CHEVROLET CORVAIR 1965 2.G Service Manual

Downloaded from www.Manualslib.com manuals search engine CHASSIS LUBRICANT
Every 6,000 miles or six months lubricate the chassis,
at the points listed below, with a water resistant EP
Chassis lubricant.
Corvair Greenbrier
Front Suspension-4 lubrication Fittings
Steering
Linkage-8 Lubrication Fittings
Clutch Pedal Pivot-1 Lubrication Fitting
Brake
Pedal Pivot-1 Lubrication Fitting
Clutch Linkage-Coat the exposed clutch linkage !located
iust
ahead and to the right of the transmission}.
38
Cor:vair
Front Suspension-4 lubrication Fittings
Steering
Linkage-4 Lubrication Fittings
Clutch Cross Shaft
At 36,000 miles (or sooner if necessary}-Remove plug
and install lubrication fitting. Lubricate with a water
resistant EP Chassis lubricant. lubricate every 36,000
miles thereafter.
~ ..... o.J .. .~-
--,.

Downloaded from www.Manualslib.com manuals search engine FAN BELT
Every 6000 miles-check condition of belt. On vehicles
. equipped with belt guides, check belt guide to belt
clearance. Belt guide clearance should be approxi­
mately 1/ 16/1 after belt is tensioned. (Seepage 50.)
DISTRIBUTOR CAM
LUBRICATOR
Every 12,000 miles-
Rotate cam lubricator
180 degrees.
Replace lubricator at
24,000 mile intervals .
The cam lubricator should
not be oiled, damage to
ignition points
may result
if proper lubricant is not
used on cam.
8R:EAKER PlATE "nACHlNG SCREWS
39
AIR CLEANER
PAPER ELEMENT TYPE (Oil-Wetted)
Every 6000 miles -Inspect or test air cleaner paper
element. If inspection reveals that element is satisfac­
tory it may
be reused ; however, element should be
inspected or tested every 6000 miles until it is
replaced. Element must not be oiled, washed, tapped
or cleaned with an air hose.
Under severe dust conditions
it may be necessary to
inspect
or test the element more often.

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After the first 6000 miles-have your Chevrolet Dealer
check the tightness of all hose damp connections.
Every 6000 miles-Check sight glass, located under the
hood, after the system has been in operation for
several minutes. Sight glass should be clear. Bubbles
or dirt indicate a leak which should be corrected
immediately by your Chevrolet Dealer.
BRAKE LININGS
Have the brake linings inspected periodically. Fre­
quency of inspection will depend on traffic, terrain
and the driving habits of the driver.
BRAKE
MAIN CYLINDER
Every 6,000 miles-Check fluid level and maintain % II
below opening with G. M. Hydraulic Brake Fluid
Supreme No. 11.
PARKING BRAKE AND CLUTCH PULLEYS
AND CABLES-CORVAIR
Every 12,000 miles-Lubricate pulleys under dash. Re­
move the tunnel cover under vehicle and lubricate
pulleys and cable bearing points with a water resist­
ant EP Chassis Lubricant. Lubricate gearshift lever
ball
and socket (see page 41 J at the same time.
40
FRONT WHEEL BEARINGS
Clean, repack with high melting point wheel bearing
lubricant, and adjust whenever brake drums are re­
moved. Replace grease seals at the same time.
ENGINE OIL COOLER
Every 12,000 miles (more often under prolonged dusty
driving
conditionsJ-Remove cover and brush or
blowout accumulated dirt.
NOTE: Material usually found in the oil cooler
consists primarily
of twigs, straw, chaff, and
leaves.

Downloaded from www.Manualslib.com manuals search engine TRANSMISSION-POWERGLIDE
Every 6000 miles-Check fluid level on dipstick with
engine idling, selector lever in NEUTRAL position,
parking brake set and transmission at operating
temperature. If fluid level is below full mark on dip­
stick,
add small amount of Automatic Transmission
Fluid Type
"A" bearing the mark AQ-ATF followed
by a
number and the suffix letter "A". Recheck
fluid
level on dipstick and again add a small amount
of fluid if needed to bring level to full mark. DO
NOT
OVERFILL.
NOTE: From the "Add Oil" mark to the "Ful/' ,
mark on the dipstick indicates a difference of
only 1 pint of fluid.
Every 1
2,000 miles (more frequently, depending on
severity of service, if vehicle is used to pull trailer,
carry full loads during high ambient temperatures,
41
operate in mountainous terrain or operate under
other severe condition .sl-Remove fluid from the
transmission sump and add two (2) quarts of fresh
fluid.
Operate transmission through all ranges and
check fluid level as described above.
If vehicle is so equipped, clean dust and dirt from
transmission oil cooler every 12,000 miles.
TRANSMISSION-3 AND 4-SPEED
Follow recommendations given under "Rear Axle"
on page 42.
TRANSMISSION CONTROL LINKAGE-
3 AND 4-SPEED
Corvair
Every 12,000 miles-Lubricate connector (indicated in the
illustration below) with a water resistant EP Chassis
Lubricant.
Every
12,000 miles-Remove tunnel cover under vehicle
and lubricate gearshift lever ball and socket with
Lubriplate.

