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1962 Chevy II
Chevrolet 1962 Chevy II Manuals
Manuals and User Guides for Chevrolet 1962 Chevy II. We have
2
Chevrolet 1962 Chevy II manuals available for free PDF download: Service Manual, Wiring Diagram
Chevrolet 1962 Chevy II Service Manual (660 pages)
Chassis
Brand:
Chevrolet
| Category:
Automobile
| Size: 119.79 MB
Table of Contents
General Information and Lubrication
3
Model Identification - Chevrolet
3
Vehicle Dimensions - Chevrolet
3
Model Identification - Chevelle
4
Vehicle Dimensions - Chevelle
4
Model Identification - Chevy II
4
Vehicle Dimensions - Chevy II
5
Model Identification - Camaro
5
Vehicle Dimensions - Camaro
5
Unit and Serial Number Locations
5
Keys and Locks
6
Lock Cylinder Assembly
8
Tumbler Requirement Diagram
8
Automatic Transmission
9
Towing
9
Pushing
9
Manual Transmission
9
Attachment of Towing Chain Hooks to Lower Control Arms
10
Towing the Camaro
10
Vehicle Lifting Points - Chevelle
10
Towing Sling Attachment
11
Attachment of Towing Chain Hooks to Axle Tube
11
Towing Sling Attachment - Rear
11
Strapping Wood Block to Rear Spring
11
Lifting Car with Drive-On Hoist
12
Vehicle Lifting Points - Chevy II
12
Lifting with Auto Jack
12
Lifting the Corvette
12
Vehicle Lifting Points - Camaro
13
Vehicle Lifting Points - Corvette
14
Frame Lift Adapters - Corvette
14
Lubrication
15
Engine Crankcase Oil
15
Crankcase Capacity
15
SAE Viscosity Oils
15
Maintaining Oil Level
16
Types of Oils
16
Crankcase Breather Cap
16
Oil Filter
16
Crankcase Ventilation Valve
17
Fuel Filter
17
Air Cleaner
17
Distributor
17
Turbo Hydra-Matic
18
Front Wheel Bearings
18
Power Steering
18
Air Conditioning
18
Lubrication Diagram - Chevrolet
19
Lubrication Diagram - Chevelle
20
Lubrication Diagram - Chevy II
21
Body Lubrication
22
Lubrication Diagram - Comaro
22
Body Lubrication Points (Corvette)
23
Lubrication Diagram - Corvette
23
Heater Air Flow
24
Heater and Air Conditioning
24
Heater General Description
24
Heater Controls
25
Control Assembly
25
Heater Schematic (Chevy II)
25
Heater Control Panel (Chevrolet Shown as Typical)
25
Component Replacement and Repair
26
Blower Assembly
26
Temperature Damper Door
26
Air and Defrost Damper Doors
26
Core Replacement
27
Heater Blower and Air Inlet (Chevrolet, Chevelle, Comaro)
27
Defroster Duct
28
Bowden Cables
28
Fan Switch Replacement
28
Chevy II Heater Assembly
28
Corvette Blower Assembly
29
Corvette Blower and Air Inlet Assembly
29
Chevy II Fan Control
29
Chevy II Blower Motor
29
Control Assembly (Comaro)
31
Chevy II Heater Components Removal
31
Defroster Duct (Chevy II)
31
Heater Control Assembly and Cables (Chevy II)
32
Corvette Heater and Blower Inlet Assembly
32
Heater Hose Routing (Chevy II)
32
Corvette Heater Core Removal
33
Heater Assembly Installation
33
Heater and Defroster Cables (Corvette)
34
Heater Hoses - Corvette
35
Air Conditioning General Description
36
Four-Season System
36
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 Components
40
Outlets and Defroster Levers
40
Fan Switch
40
Comfortron System
41
Comfortron Engine Compartment Components
41
In-Car Sensor
41
Feedback Potentiometer
41
Mode Door Diaphragm
42
Outside Air Diaphragm
42
Power Servo
42
Transducer
42
Electronic Circuit
43
Changing the Electronic Signal to Electrical Voltage
43
Changing the Electrical Voltage to a Vacuum Signal
43
