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Table Of Contents - Chevrolet 1967 Chevelle Service Manual

Chassis

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Table of Contents

General Information And Lubrication3

Model Identification - Chevrolet3

Vehicle Dimensions - Chevrolet3

Model Identification - Chevelle4

Vehicle Dimensions - Chevelle4

Model Identification - Chevy Ii4

Vehicle Dimensions - Chevy Ii5

Model Identification - Camaro5

Vehicle Dimensions - Camaro5

Unit And Serial Number Locations5

Keys And Locks6

Lock Cylinder Assembly8

Tumbler Requirement Diagram8

Automatic Transmission9

Manual Transmission9

Towing The Camaro10

Vehicle Lifting Points - Chevelle10

Attachment Of Towing Chain Hooks To Lower Control Arms10

Towing Sling Attachment11

Attachment Of Towing Chain Hooks To Axle Tube11

Towing Sling Attachment - Rear11

Strapping Wood Block To Rear Spring11

Lifting The Corvette12

Lifting With Auto Jack12

Lifting Car With Drive-On Hoist12

Vehicle Lifting Points - Chevy Ii12

Vehicle Lifting Points - Camaro13

Vehicle Lifting Points - Corvette14

Frame Lift Adapters - Corvette14

Engine Crankcase Oil15

Crankcase Capacity15

Sae Viscosity Oils15

Crankcase Breather Cap16

Types Of Oils16

Maintaining Oil Level16

Crankcase Ventilation Valve17

Turbo Hydra-Matic18

Front Wheel Bearings18

Power Steering18

Air Conditioning18

Lubrication Diagram - Chevrolet19

Lubrication Diagram - Chevelle20

Lubrication Diagram - Chevy Ii21

Body Lubrication22

Lubrication Diagram - Comaro22

Body Lubrication Points (Corvette)23

Lubrication Diagram - Corvette23

Heater And Air Conditioning24

Heater General Description24

Heater Air Flow24

Heater Controls25

Control Assembly25

Heater Schematic (Chevy Ii)25

Heater Control Panel (Chevrolet Shown As Typical)25

Component Replacement And Repair26

Blower Assembly26

Temperature Damper Door26

Air And Defrost Damper Doors26

Core Replacement27

Heater Blower And Air Inlet (Chevrolet, Chevelle, Comaro)27

Defroster Duct28

Bowden Cables28

Fan Switch Replacement28

Chevy Ii Heater Assembly28

Chevy Ii Blower Motor29

Chevy Ii Fan Control29

Corvette Blower Assembly29

Corvette Blower And Air Inlet Assembly29

Control Assembly (Comaro)31

Chevy Ii Heater Components Removal31

Defroster Duct (Chevy Ii)31

Heater Control Assembly And Cables (Chevy Ii)32

Corvette Heater And Blower Inlet Assembly32

Heater Hose Routing (Chevy Ii)32

Heater Assembly Installation33

Corvette Heater Core Removal33

Heater And Defroster Cables (Corvette)34

Heater Hoses - Corvette35

Air Conditioning General Description36

Four-Season System36

Four-Season System Components (Chevrolet)37

Four-Season System Components (Chevelle)37

Four-Season System Components (Comaro)38

Airflow - Four-Season (Chevrolet, Comaro) Comfortron (Chevrolet)38

Four-Season System (Chevrolet, Comaro)39

Comfortron Underdash Components40

Outlets And Defroster Levers40

Comfortron System41

Comfortron Engine Compartment Components41

In-Car Sensor41

Feedback Potentiometer41

Outside Air Diaphragm42

Mode Door Diaphragm42

Electronic Circuit43

Changing The Electronic Signal To Electrical Voltage43

Changing The Electrical Voltage To A Vacuum Signal43

Changing The Vacuum Signal To Mechanical Energy43

Universal System44

Chevy Ii All-Weather System44

"De-Fog" Position44

Universal System Components45

Weather System Components (Chevy Ii)46

Weather System Schematic46

Controls Corvette47

Controls - All Weather (Chevy Ii)47

Corvette Four-Season System Schematic47

Corvette Four-Season System Components48

Precautions In Handling Refrigerant-1249

Additional Cooling Hints49

Cycle Of Operation - Four-Season And Comfortron50

Cycle Of Operation - Universal And All Weather50

Precautions In Handling Refrigerant Lines51

Maintaining Chemical Stability In The Refrigerant System51

System Contaminants51

Charging Station52

Leak Testing The System52

System Charging Station52

Availability Of Refrigerant53

Leak Detector53

Pre-Delivery Inspection54

Compressor Oil54

Compressor Serial Number54

6000 Mile Inspection55

Periodic Service55

Installing Gauge Set To Check System Operation55

Performance Test55

Performance Data56

Comfortron System Operational Test56

Chevrolet Comfortron Tester57

To Install The Tester57

Quick Test Procedure57

Complete System Checks58

Checking Condition Of Thermistors (Sensors)58

Comfortron Tester Installation58

Comfortron System Tester58

System Checks59

Maintenance And Adjustments60

Evaporator Control Valve (Poa)60

Thermostatic Switch60

Checking For Proper Operation60

Comfortron Wiring Diagram - Underhood61

Comfortron Wiring Diagram - Underdash62

Adjusting Switch63

Comfortron Vacuum Diagram63

Expansion Valve64

Evaporator Pressure Control Valve - Poa64

P.o.a. Valve Installed64

Thermostatic Switch Removal64

Evacuating And Charging Procedures65

