light CHEVROLET CAMARO 1967 1.G Chassis User Guide

HEATER AND AIR CONDITIONING 1A-65

Fig.
92—Chevrolet Four-Season Ducts

Installation

Reverse

assembly.
the removal procedure to reinstall the duct

Left Outlet Duct

Removal

1.
Remove the two parking brake lever bracket to

dash brace attaching screws and move the lever and

cable so they will not interfere with the duct

removal.

2.
Remove the screw and lock washer attaching the duct

outer bracket to the hinge pillar support.

3.
Remove the screws and lock washers attaching the

duct assembly to the dash brace bracket.

4.
Carefully pull the outer end of the duct downward,

detaching the courtesy light from its bracket.

5. Loosen the screws clamping the outlet duct to dis-

tributor assembly flexible tubing at the outlet duct.

The outlet duct may now be removed from beneath

the instrument panel.

6. The duct extension assembly and the deflector as-

sembly may be removed, if desired, as seen in

Figure 95.

Installation

The duct assembly is installed by reversing the re-

moval instructions.

Center Outlet Duct

Removal

1.
Remove the right and left console trim panels.

2.
Remove the radio receiver.

3.
Remove the electric clock.
4.
Remove the knobs, nuts and bezels from the two

air conditioning controls above the clock, AIR COND.

PULL and COLD IN-HOT PULL.

5. Carefully pull the outlet duct and control cables

loose from the rear of the center console and work

it down and out from under the dash. The left hand

control cable runs through the left hand flexible

tubing and may be left in the tubing after it is dis-

engaged from the duct. The right hand control cable

must also be pulled from the duct assembly as the

duct is removed.

6. The center deflector barrel assembly may now be

removed if necessary. Snap off the hairpin clips to

remove the barrel and spacer washers.

Installation

Reverse the removal procedure for installation.

AIR DISTRIBUTOR ASSEMBLY

Removal

1.
Drain the cooling system radiator.

2.
Remove the heater hoses from the core pipes and

remove the cover attaching nuts and cover surround-

ing the core pipes.

3.
Remove the glove compartment assembly and the

glove compartment door.

NOTE:.
See "Section 1 - Body" for removal

and installation of body items.

4.
Remove the right kick pad.

5. Remove the right and left center console trim panels.

6. Remove the radio receiver assembly.

7. Remove the defroster duct.

CHEVROLET CHASSIS SERVICE MANUAL

HEATER AND AIR CONDITIONING 1A-81

HORN RELAY

r

CONN.-

14 BROWN

(TO FUSE

PANEL)
BATTERY
1

—I ^ COMPR

ESSOR

DASH y

V-^ PANEL \

GROMMET—%
1 \

_ J~ ") "^

>14 BLACK/RED STRIPE-

FUSE .20 AMP.

•WIRE ASM. BLOWER-

MOTOR
14 BLACK 1

IGNITION SWITCH1

(ACCESSORY

TERMINAL)

CONTROL SWITCH
-RESISTOR

CONN.

•14 TAN

•16 BLACK

LIGHT BLUE STRIPE

•THERMOSTAT CONTROL

EVAPORATOR & BLOWER ASM.

Fig.
117—Universal System Wiring Diagram (Typical)

CHEVROLET CHASSI

CORVETTE BODY 1B-2

Fig.
1—Steel
Reinforcing Members

by loosening the hinge retaining bolts (lower) and moving

the hood to the limit of slotted holes in hinge strap.

The upper surface of hood may be brought flush with

adjacent surfaces by shimming under hinges and adjust-

ment of bumper screw and catch bolt engagement. Figure

3 illustrates desired spacing.

Hood Catch

The hood catch should be adjusted so that catch bolts

enter lock plates freely and catch bolt length should be

adjusted so that rubber bumpers are slightly compressed

in latched position.

Entrance of catch bolt into the plate may be adjusted

by loosening the three catch bolt mounting screws enough

to allow movement of bolt assembly.

Synchronization of catch release may be made by ad-

justing the cable retainer located at left hand catch plate

assembly.

HOOD ASSEMBLY

Removal

1.
If hood is to be reinstalled, scribe a line around hood

hinge upper strap as shown in Figure 4.