Changing the Vacuum Signal to Mechanical Energy
43
Universal System
44
Chevy II All-Weather System
44
"De-Fog" Position
44
Universal System Components
45
Weather System Components (Chevy II)
46
Weather System Schematic
46
Controls Corvette
47
Controls - All Weather (Chevy II)
47
Corvette Four-Season System Schematic
47
Corvette Four-Season System Components
48
Precautions in Handling Refrigerant-12
49
Additional Cooling Hints
49
Heating
49
Cycle of Operation - Universal and All Weather
50
Cycle of Operation - Four-Season and Comfortron
50
Precautions in Handling Refrigerant Lines
51
Maintaining Chemical Stability in the Refrigerant System
51
System Contaminants
51
Gauge Set
51
Charging Station
52
Leak Testing the System
52
System Charging Station
52
Leak Detector
53
Vacuum Pump
53
Availability of Refrigerant
53
Pre-Delivery Inspection
54
Compressor Oil
54
Compressor Serial Number
54
6000 Mile Inspection
55
Periodic Service
55
Installing Gauge Set to Check System Operation
55
Performance Test
55
Performance Data
56
Comfortron System Operational Test
56
Chevrolet Comfortron Tester
57
To Install the Tester
57
Quick Test Procedure
57
Complete System Checks
58
Checking Condition of Thermistors (Sensors)
58
Comfortron Tester Installation
58
Comfortron System Tester
58
System Checks
59
Maintenance and Adjustments
60
Checking for Proper Operation
60
Evaporator Control Valve (POA)
60
Thermostatic Switch
60
Comfortron Wiring Diagram - Underhood
61
Comfortron Wiring Diagram - Underdash
62
Adjusting Switch
63
Comfortron Vacuum Diagram
63
Expansion Valve
64
Evaporator Pressure Control Valve - POA
64
P.O.A. Valve Installed
64
Thermostatic Switch Removal
64
Evacuating and Charging Procedures
65
Engine Idle Compensator
65
1967 Air Conditioning System Capacities
65
Purging the System
65
Installing Charging Station to System
66
Filling Charging Cylinder
66
Checking Oil
66
Evacuating and Charging the System
66
Charging Schematic
67
Component Replacement and Minor Repairs
68
Refrigerant Line Connections "O" Rings
68
Checking Compressor Oil Charge
68
Adding Oil to the System
68
Repair of Refrigerant Leaks
69
Refrigerant Hose Failure
69
Preparing System for Replacement of Component Parts
69
Hose Clamps
69
Foreign Material in the System
70
Condenser
70
Condenser Mounting (Chevrolet and Chevelle)
70
Receiver-Dehydrator
71
Condenser Mounting (Comaro)
71
Chevrolet and Comaro Four-Season System
72
Sight Glass Replacement - All Vehicles
72
Evaporator
72
Universal System All Vehicles Core And/Or Expansion Valve Replacement
73
Chevelle Four-Season System Removal
73
Chevelle Four-Season System Installation
73
Chevelle Four-Season System Core Replacement
73
Universal System All Vehicles Removal
74
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 Removal
76
Chevy II All-Weather System Within the Car
76
Chevy II All-Weather System Care And/Or Expansion Valve Replacement
76
Wiring-All Weather (Chevy II)
77
Evaporator Mounting - Universal Unit
78
Cable Removal - All Weather
79
Terminal Removal - Universal System
79
Underdash Wiring - Universal System (Typical)
79
Evaporator Removal - All Weather
80
Four-Season System Chevrolet, Chevelle, Corvette, and Comaro Replacement
81
Underdash Wiring - All Weather
81
Chevy II All-Weather System Replacement of Valve Assembly
82
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 Replacement
84
