service CHEVROLET CAMARO 1967 1.G Chassis Workshop Manual

CHASSIS SHEET METAL 11-21

FENDER TO W/SHIELD

MOLDING .06 ± .06

GRILLE & FENDER .06 TO—•

.18 GAP

.06 TO .18 GAP

BETWEEN HOOD &

GRILLE & FLUSH =t .06

GRILLE TO W/SHIELD —

MLDG.
FLUSH +.06

-.00^1

GRILLE & FENDER

FLUSH ± .06

FENDER FLUSH

TO .06 ABOVE DOOR

FENDER FLUSH TO .060

06 TO .18 GAP

OUTBOARD OF NORMAL

DOOR AT FENDER,

CENTER PEAK UNE.
HOOD & FENDER

FLUSH ± .06

TO FENDER AT

CORNER FLUSH TO + .06
NORMAL DOOR SURFACE

TO BE MEASURED 2" REAR-

WARD OF DOOR EDGE

TO FENDER EDGE.
FENDER

TO DOOR

.18 it .04

HEADER TO FENDER

FLUSH ± .06

FENDER TO

ROCKER .09±.06

—HOOD TO BE FLUSH

TO 4- .06 TO HEADER

TYPICAL ON

SURFACE FLUSH

CONDITION DESIRED

VIEW A
TYPICAL SECTION
REAR BUMPER

Fig.
34 - Sheet Metal Adiustments - Comoro

CHEVROLET CHASSIS SERVICE

CHASSIS SHEET METAL 11-22

wiring harness, and washer bottle from radiator

support.

5.
Remove screw connecting battery tray to radiator

support.

6. Remove shroud from vehicle if so equipped.

7.
Remove shroud and radiator (Section 13).

8. Remove screws securing support to frame, skirts,

and fenders.

9. Remove radiator support from vehicle.

Installation

Install radiator support following the removal pro-

cedure in reverse order. Refer to torque specifications

in rear of manual for correct torque values for radiator

supportj grille, and bumper.

FENDER AND SKIRT ASSEMBLY

Removal

1.
Remove front bumper (Section 14).

2.
Remove hood and hood.hinges (two men).

3.
Remove bolts securing brace to skirt and dash panel

and remove brace (fig. 32).

4.
Disconnect any components attached to fender and

skirt such as cruise control, hoses, electrical har-

ness etc.

5.
Remove screws securing radiator support to fender

and skirt.

6. Remove headlamp bezel and headlamp.

7.
Remove screws securing fender and skirt assembly

to header panel, headlamp housing and valance panel.

Remove screw securing fender extension to valance

panel.

8. Remove screws securing fender and skirt assembly

to vehicle and remove fender and skirt assembly.

9. If necessary, remove screws attaching fender ex-

tension and bumper bracket to fender and remove

extension and bracket. Replace fender trim if nec-

essary.

Installation

Install fender anci skirt assembly following the removal

procedure in reverse order. Refer to torque specifi-

cations in rear of manual for correct torque values.

HOOD ASSEMBLY

Procedures for hood removal and installation for

Camaro are the same as for Chevrolet and Chevelle.

Refer to Chevrolet and Chevelle hood removal and in-

stallation procedures, Figure 35 for Camaro hood catch,

support, and lock plate, and Figure 37 for Camaro hood

and insulator.

HOOD CATCH AND LOCK (Fig. 35)

Removal

1.
Remove catch plate assembly by removing screws

retaining catch to header panel, center support, and

radiator support.

NOTE: Before removing hood lock plate from

hood, locate position on hood by scribing around

base of lock plate.

2.
Remove lock plate by removing screws retaining lock

plate to hood and remove lock plate.
Fig.
35 - Hood Catch, Support, and Lock Plate - Camaro

Installation

Install lock and catch plate following the removal pro-

cedure in reverse order. Refer to torque specifications

in rear of manual for correct torque values. Adjust lock

and catch plate as outlined under adjustment procedure

in this section.

HOOD TRIM AND INSULATION (Fig. 37}

. Figure 37 shows the installation details of the Camaro

hood ornament and insulation pad. The insulation and

ornament retainers and nuts are accessible from under

the raised hood.

COWL VENT GRILLE

.Procedures'for Camaro cowl vent grille replacement

are the same as for Chevrolet and Chevelle. Refer to

Chevrolet and Chevelle cowl vent grille replacement.

