service CHEVROLET CAMARO 1967 1.G Chassis Workshop Manual

FUEL TANK AND EXHAUST SYSTEMS 8-17

a clamp. The clamp holds the muffler and tail pipe with

a "U" bolt and at the same time secures the muffler and

pipe to the body.
The exhaust system mounting at the end of the tail pipe

secures the pipe to a bracket assembly and insulator at-

tached to an existing underbody bracket.

VIEW B

VIEW A

Fig.
20—Chevy II—Dual Exhaust Systems

COMPONENT PART REPLACEMENT

MUFFLER ASSEMBLY

Replacement (Service)

1.
Cut the exhaust pipe near the muffler to allow suf-

ficient pipe for muffler replacement:

CAUTION: Before cutting the exhaust pipe

measure service muffler exhaust pipe extension

and make certain to allow 1-1/2" for engagement

of exhaust pipe into muffler extension.

2.
Remove "U" bolt clamp at center mounting and dis-

engage muffler from tail pipe.

3.
Install new muffler and secure with new "U" bolt

clamps.

4.
Realign and check clearances before finally tighten-

ing all hardware.

NOTE:
If bracket mounting insulators (tire

carcass mountings) are fatigued, replace to in-

sure a secure exhaust system.

EXHAUST PIPE

Replacement

On V-8 engine exhaust models, if the left exhaust pipe
has to be replaced it will be necessary to replace both

the exhaust pipe and muffler with service replacement

parts.
The right exhaust crossover pipe may be replaced

without replacing the entire system as follows:

1.
Remove nuts attaching left and right exhaust pipes

to exhaust manifolds.

2.
Remove "U" bolt clamp retaining right exhaust pipe

to exhaust system and remove pipe.

3.
Using new manifold flange gaskets, install new ex-

haust pipe.

NOTE:
Check all clearances before tightening

hardware.

TAIL PIPE AND/OR RESONATOR

Replacement

1.
Install tail pipe to rear of muffler.

2.
Position tail pipe to obtain proper clearance to rear

spring bracket and underside of frame rail.

3.
Install tail pipe clamp over rear hanger and position

on pipe to maintain vertical position of insulator

without twist.

4.
Tighten nuts on "U" bolt clamp at rear of muffler,

then secure rear tail pipe damp.

CHEVROLET CHASSIS SERVICE MANUAL

FUEL TANK
AND
EXHAUST SYSTEMS
8-18

CORVETTE

FUEL TANK

INDEX

Page

General Description.
. 8-18

Service Operations
8-18

Fuel Tank
8-18

Gauge Sending Unit
8-20

Fuel Lines.
8-20

GENERAL DESCRIPTION

20 GALLON TANK

Fig.
21
—Corvette Fuel Tanks

The Corvette
is
equipped with
a
standard
20
gallon

(approx.) tank
or an RPO 36
gallon (approx.) fiberglass

tank
(fig. 21). The
tanks
are
installed
at the
very rear

of
the
vehicle, convenient
for
direct fuel filling into
the

tank.
The
tanks
are
held
in
place
by
two metal straps
at-

tached individually
to a
removable
gas
tank frame
sup-

port.
Two
guides
at the end of
the straps
are
adjustable

for securing
the
straps onto
the
tank support. The tank

support
is
secured
to the
frame rail with flat washers,

lockwashers, bolts
and
nuts.
The
tanks' rest
on six
felt

anti-squeak pads.
One pad
centers
on the
rear frame

crossmember
and one at
each side
on the
same cross-

member.
At the
same rear location two pads
are
placed

on
the
tank
at the
metal support strap (rear) attachment
location
and
another anti-squeak
pad
cemented
on the

support
at
the front
of
the tank.

The fuel tanks
are
equipped with
a gas
gauge metering

unit,
a
fuel pickup, fuel strainer
and
vent line.
If it be-

comes necessary,
the
tank
can be
completely drained
by

removing
the
fuel pickup hose which
is
located
at
the
bot-

tom
of the
tank,
or
by removing the metering
for
quicker

draining.

A pressure vacuum type, positive vented design
cap,

conforming
to
I.C.C. regulations,
is
used on both regular

production
and
optional fuel tanks.
The cap is
inter-

changeable with past model tanks
for
service replace-

ment purposes.