Engine Idle Compensator65

1967 Air Conditioning System Capacities65

Purging The System65

Evacuating And Charging The System66

Filling Charging Cylinder66

Installing Charging Station To System66

Charging Schematic67

Component Replacement And Minor Repairs68

Refrigerant Line Connections "O" Rings68

Checking Compressor Oil Charge68

Adding Oil To The System68

Repair Of Refrigerant Leaks69

Refrigerant Hose Failure69

Preparing System For Replacement Of Component Parts69

Foreign Material In The System70

Condenser Mounting (Chevrolet And Chevelle)70

Receiver-Dehydrator71

Condenser Mounting (Comaro)71

Sight Glass Replacement - All Vehicles72

Chevrolet And Comaro Four-Season System72

Chevelle Four-Season System Removal73

Chevelle Four-Season System Core Replacement73

Chevelle Four-Season System Installation73

Universal System All Vehicles Core And/Or Expansion Valve Replacement73

Universal System All Vehicles Removal74

Evaporator Mounting (Chevrolet And Comaro)74

Evaporator Mounting (Chevelle)74

Wiring And Vacuum Lines-Four-Season (Chevrolet)75

Underhood Wiring - Four-Season (Chevelle)75

Chevy Ii All-Weather System Removal76

Chevy Ii All-Weather System Within The Car76

Chevy Ii All-Weather System Care And/Or Expansion Valve Replacement76

Wiring-All Weather (Chevy Ii)77

Evaporator Mounting - Universal Unit78

Underdash Wiring - Universal System (Typical)79

Terminal Removal - Universal System79

Cable Removal - All Weather79

Evaporator Removal - All Weather80

Four-Season System Chevrolet, Chevelle, Corvette, And Comaro Replacement81

Underdash Wiring - All Weather81

Chevy Ii All-Weather System Replacement Of Valve Assembly82

P.o.a. Installation (Camaro)83

P.o.a. Installation (Chevelle)83

P.o.a. Installation (Corvette)83

All-Weather System (Thermostatic Switch Only) Chevy Ii Replacement84

All-Weather System Chevy Ii Removal84

All-Weather System Chevy Ii Installation84

Universal Blower Assembly86

Air Inlet Valve87

Blower And Evaporator Assembly87

Air Distributor Assembly And Outlet Ducts87

Air Distributor Assembly88

Comfortron Automatic Control Components89

Heater And Air Distributor Assembly90

Thermal Vacuum Valve91

Resistor Assembly91

Refrigerant And Vacuum Hoses (Corvette)92

Comfortron Vacuum Tank92

Collision Procedure - All Systems93

Mode Shift Vacuum Diaphragm93

Comfortron Underhood Wiring94

Comfortron Underhood Vacuum Lines95

Comfortron Underdash Vacuum Lines95

Four Season Heater Components96

Comfortron Power Servo Installation97

Compressor Mount - L-6 Engines97

Comfortron Heater Components98

Compressor Failure100

Compressor Belt Tension Adjustment100

Wiring Diagrams101

Chevrolet - Four-Season Wiring Diagram101

Chevelle - Four-Season Wiring Diagram102

Camaro - Four-Season Wiring Diagram103

Universal System Wiring Diagram (Typical)104

All Weather Wiring Diagram (Chevy Ii)105

Corvette - Four-Season Wiring Diagram106

Heater And Air Conditioning Special Tools107

Corvette Body General Description108

Corvette Maintenance & Replacements108

Front End Adjustments108

Hood Assembly109

Front Emblem109

Vent Grilles109

Hood Hinge And Catch110

Cowl Area Trim111

Rear View Mirror111

Cowl Ventilator Assembly111

Windshield Removal112

Checking Windshield Body Opening112

Scribing Line Around Hood Hinge112

Windshield Installation113

Console Trim113

Special Clip113

Sun Visor And Inside Rear View Mirror113

Doors Adjustments114

Door Lock Striker114

Door Window And Vent Adjustment114

Windshield Glass And Reveal Moldings115

Trim Panel, And Inside Handles118

Weatherstrip118

Door Ventilator Assembly119

Ventilator Window Assembly Replacement119

Window Glass120

Door Weatherstrip120

Glass Run Channel - Upper121

Window Outer Seal Assembly121

Window Inner Seal121

Glass Run Channel - Rear122

Window Regulator - Manual122

Window Regulator - Power122

Door Lock And Remote Controls123

Outer Handle123

Model 19467 Ventilator Assembly123

Lock Cylinder Replacement124

Hinges - Door Assembly Removal124

Rear Quarter126

Door Sill Plate And Molding126

Rear End Folding Top Compartment Lid126

Power Window Regulator127

Rear Window - Adhesive Caulced - 19437 Model128

Locking Regulator Arm In Place128

Gas Tank Door And Rear Trim Plate130

Rear Filler Panel130

Spare Tire Mount130

Folding Top Lid Assembly130

Rugs And Interior Trim132

Cleaning Soft Trim132

Procedure For Cleaning Folding Top Material132

Procedure For Cleaning Coated Fabrics132

Carpets And Covers - All Models133

Rear Body Trim133

Applying Silane Primer133

Garnish Moldings Plus Headliner - 19437 Model134

Body Mounting134

Body Repairs134

Plastic Solder Kit136

Front Body Construction137

Center Body Construction138

Specific Repairs139

Scratched Panels, Spot Refinishing139

Underbody Construction139

Dents Or Pits In Panels, Cracks In Glaze Coat140

Bonding Strips - Roof Reinforcement140

