp panel pivot shaft, and

install motor on shaft so that the bracket is aligned

with the locating stud.

NOTE:
It may be necessary to turn knurled

knob on end of motor to permit alignment of

motor with shaft.
Slide motor onto shaft until it seats against shaft

shoulder; then install retainer in groove on locating

stud.

Install motor-to-support retaining screw making

sure ground wire is installed between screw head and

bracket.

Connect motor lead wires, making sure that contacts

are clean and that connection is secure.

Connect positive lead battery terminal, remove bolt

from hood support, close hood and check operation of

headlamp panel.

HEADLAMP MOTOR REPLACEMENT-

CAMARO (Fig. 16)

1.
Disconnect battery ground cable and when working on

right headlamp unit, remove battery from vehicle to

gain access to housing retaining bolts.

2.
Remove bezel retaining screws and bezel.

3.
Remove headlamp cover retaining screws and cover

from door assembly.

4.
Manually open door assembly (push door toward cen-

ter of vehicle) and disconnect limit switch

connections.

5. Remove four screws retaining assembly to radiator

support (note location and number of shims, if any).

6. Rotate assembly toward center of vehicle until rear

of unit is exposed, then disconnect wiring connectors

at headlamp and motor assemblies.

7. Rotate assembly until headlamp is facing downward

and carefully remove the assembly from the vehicle

opening.

8. Remove nut attaching motor assembly to pivot arm.

9. Remove two nuts and bolts retaining motor assembly

to base plate and remove motor assembly.

CHEVROLET CHASSIS SERVICE MANUAL

ELECTRICAL-BODY AND CHASSIS 12-10

10.
To install, replace motor assembly, and reverse re-

moval procedure.

REAR LIGHTING SERVICE

TAIL, STOP AND DIRECTIONAL LAMPS

Bulb Replacement (Fig. 17)

1.
Disconnect lamp socket from rear of lamp unit and

remove bulb from socket.

NOTE:
Bulb removal on station wagon models

and Corvette requires, removal of the lens to

gain access to the bulb.

2.
Replace bulb and plug socket back into lamp housing.
Lamp Housing Replacement

Chevrolet, Chevelle Station Wagon,

Camaro and Chevy II (Fig. 17)

1.
Disconnect bulb socket from rear of lamp unit.

NOTE:
On station wagons remove lens to gain

access to lamp or screws securing lamp housing

to body.

2.
Remove nuts at rear of housing retaining lamp hous-

ing to vehicle body, remove housing from vehicle.

3.
Remove lens retaining screws or nuts, remove lens

and transfer to new housing unit.

4.
To install reverse removal procedure and check op-

eration of lamp unit.

HEADLAMP

WIRING ASSEMBLY
MOTOR

INSTALLATION

TO PARKING LAMP

TO RETR. HDLP. MOTOR

TO HEADLAMP
HEADLAMP

DOOR ASSEMBLY

Fig.
16- Headlamp Motor Installation (Comoro)

CHEVROLET CHASSIS SERVICE MANUAL

ELECTRICAL-BODY AND CHASSIS 12-15

Fig.
21 - Qlal Quadrant Assembly ~ Camaro

SEAT SEPARATOR CONSOLE LAMPS

COMPARTMENT LAMP REPLACEMENT (Fig.
22)

1.
Remove (pry up) switch assembly from console open-

ing in.the instrument compartment.

2.
Remove bulb from the socket.

3.
Replace bulb and install switch assembly in console

opening.

COURTESY LAMP REPLACEMENT (Fig. 22)

1.
Remove two screws and lens at rear of console.

2.
Remove bulb from retainer.

3.
Replace the bulb, position the lens and install attach-

ing screws.

QUADRANT LAMP REPLACEMENT (Fig. 22)

1.
Remove Dial Quadrant Trim plate retaining screws

and lift trim plate assembly from console opening.

2.
Disconnect lamp socket from the retainer and re-

move bulb from the socket.