SERVICE OPERATIONS

FUEL TANK

CAUTION:
IF THE GAS
TANK SHOULD
BE

REMOVED
AND
INSTALLED, CARE SHOULD

BE EXERCISED
TO
AVOID PUNCTURING,

DROPPING
OR
DENTING
THE GAS
TANK.

Removal
(20
Gallon Tank)

WARNING: FIRST REMOVE BATTERY

CABLE.
1.
Remove
the
spare tire from tire carrier.

2.
Remove spare tire carrier bolted attachments
and

carrier
(fig. 22).

3.
Remove
the "U"
bolt attachments
at
both rear tail

pipe
(See
Figure
23).

4.
Separate
the
exhaust system
at
the transmission sup-

port crossmember
by
loosening
the "U"
bolt nuts.

5. Remove both rear muffler brackets from
the
frame

and slide
the
muffler system rearward.

CHEVROLET CHASSIS SERVICE MANUAL

FUEL TANK AND EXHAUST SYSTEMS 8-19

Fig.
22—Spare Tire Carrier Installed

6. Remove two fuel tank retaining strap bottom nuts

from forward support member located at forward

front side of tank.

7. Remove fuel tank metering unit wires (fig. 25).

8. Remove fuel pickup line and drain tank.

9. Remove gas cap, filler neck boot from the top of tank

and disconnect drain line (fig. 24).

NOTE:6
Coupe Models—Remove filler neck.

10.
Remove fuel tank support frame attachment bolts and

support.

11.
Lower tank and rotate toward the front of vehicle.

Installation (20 Gallon Tank)

NOTE:
Place hoses and wires to one side and

position anti-squeak pads to the crossmember,
END OF HOSE FLUSH

TO Va INCH BACK FROM

EDGE OF BUMPERETTE

Fig.
24-Gas Tank Filler Neck Vent Hose

cemented to the support and attached to the tank.

Replace with new pads as required.

1.
Hook retaining straps at the rear frame crossmem-

ber. (Crimp strap ends at rear frame attachment.)

NOTE:
Make certain strap ends are hooked and

anti-squeak pads are properly positioned.

2.
Slowly rotate fuel tank into position.

CAUTION: Coupe-Install filler neck after tank

is installed.

3.
Attach fuel tank support at the frame side rails.

TANK METERING UNI

WIRE CONNECTIONS

Fig.
23—Exhaust System Tail Pipe Attachment
Fig.
25—Fuel Tank Metering Unit, Wires and Lines

CHEVROLET CHASSIS SERVICE MANUAL

FUEL TANK AND EXHAUST SYSTEMS 8-20

4.
Attach the retaining straps with strap guide attached

to the fuel tank support, and secure with-the nut and

lockwasher assembly.

5. Connect the filler neck boot to the drain hose of the

tank and install boot around filler neck,

6. Connect the fuel pickup line, ground wire and make

certain that the fuel drain line is flush to 1/2" in-

board of the rear bumper opening.

7. Attach tank metering unit wires (fig. 25).

8. Replace fuel in tank. Replace gas cap.

9. Check for possible leaks.

10.
Reconnect the exhaust system by reversing the above

removal procedures (see "Exhaust System").

11.
Install spare tire carrier by securing the bolt

attachment.

12.
Install the spare tire in the tire carrier.

Removal (36 Gallon Tank)

1.
Remove cover (fig. 26).

2.
Disconnect hoses and drain tank and remove two

fittings at bottom of tank.

3.
Disconnect fuel and vent lines and wires at tank

(fig. 27).

4.
Remove straps.

installation (36 Gallon Tank)

Reverse removal procedure to install.

FUEL TANK METERING UNIT OR GAUGE

SENDING UNIT AND STRAINER

The fuel tank metering unit is located at the bottom of

the fuel tank. The fuel strainer is attached at the end of

the sending unit inside the tank.

Replacement (20 Gallon Tank)

1.
Follow fuel tank removal procedure through Step 2.

2.
Drain the tank. Disconnect the attaching wires.

3.
Remove metering unit with a fuel tank gauge unit

Spanner J-8950 (revised).

4.
'Remove metering unit and gasket.

CAUTION: Carefully remove unit so as not to

damage screen on the end of the pipe.

5. Clean strainer screen by blowing out with com-

pressed air.

6. Reverse procedure to install.

Replacement (36 Gallon Tank)

1.
Remove cover.

2.
Follow Steps 2 thru 6 as outlined under replacement

for 20 gallon tank.

