ECU CHEVROLET CAMARO 1967 1.G Chassis Manual Online

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

FUEL TANK
AND
EXHAUST SYSTEMS
8-31

EXHAUST SYSTEMS

INDEX

Page

General Description
8-31

Component Part Replacement
8-31

Muffler Assembly
8-31

Exhaust Pipe
. 8-31

Tailpipe and/or Resonator
8-32

GENERAL DESCRIPTION

The single exhaust system
cm
six* cylinder engine

models
(fig. 36)
consists
of an
exhaust pipe, extension,

muffler
and
tailpipe with necessary attaching brackets

and clamps.
On V-8
engine models with single exhaust

assemblies
(fig. 36) an
exhaust crossover pipe
is
added

to connect
the
right exhaust manifold
to the
system.
The

dual exhaust system available
on V-8
engine models
(fig.

37) includes
two
front exhaust pipes -with
or
without

resonators,
two
rear exhaust pipes, dual inlet-outlet

muffler, tailpipes and attaching hardware.

The assemblies
are
secured
to the
engine
at the ex-

haust manifolds,
to the
rear compartment pan reinforce-

ment ahead
of
axle
and
adjacent
to the gas
tank
at the
end
of the
tailpipe.
The
assemblies
are
suspended
on

brackets with insulators
for
rattle free operation.

The muffler
is an
all-welded construction with
a

•
capacity
for
muffling
the
noise
and at the
same time,

minimizing back pressure
for
maximum engine effici-

ency.
The
internal parts
are
electric welded
to
eliminate

premature failure
or
rattle.

The exhaust system center mounting
at the
muffler

location consists
of an
underbody bracket,
an
insulator

and
a
clamp.
The
clamp holds
the
muffler and tailpipe

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 tailpipe

secures
the
pipe
to a
bracket assembly
and
insulator

attached
to an
existing underbody bracket.

COMPONENT PART REPLACEMENT

EXHAUST PIPE

Replacement

1.
Loosen
"U"
bolt clamp
at
rear exhaust pipe

connection.

2.
Remove exhaust pipe
to
manifold attaching nuts,
ex-

tension
and.
packing then separate pipe from manifold

studs.

NOTE:
Right exhaust crossover pipe
on V-8

engine single exhaust models
is an
integral part

of
the
exhaust pipe assembly and
is not
serviced

separately.

3.
Separate front exhaust pipe from rear exhaust pipe

extension.

4.
To
install exhaust pipe, connect pipe
to
rear exhaust

pipe extension
or
resonator
and
secure
to
exhaust

manifold. Note clearances
for
the standard and auto-

matic control linkages, underbody
and
crossmember.

5. Tighten exhaust pipe
to
manifold attaching nuts
and

rear "U" bolt clamp nuts.

EXHAUST PIPE EXTENSION

Replacement

1.
Remove "U" bolt clamps
at
muffler inlet and exhaust

pipe
or
resonator connections.

2.
Disconnect exhaust pipe extension
at
muffler
and

exhaust pipe
or
resonator connection.
3.
To
install extension, connect extension
to
exhaust

pipe
or
resonator and
to
muffler.

4.
Install
"V"
bolt clamps
and
tighten clamp nuts.

MUFFLER ASSEMBLY

Replacement

1.
Remove "U" bolt clamp
at
muffler inlet.

2.
Remove tailpipe support clamp.

3.
Separate muffler from rear exhaust pipe
and
remove

muffler from vehicle.

4.
If
usable,
cut
tail pipe from muffler.

5. Connect muffler inlet
to
exhaust pipe and install
"U"

bolt clamp
at
muffler inlet.

6. Connect tailpipe
to
muffler outlet
and
install rear

support clamp.

7. Install
"U"
bolt clamp
at
tailpipe
to
muffler outlet

connection and tighten nuts.

TAILPIPE

Replacement

1.
Remove
"U"
bolt clamp
at
muffler outlet.
If
replac-

ing right tail pipe, eut pipe
at
muffler outlet.

2.
Remove tail pipe rear hanger clamp and detach pipe

from muffler.

&IS SBtVKE MANUAL

FUEL TANK AND EXHAUST SYSTEMS 8-32

EXHAUST PIPE EXTENSION

MUFFLER & TAIL PIPE ASSY.

Fig.
36—Single Exhaust System

3.
Position tail pipe at muffler, then install at hanger.

Do not secure attachments until clearances have been

checked. Check position of hanger so that inter-

plates are parallel.