CHEVROLET CHASSIS SERVICE MANUAL

CHASSIS SHEET METAL 11-23

SHIM

VIEW A
SHIM

VIEW B

Fig.
36 - Fender to Cowl and Rocker Panel Shimming - Camaro

CHEVROLET CHASSIS SERVICE MANUAL

CHASSIS SHEET METAL 11-24

Fig. 37 - Camaro Hood, Insulator, and Ornament

CHEVROLET CHASSIS SERVICE MANUAL

CHASSIS SHEET METAL 11-25

SPECIAL TOOLS

The only special tool required for 1967 chassis sheet

metal servicing is the hood spring removal and instal-

lation ToolJ-9559. See Figure 38.

Fig.
38 - Special Tools - All Models

Hood Spring Tool J-9559

CHEVROLET CHASSIS SERVICE MANUAL

SECTION 12

ELECTRICAL-BODY AND CHASSIS

CONTENTS
OF
THIS
SECTION

Page
Page

System 12-1

Instruments and Gauges 12-21

Directional Signal 12r40
Windshield Wipers and Washers 12-44

Wiring Diagrams 12-56

Special Tools 12-60

LIGHTING SYSTEM

INDEX

Page

General Description
!2-i

Maintenance and Adjustments
•.................. 12-2

Headlamp Adjustment......................
12-3

Headlamp Panel Travel Adjustment.
12-5

Service Operations.
. . .. 12-5

Front Lighting
12-5

Headlamp
. 12_5

Parking Lamp
12-5

Fender Lamp
. 12_^

Headlamp Panel
12-8

Headlamp Panel Motor
^2-9

Rear Lighting
l2-10

Tail, Stop and Directional Lamps
12-10
Page

Backing Lamps
12-14

License Plate Lamp
12-14

Automatic Transmission Quadrant Lamp
12-14

Seat Separator Console Lamps
. 12-15

Lighting Switch
. . 12-15

Wiper Switch.
12-15

Stoplight Switch
12-15

Dimmer Switch
12-15

Backing Lamp Switches
12-15

Neutral Safety Switches
12-17

Parking Brake Alarm Switch
................. 12-19

Instrument Panel Compartment Lamp/Switch
12-19

Cirgarette Lighter
12-19

GENERAL DESCRIPTION

.
The lighting system includes: the main lighting switch,

stop light, dimmer, and backing lamp switches, head-

lamps, parking lamps, stop, tail and directional lamps,

instrument illumination and indicator lamps, and the

necessary wiring to complete the various circuits. A

fuse panel provides convenient power take offs and fuse

clips for the appropriate circuits (fig. 1).

Chevrolet and Chevelle headlamp installation is all

new in that the headlamps are located in the radiator

support with adjusting screws and springs. Eliminating

the need for having separate headlamp housings. Chev-

rolet and Chevelle headlamp retainers and springs are

interchangeable.

Chevy n headlamp housings are new because of revised

front end styling and Corvette front end lighting is basi-

cally carryover.

Front fender lamps have been added as an option for

Chevrolet models and as standard equipment on Caprice

series.

Camaro models use single headlamps and the Rally

Sport model headlamps are covered by a retractable

section of the grille when lamps are not used. The sec-

tion of the grille covering the headlamps folds back when

lights are required; the headlamps are stationary. The

covering is retracted by a small electric motor mounted

to the headlamp housing. The headlamps are automat-

ically uncovered when the headlight switch is pulled "ON"

for illumination. If at any time the electrical circuit

becomes inoperative, the lamps can be uncovered manu-

ally. The ignition switch must be
"ON"
in order to close

the headlamp doors.

Parking lamp for Chevelle and Chevrolet models are
new due to revised front end sheet metal and bumper

styling. Parking lamps are located in the bumper on

Chevrolet, Chevelle and Chevy n models

Camaro parking lamps are located in the radiator

grille except for the Rally Sport models on which the

parking lamps are in the valance panel. For styling

reasons, the lens is white and an amber glass bulb is

used. All Camaro parking lamps require a separate

ground wire to assure a good ground contact because of

the plastic grille and painted contact surfaces.

The Chevrolet tail, stop, and directional lamps are in

one housing with a three section lens design on Impala

and Caprice sedans. The center lens for Impala series

is the back-up lamp. The center lens on the Caprice is

a tail lamp with the back-up lamps being located in the

rear bumper. Chevrolet station wagons have three indi-

vidual housings with three lenses, the center lamp being

the back-up. Biscayne and Bel-Air sedans have a single

housing and lens for tail, stop, and directional lamp with

a similarly constructed back-up lamp inboard and adja-

cent to it.