FUEL LINES

20 Gallon Tank

The fuel lines are conveniently located along the out-

side of the right frame rail (fig. 28). The lines extend
Fig.
26—Gasoline Tank (36 Gallon) Compartment Cover

from the fuel tank pickup at the bottom of the tank, along

the rear frame crossmember to the right frame rail,

extending through the rail at the kickup area and along the

top inside edge of the frame to the fuel pump, Flexible

hoses are located at the fuel tank pickup and at the fuel

pump.

36 Gallon Tank

The 36 gallon tank fuel lines are routed from the bot-

tom of both sides of the tank to the right frame rail

(fig. 20).

Maintenance

CAUTION: Always drain gasoline from the

complete fuel system including carburetor, fuel

pump and all fuel lines and fuel tank if the vehi-

cle is to be stored for any great length of time.

This precaution will prevent accumulation~ol

gum formation and resultant poor engine

performance.

. The fuel lines should occasionally be inspected for

leaks,
kinks or dents, especially when work has been

done on the underside of car or after the car has been

traveling over rough or stone roads at higher speeds.

If evidence of dirt is found in the carburetor or fuel pump

at disassembly, the lines should be disconnected and

blown put. Check the fuel tank strainer for damage or

omission.

Fuel lines are beaded-type ends for connection to

hoses and flared ends for secure metal-to-metal line

connections.

CHEVROLET CHASSIS SERVICE MANUAL

FUEL TANK AND EXHAUST SYSTEMS 8-21

Fig.
27-Gasoline Tank (36 Gallon) Wiring

CHEVROLET CHASSIS SERVICE MANUAL

FUEL TANK
AND
EXHAUST SYSTEMS
8-24

EXHAUST SYSTEMS

INDEX

Page

General Description. ..........
8-24

Service Operations
8-24

Muffler Assembly.
8-24

Side Mounted Exhaust.
. . . 8-25

GENERAL DESCRIPTION

Fig.
30—Standard Dual

All Corvettes
are
equipped with dual exhaust systems

(fig.
30).
Each exhaust assembly
is
connected
to its own

exhaust manifold
and
carries
the
exhaust gases
to the

rear, discharging them
on
each side
of
the rear bumpers.

The dual exhaust system includes
two
front
and
rear

exhaust pipe sections, mufflers, tail pipes and attaching

hardware.
The
system
is
suspended
on
brackets with

insulators
for
rattle free operation. Adjustment
is
only

required
at the
rear muffler bracket.
In addition
to the
regular dual system
an
optional side

mounted, off-road exhaust system
is
available
as an
RPO

(fig.
31).
Extending between front
and
rear wheels,
the

dual units
are
mounted outboard
of the
frame side rails

at
the
rocker panel level,
and
completely replaces
the

regular dual assemblies*

Flow characteristics
are
improved and back pressures

reduced
by
the more direct exhaust routing and
by the use

of chambered pipes
for
sound muffling
in
place
of con-

ventional mufflers.

SERVICE OPERATIONS

Proper relationship
of
parts
is
necessary
in the ex-

haust system
for
carefree operation. Annoying rattles

are usually
a
result
of
incorrect alignment
of
the exhaust

system
due to
incorrect clearances.

MUFFLER ASSEMBLY

Replacement (Also Rear Exhaust
and
Tail Pipes)

Remove
"U"
bolt attachments
at
both rear tail pipe

shields.
2.

crossmember

1.
Separate
the
exhaust system
at the

tube
by
loosening the
"IT"
bolt nuts.

3.
Remove both rear muffler brackets from
the
frame

and slide
the
muffler system forward.

CAUTION: Before cutting
the
rear exhaust

pipe, measure service muffler exhaust pipe
end

and make certain
to
allow
1 1/2" for
engage-

ment
of the
rear exhaust pipe into service
muf-

fler pipe.

CHEVROLET CHASSIS SERVICE MANUAL

FUEL TANK AND EXHAUST SYSTEMS 8-25

4.
Cut the exhaust pipe near the muffler (see cau-

tion above) to allow sufficient pipe for muffler

replacement.

5.
^
Replace muffler and secure with new clamps.

NOTE:
Clamps must be assembled with nuts

attached toward the rear of the vehicle -

reference 90° to sawcuts in service muffler

pipe.