4.
Tighten nuts at "U" bolt clamp then secure rear tail

pipe clamp.
RESONATOR

Replacement

1.
Cut exhaust pipe at resonator inlet.

2.
Loosen "U" bolt clamp nuts and separate resonator

from rear exhaust pipe extension.

3.
Assemble resonator to front and rear exhaust pipes!

4.
Install front and rear "U" bolt clamps and tighten

nuts.

CHEVROLET CHASSIS SERVICE MANUAL

STEERING 9-3

Fig.
4-Checking Wheel PuI!-Corvette

c. If torque does not lie within limits given in speci-

fications at rear of manual, adjustment is

necessary.

4.
Corvette and telescopic columns:

a. Use Tool J-5178 to measure.pull at rim of wheel

required to keep wheel in motion (fig. 4).

b.
If pull does not lie within limits given in specifi-

cations in rear of manual, adjustment of worm

bearings is necessary.

NOTE:
If vehicle is equipped with a tilt steer-

ing column, it will be necessary to disconnect

the steering coupling to obtain a torque reading

of the steering column. This torque should then

be subtracted from any reading taken on the

gear.

5. To adjust worm bearings, loosen worm bearing ad-

juster locknut and turn worm bearing adjuster shown

in Figure 3 until there is no perceptible end play in

worm. Check pull at steering wheel, readjusting: if

necessary to obtain proper pull. Tighten locknut and

recheck pull. If the gear feels "lumpy" after adjust-

ment of worm bearings, there is probably damage in

the bearings due to severe impact or to improper

adjustment and the gear must be disassembled for

replacement of damaged parts.

6. After proper adjustment of worm is obtained and all

mounting bolts securely tightened, adjust lash ad-

juster screw. First turn the steering wheel gently

from one stop all the way to the other, carefully

counting the total number of turns. Then turn wheel

back exactly half way, to center position. Turn lash

adjuster screw clockwise to take out all lash in gear

teeth, and tighten locknut. Check pull at steering

wheel taking highest reading as wheel is turned

through center position. See specifications in rear of

manual for proper sector lash adjustment. Readjust

if necessary to obtain proper pull.
NOT MORE THAN

T/a INCH FROM

CENTERLINE

Fig.
5—Steering Wheel Alignment

NOTE:
If maximum specification is exceeded,

turn las£ adjuster screw counterclockwise, then

come up on adjustment by turning the adjuster in

a clockwise motion.

7. Tighten locknut then recheck pull, as it must lie be-

tween specified readings.

Fig.
6—Adjusting Steering Ratio—Corvette

CHEVROLET CHASSIS SERVICE MANUAL

STEERING 9-4

8. Reassemble pitman arm to sector shaft, lining up

marks made during disassembly. Refer to torque

specifications at rear of manual for correct torque

value.

9. Install horn cap or ornament and connect steering

column harness at chassis connector.

NOTE:
Chevy.n models are equipped with a

shim at the frame to steering gear mounting

bolts.
Shims may be removed or installed as

required for proper steering gear alignment.

STEERING WHEEL ALIGNMENT AND

HIGH POINT CENTERING

1.
Set front wheels in straight ahead position. This can

be checked by driving vehicle a short distance on a

flat surface to determine steering wheel position at

which vehicle follows a straight path.

2.
With front wheels set straight ahead, check position

of mark on wormshaft designating steering gear high

point. This mark should be at the top side of the shaft

at 12 o'clock position and lined up with the mark in

the coupling lower clamp.

3.
If gear has been moved off high point when setting

wheels in straight ahead position, loosen adjusting

sleeve clamps on both left and right hand tie rods,

then turn both sleeves an equal number of turns in

the same direction to bring gear back on high point.

CAUTION: Turning the sleeves an unequal
number of turns or in differential directions will

disturb the toe-in setting of the wheels.

4.
Readjust toe-in as outlined in Section 3 (if necessary).

5. With wheels in a straight ahead position and the

steering gear on highpoint, check the steering wheel

alignment by measuring the distance from each hori-

zontal spoke to the horizontal centerline of the

steering wheel (fig. 5). If the horizontal spokes are

over 1-1/8 inches from the horizontal position the

wheel should be removed and centered. (See steering

wheel removal in this section.)

TOE-IN ADJUSTMENT

Adjust the steering linkage for proper toe-in setting as

outlined in Section 3.