Rear Body Construction141

Cracked Panels142

Typical Body Bonds142

Mixing Plastic Solder Material142

Fractured Panels144

Typical Pitted Panel144

Typical Cracked Panel144

Cracked Panel Preparation144

Hard Top Weatherstrip And Moldings145

Panel Replacement146

Hard Top Window Moldings146

Marking Molding Position146

Installing Reveal Molding Retainers146

Applying Sealer To Frame147

Pulling Cord From Weatherstrip147

Installing Window Assembly147

Applying Sealer To Weatherstrip147

Hard Top Care And Storage148

Rear Window Removal148

Rear Window Installation148

Applying Cement To Window148

Garnish Moldings And Latches149

Weatherstrip And Drip Moldings150

Vinyl Covering On Removable Hardtop150

Vinyl Roof Cover Repairs152

Scuffs Or Small Cuts Near Exterior Moldings152

Hardtop Weatherstrips And Moldings152

Care Of The Folding Top153

Care Of Rear Window153

Wrinkles, Blisters And Bubbles153

Folding Top Adjustments154

Folding Top Trim Installation154

Trim Of Header155

Rear Bow Retaining Screws155

Installing Trim And Weatherstrip To Rear Bow155

Top Assembly Removal And Installation156

Rear Bow Hold-Down Locks156

Top Trim And Rear Window Assembly157

Installing Binding157

Top Frame And Linkage157

Side Rail Weatherstrips158

Hardtop Attachments Of Rear Bow158

Header Weatherstrip158

Hardtop Attachments Of Lock Pillar Area158

Frame And Linkage159

Adding Hardtop (Roof Panel Assembly)159

Side Rail Weatherstrip159

Corvette Body Special Tools160

Frame General Description161

Frame Repair Procedures161

Checking Frame Alignment161

Tramming Sequence161

Frame Dimensions (Chevrolet)162

Frame Dimensions (Chevelle)163

Frame Dimensions (Corvette)164

Front Suspension General Description165

Front Suspension - Chevrolet166

Front Suspension - Chevelle & Camaro166

Front Suspension Maintenance And Adjustments167

Front Wheel Bearing Adjustment167

Front Suspension - Corvette167

Front Suspension - Chevy Ii168

Caster And Camber168

Front End Alignment169

Caster And Camber Adjustment169

Riding Height And Coil Spring Sag170

Steering Axis Inclination Adjustment170

Toe-In Adjustment170

Checking Riding Height171

Front Suspension Repair Procedures172

Front Brake Drum - Chevrolet, Camaro, Chevelle, Chevy Ii172

Front Wheel Hub172

Steering Knuckle Removal173

Steering Knuckle Installation173

Installing Front Hub Inner Bearing173

Backing Plate Removed - Chevy Ii173

Shock Absorber Removal174

Shock Absorber Installation174

Upper Control Arm Support Installed - Chevy Ii174

Stabilizer Bar Removal175

Stabilizer Bar Installation175

Strut Rod Removal175

Removing Shock Absorber And Bracket - Chevy Ii175

Front Spring Removal176

Spring Removal Tools176

Front Spring Removal - Chevrolet176

Installing Spring Compressor - Chevy Ii178

Compressing Front Spring - Chevy Ii178

Removing Spring And Seal Assembly - Chevy Ii178

Spring Seat - Exploded View - Chevy Ii178

Lower Control Arm Spherical Joint180

Removing Lower Ball Joint - Chevelle & Camaro180

Installing Lower Ball Joint181

Disassembling Lower Ball Stud181

Lube Fittings182

Lower Control Arm Attachment182

Lower Control Arm Bushing - Chevrolet183

Lower Control Arm Bushing - Chevelle & Camaro183

Lower Control Arm Bushing - Small - Chevelle & Camaro183

Removing Lower Control Arm Pivot Bushing - Chevy Ii184

Removing Lower Control Arm Cross Shaft Bushing184

Installing Lower Control Arm Cross Shaft Bushing184

Cross Shaft And/On Bushings185

Upper Control Arm Spherical Joint185

Upper Control Arm186

Upper Control Arm Cross Shaft And/Or Bushings187

Removing Pivot Shaft Bushing - Chevy Ii188

Installing Pivot Shaft Bushing - Chevy Ii188

Removing Upper Control Arm Cross Shaft Bushings188

Installing Upper Control Arm Cross Shaft Bushing188

Front Suspension Special Tools190

Rear Suspension And Drive Line191

Rear Suspension General Description191

Chevrolet Rear Suspension Components192

Chevelle Rear Suspension Components192

Chevy Ii Rear Suspension Components193

Camaro Rear Suspension Components193

Rear Suspension Maintenance And Adjustments194

Corvette Rear Suspension And Driveline Components194

Riding Height Check195

Wheel Alignment (Corvette)195

Measuring Rear Riding Height (Chevrolet And Chevelle)195

Adjusting Rear Wheel Camber (Corvette)195

Wheel Bearing Adjustment (Corvette)196

Toe-In Adjusting Shim Location (Corvette)196

Checking Wheel Bearing Adjustment (Corvette)196

Removing Drive Spindle From Support (Corvette)196

Rear Suspension And Drive Line Component Parts Replacement197

Coil Spring Installation (Chevrolet)198

Installing Coil Spring To Lower Control Arm (Chevrolet)198

Coil Spring Installation (Chevelle)198

Leaf Spring, Spring Seat Pads, Spring Eye Bushings Chevy Ii199

Rear Spring - Exploded View199

Removing Lower Pad Bracket (Chevy Ii)199

Removing Front Eye Bushings (Chevy Ii)199