Downloaded from www.Manualslib.com manuals search engine REAR AXLE
Check lubricant level, with 'axle at operating tempera­
ture, at the dipstick whenever engine oil is checked.
The dipstick is used to check lubricant level only;
do not attempt to fill axle at the dipstick tube.
,f lubricant level is at or below ADD mark on dip­
stick,
fill to level of the filler plug hole with SAE 80
Multi-purpose Gear Lubricant meeting the require­
ments
of U.S. Ordnance Spec. MIL-L-2105B.
Check 3-or
4-speed lubricant level, if the rear axle
lubricant level is low.
42
BATTERY
Every 6000 miles-Clean and
oil battery terminals and
oil felt washer. Clean
top
of battery with di­
luted
ammonia or soda
solution and flush with
clean
water. Check state
of charge especially in
freezing weather. An un­
dercharged battery may
freeze and break.
FUEL FILTER
Greenbrier Ballery and Transmission Oil Cooler Access Door
Corvair, Corsa and Greenbrier
Replace filters, located in each carburetor inlet, only
if flooding occurs.
Corsa Turbocharged
The fuel filter is a separate unit mounted on the air
cleaner support bracket at the left of the air cleaner. It
should be replaced at 12,000 mile intervals. At the
same interval, also clean the screen located in the car­
buretor inlet.

Downloaded from www.Manualslib.com manuals search engine BODY LUBRICATION POINTS
Most body lube points do not need frequent, heavy
lubrication. However, periodic checks
of certain points
on the Corvair body,
and lubrication when needed will
eliminate annoying squeaks and noises. Be careful not
to over-lubricate.
Wipe off all surplus lubricant.
The following items should
be lubricated periodically:
1. Door
Hinges-Wipe off dirt and apply lubriplate.
2. Door lock Striker-Wipe off dirt and apply stick
type lubricant.
3. Top lift Cylinder
Rods-Clean and lubricate with
G.M. Hydraulic Brake Fluid.
4. Door
Jamb Switch-Apply lubriplate.
5. Front and Rear Compartment lid lock-Apply lubri­
plate.
6. Front Compartment lid Torque Rods-Apply G.M .
lubriplate to bearing points.
43
7. Gas Tank Filler Door Hinge-Apply dripiess oil.
8 . Glove
Box Door Hinge-Apply dripless oil.
9. Rear Folding Seat Back Support link Assembly and
Filler Panel Hinge-Apply dripless oil to bearing
points.
The following should
be lubricated whenever acces­
sible.
10. Door Outside Handle lock Cylinder Shaft-Apply
lubriplate.
11. Door Window Regulator and Cams-Apply lubri­
plate.
12. Door
lock Parts-Apply lubriplate.
13. Door locking Mechanism-Apply lubriplate.
14 . Front
and Rear Compartment Hinges-Apply G.M.
lubriplate.