2.
With aid of a helper to support hood, remove screws

retaining hinge straps and support assembly to hood.

If hinges are removed from vehicle, note amount of

shims under each hinge.

Installation

In replacing original hood, align hinge with scribe

marks made on removal and install retaining screws re-

moved from hinges and support.
If adjustment is required, proceed as outlined in this

section under Adjustments - Hood - Hood Catch.

HOOD PROP

Safety Retention Feature

When extended under hood service operations are

anticipated, the hood prop track and slide should be se-

cured by placing a 1/4" bolt and nut through the existing

holes.
This will prevent accidental closing of the hood

that could result in a serious injury.

FRONT EMBLEM

The front emblem is retained by special nuts which

may be reached by raising hood (fig. 5).

wiper arm on side of car
VENT GRILLES

Removal

1.
Remove windshield

affected.

2.
Remove four screws attaching grille to body (fig. 5).

3.
Lift grille far enough to gain access to windshield

washer hose and remove hose from nozzle.

4.
Remove grille from vehicle.

Installation

Grille may be installed by following removal procedure

in reverse order.

INSTRUMENT PANEL TRAY

The instrument panel tray may be removed from the

CHEVROLET CHASSIS SERVICE MANUAL

CORVETTE BODY 1B-15

Fig.
32—Removing Regulator

GLASS RUN CHANNEL-REAR

Removal

For parts identification refer to Figure 41.

1.
Remove door trim assembly as outlined in this

section.

2.
Remove window glass assembly as outlined in this

section.

3.
Remove 2 channel retaining screws and pass chan-

nels out through large opening in door inner panel

(fig. 42).

Fig.
33—Removing Ventilator Assembly 19437
Installation

1.
Position run channel in door and install bolts loosely.

2.
Install window glass as outlined in this section.

3.
Make necessary adjustments to channel as outlined

under Doors - Adjustments - Door Windows.

4.
Replace door window and door trim panel.

WINDOW REGULATOR-MANUAL

For parts identification see Figure 41.

Removal

1.
Remove trim panel as outlined in this section.

2.
Remove door window glass as outlined in this

section.

3.
Remove screws retaining regulator assembly to

door panel.

4.
Remove screws holding lower guide rail to door

panel.

5. Remove regulator assembly from large access open-

ing as shown in Figure 43.

Installation

Regulator may be installed by following removal pro-

cedure in reverse order. Always lubricate all guide rails

and rollers when regulator is disassembled. Test regula-

tor thoroughly before installing door trim panel. Adjust

window as outlined in this section.

WINDOW REGULATOR-POWER

In cases where window will not operate, check electri-

cal connections first. Figure 44 illustrates lpcation of

junctions, switches and circuit breaker.

Removal

Perform operations 1 thru 5 under Window Regulator-

Manual Removal. Note, however, that electrical connec-

tors must be removed from motor before performing

any operation on regulator. Figure 44 illustrates in-

stallation of regulator on door and regulator wiring.

Disassembly

NOTE:
Do not attempt to remove motor from

regulator until the following operations are per-

formed. THIS IS A SAFETY ITEM; arm is

spring-loaded and may cause injury if not locked

in position when motor is removed.

Refer to Figure 45.

1.
Place regulator assembly in vise.

2.
Using jumper leads to 12 volt power supply, operate

motor until semi-circular hole in sector gear cen-

ters over one of two weld nuts on mounting plate.

3.
Screw a l/4"-20 x 1" bolt into weld nut so that end

passes through hole in sector gear. It may be neces-

sary to enlarge hole in gear slightly with file or

drill. Install nut on bolt to lock arm in position.

Installation

1.
Be sure lock bolt has been removed if regulator

has been disassembled.

2.
Install lubricated regulator assembly and guide rails

in door in reverse order of removal.

3.
Install window as outlined in this section.

4.
Making sure connectors are securely installed on

motor, test operation of window thoroughly.

5. Install door trim panel and handles as outlined in

this section.

CHEVROLET CHASSIS SERVICE MANUAL

CORVETTE BODY 1B-22

16.

17.

Fig.
47-Door Handle and Lock Cylinder
18.

19.

20.

21.