Rear Spring Shackle Exploded View - Station Wagon (Chevy Ii)200

Rear Spring - Exploded View (Camaro)200

Removing Spring Front Bushing (Camaro)200

Shock Absorber201

Installing Spring Front Bushing (Camaro)201

Shock Absorber Mounting - Exploded View (Chevelle)201

Removing Shock Absorber Eye Bolt (Chevy Ii)202

Shock Absorber Mounting - Exploded View (Chevy Ii)202

Shock Absorber Mounting - Exploded View (Camaro)203

Rear Suspension Upper Control Arm Attaching Points (Chevrolet)203

Upper Control Arm Bushing Removal (Chevrolet)203

Upper Control Arm Bushing Installation (Chevrolet)204

Lower Control Arm Front Bushing Removal (Chevrolet)204

Lower Control Arm Front Bushing Installation (Chevrolet)204

Chevelle Upper And Lower205

Lower Control Arm Rear Bushing Removal (Chevrolet)205

Lower Control Arm Rear Bushing Installation (Chevrolet)205

Control Arm Bushing Removal (Chevelle)206

Control Arm Bushing Installation (Chevelle)206

Carrier Mounted Suspension Bushing Removal (Light-Duty) (Chevelle)206

Carrier Mounted Suspension Bushing Installation (Light-Duty) (Chevelle)206

Rear Suspension Tie Rod - Chevrolet207

Carrier Mounted Suspension Bushing Removal (Heavy-Duty) (Chevelle)207

Carrier Mounted Suspension Bushing Installation (Heavy-Duty) (Chevelle)207

Upper And Lower Control Arm Assembly (Chevelle)207

Rear Suspension And Drive Line Component Parts Replacement (Corvette)208

Wheel Spindle And Support208

Rear Suspension Tie Rod Attaching Points (Chevrolet)208

Tie Rod Bushing Replacement (Chevrolet)208

Wheel Spindle And Support Cross-Section209

Bearing Cup Removal (Corvette)209

Installing Spindle Bearing Cup (Corvette)209

Unseating Drive Spindle Outer Bearing (Corvette)209

Differential Carrier Support Bracket Replacement210

Strut Rod And Bracket210

Shock Absorber Installation (Corvette)210

Removing Strut Rod Shaft (Corvette)210

Marking Camber Cam And Bracket (Corvette)211

Strut Rod Bushing Replacement211

Spring Mounting (Corvette)211

Removing Clamp Plate (Corvette)212

Lowering Spring (Corvette)212

Removing Center Bolt (Corvette)212

Aligning Spring Leaves (Corvette)212

Torque Control Arm213

Torque Control Arm Bushing Cross-Section (Corvette)213

Drilling Out Retainer Flare (Corvette)213

Suspension Crossmember214

Removing Bushings (Corvette)214

Installing Bushings (Corvette)214

Flaring Tool Back-Up Plate (Corvette)214

Stabilizer Shaft Replacement215

Removing Crossmember (Corvette)215

Crossmember Mount Cross-Section (Corvette)215

Stabilizer Shaft Installation (Corvette)215

Rear Axle Cross-Section217

Axle Bolts And Wheel Nuts217

Rear Axle Cross-Section (Corvette)218

Rear Axle Noise Diagnosis219

Bearing Noise219

Failure Analysis219

Component Parts Replacement220

Axle Assembly220

Differential Gear Failure220

Differential Pinion Shaft Removal221

Wheel Bolt Replacement221

Wheel Bearing Removal221

Pinion Flange, Dust Deflector And/Or Oil Seal222

Wheel Bearing And/Or Oil Seal Installation222

Measuring Drive Pinion Bearing Preload222

Drive Pinion Nut Removal222

Drive Pinion Flange Removal223

Drive Pinion Flange Oil Seal Installation223

Drive Pinion Flange Installation223

Axle Driveshaft224

Removing Driveshaft224

"U" Joint Trunnion Seal Installation224

Removing Carrier Front Support225

Removing Companion Flange Nut225

Removing Companion Flange225

Differential Carrier226

Installing Pinion Oil Seal226

Installing Carrier Assembly226

Pinion Seal Installed226

Propeller Shaft And Universal Joints General Description227

Positraction Differential Unit227

Measuring Positraction Rotating Torque227

Light-Duty Propeller Shaft Cross-Section (Dana Design)227

Table Of Contents227

Propeller Shaft (Dana)228

Heavy-Duty Propeller Shaft Cross-Section (Saginaw Design)228

Propeller Shaft Sleeve And Damper Assembly228

Removing Propeller Shaft From Companion Flange228

Removing Bearing Caps229

Installation229

Propeller Shaft (Saginaw)230

Service Kit Trunnion (Saginaw)230

Pressing Trunnion Bearing From Propeller Shaft230

Bearing Partially Pressed From Propeller Shaft231

Removing Bearing From Propeller Shaft231

Installing Trunnion To Propeller Shaft231

Installing Snap Ring To Retain Trunnion231

Rear Suspension Special Tools232

Duo-Servo Brakes234

Main Cylinder235

Brake Pipe Distribution And Switch Assembly235

Hydraulic Brake Fluid236

Bleeding Hydraulic System236

Pressure Bleeding236

Camaro Pressure Regulator Valve236

Manual Bleeding237

Correct Bleeding Sequence237

Brake Bleeder Adapter Tool J-22489-Installed237

Bleeding Brakes Using Brake Bleeder Wrench Tool J-21472237

Push Rod To Main Cylinder Clearance238

Hydraulic Brake Lines238

Correct Main Cylinder Fluid Level238

Hydraulic Brake Tubing239

Double Lap Flaring239

Brake Pedal Free Movement239

Brake Adjustment240

Service Brake240

Parking Brake241

Parking Brake System - Chevrolet And Chevelle243

