radio CHEVROLET CAMARO 1967 1.G Chassis Workshop Manual

GENERAL INFORMATION 0-7

a vise using leather or wood on each side to prevent

damage to the cylinder,

7. Stake the retainer securely in place by staking the

cylinder metal over both edges of the retainer ends

using a suitable staking tool at right angles to the

top of the retainer and from the cast metal of the

cylinder over the retainer at each corner.

PUSHING, TOWING AND LIFTING

Pushing

NOTE:
Towing car to start is not recommended

due to the possibility of the disabled car ac-

celerating into tow car.

AUTOMATIC TRANSMISSION

Do not attempt to start the engine by pushing the car.

Should the battery become discharged, it will be neces-

sary to use an auxiliary battery with jumper cables to

start the engine.

CAUTION: To prevent damage to electrical

system, never connect booster batteries in ex-
cess of 12 volts and connect positive to positive

and negative to negative.

Manual Transmission

When a push start is necessary turn off all electrical

loads such as heater, radio, and if possible, lights, turn

on the key, depress the clutch, and place the shift lever

in high gear. Release the clutch when your speed reaches

10 to 15 miles per hour.

TOWING

The car may be towed safely on its rear wheels with

the (selector lever in "N" (Neutral) position at speeds

of 35 miles per hour or less under most conditions.

However, the drive shaft must be disconnected or the

car towed on its front wheels if 1) Tow speeds in excess

of 35 MPH are necessary, 2) Car must be towed for ex-

tended distances (over 50 miles) or, 3) Transmission is

not operating properly. If car is towed on its front

wheels, the steering wheel should be secured to maintain

a straight ahead position.

DRIVE ON HOIST

BUMPER JACK LIFTING AT FRAME ATTACHMENT ONLY

FLOOR JACK OR HOIST LIFT

Fig.
21-Vehicle Lifting Pointe-Chevroiet

CHEVROLET CHASSIS SERVICE MANUAL

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-66

Fig.
93—Chevelle Four-Season Ducts

8. Remove the radio speaker and grille.

9. Remove the right outlet duct.

10.
Disconnect the bowden cables from their brackets

and operating levers on the distributor assembly.

11.
Disconnect the flexible tubing from the center and

left side outlet ducts at the air distributor assembly.

12.
Remove the heated air distributor ducts from the

air-distributor assembly.

13.
Remove the single remaining distributor to dash

panel attaching nut (the others were removed from

beneath the hood when the core cover was removed

in Step 2) located at the right end of the air dis-

tributor assembly.

14.
Carefully pull the assembly out from under the

dash, disconnecting the compressor switch wiring

connector and the water valve control switch vacuum

lines.
Installation

Reverse the removal procedure to reinstall the air

distributor assembly.

COMFORTRON AUTOMATIC

CONTROL COMPONENTS

The Comfortron system is the same as the Chevrolet

Four Season system insofar as the basic system compo-

nents are concerned. , Most removal and installation

procedures wUl remain as stated for the Four Season

system except where the automatic control components

are encountered. Each such component will be covered

in the pages which follow.

CHEVROLET CHASSIS SERVICE MANUAL

HEATER AND AIR CONDITIONING 1A-67

Fig.
94—Camaro Four-Season Ducts

Heater and Air Distributor Assembly

Removal

rfooo

1.
Disconnect battery ground cable.

2.
Drain radiator (do not purge refrigerant system).

3.
Disconnect all connectors attached to the Comfortron

wiring harness which are on the engine side of the

firewall. Push the wiring harness grommet through

the firewall to the rear.

4.
Disconnect the four vacuum hoses coming from the

underdash through the large firewall grommet. Push

the hose grommet through the firewall to the rear.

5.
Remove the nuts from the heater and air distributor

case studs which project through the firewall from

the dash side.

6. Disconnect the heater hoses from the core tubes.

Under Dash

1.
Remove glove box assembly.

2.
Remove the dash center face plate, ash tray assem-

bly, and any radio and/or tape equipment.

3.
Remove the Comfortron control assembly mounting

screws and lower the control unit.
4.
Remove the vacuum line from the kick pad valve

diaphragm.

5.
Disconnect all harness connectors between the Com-

fortron harness and the rest of the dash wiring.

6. Remove the air distributor duct which supplies the

dash outlets.

7.
Remove the screws attaching the heater and air

distributor to the firewall.

8. Pull the assembly rearward then down to remove

from the dash. Pull the Comfortron wiring harness

and vacuum hose assembly through the firewall.

