lock 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 11-2

Fig.
1
- Front End Sheet Metal - Chevrolet

1.
Fender

2.
Hood Hinge

3. Hood

4.
Cowl Vent Grille

5. Molding

6. Trim

7. Radiator Support

8. Shroud
9. Radiator

10.
Hood Lock

11.
Hood Catch

12.
Battery Tray

13.
Skirt

14.
Dust Shield

15.
Bracket'

16.
Brace

CHEVROLET CHASSIS SERVICE MANUAL

CHASSIS SHEET METAL 11-3

Fig.
2 - Front End Sheet Metal - Chevelle

1.
Fender

2.
Hood Hinge

3. Hood

4.
Cowl Vent Grille

5. Trim

6. Molding

7. Brace

8. Filler Panel

9. Reinforcement
10.
Radiator Support

11.
Shroud

12.
Radiator

13.
Hood Lock

14.
Seal

15.
Tie Bar

16.
Hood Catch

17.
Skirt

18.
Battery Tray

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 11-11

CHEVY II

INDEX

Page

General Description 12

Maintenance and Adjustments 12

Hood ........ 13

Hinge 13

Bumpers 13

Catch Assembly . . . 13

Lock 13

Fenders . 13

Sheet Metal 13

Component Part Replacement 14
Page

Battery Tray 14

Radiator Support 14

Fender Assembly ...................... 14

Trim 15

Skirt 15

Hood Assembly 18

Catch Assembly and Lock • 18

Trim 18

Front End Assembly 18

1.
Fender

2.
Hood Hinge

3. Hood

4.
Trim

5. Molding
Fig.
16 - Front End Sheet Metal - Chevy II

6. Brace

7. Headlamp Filler Panel

8. Filler Panel

9. Radiator Support

10.
Shroud
11.
Radiator

12.
Skirt

13.
Hood Lock

14.
Hood Catch

15.
Baftery Tray

CHEVROLET CHASSIS SERVICE MANUAL

CHASSIS SHEET METAL 11-13

HOOD ADJUSTMENT

The alignment of the hood in relation
to*
other sheet

metal parts is controlled by the position of the hood

hinges and the height of the two bumpers, located one at

each end of the radiator support. The adjustments at

the hood latch must be made after the hinges and bumpers

are positioned to yield the dimensions shown in Figure

17.
Latch adjustments are made so that effort required

to open and close the hood is reasonable, and hood align-

ment obtained by hinge and bumper adjustment is main-

tained when the hood is closed. Note that the hood latch

is not designed or intended to correct basic hood align-

ment faults.

To align the hood and lock, proceed as follows:

HOOD HINGE (Fig. 18)

1.
Note that the mounting holes in the body-mounted

end of the hinge are slotted to provide up and down

movement of the hood assembly while the hood

mounted end is slotted to provide fore and aft move-

ment.

2.
Scribe a mark around the entire hinge plate which

will be involved in the adjustment.

3.
Loosen the appropriate screws and shift the position

of the hood on the hinge plate the approximate amount

to correct misalignment, using the scribed marks to

check amount of movement. Check condition of ad-

justment by tightening cap screws and closing hood.

Fig.
18 - Hood Hinge - Chevy II
Fig.
19 - Hood Lock, Catch and Support - Chevy II

HOOD BUMPERS

Hood bumpers must be adjusted until hood and fender

line up as shown in Figure 17.

HOOD CATCH AND LOCK (Fig. 19)

Hood lock plate mounting holes are slotted to provide

fore and aft adjustment of the hood lock bolt. The hood

lock bolt itself is adjustable for up and down positioning

of the lock bolt head so that its proper engagement in the

latch assembly may be provided for. 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 so that the effort

required to release the hood catch is reasonable.

FENDER ADJUSTMENT (Figs. 17 and 20)

DO NOT CHANGE SKIRT ASSEMBLY-TO-DASH SHIM-

MING IN AN EFFORT TO ADJUST THE DOOR-TO-

FENDER GAP OR ANY OTHER SHEET METAL AP-

PEARANCE ITEM.

The front fenders are shimmed independently of the

skirt assemblies, unlike conventional- vehicles on which

almost the entire front end sheet metal assembly is

shimmed and adjusted as a unit.

Figure 20 shows the locations of front fender shims.

1.
The rocker panel extension location allows adjust-

ment to make fender outer surface flush with door

outer surface.

2.
The upper or plenum chamber location provides a

means of adjusting fender upper surface so that it

is flush with the upper surface of the cowl.

3.
The locations atop the skirt assembly are shimmed

to close the gap created between the fender mounting

flange and skirt assembly when the plenum chamber

CHEVROLET CHASSIS SWVICE 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

5.

6.

7.

8.
2.
Install all fender mounting screws, replacing original

shimming. Refer to removal procedure for screw

location.

3.
Install hydraulic lines at main cylinder and right

hand skirt. Install fuel line at right hand skirt.

4.
Install steering gear as outlined in Section 9. Do

not fail to perform adjustment procedure listed under

Mast Jacket - Installation.

CAMARO

INDEX

Page

General Description 20

Maintenance and Adjustments 20

Hood / . 20

Hinge 20

Bumpers ' . . . 20

Catch Assembly 21

Lock . 21

Fenders 21

Sheet Metal 22
CHASSIS SHEET METAL 11-19

Install pitman arm as outlined in Section 9 under

Maintenance and Adjustments - Steering Gear Ad-

justments.

Remove jack stands and jack.

Bleed brakes as outlined in Section 5.

Perform body alignment as outlined in Fisher Body

Service Manual.

Page

Component Part Replacement . 22

Battery Tray 22

Radiator Support 22

Fender and Skirt Assembly 22

Hood Assembly . 22

Lock and Catch Assembly 22

Trim and Insulation . . . 24

Cowl Vent Grille . . 24

Fig.
32 - Front End Sheet Metal - Camaro

1.
Fender

2.
Hood Hinge

3. Hood

4.
Cowl Vent Grille
5. Trim

6. Molding

7. Fender Extension

8. Bumper Bracket
9. Valance Pane!

10.
Header Panel

11.
Radiator Support

12.
Radiator
13.

14.

15.
Shroud

Hood Lock

Radiator Cap
16.

17.

18.
Bracket (V-8

Hood Catch

Brace
Engine
Only)
19.

20.

21.
Skirt

Seal

Battery
Tray

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