1.
Screw - Handle Retaining

2.
Reinforcement

3. Gasket - Rear

4.
Handle Assembly

5. Cylinder Assembly - Lock
6. Escutcheon

7.
Retainer

8. Rod - Lock Cylinder

9. Gasket - Front

14.
Cut off painted portion of cartridge nozzle along

edge of paint line.

15.
Mix adhesive caulking material and accelerator

] thoroughly according to directions on container.
NOTE:
Once caulking material is mixed, there

will be approximately 35 minutes of working

time with the material. Subsequent steps should

be performed immediately after caulking ma-

terial is mixed.

Place caulking material in cartridge as shown in

Figure 59.

Carefully apply a smooth continuous bead of caulking

material on inside surface of glass next to edge

completely around glass (fig. 60). Caulking material

should be approximately 1/4 inch wide at the base

and form a pyramid 3/8 inch high. If during appli-

cation the pyramid collapses, wait about 2-3 minutes

for material to set up. If an air bubble is encoun-

tered in material back up the applicator and apply

sufficient material to fill void and to dispense the

bubble before continuing.

The reveal molding clips are self sealing and do

not require sealing before installing the rear glass.

With aid of helper, lift glass and carefully position

glass on spacers, matching up marks on glass and

body as shown in Figure 61.

Press glass lightly to set caulking material to rear

window opening flanges. Paddle material where nec-

essary to insure proper seal.

Watertest rear window immediately using a cold

water spray. If any water leaks are encountered, use

flat bladed screw driver or stick and paddle caulking

material into leak point to correct leak. Correction

of leak is usually more effectively performed by

paddling material from inside the body.

CAUTION: Do not run a heavy stream of water

directly on caulking material while the material

is still soft.

22.

Install the reveal moldings in the following sequence:

Top,
sides, lower and the caps in each upper corner.

23.
Carefully remove masking tape from inside of glass

and install garnish moldings.

Fig.
49—Door Sill Plate and Molding

Fig.
48—Door Hinge
1.
Plate - Door Sill

2.
Retainer - Sill Molding

3. Sill Molding
4.
"U" Nut - Sill Molding Retainer

5. Special Nut

6. Spring Nut - Sill Molding

CHEVROLET CHASSIS SERVICE MANUAL

CORVETTE BODY 1B-29

CUSHION

CUSHION ASNi.^ty** ACCESS

#2 BODY BRACKET

( 67 ONLY)
SHIM

( 37 POSITION).

CUSHION ASM.

( 37)

SHIM

( 67 POSITION)

CUSHION

( 37 ONLY)

#1 BODY BRACKET

Fig.
65—Body Mounts

PRECAUTIONS

Creams are available to protect the skin from a con-

dition known as occupational, or contact dermatitis. This

common type of dermatitis is not contagious. Improved

resin formulas in the approved kits have almost elimi-

nated skin irritation. Cream is supplied with the kit for

men who may have a tendency toward skin irritation

from the resins or dust.

The application of these creams is recommended

whenever the Resin Kit materials are used. Generally,

the cream is not required when the plastic solder kit is

being used. Directions for using the cream is as follows:

a. Wash hands clean. Dry thoroughly.

b.
Squeeze about 1/2 inch (or 1/2 teaspoonful) of

#71 cream into palm of hand.

c. Spread evenly and lightly until cream disappears.

Work cream into cuticle, between fingers and

around wrists.

d. Apply second coat, repeating Steps b and c.

e. Hold hands briefly under cold running water to

set cream.

2.
Remove resin mixture from hands as soon as possi-

ble and imperatively before mixture starts to gel.

This can be observed by the action of the material

being used. Resin may be removed with lacquer

thinner by washing in soap and water.

3.
Respirators are recommended when grinding. Also

some minor skin irritation from glass and powdered

cured resin may be evident. Washing in cold water

will help to minimize.

4.
Use a belt sander with a vacuum attachment for dust

control if possible.
5. Resin mixtures may produce toxic fumes and should

be used in well ventilated areas.

6. Be careful not to get any resin material on clothing.

7. Use the right materials for the job. It is important

to use the approved kits because Chevrolet's rigid

quality standards assure you the right material to

do the job. Other materials available may not meet

the required engineering and safety standards.