Installation

1.
Place the entire case assembly with wiring, vacuum

hoses,
and control assembly into the car on the floor.

2.
Pass the underhood wiring harness and vacuum hose

harness as far as possible through the appropriate

firewall holes.

3.
Lift the assembly up into position and pass the case

studs through the firewall mounting holes. Attach

the case to the firewall with the mounting screws.

4.
Mount the dash outlet air distributor duct to the face

of the case.

CHEVROLET CHASSIS SERVICE MANUAL

HEATER AND AIR CONDITIONING 1A-68

Fig.
95—Corvette Four-Season Ducts

5. Connect the various Comfortron harness connectors

to the dash wiring and connect the vacuum hose to

the kick pad valve diaphragm. Push the vacuum hose

harness and wiring harness through the firewall to

the proper location and install their respective

grommets.

6. Raise the control unit into place and install the

mounting screws. Check that all connections are

complete.

7. Replace any radio and/or tape equipment, the ash

tray assembly, and face plate.

8. Replace the glove box assembly.

9. Connect the heater hoses to the core tubes, and

attach the nuts to the case studs through the firewall.

10.
Reconnect the four vacuum hoses as follows: Purple

to the cylinder on the thermo-vacuum valve, yellow

tracer to the body of the thermo-vacuum valve, red

tracer to the vacuum source "Tee" connection, and

white tracer to the vacuum tank inlet.

11.
Connect the wiring harness to the underhood air

conditioning components.

12.
Refill cooling system, connect battery ground cable

and check system performance.

Vacuum Tank

The vacuum tank is mounted on the firewall as shown

in Figure 97. Notice that the two vacuum lines are

clamped to the vacuum tank ports. *

Thermal Vacuum Valve

This heat operated vacuum valve is located in the

heater core input line. Figure 98 illustrates valve instal-

lation with clamps attaching the water hoses as well as

the vacuum hoses in place.
Resistor Assembly

Figure 99 illustrates the location and installation of

the blower speed resistor assembly.

Relays

Two relays are used in the system, both mounted on the

evaporator case as shown in Figure 100. The mounting

bracket forms a common ground for the relays and as a

plug for the hole in the evaporator housing used in the

Four Season system for resistor installation.

Sensors (Thermistors)

Ambient Switch and Sensor

This combination unit, which engages the compressor

clutch at about 40°F and also senses outside air tem-

perature and sun load, is mounted to the firewall within

the engine compartment with its long neck extending

deep into the cowl vent plenum chamber. Figure 98 il-

lustrates this installation,

In-Car Sensor

This sensor is located beneath the lip of the instru-

ment panel overhand just to the right of the driver as

shown in Figure 101.

Removal

1.
Remove glove box assembly.

2.
Disconnect sensor wires connector at harness.

3.
Remove sensor mounting screws, remove sensor

and pull wires and connector through hole in dash.

Installation

1.
Insert connector and

through the dash hole.
wires of replacement sensor

CHEVROLET CHASSIS SERVICE MANUAL

CORVETTE BODY 1B-4

Fig.
3-Hood Spacing

vehicle as a unit by removing six screws around the

outer edge of opening, two screws retaining striker plate

and four screws which fasten compartment support to

cowl cross brace under dash. For parts identification

refer to Figure 6.

COWL AREA TRIM

Figure 7 illustrates instrument panel pads, cowl

"kick'.' panels, radio grille cover and console-to-dash

trim panel.

Figure 8 illustrates trim and moldings which are in-

stalled in the console area.

When installing instrument panel pads, it is advisable

to use new clips. Position of these clips upon installation

is illustrated in Figure 9.

REAR VIEW MIRROR

Outside

Removal

The outside rear view mirror may be removed from

the'
door by removing the set screw, located on the in-
board side of the mirror support, with an alien wrench.

Installation

Mirror may be installed by following the removal

procedures in reverse order. ,

Inside

Installation of inside mirror may be seen in Figure 10.

Tension of mirror stud may be adjusted by loosening or

tightening adjusting screw.

SUN VISOR

Attachment of sun visor assembly to windshield header

is made as shown in Figure 10. Turning adjusting screw

in increases friction.

COWL VENTILATOR ASSEMBLY

The following outline covers either the right of left

hand side. Refer to Figure 11.