Parking Brake System - Camaro244

Parking Brake System - Chevy Ii245

Parking Brake - Corvette246

Lever Assembly246

Parking Brake System - Corvette246

Removing Or Installing Cover Lower Mounting Screws247

Removing Or Installing Trim Seal247

Removing Or Installing Front Cable247

Shoes And Linings249

Organic Linings249

Unhooking Pull Back Spring249

Removing Hold-Down Springs And Pins249

Metallic Linings250

Backing Plate Contact Surfaces250

Checking Operation Of The Actuating Lever251

Identification Of Warn Metallic Brake Lining251

Identification Of Worn Lining251

Main Cylinder For Drum Type Brakes - Exploded View252

Chevelle Wheel Cylinder - Exploded View254

Brake Drum Access Hole256

Disc Brakes General Description257

Disc Brakes Maintenance And Adjustments257

Disc Brake - Cutaway View258

Brake Caliper259

Pressure Regulator Valve - Chevrolet And Camaro259

Caliper Assembly - Exploded View260

Installing Piston In Caliper Bore Using Tool J-22591261

Installing Boot Seal In Caliper Bore Using Tool J-22592261

Brake Disc Checking Procedure262

Installing Caliper On Disc262

Dial Indicating Disc Runout262

Parking Brake Shoes263

Power Brakes General Description264

Power Brakes Maintenance And Adjustments264

Power Brakes Component Replacement264

Brakes Special Tools265

Engine Tune Up266

Engine Mechanical Checks And Adjustments266

Spark Plug Removal266

Test Compression266

Service And Install Spark Plugs267

Checking Compression267

Distributor (In Line)267

Spark Plug Detail267

Service Ignition System268

Magnetic Pulse (Breakerless) Distributor268

Point Alignment268

Checking Fan Belt Tension269

Manifold Heat Control Valve (In Line)269

Manifold Heat Control Valve (V8)269

Remote Choke Adjustment271

Service Fuel Lines And Fuel Filter271

Service Cooling System271

Check And Adjust Accelerator Linkage271

Instrument Check-Out272

Choke Adjustment272

Check And Adjust Dwell272

Check Dwell Variation272

Additional Checks And Adjustments273

Check And Adjust Ignition Timing273

Adjust Idle Speed And Mixture273

Testing Crankcase Ventilation Valve273

Idle Speed And Mixture Screws274

Ignition Switch275

Distributor Resistance275

Secondary Resistance275

Ignition Output And Secondary Leakage275

Cooling System276

Cylinder Head Torque And Valve Adjustment276

Engine Mechanical General Description277

Engine Mechanical Component Replacement And Adjustment277

In Line Engines (Typical)278

Synchromesh Transmission278

Manifold Assembly279

Rocker Arm Cover279

Valve Mechanism279

Valve Lifters280

Valve Adjustment280

Valve Stem Oil Seal And/Or Valve Spring281

Cylinder Head Assembly281

Air Adapter Tool281

Compressing Valve Spring281

Engine Blocked For Pan Removal282

Pan Gaskets And Seals282

Removing Oil Seal (Lower Half)283

Removing Oil Seal (Upper Half)283

Oil Seal (Rear Main)284

Crankshaft Pulley And Hub284

Torsional Damper284

Crankcase Front Cover285

Oil Seal (Front Cover)285

Measuring Lobe Lift286

Timing Gear Marks286

Checking Camshaft Gear Runout286

Timing Gears287

Checking Timing Gear Backlash287

Installing/Removing Crankshaft Gear287

Engine Mounts288

Front Mount Replacement288

Rear Mount Replacement288

Engine Mechanical (V8) General Description289

Engine Mechanical (V8) Component Replacement And Adjustment290

Intake Manifold291

Exhaust Manifold291

Cylinder Head Torque Sequence304

Intake Manifold Torque Sequence304

Engine Special Tools305

Engine Cooling General Description306

Engine Cooling Maintenance And Adjustments306

Coolant Level306

Coolant System Checks306

Service Procedures309

Fuel Level Sight Plug312

Float Adjustment312

Fuel Filter Maintenance313

Choke Coil Replacement313

Throttle Linkage Adjustment314

Air Cleaners General Description315

Air Cleaners Service Procedures316

Polyurethane Element Maintenance316

Oil Bath Maintenance316

Oil Wetted Paper Element Replacement317

Oil Wetted Paper Element Testing317

Testing Air Cleaner317

Fuel Pump General Description318

Fuel Pump Service Procedures318

Filling Tool With Oil318

Engine Fuel Special Tools320

Air Injection Reactor System General Description321

Air Injection Reactor System Maintenance Procedures321

Drive Pulley321

Air Manifold, Hose And Tube322

Air Injection Pump322

Mixture Control Valve322

Air Manifold Hose And Tube Routing (Typical)323

Air Injection Tube324

Air Injector Reactor System Special Tools325

Installing Pressure Relief Valve325

Pressure Setting Plug325

Engine Electrical326

Types Of Batteries326

Dry Charged Batteries327

Activating Dry Charged Batteries327

Wet Charged Batteries327

Common Causes Of Failure328

Level Indicator328

Electrolyte Level328

Battery Charging Procedures329

12 Volt Battery Suggested Charging Rates329

Carrier And Hold-Down329

Battery Safety Precautions329

Battery Testing Procedures330

Installing Batteries330

Battery Visual Inspection330