8. Keep the materials, utensils and work area clean

and dry. These repairs involve chemical reactions,

and dirt or moisture may upset the chemical bal-

ances and produce unsatisfactory results.

9. Before starting repair operations, look for hidden

damage by applying pressure around the damaged

area, looking for hairline cracks and other breakage.

Check for minor damage at other points in the vehi-

cle such as around exhaust pipes, grille, headlamps

and points of wear or rub. Early repair of this

minor damage may prevent major repair later.

PLASTIC SOLDER
KIT

The Plastic Solder Repair Kit is used for minor re-

pairs on the Corvette body. These materials will produce

an easy, quick and lasting repair in the case of small

cracks, surface imperfections and small holes.

1.
Use paint remover or power sander, and remove

finish from damaged area. Carefully inspect for

other areas requiring repair.

2.
Mix the materials (fig. 72).

3.
Apply the material, using a putty knife or rubber

squeegee, Figure 73. Work the material into the

repair and build the material up to the desired

CHEVROLET CHASSIS SERVICE

CORVETTE BODY 1B-46

Fig.
99—Inner Forward Weatherstrip

or material from a hidden area directly on complaint

. car (such as under reveal moldings).

2.
Using an electric wood burning needle or low heat.

soldering gun, scrape off an appropriate amount of

vinyl from scrap piece of material or from hidden

area and immediately apply to scuffed or cut area on

car.

CAUTION: Be certain low heat is maintained to

prevent discoloration of cover.

3.
Carefully blend applied vinyl to fabric roof cover,

utilizing electric needle or soldering gun.

Wrinkles, Blisters and Bubbles

1.
Pierce each wrinkle, blister and bubble on fabric

roof cover with a small needle.

2.
Completely saturate a clean shop towel with water

and wring out.

3.
Apply cloth to wrinkle or blistered area.

4.
Apply a home type laundry iron over shop towel using

back and forth strokes until towel is dry. (If iron

has heat control settings, control should be set to

"wool".)

CAUTION: Do not continue to use iron after

towel has become dry as
excess,
heat may cause

permanent damage to vinyl roof cover.

5.
Remove towel and4nspect area. If slight wrinkles or

blisters are still present, perform the following

steps:

6. Using a syringe and hypodermic needle filled with

clear water, inject sufficient water into wrinkle or

bubble to dampen fabric backing.

7.
Repeat steps 2 through 4.
FOLDING TOP

CARE OF THE FOLDING TOP

To avoid water stains, mildew, or possible shrinkage

of the top material, do not keep the top folded for ex-

tended periods of time if it is damp or water soaked.

Permit top to dry out in a raised position before stowing.

Also avoid pasting advertising stickers, gummed labels

or masking" tape on the plastic back window. In addition

to being difficult to remove, the adhesive on these

stickers may also be injurious to the plastic composition

of the window.

Care of Rear Window

The large plastic rear window in the folding top will

remain in good condition for the life of the top if given

proper care. Due to the texture of the plastic window,

it is susceptible to scratches and abrasions; therefore,

when cleaning the window, follow the steps outlined below.

Fig.
100-Applying Sealer

CHEVROLET CHASSIS SERVICE MANUAL

CORVETTE BODY
1B-47

REAR

BOW

ASSY.

VIEW
C

Fig.
101—Folding
Top
Adjustments

MATERIAL
FOR
ATTACHMENT

FRONT HEADER PANEL

PAD
WIRE-ON

BINDING

WINDOW

EXTENS

SECTION
E-E

AY STRAP

SECTION

A-A

CEMENT SECURELY

REAR RAIL ONLY

Fig.
102—Folding
Top
Trim Installation

1.
To
remove superficial dust,
do not use a
dry cloth.

Use
a
soft cotton cloth moistened with water
and

wipe cross-wise
of
the window.

2.
To
wash
the
rear window,
use
cold or tepid (not hot)
water
and a
mild neutral soap suds. After washing,

rinse with clear water
and
wipe with
a
slightly

moistened clean soft cloth.
A
high quality plastic

window cleaner
is
available from Chevrolet parts

sources.