Removal

1.
Disconnect positive cable from battery.

CHEVROLET CHASSIS SERVICE MANUAL

CORVETTE BODY 1B-31

1
^JS^ST**-

Fig.
67—Center Body Construction

1.
Panel—Instrument

2.
Pad Assembly Instrument

Panel - Right

Hand

4.
Reinforcement -. Door

Upper Front

5. Panel - Door Inner

Upper
6. Reinforcement - Upper Rear

7. Cover - Front Access Hole

8. Reinforcement - Door Outer

Panel inner

9. Cover - Rear Access Hole

10.
Pillar Assembly - Door Lock

11.
Panel - Door Lower

Inner
12.
Sill - Door

13.
Molding - Rocker

14.
Panel - Side Door

Outer

15.
Panet - Door Hinge

Reinforcing

16.
Reinforcement Assembly

- Side Door Inner
17.
Bonding Strip - Side

Door Upper Bonding

18.
Pillar Panel - Hinge

19.
Hinge Assembly

20.
Pad Assembly Instrument

Panel - Left Hand

21.
Bracket - Radio Mounting

22.
Bracket - Clock Mounting

CHEVROLET CHASSIS SERVICE MANUAL

ENGINE-ELECTRICAL 6Y-23

condenser leak or to a defective connection. This

will cause burned points and ignition failure upon

initial starts and at high speeds.

4.
Capacity - Capacity is determined by the area of

the metallic elements and the insulating and im-

pregnating materials.

For a complete check of the condenser, use a tester

which will check for all of the above conditions. Follow

the instructions given by the manufacturer of the

test equipment. Condenser capacity should be
.18-:
23

microfarads.

REPLACEMENT

Four and Six Cylinder Engine Distributor (Fig. 4i)

1.
Release distributor cap hold-down screws, remove

cap and place it out of the work area.

2.
Remove rotor.

3.
Disconnect condenser lead wire from contact point

quick-disconnect terminal.

4.
Remove condenser attaching screw, lift.condenser

from breaker plate and wipe breaker plate clean.

5. Install new condenser using reverse of procedure

outlined above.

Eight Cylinder Engine Distributor

1.
Remove distributor cap.

2.
Loosen condenser lead attaching screw (fig. 6i) and

lift out condenser lead clip.

3.
Remove screw holding condenser bracket to breaker

plate and slide condenser from bracket.

4.
To replace condenser reverse the above procedure.

NOTE:
Make sure that new condenser lead is

installed in proper position (fig. 6i).

DISTRIBUTOR

(BREAKER POINT TYPE)

REMOVAL

1.
On radio equipped Corvettes, remove ignition shield

from over distributor and coil. One bolt is accessible

from top of shield, the other two are at rear of

shield, facing firewall.

2.
Release the distributor cap hold-down screws, re-

move the cap and place it clear of the work area.

NOTE:
If necessary, remove secondary leads

from the distributor cap after first marking the

cap tower for the lead to No. 1 cylinder. This

will aid in the reinstallation of leads in the cap.

3.
Disconnect the distributor primary lead from the coil

terminal.

4.
Scribe a realignment mark on the distributor bowl

and engine in line with the rotor segment.

5. Disconnect vacuum line to distributor and tachometer

drive cable (Corvette). Remove the distributor hold-

down bolt and elamp and remove the distributor from

the engine. Note position of vacuum advance mecha-

nism relative to the engine.

CAUTION: Avoid rotating the engine with the

distributor removed as the ignition timing will

be upset.
Rg.
121-L-6 Distributor-Exploded View

1.
Breaker Plate Attaching

Screws

2.
Condenser Attaching

Screws

3. Condenser

4.
Breaker Plate Assembly

4a.
Cam Lubricator

5. Vacuum Control Assembly

6. Vacuum Control

Attaching Screws

7. Housing

8. Cap

9. Rotor

DISASSEMBLY
10.
Contact Point

Attaching Screw

11.
Contact Point Assembly

12.
Weight Cover

Attaching Screws

13.
Weight Cover

14.
Weight Springs

15.
Advance Weights

16. Cam Assembly

17.
Main Shaft Assembly

18.
Roll Pin

19.
Drive Gear

It is advisable to place the distributor in a distributor

testing machine or synchroscope prior to disassembly.

CHEVROLET CU
SERVICE MANUAL

ENGINE-ELECTRICAL 6Y-27

timing mark on pulley lines up with timing tab.

2.
Position distributor to opening in block in normal

installed attitude (fig. 15i), noting position of vacuum

control unit.