Full Charge Hydrometer Test330

Testing Specific Gravity331

Charging System General Description332

Delcotron Cross-Section View332

Voltage Regulator Assemblies333

Circuity - Voltage Regulator Assemblies (Except Corvette)333

Circuitry - Voltage Regulator Assemblies (Corvette)334

Typical Wiring Diagram Showing Lead Connections334

Battery System Condition Test335

Adjusting Voltage Setting335

Delcotron Diode And Field Test337

Indicator Lamp/Initial Field Excitation Circuit Tests337

Field Circuit Resistance Wire Checks338

Field Relay Checks And Adjustment339

Closing Voltage Adjustment339

Other Harness Checks339

Generator Removal And Installation339

Brush Replacement340

Double Contact Regulator341

Field Relay Adjustment342

Ignition Systems General Description343

Magnetic Pulse Distributor343

Ignition Pulse Amplifier Unit343

Distributor Contact Points344

Breaker Point System344

Breakerless System344

Ignition Coil Check (Breakerless)344

Breaker Plate And Attaching Parts345

Checking Breaker Arm Spring Tension345

Setting Dwell Angle346

Distributor Lead Arrangements346

Top View Of Distributor346

Inaccurate Gauging Of Rough Points346

Distributor Condenser347

Eight Cylinder Engine Distributor347

Setting Point Opening347

Adjusting Dwell Angle347

Distributor (Breaker Point Type)348

Distributor - Exploded View348

Breakerless (Magnetic Pulse) Distributor Removal352

Breakerless (Magnetic Pulse) Distributor Disassembly352

Breakerless (Magnetic Pulse) Distributor Installation352

Distributor Off-Engine Test352

Ignition Pulse Amplifier Disassembly353

Ignition Pulse Amplifier Component Checks353

Pulse Amplifier Panel Board353

Pulse Amplifier Component Checks353

Ignition Switch Replacement354

Pulse Amplifier Internal Circuitry354

Transistor Checking354

Spark Plugs Cleaning And Regapping355

Removing Ignition Switch Nut355

Unlocking Ignition Switch Connector355

Setting Spark Plug Gap355

Starter Circuit General Description357

Starter Circuit Maintenance And Adjustments357

Starting Motor Cross Section357

Resistance Checks357

Starting Motor Removal And Installation358

Starting Motor And Solenoid Check358

Starting Circuit Diagram358

Starter Mounting358

Clutch And Transmissions360

Clutch General Description360

Clutch Maintenance And Adjustments360

Linkage Inspection360

Clutch Linkage Adjustment361

Chevelle Clutch Pedal Free Travel Adjustment361

Clutch Component Parts Replacement362

Clutch Assembly362

Chevy Ii Clutch Pedal Free Travel Adjustment362

Clutch Pedal Free Travel Adjustment362

Clutch Pedal363

Clutch Cross Shaft363

Release Bearing Lubrication And Comparison363

Lower Linkage Details364

Three-Speed (Saginaw Fully Synchronized) Transmission365

Corvette Lower Linkage Details365

Clutch And Transmissions Maintenance And Adjustments366

Chevrolet, Chevelle, Chevy Ii, Camaro Shift Linkage Adjustment366

Floor Shift Linkage Adjustment366

Shift Control Lever And Bracket Assembly366

Speedometer Driven Gear366

Extension Oil Seal Replacement366

Transmission Side Cover367

Transmission Replacement (Exc. Corvette)367

Component Part Replacement367

Transmission Overdrive368

Corvette Transmission Replacement368

Servicing The Overdrive369

Governor Switch And Pinion369

Sun Gear Solenoid, Oil Seal And Control Cable Bracket369

Case Rear Oil Seal369

General Description369

Electrical Unit Checks370

Adjusting Relay Point Opening370

Overdrive Relay370

Ignition Grounding Contact370

Diagnosis - Overdrive371

Overdrive Electrical Circuit Wiring Diagram372

Three-Speed Heavy Duty Transmission (Warner Model T 16)373

Side Cover Assembly373

Warner T-16 3-Speed Lever And Linkage Adjustment374

Side Cover Assembly - Layout374

Four-Speed Transmission (Muncie)375

Shift Linkage Adjustment375

Corvette And Camaro Shift Linkage Adjustment375

Gear Shift Lever Reverse Blocker Cable376

Four-Speed (Muncie) Transmission Gearshift Linkage376

Speedometer Driven Gear And Oil Seal378

Extension Oil Seal378

Four-Speed (Saginaw) Transmission379

Transmission Replacement379

Shift Linkage Adjustment (Chevrolet & Chevelle)380

Shift Linkage Adjustment (Chevy Ii)380

Shift Linkage Adjustment (Camaro And Corvette)380

Aluminum Powerglide382

Periodic Oil Change383

Periodic Low Band Adjustment383

Manual Shift Linkage Check & Adjust383

Floor Shift Linkage384

Chevrolet Shift Linkage Adjustments384

Chevy Ii Linkage Adjustment386

Camaro Linkage Adjustment386

Camaro Shift Linkage Adjustment386

Corvette Powerglide Control Lever And Bracket Assembly388

Floor Mounted Control Lever And Bracket Assembly388

Throttle Valve Linkage Adjustment388

Neutral Safety Switch Adjustment389

Throttle Return Check Valve Adjustment389

Corvette Powerglide Transmission390

Converter Holding Tool390

Warming Up Transmission391

Checking Fluid Level And Condition391

Manual Linkage391

