CHEVROLET CAMARO 1967 1.G Chassis Workshop 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 11-6

NOTE:
All gap tolerances

between hood & adjacent

panels to be held constant

as far as possible.

FLUSH
TO .06

OVER
DOOR

HOOD
TO
FENDER

FLUSH
TO .06 LOW

12 - .17 REF. AT

RAD.
SUPT.
.18 it .04

.07 TO J3l.

OVER
DOOR

FLUSH
TO .06

OVER
DOOR

X

.09 ± .06

.75
± .40 REF.

NOTE:

washer (Section 14)

to align front bumper

parallel to grille bars
NOTE:
Adjust grille ext.

molding to line up with

hood molding ± .03

Fig.
5 - Sheet Metal Adjustments - Chevelle

HOOD ASSEMBLY (Fig. 10)

Hood may be removed either with or without hinges.

To shorten aligning time, scribe a mark on hood around

the hinge plate. See adjustment procedures in this sec-

tion for hood adjustment. Hood hinge springs may be

easily and safely removed and installed using Tool J-9559

as follows:

1.
Remove bolt from Tool J-9559.. Open hood far

enough to allow passage of tool between hood and

fender and insert encls of tool between coils of spring

until barrel of tool contacts outer diameter of spring.

2.
Open hood full while holding spring (with tool in-

stalled) in hand; when hood is in opened position,
remove spring as shown in Figure 11. .

3.
When spring is removed, insert long bolt supplied

with J-9559 through holes in ends of tool, passing 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 "CTt 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 hoist as shown in Figure 12.

3.
Stretch the spring enough to allow insertion of

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

on hinge at once.

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 11-8

Fig.
8 - Chevrolet Radiator Support to Frame,

Fenders, and Skirts

The temperature of the body must be maintained at a

moderate level between approximately 65 and 90 degrees.

Too warm a body will cause the wood grain film to stick

prematurely while too cool a body will reduce the adhe-

sion of the wood grain film. Cool, the body panel with

cool water when too warm and heat the body panel with

a heat gun or a heat lamp when too cold. Just prior to

application of the transfer film clean the painted surface

with a non-petroleum base volatile cleaner and allow to

dry.

Follow the steps below for easy application of the film.

1.
Cut the tape backing the entire width of the transfer
at the approximate centerline of the film exercising

care not to damage the transfer film.

2.
Peel the paper backing from one half of the film.

3.
Align the upper edge of the half of the film with the

paper backing to the lower edge of the pierced mold-

ing holes making sure that the transfer is centered

on the panel.

4.
Starting at the center of the transfer and using a

water dampened rag, press that half of the transfer

with the backing removed on to the panel. Work

outboard from the middle to the edges. Remove all

air bubbles.

CHEVROLET CHASSIS SEKV1CE MANUAL

CHASSIS SHEET METAL 11-9

Fig.
9 - Chevelle Radiator Support to Frame,

Fenders, and Skirts

Fig.
10 - Hood Replacement
NOTE:
The transfer can be pulled back from

the panel and reinstalled if large air pockets

develop. Exercise care not to stretch the ma-

terial. Small air bubbles may be removed by

piercing the film at the bubble with a pin and

pressing the bubble down.

5. Remove the backing from the other half of the trans-

fer. Apply this half in the same manner working

from the center to the end and from the middle to

the upper and lower edges.

6. Fold the transfer over the door or quarter edges and

press to the hemming flanges. Application of heat

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

transfer over the edge.

NOTE:
If the transfer film will not adhere to

the flange, brush a clear vinyl adhesive to the

back edge of the film and reapply.

7. Install the moldings.

CHEVROLET CHASSIS SERVICE MANUAL

CHASSIS SHEET METAL 11-10

Fig.
11 - Removing Spring with J-9559
Fig.
13- Hood,' Insulator, and Molding - Chevrolet

Fig.
14- Hood and Hood Ornament - Chevelle

Fig.
12 - Installing J-9559 in New Spring
Fig.
15 - Removing Rear Wheel Cover

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 11-12

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 11-13

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