CHEVROLET
Oi
SERVia

CORVETTE BODY 1B-52

and pull weatherstrip and trim from rear bow.

Section A-A shows installed position of these com-

ponents. Refer also to figure 105.

installation

1.
Find and mark center of header, #3 bow, rear bow

and leading and trailing edges of top trim. Align

these marks during installation and recheck their

alignment from time to time while installation is in

progress, especially during tacking or stapling.

2.
Assemble top trim and weatherstrip to rear bow,

referring to Section A-A and Figure 105. Note that

filler strip locks this assembly together and goes

in last. Align center marks.

3.
If new pads are required, install at this time, align-

ing with marks made when old pads were removed.

Figure 106 shows pad construction; Figure 107 shows

pad installed.

4.
Install top trim-rear bow assembly on top frame

with four screws removed at disassembly.

5.
Lock down rear bow in desired "top up" position.

Pull up stay straps and staple or tack to #3 bow

(fig. 108).

6. Pull leading edge of trim iip to header and align

center marks. Smooth out fabric and clamp, tack

or staple temporarily to header.

7.
Draw window extension up to #3 bow, aligning cen-

tering marks. Turn an ample amount of fabric under

and tack to #3 bow. Apply neoprene trim cement,

GM Part #3695016 or equivalent, to area shown in

View D of Figure 102. Follow directions on package.

8. Draw roof portion of trim over #3 bow, align marks

and tack on staple.

9. Trim off excess material and install wire-on binding

as shown in Figure 109 and View D of Figure 102.

Install binding caps.

10.
Remove temporary clamps or fastenings holding trim

to header.

11.
With header locked down, pull trim assembly up tight

and mark for final installation.

12.
Apply trim cement to header and rear side rail.

13.
Release header from windshield. Tack or staple trim

to header (fig. 103).

14.
Apply trim to rear side frame, previously cemented.

15.
Install weatherstrips which were removed at dis-

assembly and install retaining screws in header

weatherstrip.

16.
Make any adjustments necessary, following instruc-

tions listed under Folding Top—Adjustments.

FRAME AND LINKAGE

Figure 110 illustrates construction features of the

folding top frame and linkage. Various cross sections in

Figure 110 show the pivoting joints and their assembly.

If an operation is being performed which requires

removal of folding top trim, follow directions in this

section. The entire frame assembly may be removed and

replaced as a unit. Follow instructions for Folding Top

Trim and Rear Window Assembly and Top Assembly—

Removal and Installation.

The pivoting joints should be lubricated with light

machine oil once a year. Apply oil sparingly so as not

to stain top trim.
WEATHERSTRIP

Side Rail Weatherstrip

Figure 111 illustrates installation of side rail weather-

strip which acts to seal window opening. The weather-

strip is held in place by studs which are part of the

weatherstrip assembly, and by neoprene base cement

which is applied between weatherstrip and side rail

surface.

When replacing weatherstrip remove all rust, old

cement and foreign material from the surfaces to be

cemented, to assure successful bonding. Use only good

quality neoprene cement suitable for weatherstrip

application.

Header Weatherstrip

Weatherstrip assembly is retained to the header panel

by a combination of studs, sheet metal screws and special

fasteners as shown in Figure 112, along with neoprene

base weatherstrip cement.

Figure 99 shows' a cross section of weatherstrip taken

through a special fastener. To replace fastener, rotate

ninety degrees to align fastener head with slot. Follow

directions for cementing in the Side Rail Weatherstrip

instructions preceding this write up.

ADDING HARDTOP (ROOF PANEL ASSEMBLY)

An available roof panel assembly (hardtop) complete

can be added to convertible model Corvettes. The hard-

ware is included with the panel assembly.

Reworking of a plastic part (one for each side of the

roof panel) can be used as a marker for drilling of two

required holes in the folding top compartment lid* Hard-

ware is attached at four locations — two on the lid and

two (one each side) at the lock pillar area as follows:

1.
Rework two plastic retainers (#6280765) (used on

Chevrolet and Corvair door inner panels for trim

retention) as shown by Figure 113.

2.
Slide the reworked plastic retainers into the bolt re-

tainer slots on each side of the hardtop rear bow

(position plastic tip inboard).