Basic Pressure Checks392

Pressure Test Plug392

Powerglide Basic Pressure (Mainline) Check Chart393

1967 Shift Points - Powerglide394

Turbo Hydra-Matic Transmission395

Turbo Hydra-Matic Diagnosis Procedure400

Turbo Hydra-Matic Shift Points401

Case Porosity - Repair401

Oil Pressure Check401

Clutch Special Tools402

Manual Transmission Special Tools403

Aluminum Powerglide Special Tools404

Turbo Hydra-Matic Special Tools405

Fuel Tank And Exhaust Systems407

Draining Fuel Tank408

Siphon Construction408

Fuel Tank Removal And Installation409

Gauge Unit Assembly409

Fuel Tank Vent Line410

Gauge Unit And Fuel Strainer410

Exhaust Systems411

Muffler Assembly411

Exhaust Pipe411

Tail Pipe And/Or Resonator411

Single Exhaust Systems412

Dual Exhaust Systems413

Fuel Tanks General Description414

Fuel Tanks Component Part Replacement414

Fuel Pipe Retainer Clip414

Filler Neck And Vent Assemblies415

Installing Fuel Line Retainer Clip415

Fuel Tank Gauge Unit Removal416

Chevy Ii Fuel Tanks419

Corvette Fuel Tank424

Standard Steering441

Steering Gear Adjustment Points442

Checking Wheel Pull - Corvette443

Steering Wheel Alignment443

Adjusting Steering Ratio - Corvette443

Steering Wheel Regular Production444

Regular Wheel And Horn Attachments444

Simulated Wood445

Corvette Telescoping445

Steering Column Wiring Connector445

Removing Steering Wheel With J-2927445

Steering Coupling446

Corvette Telescoping Wheel Option446

Removing Or Installing Dash Panel Covers And Seal447

Steering Column Escutcheon447

Powerglide Indicator Connection448

Steering Coupling Clearance Adjustment448

Steering Gear - Chevrolet, Chevelle, Camaro And Corvette449

Steering Column450

Mast Jacket Cover Attachments - Chevy Ii450

Sector Shaft Seal Replacement450

Steering Column To Dash Panel451

Synchromesh Steering Column - Exploded View452

Removing Wiring Protector453

Column Secured In Bench Vice453

Upper Bearing Preload Spring And Cancelling Cam453

Removing Or Installing "C" Ring Retainer453

Removing Turn Signal Switch Cover From Column454

Upper Shift Lever Spring And Bowl Washer454

Bottoming Shift Levers Using Spanner Wrench J-22568454

Column Mounted Powerglide Lever Or Floor Shift Column - Exploded View455

Disassembly - Column Mounted Powerglide Lever Or Floor Shift Column456

Powerglide Dial Indicator Assembly456

Assembly - Column Mounted Powerglide Lever Or Floor Shift Column457

Shift Tube And Steering Shaft457

Tolerance Ring Kit - First And Final Adjustment457

Tilt Steering Column - Exploded View458

Disassembly - Tilt Column459

Assembly - Tilt Column461

Disassembly - Standard Corvette Column463

Standard Corvette Column - Exploded View464

Assembly - Standard Corvette Column465

Disassembly - Corvette Telescoping Column466

Corvette Telescoping Column - Exploded View466

Assembly - Corvette Telescoping Column467

Removing Lower Bearing Retaining Ring467

Removing Bumper Key Strap467

Steering Linkage469

Relay Rod - All Models Except Corvette471

Relay Rod - Corvette471

Freeing Ball Stud471

Steering Arm472

Steering Damper - Corvette472

Power Steering General Description473

Power Steering Maintenance And Adjustments473

Power Steering Gear474

Pump Belt Tension474

Hydraulic System Checks474

Steering Component Replacement And Repairs475

Power Steering Pump475

Control Valve And Adapter Assembly476

Power Cylinder - Exploded View477

Power Steering Hose Installation478

Steering Special Tools480

Wheels And Tires General Description481

Wheels And Tires Maintenance And Adjustments481

Tire Rotation484

Tires Service Operations485

Wheels Static Balancing (W/Tire)485

Wheels Dynamic Balancing (W/Tire)485

Wheels Run Out (W/O Tire)485

Wheels Service Operations486

Tire Installation Safety Precautions486

Valve Assembly486

Chassis Sheet Metal488

Hood Adjustment488

Hood Bumpers488

Front End Sheet Metal - Chevrolet489

Front End Sheet Metal - Chevelle490

Chassis Sheet Metal Component Part Replacement491

Sheet Metal Adjustments491

Radiator Support491

Sheet Metal Adjustments - Chevrolet492

Sheet Metal Adjustments - Chevelle493

Hood Catch And Lock494

Hood Trim And Insulation494

Cowl Vent Grille494

Rear Wheel Cover494

Sheet Metal Adjustment - Chevy Ii499

Front End Sheet Metal - Camaro506

Electrical-Body And Chassis513

Lighting System513

Fuse Panel Assembly514

Headlamp Adjustment - T-3 Headlamps515

Horizontal Adjustment515

Vertical Adjustment516

How To Select A Level Aiming Area516

To Compensate For Unlevel Floors516

Electrical-Body And Chassis Service Operations517

Headlamp Panel Travel Adjustment517

Front Lighting517

Parking Lamp Replacement517

Fender Lamp Service518

Headlamp Assemblies518

Headlamp Panel Replacement - Corvette520

Headlamp Panel Motor521

Headlamp Motor Replacement521

Rear Lighting Service522

Tail, Stop And Directional Lamps522

Bulb Replacement522