CORVETTE STEERING RATIO (Fig. 6)

The Corvette steering ratio may be changed as follows:

CAUTION: Do not use the rearward hole in the

steering arm with power steering equipment or

interference may result.

1.
Remove tie rod ball stud nut at steering arm and

disconnect tie rod from steering arm.

2.
Move tie rod end to forward hole for 17.6:1 ratio

(fast ratio) or rear hole for 20.2:1 ratio (standard

ratio).

3.
Install tie rod stud nut and tighten securely. Repeat

operation on opposite steering arm.

COMPONENT REPLACEMENT AND REPAIRS

STEERING WHEEL

REGULAR PRODUCTION (Fig. 7)

Removal

1.
Disconnect steering column harness from chassis

wiring harness at connector (fig. 8).

2.
Pull out horn button cap or center ornament and

retainer.

3.
Remove three screws from the receiving cup.

4.
Remove the receiving cup, belleville spring, bushing,

and pivot ring.

5. Remove the steering wheel nut and washer.

6. Using Tool J-2927, install centering adapter on

steering shaft, thread puller anchor screws into

threaded holes provided in steering wheel. Turn

center bolt of tool clockwise to remove steering

wheel (fig. 9).

Installation

CAUTION: Direction signal control assembly

must be in "neutral position when assembling

steering wheel to prevent damage to cancelling

cam and control assembly.

1.
With directional cancelling cam and horn contact as-

sembly in place, set wheel onto steering shaft.
Fig. 7—-Regular Wheel and Horn Attachments

CHEVROLET CHASSIS SERVICE MANUAL

STEERING 9-5

Fig.
8—Steering Column Wiring Connector

Secure with washer and nut. Refer to torque speci-

fications at rear of manual for correct torque values.

Install belleville spring (with dish of spring up), pivot

ring, bushing and receiving cup with screws.

Install retainer and horn button cap or center

ornament.

Connect steering column harness to chassis wiring

connector.

Fig.
9—Removing Steering Wheel with J-2927
Fig.
10—Simulated Wood Steering Wheel and Attaching Parts

SIMULATED WOOD (Fig. 10)

Removal

1.
Disconnect steering column harness from chassis

wiring harness at connector.

2.
Remove horn cap assembly by pulling up.

3.
Remove contact assembly attaching screws and re-

move contact assembly.

NOTE:
If steering wheel only is to be replaced,

perform step 4. If directional signal cancelling

cam is to be replaced, omit step 4 and proceed

with steps 5 and 6.

4.
Remove remaining screws from steering wheel and

remove wheel from hub assembly.

5. Remove steering wheel nut and washer.

6. Using Tool J-2927, install centering adapter on

steering shaft, thread puller anchor screws into

threaded holes provided in hub assembly. Turn

center bolt of tool clockwise to remove hub

assembly.

Installation

CAUTION: Directional signal control assembly

must be in neutral position when assembling hub

assembly to prevent damage to cancelling cam

and control assembly.

1.
With directional cancelling cam and horn contact in

place, install hub assembly on steering shaft. Secure

with washer and nut. Refer to torque specifications

at rear of manual for correct torque value.

2.
Attach steering wheel to hub assembly using the six

attaching screws and tighten securely.

3.
Place horn contact on steering wheel and attach with

three screws. Tighten securely.

4.
Snap horn button in place.

5. Connect steering column harness to chassis wiring

connector.

CORVETTE TELESCOPING (Fig. 11)

Removal

1.
Disconnect steering column harness at wiring

connector.

2.
Pry off horn button cap.

3.
Remove three screws securing horn contact to spacer

and hub.

4.
Remove two screws securing lock screw to lock

knob,
and remove lock screw, lock knob, and spacer.

CHEVROLET CHASSIS SERVICE MANUAL

STEERING 9-6

Fig.
11
—Corvette Telescoping Wheel Option

5.

7.
NOTE:
If steering wheel only is to be replaced,

perform Step 5 below only. If directional signal

cancelling cam is to be replaced, omit Step 5

and proceed with Steps 6 and 7.

Remove six screws securing steering wheel to hub

and remove wheel.

Remove nut and washer from shaft and using steering

wheel puller Tool J-2927, remove steering wheel and

hub from vehicle.

Slide cancelling cam and spring off shaft.

Installation

NOTE:
Refer to torque specifications at rear of

manual for correct torque values.