3.
To install, insert bulb into the socket and snap the

socket assembly into the retainer.

Position the trim plate assembly into the console

opening and install the retaining screws.
4.

LIGHTING SWITCH REPLACEMENT (Fig. 24)

1.
Disconnect battery ground cable.

2.
Pull control knob out of headlamp ON position.

3.
Reach under instrument panel and depress the switch

shaft retainer (Fig. 25) and remove knob and shaft

assembly.

4.
Remove ferrule nut using Tool J-21932 and remove

switch assembly from instrument panel.

NOTE:
Some Chevelle models require use of

ToolJ-4880.

5. Disconnect the multi-plug connector from the lighting

switch. A screw driver may be inserted in the side
of the switch to pry the connector from the switch.

6. Connect the multi-plug connector to the replacement

switch (Fig. 23). Connect battery cable to battery

terminal and check operation of the light switch'in all

positions.

NOTE:
Ground switch- to check dome lamp

operation.

7. Position switch and bezel to panel mounting hole and

install ferrule jmt.

8. Insert switch control knob and shaft assembly into

switch until retainer engages shaft.

WIPER SWITCH REPLACEMENT (Fig. 26)

1.
Disconnect battery ground cable.

2.
Remove the connectors from the rear of the switch.

NOTE:
On Air Conditioned models it is nec-

essary to remove left A/C outlet duct for acces-

sibility to rear of switch.

3.
Loosen set screw and pull knob from switch shaft.

4.
Remove retaining nuts using special Tool J-21932

and withdraw wiper switch from behind console.

NOTE:
Some Chevelle models require special

ToolJ-4880.

5. To install, reverse removal procedure and check

operation of wipers.

STOPLIGHT SWITCH REPLACEMENT (Fig. 27)

1.
Disengage retaining fingers, disconnect wiring har-

ness connector from switch and unscrew switch from

mounting clip.

2.
Depress brake pedal and push new switch into clip

until shoulder bottoms out against clip.

3.
Check switch position for proper operation. Elec-

trical contact should be made when the brake pedal is

depressed 3/8" to 5/8" from fully released position.

DIMMER SWITCH REPLACEMENT (Fig. 28)

1.
Fold back upper left corner of front floor mat, disen-

gage connector lock fingers, and disconnect multi-

plug connector from dimmer switch.

2.
Remove two screws retaining dimmer switch to toe

pan.

3.
Connect multi-plug connector to new switch and

check operation. Install new switch to toe pan with

two screws. Replace floor mat.

BACKING LAMP SWITCH REPLACEMENT

Located on Mast Jacket (Fig. 29)

1.
Disconnect wiring connector at switch terminals.

2.
Remove switch attaching screws and switch from

mast jacket.

3.
Position new switch to mast jacket, install the re-

taining screws and connect wire connector to switch.

NOTE:
Position gear shift in neutral before

assembling switch to mast jacket.

4.
Check operation of switch.

Located on Transmission (Fig. 30)

1.
Raise and support vehicle.

CHEVROLET CHASSIS SERVICE MANUAL

ELECTRICAL-BODY AND CHASSIS 12-35

SERVICE OPERATIONS

INSTRUMENT CLUSTER

REMOVAL AND INSTALLATION (Fig. 49)

1.
Remove mast jacket assembly. Refer to Section 9

for removal procedures.

2.
Disconnect tachometer drive cable at distributor.

3.
Disconnect the headlamp panel control switch from

instrument cluster.

4.
Remove lighting switch as outlined in this section.

10 10-A 1112 13

14
15 16 17 18 19

Fig.
49- Instrument Cluster Connections

1.
Cluster Illuminating

Bulbs

2.
Direction Signal Indicator

Bulb L.H.

3. Direction Signal Indicator

BulbR.H.

4.
Headlamp Actuating Motor

Indicator

5. Headlamp Hi Beam

Indicator

6. Parking Brake Alarm

Indicator

7. Ground Lead Attaching

Point

8. Temperature Indicator
"1"

Terminal
9.