Rear Lighting Composite523

Backing And License Lamps525

Parking Brake Alarm Switch Replacement531

Instrument Panel Compartment Lamp/Switch Replacement531

Cigarette Lighter Replacement531

Chevrolet Instruments And Gauges General Description533

Chevrolet Instruments And Gauges Service Operations534

Instrument Cluster Removal And Installation534

Instrument Cluster Lamp Replacement534

Printed Circuit Replacement534

Speedometer Cable Replacement Or Lubrication535

Fuel Gauge Replacement535

Instrument Cluster Connections535

Clock Or Tachometer Replacement536

Ammeter Temperature And Oil Pressure Gauges Replacement536

Oil Pressure Indicator536

Optional Gauge Cluster536

Instrument Panel Wiring537

Chevelle Instruments And Gauges General Description538

Chevelle Instruments And Gauges Service Operations538

Generator Indicator538

Temperature (Cooling System) Indicator538

Fuel Gauge And/Or Ammeter Replacement539

Clock Replacement539

Speedometer Replacement539

Speedometer Cable539

Instrument Cluster Assembly540

Chevy Ii Instruments And Gauges543

4. Gen Indicator544

5. Temp Indicator544

O I L " Indicator544

Corvette Instruments And Gauges546

Fuel Gauge Connector546

Parking Brake Alarm Indicator547

Camaro Instruments And Gauges548

Windshield Wipers And Washers556

Wiper Transmission Assembly556

Wiper Motor Assembly557

Non-Depressed Park Wiper558

Wiper Motor And Gear Box Assembly558

Windshield Washer Pump560

Depressed Park 2-Speed Wiper Chevrolet General Description561

Motor Section Disassembly562

Brush Plate And Circuit Breaker Removal562

Armature Removal562

Case And Field Assembly Removal563

Gear Box Section566

Washer Pump Unit Removal And Installation567

Relay Switch - Latch And Terminal Board Assembly567

B-Drive Gear Disassembly567

Drive Gear - Assembly567

Depressed Park 2-Speed Wiper And Washer568

Wiper Motor And Washer Pump Assembly568

Wiper Transmission Removal And Installation569

Wiper Assembly Repairs569

Wiper Assembly Exploded View570

Relay Control And Latching Mechanism571

B-Drive Gear Mechanism571

Washer Pump Section572

Washer Pump Assembly572

Front Lighting & Engine Compartment - Chevrolet573

Fuse Panel - Chevrolet574

Instrument Panel Cluster - Chevrolet575

Body And Rear End Lighting (Exc Wagon) - Chevrolet576

Body And Rear End Lighting (Wagon)577

Front Lighting And Engine Compartment578

Fuse Panel - Chevelle579

Instrument Panel And Cluster - Chevelle580

Body And Rear Lighting - Chevelle581

Front Lighting & Engine Compartment - Chevy Ii582

Fuse Panel - Chevy Ii583

Instrument Panel And Cluster - Chevy Ii584

Body And Rear Lighting - Chevy Ii585

Front Lighting & Engine Compt - Corvette586

Fuse Panel - Corvette587

Instrument Panel And Cluster - Corvette588

Body And Rear Lighting - Corvette589

Front Lighting & Engine Compt - Camaro590

Fuse Panel - Camaro591

Instrument Panel And Cluster - Camaro592

Body And Rear Lighting - Camaro593

Radiator And Grille General Description594

Radiator And Grille Service Operations594

Radiator And Shroud - All Vehicles594

Radiator And Fan Shroud - Corvette594

Grille Assembly - Chevrolet595

Radiator And Shroud - Chevrolet595

Grille Assembly - Chevelle596

Radiator And Shroud - Chevelle596

Grille Assembly - Chevy Ii597

Grille Assembly - Corvette598

Grille Assembly - Camaro598

Front Bumper Assembly602

Rear Bumper Assembly603

Rear License Plate Housing608

Cruise Master System610

Component Operation611

Engagement Switch611

Brake Release Switches612

Magnetic Speed Sensing Assembly613

Vacuum Switch, Air Bleed And Filter, And Low Limit Speed Switch614

Regulator Cross Section614

Regulator Exploded View615

Electrical System Check Out618

Engagement Switch Test618

Servo And Vacuum System Check Out618

Cruise Master System Checks619

Automatic Level Control General Description620

Vacuum And Electrical Diagram620

Heating And Air Conditioning Specifications628

Front Suspension Specifications628

Wheel Alignment Specifications628

Riding Height Measurement629

Bolt Torques629

Rear Suspension Specifications630

Brakes Specifications632

Brakes Torque Chart632

Engine Specifications633

Engine Torques638

Engine Mount Torque Chart638

Tune Up Chart639

Engine Electrical Specifications640

Battery Specifications640

Generator Specifications640

Regulator Specifications641

Starting Motor Specifications641

Distributors Specifications642

Coil Specifications643

Transmission And Clutch Specifications644

Steering Specifications646

Steering Torque Chart647

Wheels And Tires Specifications648

Tire Usage And Recommended Tire Inflation Pressures648

Body And Chassis Electrical Specifications652

Fuses And Circuit Breaker653

Bumpers Specifications655

Decimal Equivalents657

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This manual is also suitable for:

1967 camaro 1967chevy ii 1967 corvette 1967 chevy ii