1.
If necessary, slide cancelling cam and spring on end

of shaft.

2.
If hub was removed from steering wheel, attach hub

to steering wheel with screws removed during dis-

assembly.

3.
Place steering wheel and hub assembly in position

and secure to column with washer and nut.

4.
Position spacer on steering wheel.
5. Position lock knob on steering wheel.

6. Install lock screw through lock knob, turn into shaft,

and adjust to lock position.

7. Attach spacer to wheel with three screws.

8. Place lock knob in lock position and attach to lock

screw with two screws.

9. Remove three screws holding spacer. Attach horn

contact to spacer and steering wheel with three

screws.

10.
Install horn button cap.

11.
Connect steering column harness at chassis plug.

STEERING COUPLING (Fig. 12)

Removal

NOTE:
Chevy n models are equipped with a

clamp arrangement rather than the conventional

"rag joint" steering coupling. Refer to Steering

Gear - Chevy II, for service procedures.

1.
Remove nuts and washers securing steering coupling

to flanged end of steering column (fig. 12).

2.
Remove coupling clamp bolt (fig. 12) and slightly

spread coupling clamp.

CHEVROLET CHASSIS SERVICE MANUAL

STEERING 9-7

Fig.
12-Steering Coupling

3.
Disconnect transmission controls from levers at

bottom of column, if so equipped.

4.
Inside vehicle, remove trim cover or boot, pro-

tective covers, and seal from dash panel as shown

in Figure 13. On Corvette models the covers are re-

moved in the engine compartment side. Also on

Corvette models, remove screws securing escutcheon

(fig. 14) to instrument panel.

5. Disconnect Steering column harness and back-up

lamp/neutral safety switch at connector plugs.

Fig.
13—Removing or Installing Dash Panel Covers and Seal

Fig.
14—Steering Column Escutcheon—Corvette

CHEVROLET CHASSIS SERVICE MANUAL

STEERING 9-8

DIAL

UPPER COVER

FASTENER

CHEVROLET
SCREW

CHEVELLE

Fig.
15—Powerglide Indicator Connection—Chevrolet and Chevelle

6.
Chevrolet and Chevelle only:

a. Remove lower mast jacket cover (fig. 15).

b.
If vehicle is equipped with Powerglide, remove

indicator pointer wire by removing screw from

six o'clock position at bottom of mast jacket (fig.

15).
Work indicator wire out of position and

remove.

Remove instrument panel column mounting bracket

attaching hardware and remove bracket.

CAUTION: Do not allow steering column to

hang down from dash panel area or distortion to

column will result. When instrument panel

mounting bracket is removed, be sure column is

supported in its normal position.

NOTE:
The following step requires two men,

one in the driver's seat and one at engine

compartment.

8

Lift steering column upward enough to permit re-

moval of steering coupling from steering gear.

Mechanic at engine compartment can pilot column

shift levers, if so equipped, through dash panel open-

ing as column is listed. If it is necessary to leave

the vehicle at this point, place steering column in

correct mounted position and loosely install instru-

ment panel mounting bracket to support column.

9. Remove steering coupling from vehicle.

Installation

1.
Lift steering column enough to provide clearance and

loosely install steering coupling on steering gear

shaft. Be sure column is supported in its normal

mounted position at all times when not moving for

clearance. Mechanic at engine compartment can

pilot column shift levers through dash panel opening

as column is moved.

2.
Slide steering coupling into correct installed position

and install clamp bolt (fig. 12).
3.
Secure steering coupling to flanged end of steering

column with washers and nuts. Maintain coupling ad-

justment shown in Figure 16.

4.
Install instrument panel column mounting bracket.

Refer to torque specifications at rear of manual for

correct torque values.

5. Chevrolet and Chevelle only:

a. If vehicle is equipped with Powerglide, work shift

indicator pointer wire into position on column and

secure with screw at six o'clock position at bot-

tom of mast jacket (fig. 15).

b.
Install mast jacket lower cover (fig. 15).

6. Connect steering column harness at connector plug.

Connect back-up lamp/neutral safety switch plug, if

so equipped.

7. Inside vehicle, install seal, protective covers, and

trim cover or boot (fig. 13). On Corvette models the

' covers are installed in the engine compartment side.

8. Connect transmission controls to shift levers at

bottom of column if so equipped.