6. Reverse procedure for installation.

NOTE:
If bracket mounting insulators (tire

carcass mountings) are fatigued, replace to in-

sure a secure exhaust system.
7. In the event the tail pipe bezel has been damaged and

replacement is required, remove three screws and

replace the bezel. i

SIDE MOUNTED EXHAUST (Fig. 31)

Replacement

1.
Raise and support vehicle.

2.
Remove sill molding attaching screws and disengage

molding from the retainer.

3.
Remove cover retaining screws, cover and retainer

assembly.

4.
Remove exhaust pipe-to-manifold attaching nuts, and

rear bracket retaining nut, then detach exhaust pipe

from manifold studs and remove from vehicle.

Fig.
31—Side Mounted Exhaust System

CHEVROLET
CHASSIS SEKVK

FUEL TANK AND EXHAUST SYSTEMS
8-26

5. To install, assemble the bolt, washers, insulator, install pipe-to-manifold retaining nuts. Tighten all

cover bracket and retaining nut to the exhaust pipe retaining nuts.

rear bracket. . 7. Position molding retainer and cover to sill and in-

6. Insert rear bracket bolt in frame opening, position stall retaining screws.

exhaust pipe to the manifold attaching studs and 8. Position sill molding and install retaining screws.

CHEVROLET CHASSIS SERVICE MANUAL

FUEL TANK AND EXHAUST SYSTEMS 8-27

CAMARO

INDEX

Page

General Description 8-27

Service Operations

Fuel Tank 8-28

Fuel Lines 8-28

Metering Units (Gauge Sending Unit) 8-28

GENERAL DESCRIPTION

All models use an 18.5 gallon capacity (approx.) fuel

tank mounted between the frame rails behind the rear

axle (fig. 32). All fuel tanks are vented through an anti-

surge type filler cap assembly consisting of cap and
handle. The carrying straps hook through a double slot

in the front of the rear compartment reinforcements and

attach to strap bolts positioned in slots provided at the

rear panel reinforcements. A conventional fuel meter

VIEW B

Fig.
32—Fuel Tank Assembly

CHEVROLET CHASSIS SERVICE MANUAL

FUEL TANK AND EXHAUST SYSTEMS 8-28

assembly is mounted on top of the tank and cannot be

removed for service without lowering the tank. The

upper filler neck assembly is routed through an opening

in the rear panel above the bumper and through the trunk

floor pan (fig. 33). The filler neck is not centered in the

rear panel but offset to the right to obtain the proper fill

rate.

The fuel pickup pipe is an integral part of the tank

meter unit^ located at the top front center of the tank. A

fine mesh screen is located at the bottom end of the fuel

pickup pipe to prevent the entrance of foreign material

into the fuel system.

Fig.
33—Filler Neck Assembly

COMPONENT PART REPLACEMENT

FUEL TANK

Draining Tank

Refer to Chevrolet page 8-2.

Removal and Installation

1.
Drain fuel tank. .'...' .

2.
Raise vehicle.

3.
Disconnect fuel pickup line, gauge wire and ground

lead from tank unit.

4.
Loosen filler neck inlet hose clamp.

5. Remove tank support strap bolts and straps, then

lower tank carefully.

6. Reverse procedure to install.

FUEL TANK GAUGE SENDING UNIT (Fig. 34)

Replacement

1.
Remove fuel tank.

2.
Remove cam lock using special Tool J-8950.

3.
Remove meter unit and rubber gasket.

CAUTION: Carefully remove unit so as not to

damage screen on end of pipe.

4.
Clean screen by blowing out with compressed air.

5. Reverse removal procedure to install.
FUEL LINES (Fig. 35)

The gasoline lines extending from fuel tank to fuel

pump,
are routed on the underside of the underbody, on

the right side, opposite the single exhaust system. The

lines extend from the fuel tank to the right side of the

engine to the fuel pump and over the front of the engine

to the carburetor.

Maintenance

CAUTION:

plete fuel
Always drain gasoline from corn-

including carburetor, fuel

pump and
fuel lines and fuel tank if the

vehicle is to be stored for any
eciable

length of time. This precaution will prevent

accumulation of gum formation and resultant

poor engine performance.

The fuel lines should occasionally be inspected for

leaks,
kinks, or dents. If evidence of dirt is found in the

carburetor or fuel pump disassembly, the lines should be

disconnected and blown out. Check the fuel tank strainer

for damage or omission. Fuel lines are of 5/16" diameter

tubing for regular installation with beaded-type ends for

connections to hoses and flared ends for secure line

connections.

CHEVROLET CHASSIS SERVICE MANUAL