Chevelle tail, stop, and directional lamps are a single

lens design that follows through with the rear fender

styling. The back-up lamp is located in r.ear bumper.

Camaro models except Rally Sport have tail lamps

with integral back-up lamps mounted inboard of the rear

fenders between the trunk opening and bumper. The

Rally Sport model has dual tail lamps in the rear housing

and valance mounted back-up lamps.

Corvette, Chevy n, and Corvair tail and directional

signal lights are carryover. The Corvette has new back-

up lamps center mounted above the license plate opening.

CHEVROLET CHASSIS SERVICE

ELECTRICAL-BODY AND CHASSIS 12-2

FJg.
1 - Fuse Panel Assembly

All power window and tailgate circuits require the igni-

tion switch to be "ON" to open or close the windows un-

like past model designs which were operated independ-

ently of the ignition switch.

The windshield wiper and washer switch is new in that

washer button in the center of the knob has been deleted
and its function will be accomplished by pushing the knob.

A set screw is used to retain the knob to the shaft.

In addition to fuses, the wiring harness incorporates

fusible links to protect the wiring. Links are used rather

than a fuse in wiring circuits that are not normally fused,

such as the ignition circuit. Fusible links in the Chevro-

let wiring are four gauge sizes smaller than the cable it

is designed to protect. The links are marked on the

insulation with wire gauge size because of the heavy insu-

lation which makes the link appear a heavier gauge than it

actually is.

Engine compartment wiring harness incorporate sev-

eral fusible links. Each link is identified with its gauge

size.
A fusible link is a length of special wire (normally

four wire gauges smaller than the circuit it is protecting)

used in wiring circuits that are not normally fused, such

as the ignition circuit. The same size wire with a spe-

cial hypalon insulation must be used when replacing a

fusible link.

The links are:

1.
The pigtail lead at the battery positive cable (except

Corvette) is a 14 gauge, brown fusible link protecting

the 10 gange battery charging circuit. This wire is

an integral part of the battery cable assembly and

servicing requires replacing the complete battery

cable assembly. On Corvette models this link is

installed as a molded splice at the solenoid "Bat"

terminal and servicing requires splicing in a new

link.

2.
A 16 gauge black fusible link is located at horn relay

to protect all unfused wiring of 12 gauge or larger.

It is a serviceable piece with an in-line connector

and is not integral with the wiring harness.

3.
The generator warning light and field circuitry (16

gauge wire) is protected by a fusible link (20 gauge

orange wire) used in the "battery feed to voltage

regulator #3 terminal" wire. The link is installed

as a molded splice in the generator and forward lamp

harness and is serviced by splicing in a new 20 gauge

wire as required.

4.
The ammeter circuit on all models is protected by

two orange, 20 gauge wire fusible links installed as

molded splices in the circuit at the junction block or

the solenoid "Bat" terminal (Corvette only) and at the

horn relay. Each link is serviced by splicing in a

new 20 gauge wire as required.

The wiring harnesses use a standarized. color code

common to all Chevrolet vehicles. Under the color code,

the color of the wire designates a particular circuit. The

harness title indicates the type of harness, single of mul-

tiple wire, and also describe the location of the harness.

The body harness is a flat, solid wire assembly and is

routed through the vehicle near the center of the body.

Composite wiring diagrams (figs. 104 thru 124) are in-

cluded at the end of this section.

MAINTENANCE AND ADJUSTMENTS

Maintenance of the lighting units and wiring system

consists of an occasional check to see that all wiring

connections are tight and clean, that the lighting units are

tightly mounted to provide good ground and that the head-

lamps are properly adjusted. Loose or corroded con-

nections may cause a discharged battery, difficult start-

ing, dim lights, and possible damage to generator and

regulator. Wire harnesses must be replaced if insulation

becomes burned, cracked, or deteriorated. Whenever it
is necessary to splice a wire or repair one that is bro-

ken, always use solder to bond the splice. Always use

rosin flux solder on electrical connections. Use insulat-

ing tape to cover all splices or bare wires.

When replacing wires, it is important that the correct

size be used. Never replace a wire with one of a smaller

size.

Each harness and wire must be held securely in place

by clips or other holding devices to prevent chafing or

CHEVROLET CHASSIS SERVICE MANUAL

ELECTRICAL-BODY AND CHASSIS 12-3

Fig.
2 - T-3 Safety Aimer

wearing away the insulation due to vibration.