10.

10A.

11.

12.

13.

14.

]5.

16.

17.

18.

19.

20.

21.
Temperature Indicator "S"

Terminal

Ignition Switch Receptacle

ignition Switch Illuminating

Bulb

Oil Pressure Indicator

Tachometer

Lighter Receptacle

Trip Odometer

Wiper Switch Receptacle

Speedometer

Ammeter "Gen" Terminal

Ammeter "Battery" Terminal

Lighting Switch Receptacle

Fuel Gauge
"1"
Terminal

Fuel Gauge "S" Terminal

5. Remove the ignition switch. Refer to Section 6Y

for removal procedure. Then disconnect ignition

switch lamp support at instrument panel.

6. Disconnect oil pressure line at oil pressure gauge

then remove the lead wires from ammeter, wiper

switch and cigarette lighter. Disconnect trip odom-

eter at mast jacket support.

7. Remove the instrument cluster-to-dash retaining

screws and pull cluster assembly slightly forward

to obtain clearance for removal of speedometer

cable, tachometer cable, cluster ground wire, fuel

gauge lead wires and remaining indicator and cluster

illuminating lamps.

8. To install cluster in dash panel, reverse removal

procedure.

FUEL GAUGE

The gasoline fuel gauge circuit consists of an electri-
cal indicator in the instrument cluster and a float-

controlled rheostat in the fuel tank.

Since the fuel gauge consists of two remotely located

units and connecting wires, it is sometimes difficult to

determine which unit is at fault when the gauge fails to

operate properly. Cluster removal is necessary to re-

place the fuel gauge.

NOTE:
Be sure to check gas gauge fuse in fuse

panel before attempting to trouble shoot for

inoperative gauge or tank sending unit.

SPEEDOMETER AND/OR TACHOMETER

Removal and Installation

Cluster must be removed from vehicle to service

speedometer head assembly (see Cluster Removal pro-

cedure)
.
With cluster removed from vehicle:

1.
Remove five screws securing cluster back panel to

cluster assembly; separate the parts carefully.

CAUTION: Care must be used to avoid marring

instrument cluster face.

2.
Remove two screws securing speedometer or ta-

chometer head to cluster back panel; carefully re-

move speedometer or tachometer head.

NOTE:
Servicing of speedometer or tachom-

eter head should be performed by an authorized

AC service station.

3.
Reverse above procedure to install speedometer.

Cable Replacement or Lubrication

1.
Disconnect the. cable from the speedometer or ta-

chometer head. Remove the old cable by pulling it

out from speedometer end of conduit.

NOTE:
If old cable is broken it may be nec-

essary to remove lower piece from transmission

or distributor end of conduit as applicable.

2.
Lubricate the lower 3/4 of cable with
AC
speedom-

eter cable lubricant and push the cable into the con-

duit. Connect the upper end to the speedometer or

tachometer head and road test vehicle for proper

operation.

TEMPERATURE GAUGE

The temperature indicator requires very little service

other than testing for malfunctioning and replacing de-

fective units. Cluster must be removed to service tem-

perature gauge.

Do not attempt to repair either the engine unit or the

gauge. When installing new engine unit, do not use

thread compound on unit threads, as this will increase

electrical resistance of unit and cause faulty reading

on gauge.

AMMETER OR OIL PRESSURE GAUGE

The ammeter or oil pressure gauge requires very

little attention other than keeping ammeter terminals

clean and tight. If the oil pressure control line should

become restricted it should be blown out or replaced.

Cluster must be removed to service these gauges.

HftVKI MANUAL

RADIATOR AND GRILLE 13-2

Fig.
1 - Radiator and Shroud - Chevrolet

3.
Remove fan.

4.
Remove bolts along top of radiator support, right and 4.

left radiator hold down clamps, and shroud center

bracket.

5. Remove horns and bolts retaining fan shroud to radi- 5.

ator support.

6. With helper, work radiator and fan shroud from vehi-

cle.