3.
Position rotor to point toward front of engine (with

distributor housing held in installed attitude), then

turn rotor counter-clockwise approximately 1/8 turn

more toward left cylinder bank and push distributor

down to engine camshaft. It may be necessary to ro-

tate rotor slightly until camshaft engagement is felt.

4.
While pressing firmly down on distributor housing,

kick starter over a few times to make sure oil pump

shaft is engaged. Install hold-down clamp and bolt

and snug up bolt.

5. Turn distributor body slightly until points just open

and tighten distributor clamp bolt.

6. Place distributor cap in position and check to see

that rotor lines up with terminal for No. 1 spark

plug.

7. Install cap, check all high tension wire connections

and connect spark plug wires if they have been re-

moved. It is important that the wires be installed in

their location in the supports.

NOTE:
The brackets are numbered to show the

correct installation. Wires must be installed as

indicated to prevent cross firing.

8. Connect vacuum line to distributor and distributor

primary wire to coil terminal.

9. Start engine and set timing as described under Turn-

Up in Section 6.

BREAKERLESS (MAGNETIC PULSE)

DISTRIBUTOR

REMOVAL (CORVETTE)

1.
If vehicle is equipped with radio, remove three bolts

securing ignition shield over distributor and coil.

One bolt is accessible from the top of shield, the

other two are at rear of shield, facing firewall.

2.
Disconnect tachometer drive cables from distributor

housing.

3.
Disconnect pickup coil leads at connector.

4.
Remove distributor cap.

5. Crank engine so rotor is in position to fire No. 1

cylinder and timing mark on harmonic balancer is

indexed with pointer.

6. Remove vacuum line from distributor.

7. Remove distributor clamping screw and hold-down

clamp.

8. Remove distributor and distributor-to-block gasket.

It will be noted that the rotor will rotate as the

distributor is pulled out of the block. Mark the re-

lationship of the rotor and the distributor housing

after removal so that the rotor can be set in the

same position when the distributor is being installed.

DISASSEMBLY (Fig. 16i)

NOTE:
If a distributor is being disassembled

for replacement of the stationary magnetic

pickup assembly only, it will be necessary to

perform only Steps 3, 4, 5, 7, 8, 9, and 12 of the

service procedure listed below.
1.
Remove screws securing rotor and remove rotor.

2.
Remove centrifugal weight springs and weights.

3.
Remove the tachometer drive gear from the distribu-

tor (Corvette only).

4.
Remove roll pin, then remove distributor drive gear

and washer.

CAUTION: To prevent

magnet, support drive gear
;e to the permanent

?n
driving out roll

pin.

5. Remove drive shaft assembly.

6. Remove centrifugal weight support and timer core

from drive shaft.

7. Remove connector from pickup coil leads.

8. Remove retaining ring which secures magnetic

core support plate to distributor shaft bushing in

housing.

9. As a unit, remove the entire magnetic pickup assem-

bly from the distributor housing.

10.
Remove brass washer and felt pad.

11.
Remove vacuum advance unit.

12.
To reassemble distributor, perform the above steps

in reverse order.

INSTALLATION (CORVETTE)

1.
Check to see that the engine is at firing position for

No.
1 cylinder (timing mark on harmonic balancer

indexed with pointer).

2.
Position a new distributor-to-block gasket on the

block.

3.
Before installing distributor, index rotor with hous-

ing as noted when distributor was removed. Install

distributor in block so that vacuum diaphragm faces

approximately 45° forward on the right side of the

engine and the rotor points toward contact in cap for

No.
1 cylinder.

4.
Replace distributor clamp leaving screw loose

enough to allow distributor to be turned for timing

adjustment.

5. Install spark plug wires in distributor cap. Place

wire for No. 1 cylinder in tower (marked on old cap

during disassembly) then install remaining wires

clockwise around the cap according to the firing

order (1-8-4-3-6-5-7-2).

6. Attach distributor to coil primary wires.

7. Replace distributor cap.

8. Adjust timing and then fully tighten distributor clamp

screw.

9. Attach vacuum line to distributor.

10.
Connect tachometer drive cables to distributor body.

11.
Replace ignition shields.

DISTRIBUTOR OFF-ENGINE TEST

The distributor's centrifugal and vacuum advance can

be checked in a distributor testing machine or synchro-

scope specially adapted or designed to accommodate this

type distributor. However, since this involves removing

the distributor from the engine, this test may be post-

poned until other system checks have been made. A dwell

reading cannot be obtained on this distributor and it is not

likely that the centrifugal or vacuum advance will be a

cause of trouble.