By referring to the wiring diagrams, circuits may be

tested for continuous circuit or shorts with a conventional

test lamp or low reading volt meter.

HEADLAMP ADJUSTMENT-

T-3 HEADLAMPS

CAUTION: Check and tighten radiator support

grille retaining bolts prior to attempting head-

lamp aiming. Distorted grille or supports in

this area will hinder proper aiming of head-

lamps. On Corvette models make sure head-

lamp panel is adjusted properly - refer to

"Headlamp Panel Travel Adjustment".

When aiming headlamps, vehicle should be filled to ca-

pacity with gas, oil, and water but no load. Tires should

be uniformly inflated to recommended pressure.

the T-3 Safety Aimer-Type B (fig. 2), is used for the

headlamp aiming description that follows. An adapter is

required with the Type B T-3 Aimer when adjusting the 7

inch headlamp used on the Chevy n vehicle.

1.
Drive vehicle onto selected aiming area. Bounce

vehicle several times and allow to settle.

2.
Remove headlamp bezels.

3.
Mount the T-3 Aimers on either the No. 1 or No. 2

pair of headlamps so that "the points of the headlamps

engage the smooth inner ring of the aimers.
HORIZONTAL

AIMING

SCREW

STRING OVER

"2R" ON AIMER ARM

Fig.
4—-Headlamp Horizontal Adjustment

NOTE:
In the dual headlamp installation, the

inboard unit is designated No. 1 and the outboard

unit is designated No. 2.

4.
Secure the aimers to the headlamp units by firmly

pressing knob at center of each aimer (fig. 3). Ro-

tate crossarms inboard to approximate horizontal

position.

NOTE:
Moisten suction cups slightly to obtain

maximum holding force.

5. With both aimers in place, knot both ends of elastic

string and, using slots provided, fasten string across

horizontal crossarms of each aimer.

6. Rotate both aimers so that the string just clears the

points on the crossarms.

HORIZONTAL ADJUSTMENT

7. a. Turn horizontal aiming screw, Figure 4, on left-

VERTICAL ADJUSTMENT SCREW

Fig.
3 - Installing Aimer on Headlamp Unit
Fig.
5 - Headlamp Vertical Adjustment

CHEVROLET CHASSIS SERVICE MANUAL

ELECTRICAL-BODY AND CHASSIS 12-4

b.
hand lamp until the string is positioned over the

crossarm centerline. Turn the screw clockwise

in making the final adjustment to take up play in

the headlamp mechanism.

Repeat the above procedure on the right-hand

lamp to complete the horizontal adjustment of the

headlamps.

VERTICAL ADJUSTMENT

8. a. Numeral "2" (fig. 5) should appear in the "down"

window of each aimer. If not, loosen knob at

underside of aimer arm and slide back and forth

until the numeral does appear.

NOTE:
This setting will give a 2" drop of the

headlamp high beam spot centerline on a screen

placed 25 feet forward of the vehicle. Check

state laws for proper vertical setting.

b.
Turn headlamp vertical aim screw (fig. 5) on left-

hand unit counter-clockwise until the bubble is at

the inner end of the glass tube. Then turn screw

clockwise until bubble is centered in tube.

c. Repeat this procedure on right-hand headlamp

unit to complete vertical adjustment of lamps.

9. Recheck the string at the ends of each crossarm for

correct setting and the bubble on each aimer for

centered position.

10.
Remove the aimers by pulling on the suction cup tabs

through the openings in the aimers (fig. 6).

11.
With headlamps properly aimed, replace headlamp

bezels.

HOW TO SELECT A LEVEL AIMING AREA

1.
Select area you believe to be level.

2.
Remove headlamp bezels and install Aimers on each

headlamp (fig. 3) making sure aiming lugs engage

smoooth inner ring of the Aimer.
"
To install Aimer,

press firmly on the knob extending out from the cen-

ter of the Aimer base. This forces the suction cup

into place on the Sealed Beam unit.:

3.
Loosen the slider knob beneath the aimer arm and

set the numeral "2" in the DOWN view window (fig.

7).
Back vertical lamp adjustment out on each lamp

until bubble is outside of black line of vial, then cen-

ter bubble in between black line of vial by turning

clockwise.
VERTICAL AIMING SCREW

VIEW WINDOWS

BUBBLE

Fig.
6 - Removing Aimer from Headlamp
Fog.
7- Selecting Level Aiming Area

4.
After botli bubbles are centered, turn the car around

end for end, making sure the tires are in the spots

made on the floor before the car was moved.