7. Reverse procedure to install. 6.

7.

GRILLE ASSEMBLY-CHEVROLET

Removal (Figs. 6 and 7)

1.
Raise hood and disconnect battery leads. 8.

2.
Remove bumper (Section 14).

3.
Remove bolts securing hood catch assembly to radi-

ator support, hood catch support and tie bar, and re- 9.
move hood catch from vehicle.

Remove screws attaching headlamp bezels to grille

reinforcements, fenders, and filler panel. Remove

bezels and headlamps from vehicle. •

Remove screws and rivits- from each fender trim

plate and remove fender trim plates with reinforce-

ments from vehicle. Refer to Figure 6 for attaching

hardware locations.

Remove rivits securing top of grille to tie bar.

Remove screw and rivits securing bottom" of grille to

filler panel and remove grille. If necessary, remove

nuts attaching name plate to grille and replace name

plate.

Remove screws attaching hood catch support to radi-

ator support and filler panel and remove catch sup-

port from vehicle. -

Remove screws attaching tie bar to fenders, radiator

CHEVROLET CHASSIS SEJMCE MANUAL

RADIATOR AND GRILLE 13-3

Fig.
2 - Radiator and Shroud - Chevelle

support, and grille reinforcements and remove tie

bar.

10.
Remove screws securing grille reinforcements to

filler panel and remove reinforcements.

11.
Remove filler panel attaching hardware and remove

filler panel from vehicle.

Repair

If tie bar, filler panel, hood latch support, or any other

components removed are undamaged, they may be used

for the new grille installation. Where rivets were re-

moved, make new attachments using screws and nuts,

patent clips, or rivets.
Installation

Install grille and related components following the re-

moval procedure in reverse order. Refer to torque

specifications in rear of manual for correct torque

values.

GRILLE ASSEMBLY-CHEVELLE (Fig. 8)

Removal

1.
Raise hood and disconnect battery leads.

2.
Remove screws from each headlamp bezel and re-

move headlamp bezels from vehicle. Remove head-

lamps.

CHEVROLET
Ch
SERVICE MANUAL

RADIATOR
AND
GRILLE
13-4

Fig. 3 - Radiator and Shroud - Chevy II

3.
Remove screws and nuts attaching grille extensions

to fenders and remove grille extensions.

'
4. Remove rivets attaching top of grille to tie bar.

5.
Remove screws attaching hood latch plate to tie bar,

catch support bracket, and radiator support and re-

move latch plate from vehicle.

6. Remove rivets securing grille reinforcements to tie

bar and filler panel and remove reinforcements.

7. Remove screws attaching tie bar to fenders, hood

catch
•
support, and radiator support and remove tie

bar.

8. Remove bumper (Section 14).

9. Remove rivet and screw securing hood catch support

to filler panel and radiator support and remove catch

support from vehicle.

10.
Remove rivets securing bottom of grille to filler

panel and remove grille.

11.
Remove attaching hardware securing filler panel and

filler panel reinforcements to fenders, fender

braces, and radiator support, and remove filler

panel.

12.
If necessary, remove nuts attaching name plate to

grille and replace name plate.
Repair

If any components removed are undamaged, they may

be used for the new grille installation. Where rivets

were removed, make new attachments using screws and

nuts,
patent clips, or rivets.

Installation

Install grille and related components following the re-

moval procedure in reverse order. Refer to torque spec-

ifications in rear of manual for correct torque values.

GRILLE ASSEMBLY-CHEVY
I! (Fig. 9)

Removal

1. Raise hood and disconnect battery leads.

2.
Remove bumper (Section 14).

3.
Remove screws and nuts securing hood catch assem-

bly to radiator support, grille, and catch support

bracket and remove catch from vehicle.

4.
Remove screws from each headlamp bezel and re-

move bezels from vehicle. Remove headlamps.

5.
Remove screws securing hood catch support to filler

panel and radiator support and remove catch support.

CHEVROLET CHASSIS SERVICE MANUAL