COIL REPLACEMENT

1.
Disconnect ignition switch and distributor leads from

CHEVROLET CHASSIS SERVICE MANUAL

ENGINE-ELECTRICAL 6Y-28

terminals on eoil. On Corvettes equipped with radio,

remove bolts securing ignition shield over distribu-

tor and coil.

2.
Pull high tension wire from center terminal of coil.

3.
Remove the two coil support mounting bolts or loosen

friction clamp screw and remove coil.

4.
Place new coil in position and install attaching bolts

or tighten clamp screw.

5.
Place high tension lead securely in center terminal

of coil and connect ignition switch and distributor

primary leads to terminals on coil. Replace ignition

shield on Corvettes.

6. Start engine and test coil operation.

IGNITION PULSE AMPLIFIER

DISASSEMBLY

To check the amplifier for defective components, pro-

ceed as follows:

1.
Remove the bottom plate from the amplifier.

2.
To aid in reassembly, note the locations of the lead

connections to the panel board.

3.
Remove the three panel board attaching screws, and

lift the assembly from the housing.

4.
To aid in reassembly, note any identifying markings

on the two transistors and their respective locations

on the panel board and heat sink assembly.

5.
Note the insulators between the transistors.and the

heat sink, and the insulators separating the heat sink

from the panel board.

6. Remove the transistor attaching screws, and sepa-

rate the two transistors and heat sink from the panel

board.

7.
Carefully examine the panel board for evidence of

damage.

MOUNTING

SCREW

RESISTOR R5 jgSfe. / DIODE Dl

TRANSISTOR TR2

(UNDERNEATH)

1H L >©V

[So

To
I
/'%**jt\
\
TRANSISTC>R"""

1 X ^^w^ X \ (UNDERNEATH)

9^ESISTORR^^^H|^^^^^H

^B
RESISTOR
R4
^HPH^^H

WM'
RESISTOR
R3
I^B^^^^I^U

N .6 ®

mm

N%|/MOUNTING

• tr^i^w ^\ vjR SCREW

CAPACITOR
Cl\
pNkj^^A^
\
RESISTOR
Rl

MOUNTING ^55S^^ \ CAPACITOR C3

SCREW I RESISTOR R6 CAPACITOR C2

TRANSISTOR TR3
COMPONENT CHECKS (Figs. \7\ and 18i)

With the two transistors separated from the assembly,

an ohmmeter may be used to check the transistors and

components on the panel board for defects. An ohmmeter

having a 1-1/2 volt cell, which is the type usually found

in service stations, is recommended. The low range

scale on the ohmmeter should be used except where

specified otherwise.

A 25 watt soldering gun is recommended, and a 60% tin

40%
lead solder should be used when re-soldering. Avoid

excessive heat which may damage the panel board. Chip

away any epoxy involved, and apply new epoxy which is

commercially available.

In order to check the panel board assembly, it is

necessary to unsolder at the locations indicated in Fig-

ure 18i the two capacitors C2 and C3. In all of the fol-

lowing checks, connect the ohmmeter as shown and then

reverse the ohmmeter leads to obtain two readings. The

amplifier circuitry is shown in Figure 19i.

1.
Transistors TR1 and TR2: Check each transistor by

referring to Figure 20i. If both readings in Step 1

are zero, the transistor is shorted. If both readings

in Step 2 are zero, the transistor is shorted; and if

both readings are infinite, the transistor is open.

Interpret Step 3 the same as Step 2.

2.
Trigger Transistor TR3:
11
both readings in Step 1

are zero, the transistor is shorted. If both readings

in Step 2 are zero, the transistor is shorted; and if

both readings are infinite, the transistor is open.

Interpret Step 3 the same as Step 2.

3.
Diode Dl: 11 both readings are zero, the diode is

shorted; and if both readings are infinite, the diode

is open.

4.
Capacitor Cl: If both readings are zero, the capaci-

tor is shorted.

5.
Capacitors C2 and C3: Connect the ohmmeter across

CHECKING

RESISTOR Rl

UNSOLDER
I
CHECKING TRIGGER

TRANSISTOR TR3
CHECKING

CAPACITOR C

Fig.
171—Pulse Amplifier Panel Board
Fig.
18i—Pulse
Amplifier
Component
Checks

CHEVROLET CHASSIS SERVICE MANUAL