.5.
If the bubbles are still within the two outside black

marks on the vials, the floor is level enough to use

the Aimer as it comes from the factory.

NOTE:
A quick level check can be made by

using the T-3 Safety-Aimer as a level. Use

with a true eight to ten foot two by four as an

extension. Make sure pads on base of Aimer

are used. Place the board where you expect the

wheels to be and take readings as outlined above.

6. If either bubble moves outside the black lines of the

vial there is too much slant to the floor. Try driving

the car in at different angles onto the aiming area.

If bubbles can
not
be centered follow procedure under

"How to Compensate for Unlevel Floor."

NOTE:
When level portion of floor is obtained,

mark tire spots on floor so spots can be used

next time without calibrating Aimer.

TO COMPENSATE FOR UNLEVEL FLOORS

If your floor is not level within the limits specified, the

T-3 Aimer can be calibrated to compensate for the error

in the floor. Follow this procedure with both aimers.

1.
Drive the car onto the area for which you wish to

compensate the aimers, and install the aimers in

place on the headlamps.

2.
Loosen knob beneath the aimer arm and move the

slider until the bubble is centered.

3.
Record the numeral in the view window. (This nu-

meral is to be used only for recalibration.)

4.
Move the slider to a position halfway between this

recorded numeral and the numeral "2" in the
DOWN

window. (This numeral is used only in recalibration

and not for headlamp aiming.)

5.
Recalibrate aimers by turning screw shown in Figure

8 until the bubble is centered.

6. The T-3 Aimers are now calibrated for the selected

area. All future aiming must be done in the same

area and with the car pointed in the same direction.

Mark the tire spots on the floor so that other vehi-

cles can be located in the same position.

CHEVROLET CHASSIS SERVICE MANUAL

ELECTRICAL-BODY AND CHASSIS 12-5

Fig.
8—Turning Level Adjusting Screw to Calibrate Aimer

HEADLAMP PANEL TRAVEL ADJUSTMENT

Corvette (Fig. 9)

The headlamp panel travel is limited by two adjusting

screws which are located on the arms of the shaft

mounted stop.
Fig.
9—Headlamp Panel Travel Adjusting Screw

1.
Raise hood and as a safety precaution install a bolt

through the hole in the hood support - secure bolt

with a nut.

2.
Adjusting screw (A) limits headlamp panel travel in

open position - adjust this screw so that mounting

face of panel is within 2 degrees of vertical in the

fully open position.

NOTE: Each headlamp operates independently

of the other, therefore individual adjustment is

required for each panel.

3.
Adjusting screw (B) limits headlamp panel travel in

closed position - adjust this screw so that panel is

flush to upper body panel in the fully closed position.

4.
Lock both screws by tightening lock nut against stop.

5.
Remove safety bolt as installed in Step 1 and close

the hood.

SERVICE OPERATIONS

FRONT LIGHTING

HEADLAMP REPLACEMENT (Figs. 10 and 13)

1.
On Corvette and Camaro Rally Sport models, rotate

the headlamp panel to the open position.

2.
Remove headlamp bezel retaining screws and remove

bezel. On Chevrolet, Chevelle and Camaro models

lift bezel to disengage retaining tabs from slots in

filler panel.

3.
On Chevy n models remove three retaining ring at-

taching screws. On other models disengage spring

from the retaining ring and remove two attaching

screws.

4.
Remove retaining ring, disconnect sealed beam unit

at wiring connector and remove the unit.

5.
Attach connector to replacement unit and position

unit in place making sure the number molded into the

lens face is at the top.

NOTE: In the dual headlamp installation the

inboard unit (NO. 1) takes a double connector, the
outboard unit (No. 2) takes a triple connector

plug.

6. Position retaining ring into place and install the re-

taining ring attaching screws and spring (as

applicable).

7.
Check operation of unit and install the headlamp

bezel.

PARKING LAMP REPLACEMENT

Bulb

1.
Remove two lens retaining screws and disengage lens

from housing.

2.
Replace bulb, check operation of lamp, reinstall lens

and retaining screws.

Lamp Housing

Chevrolet, Chevelle and Chevy II (Figs. 10 and 11)

1.
Disconnect lamp wire assembly in-line connector

from wiring harness.

CHEVROLET CHASSIS SERVICE MANUAL