Downloaded from www.Manualslib.com manuals search engine SPECIFICATIONS
SERIAL AND UNIT NUMBERS
Engine Number Stamped on the engine block behind and to left of the fu el pump.
Body Number Corvair-Stamped on a plate attached to top of rear rail to left of engine mount , within the engine compartment.
Corvair Greenbrier-Stamped on a plate attached to the front inner body panel, with in the drive compartment.
Serial Number Corvair-Stamped on veh icle identification plate attached to left rear side rail, within the engine compartment. Corvair Greenbrier-Stamped on vehicle identification plate attached to the left front door lock pillar.
DIMENSIONS
length: Corvair Greenbrier ................................. 179.7 in.
Co r
vair ........................................... 183 .3 in .
Width :
Corva ir
Greenbrier ............... .•... ... .......... 70.0 in.
Co rvair ........................................... 69.7 in.
Height :
Corvair
Greenbrier ............. ........ ........... " 68.5 in.
Corvair Sport Sedan ............. .. ................ " 51.2 in.
Corvai r Sport Coupe ................................. 51.3 in.
Corva ir Convertible ...........•............ ....... " 51.5 in.
Wheel. Bas e:
Corvair Greenbri.er ... ............................. '95.0 in.
Corvair ........................................ . . 108 .0 in.
Turning Diameter:
Corvair
Greenbrier ..... .................•.......... 42.6 ft .
Corvair ........................................... 36.0 ft . Greenbrier-load length .............................. 106 .2 in. Greenbrier-load Width . .....•........................ 59.4 in. Greenbrier-load Compartment Height .. , ............... 54.0 in.
44
S ide loading Doors-Width ................. '.' ... .4.90 x 53. 5 in.
Rear loading Doors .............................. 36.0 x 44.6 in .
CAPACITIES
Gasol ine Tank :
Corvair
Greenbrier ... .............................. 18.5 gal. Co rvair ......................•..........•........ 14.0 gal. Crankcase Refill .................. ........ .. ............ 4 qt. Add for filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1 pt .
Transmission :
3.Speed ..................•......................... . 2 pt. 4·Speed ..................... ........................ 3 pt.
D ifferent ial ... .. .............•....................... 4% pt . Cooling Sys tem ............ .. ................ Air Coo led Engine
ENGINE SPECIFICATIONS
Horsepower: 95 hp Turbo·Air 164 ... ................ ..... 95 @ 3600 rpm 110 hp Turbo·Air 164 .............. : ......... 110@ 4400 rpm 140 hp Turbo·Air 164 ..... :oO .............. 140 @ 5200 rpm 180 hp Turbocharged 164 .................... 180 @ 4000 rpm
Compression Ratio:
95 hp Turbo·Air 164 ................................. 8.25 :1 110 and 140 hp Turbo -Air 164 ........................ 9 .25:1 180 hp Turbocharged 164 ........ ... ........ _ ........ 8.25 :1
Displacement .................................... . .. 164 cu. in.
Bore and Stroke (all engines) ................. ....... 3K 6"x2 .94" Firing Order ............... ....................... 1.4·5 -2 ·3-6
Spark Plugs: 95 hp Turba·Air 164 (Gap .. 035) ............. ....... AC·46·FF 11 0 and 140 hp Turba·Air 164 and 180 hp Turbocharged 164 (Gap .030) ...........•.......... AC·44-FF

Downloaded from www.Manualslib.com manuals search engine Idle Speed: 95 hp Turbo-Air 164 w/monuol trans. (In Neutral) .... 450-500 rpm 110 hp Turbo-Air 164 w/manual trans. (In Neutral) .... 600-650 rpm 140 hp Turbo-Air 164 w/manualtrans. (In Neutral) .... 600-650 rpm 180 hp Turbocharged 164 (In Neutral) .................. 850 rpm All Powerglide (In Drive) .............. , .......... 450-500 rpm
Ignition Timing:. 95 hp Turbo-Air 164 (manual transmission) ............ 6° BTDC 110 hp Turbo-Air 164 (manual transmission) ............ 14° BTDC 140 hp Turgo-Air 164 .............................. 18°BTDC
180 hp Turbocharged 164 .......................... 24° BTDC All Powerglide ...........................••....•• . 14° BTDC
Axle Ratios: Engine 95 hp Turbo-Air 164 110 hp Turbo-Air 164
140 hp Turbo-Air 164 180 hp Turbocharged 164
Transmission All 3-and 4-Speed Powerglide
3 -and 4-Speed All
Standard Ratio "
3.27:1
3.27:1
3.55:1 3.55:1
3.55: 1 'Standard Ratio For Corvair Greenbrier and Air Conditioning Equipped Vehicles 3.55:1.
BULB SPECIFICATIONS
Headllamp Unit (Sealed Beam)
Candle Power
Outer-High Beam ......•.........•...... 37% W low Beam ....•.............•..... 55W Inner-High Beam Only ................... 37'!z W
Parking lamp-Directional Signal and Tail-Stap-D irectional Signal lamps ... ...•... 4-32
Back-Up lamps ............................ 32 Instrument lamps ....................••.... 3
Temp. Press., Gen. Fan., and Glove Compartment lamps ..•.............•..... 2 Headlamp High Beam Indicator,' Directional Signal Indicator , and Heater Control Panel lamps •.....•..................•.. 1
Number
4002
4001
1157
1156
GE 1816
1895
1445
45
Dome Lomp ' ................... .. ......... 12 Courtesy lamp .........••.................. 6 license Plate lamp .....•..............•.... 4
Radio Dial lamp ........•.......•.......... 2
BATTERY RATINGS
Corvair-12 volt; 54 plate; 44 amp/hr . Corvoir 95 and Greenbrier-12 volt; 54 plate; 42 amp/hr .
FUSES AND CIRCUIT BREAKER
211 631
67
1893
A circuit breaker in the light control switch protects
the head lamp circuit, thus eliminating one fuse. Where
current load is too heavy, the circuit breaker intermittently
opens and closes, protecting the circuit until the cause
is found and eliminated.
Fuses, located in the junction block beneath the
dash are:
1. Healer Blower
Glove Comparlment lamp ........ 3AG/ AGC-1 0 amp
2. Tail and Slop lamps,
Dome lamp ................. .. 3AG / AGC-1 0 amp.
3.
Heater (Total System) Back-up lamp ................. 3AG/ AGC-20 amp.
4. Radio (AM or AM-FM) ........... 3AG/ AGC-2 Y2 amp.
(AM-FM Stereo) .. . .... 3AG/ AGC-71/2 amp.
5. Instrument Panel lamps Radio Panel lamp Heater Conlrol Panel lamp ........ 3AG/ AGC-3 amp. 6. Windshield Wiper Molor ......... 3AG/ AGC-20 amp.
Air Conditioner Fuses ........... 3AG! AGC-15 amp. (Located in 14GA red and 12GA gray wires in area of
ignition switch.)