3.
Mark the hardtop reveal molding at the approximate

location of the two plastic retainers,

4.
Mark the tips of the two plastic retainers with a

china marker pencil.

5.
Close the soft top compartment lid.

6. With aid of an ^assistant, position front of hardtop

onto header and lower onto vehicle. Do not fasten

latches at windshield header.

7.
Apply hand pressure at reveal molding marks.

8. Mark roof panel attachment hole location at each

lock pillar area (fig. 114).

9. With aid of an assistant, lift roof panel straight up

off body and set roof panel aside.

10.
Mark the drill position at the four china marks with

a center punch.

11.
Place a 2" x 4" board under the top compartment lid

to prevent drill damage to folding top material. Make

certain the compartment lid is securely locked

before drilling.

12.
Drill 1/8" pilot hole at the 4 marked locations.

CHEVROLET CHASSIS SERVICE MANUAL

FRONT SUSPENSION 3-8

REPAIR PROCEDURES

Unless otherwise indicated all repair procedures will

apply to all five vehicles covered in this manual.

CAUTION: During any operations which in-

clude breaking the ball stud loose from the

knuckle boss extreme care must be used to as-

sure that the ball stud seal is not damaged or

cut. A recommended way to loosen the stud is to

place a flat bar stock against the knuckle boss

and strike the bar rather than the knuckle.

FRONT BRAKE DRUM-CHEVROLET, CAMARO,

CHEVELLE, CHEVY It

Removal

1.
Remove hub caps, partially loosen wheel nuts and

raise vehicle from floor. Remove wheel nuts and

wheel.

2.
Remove brake drum. In some cases it may be nec-

essary to back off brake adjustment because of

scored drum or unevenly worn brake linings.

3.
Check brake drum for concentricity, damaged pilot

diameter or scored braking surface. Lightly sand

braking surface and wipe clean.

Installation

1.
Install drum over hub bolts making sure alignment

dowel on drum web indexes with hole in wheel hub.

This will assure proper drum alignment with hub

bolts and hub pilot diameter.

2.
Install wheel and partially tighten wheel nuts.

3.
Re-adjust brake shoes to original setting. It may be

necessary to re-adjust brake shoes on both front

and/or rear wheels to assure balanced brake adjust-

ment. See Section 5 for brake adjustment procedure.

4.
Lower vehicle to floor, tighten hub wheel nuts and in-

stall hub cap.

FRONT WHEEL HUB

Replacement

1.
Remove hub caps, break loose the wheel stud nuts
VM" DIA. PIPE OR ARBOR

>l

INNER CUP

OUTER CUP
JL
RADIUS

e^

Fig.
10 - Pressing Front Hub Bolts (Typical)
Fig.
11 - Front Wheel Bearing Cop Removers

and raise vehicle. Remove wheel nuts, wheel and

tire and brake drum or (on Corvette) brake caliper

and brake disc.

NOTE:
On the Corvette, the hub and brake disc

are serviced as a complete assembly.

2.
Pry out hub grease cap, cotter pin, spindle nut and

washer,
and
remove hub. Do not drop wheel bearings.

3.
Reverse this procedure to install.

Replacement of Wheel Hub Bolts

It may be necessary to replace damaged wheel hub

bolts.
In this case, service the hub in the following

manner.

1.
Remove the hub bolts with a press or hammer.

These bolts are not peened into the hub. Do not

damage wheel mounting surface on hub flange.

2.
Install new serrated bolt into hole in
hub.
Tap lightly

with a hammer to start bolt serrations in hole, mak-

ing sure that bolt is square with hub flange.

3.
Press bolt into flange until head is fully seated

against hub flange (fig. 10).

FRONT WHEEL BEARINGS

Removal '

1.
Remove wheel hub as described above.

NOTE: Discard cotter pin. Install new cotter

pin when assembling.

2.
Remove outer roller bearing assembly from hub with

fingers. The inner bearing assembly will remain in

the hub and may be removed after prying out the

inner bearing lip seal assembly. Discard seal.

3.
Wash all parts thoroughly in cleaning solvent and

blow dry.

CHEVROLET CHASSIS SERVICE MANUAL