CHEVROLET

CHEVELLE

CORVETTE
CAMARO

Fig.
16—Steering Coupling Clearance Adjustment

CHEVROLET CHASSIS SERVICE MANUAL

STEERING 9-9

STEERING GEAR-CHEVROLET, CHEVELLE,

CAMARO, AND CORVETTE (Fig. 12)

Removal

1.
Remove retaining nuts, lock washers, and bolts at

steering coupling. (No bolts are used on Corvette.)

On Corvette, loosen clamp bolt and slide coupling

upper flange upward on steering shaft.

2.
Remove pitman arm nut and washer from sector

shaft and mark relation of arm position to shaft.

3.
Remove pitman arm with Tool J-6632 as shown in

Figure 2.

4.
Chevelle only: . ,

a. Remove stabilizer bar to frame mounting

brackets.

b.
Remove bolt, washer, and nut securing left front

bumper bracket and brace to frame. (See Section

14,
Figure 3.) Scribe a mark around adjustment

washer for position reference, then loosen bolt

at adjustment washer location enough to release

washer from notches in bracket.

NOTE:
On Camaro models, use care not to bend

or fracture brake pipe when removing steering

gear.

5. Remove screws securing steering gear to frame and

remove gear from vehicle.

Installation

1.
Place gear into position so that steering coupling

mounts properly to flanged end of steering shaft.

Secure gear to frame with washers and bolts. On

Corvette models, install gear with bolts, washers,

and nuts. Maintain coupling adjustment shown in

Figure 16.

2.
Chevelle only:

a. Holding front bumper in place, loosely install

bolt, washer, and nut to secure bumper bracket

and brace
to.
frame.

b.
Position .adjustment washer in notches of bumper

bracket' and align washer with mark made during

removal. Tighten mounting bolts.

c. Install stabilizer bar to frame mounting brackets.

Refer to torque specifications at rear of manual

for correct torque values.

3.
Install pitman arm aligning marks made during re-

moval and secure with washer and retaining nut.

4.
Secure steering coupling to flanged end of steering

column with lock washers, and nuts.

CHEVY II (Fig. 17)

Removal

1.
Remove clamp nut and bolt from clamp securing

column to steering gear and loosen clamp.

2.
Remove pitman arm retaining nut and washer. Scribe

mark on arm and shaft, and remove arm using Tool

J-6632.

3.
Remove nuts, washers, and bolts securing steering

gear to frame and remove gear from vehicle.

Installation

NOTE:
Steering assembly alignment must be

checked each time a steering gear is installed.

Proceed with steering alignment and gear in-

stallation as outlined below.
STEERING COLUMN

NUT

STEERING GEAR

CLAMP

BOLT

Fig.
17—Steering Column to Steering Gear—Chevy II

1.
Support steering gear in position and loosely install

bolts,
washers, and nuts.

2.
Slide steering gear to steering shaft clamp into po-

sition and install clamp bolt and nut. Tighten nut

securely; refer to torque specifications at rear of

manual for correct torque value.

3.
Disconnect transmission control linkage, if so

equipped, from lower column shift tube levers.

4.
Remove screws attaching upper and lower mast

jacket covers together and remove lower cover

(fig. 18).

5. Loosen collar, clamp, retainer, and seal at toe plate.

6. Loosen screws and bolts securing instrument panel

column mounting bracket to underside of instrument

panel. Remove two forward bracket mounting bolts

and remove wedge shims.

7. Tighten the forward upper steering gear mounting

bolt to 5 lb. ft., so that the forward upper boss is

contacting the frame.

8. Determine the gap at the rear mounting bolt area and

shim as required.

9. Tighten rear (closest to driver's seat) bracket

mounting bolt to 5 lb. ft.

10.
Holding wedge shims in correct position install and

tighten remaining bracket mounting bolts and screws;

refer to torque specifications at rear of manual for

correct torque values.

11.
Tighten rear (closest to driver's seat) bracket

mounting bolt to torque valve specified in

specifications.

12.
Tighten all steering gear mounting bolts and nuts to

torque values specified in specifications.

13.
Install mast jacket lower cover.

14.
Tighten seal, retainer, clamp, and collar at toe

plate.

15.
Connect transmission control linkage at lower shift

levers. Adjust linkage as outlined in Section 7.

Adjust back-up/neutral start switch as outlined in

Section 12.

16.
Install pitman arm at aligning marks made during

removal, and install arm retaining washer and nut.

CHEVROLET CHASSIS SERVICE MANUAL