Downloaded from www.Manualslib.com manuals search engine Corvair passenger cars are designed primarily for
passenger conveyance. However, it is well known that
many owners do use the Corvair to pull trailers, and
when available trailer hauling options have been used,
the owners
have experienced very satisfactory service.
When a trailer is attached to a car, the car becomes
not only a load-carrying vehicle, but a load-pulling
vehicle. The demands of this type of operation are very
different from those for which the automobile is pri­
marily designed and may present problems, such as
spring
and tire loading, braking, cooling, lighting, and
steering. However, careful driving practices and the use
of factory-recommended options will better satisfy the
requirements
of trailer hauling.
If in the opinion of the manufacturer a part or com­
ponent of a motor vehicle has been adversely affected
46
by misuse of the vehicle with trailer loads, such part or
component will not be covered by the manufacturer's
warranty.
The size of and equipment for trailers, including
such items as hitches and safety chains, brakes, lights,
power-weight ratios and over-all length, are generally
subject to safety regulations in all states, and it is the
responsibility of the user to make certain that he is in
full
compliance with the regulations of the states in
which he plans to operate with a trailer of the Interstate
Commerce Commission,
if applicable, before doing so.
Further, when
operating a car with a trailer attached,
the driver must realize that the performance, steering
characteristics,
and braking distance of his car have
been altered, and that he must exercise greater caution
to safely handle his car and trailer.

Downloaded from www.Manualslib.com manuals search engine MINOR TROUBLE SHOOTING GUIDE
FUEl SYSTEM AND ENGINE ElECTRICAL SYSTEM COOLING SYSTEM
"i ... I/) -0 If your car acts .. .. ..c * c+, 0 ... > 0)0 -0* in the following III * ::s .. cu·-... I/) c CUc c-o ... ...J +,+' 0
0 c .. .. I/) -I) C
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~ J:l (/)f +' ~ C
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.!:!(/) cu c.2 C OC ... I-~ 0« (/) ::s 0 cu -::s ::s ~ Cl/) '';:; t: 0. CU+' "'0 O.!! Q)'.-0 ~c. 0 "J:l Qj 0'" +'c O+' iii~ ~ .. +'c 0) Check here in sequence LL. -0 ::S ... :ti' 0 .-.. , 1)0 CUo (/) >,g +'CU -0 ~c& +' -0 O)::S .. >, LL.cu > .~ c: C._ E·-cu-Cl/) cu Oc ... -C ::s, shown for possible causes. ~ « .. ::s.~ ~ "'c "'::s c.C ... III I/) 0" I) -0 +' ... 0 ~ ...J -oCU oll! I) $c: "0) cu-o
1::-0 EC .. r;:'c, "0 "'c 0. I) :::C _cu C .. 0 00 .!! C.!! +"-.. +'0 C .. C ... c c .. 0 O::s
0 E ::s -CUO) ~E .-.. cuc CUO .. ~ ~+' -0 +' (5 80 ~ ~o ~a:: 8...J t)cu CO :.;:LIJ ~I-0 ~I-..... 0 r;: LIJ (/) :::-0 Cl
On the following pages, see paragraph: A
B D B·C-D E D L E F F K G G J H I G M N 0
See information on page number: 8 9-32 39 3-6 42 9
CAR WILL NOT START:
Engine Will Turn Over 1 4 3 6
2 5 7
Engine Will Not Turn Over 2 1 3 4
CAR WILL START -BUT:
Only After Repeated Tries 1
Stalls in a Few Seconds 2 1 3
Stalls When Hot 1 2 3 4
Idles Rough 1 2 3
Engine Overheats 1 2 3
"Oil" Indicator Comes On 1
"Gen" Indicator Comes On 3 2 4 1
*See Your AuthOrized Chevrolet Dealer 47