All-Weather System Chevy II Installation
84
All-Weather System Chevy II Removal
84
Universal Blower Assembly
86
Air Inlet Valve
87
Blower and Evaporator Assembly
87
Air Distributor Assembly and Outlet Ducts
87
Air Distributor Assembly
88
Comfortron Automatic Control Components
89
Heater and Air Distributor Assembly
90
Resistor Assembly
91
Relays
91
Thermal Vacuum Valve
91
Vacuum Tank
91
Control Head
92
Refrigerant and Vacuum Hoses (Corvette)
92
Comfortron Vacuum Tank
92
Collision Procedure - All Systems
93
Mode Shift Vacuum Diaphragm
93
Comfortron Underhood Wiring
94
Comfortron Underdash Vacuum Lines
95
Comfortron Underhood Vacuum Lines
95
Fuses
96
Four Season Heater Components
96
Comfortron Power Servo Installation
97
Compressor Mount - L-6 Engines
97
Comfortron Heater Components
98
Compressor
99
Compressor Failure
100
Compressor Belt Tension Adjustment
100
Wiring Diagrams
101
Chevrolet - Four-Season Wiring Diagram
101
Chevelle - Four-Season Wiring Diagram
102
Camaro - Four-Season Wiring Diagram
103
Universal System Wiring Diagram (Typical)
104
All Weather Wiring Diagram (Chevy II)
105
Corvette - Four-Season Wiring Diagram
106
Heater and Air Conditioning Special Tools
107
Hood
108
Corvette Maintenance & Replacements
108
Front End Adjustments
108
Corvette Body General Description
108
Hood Assembly
109
Hood Prop
109
Front Emblem
109
Vent Grilles
109
Hood Hinge and Catch
110
Cowl Ventilator Assembly
111
Sun Visor
111
Rear View Mirror
111
Cowl Area Trim
111
Windshield Removal
112
Checking Windshield Body Opening
112
Scribing Line Around Hood Hinge
112
Windshield Installation
113
Console Trim
113
Special Clip
113
Sun Visor and Inside Rear View Mirror
113
Door Hinges
114
Doors Adjustments
114
Door Window and Vent Adjustment
114
Door Lock Striker
114
Windshield Glass and Reveal Moldings
115
Trim Panel, and Inside Handles
118
Weatherstrip
118
Door Ventilator Assembly
119
Ventilator Window Assembly Replacement
119
Door Weatherstrip
120
Window Glass
120
Glass Run Channel - Upper
121
Window Outer Seal Assembly
121
Window Inner Seal
121
Glass Run Channel - Rear
122
Window Regulator - Manual
122
Window Regulator - Power
122
Model 19467 Ventilator Assembly
123
Outer Handle
123
Door Lock and Remote Controls
123
Lock Cylinder Replacement
124
Hinges - Door Assembly Removal
124
Rear Quarter
126
Door Sill Plate and Molding
126
Rear End Folding Top Compartment Lid
126
Power Window Regulator
127
Rear Window - Adhesive Caulced - 19437 Model
128
Locking Regulator Arm in Place
128
Folding Top Lid Assembly
130
Spare Tire Mount
130
Rear Filler Panel
130
Gas Tank Door and Rear Trim Plate
130
Rugs and Interior Trim
132
Procedure for Cleaning Coated Fabrics
132
Cleaning Soft Trim
132
Procedure for Cleaning Folding Top Material
132
Carpets and Covers - All Models
133
Rear Body Trim
133
Applying Silane Primer
133
Garnish Moldings Plus Headliner - 19437 Model
134
Seats
134
Body Mounting
134
Body Repairs
134
Precautions
136
Plastic Solder Kit
136
Body Mounts
136
Resin Kit
137
Front Body Construction
137
Center Body Construction
138
Scratched Panels, Spot Refinishing
139
Underbody Construction
139
Specific Repairs
139
Dents or Pits in Panels, Cracks in Glaze Coat
140
Bonding Strips - Roof Reinforcement
140
Rear Body Construction
141
Cracked Panels
142
Typical Body Bonds
142
Mixing Plastic Solder Material
142
Fractured Panels
144
Typical Pitted Panel
144
Typical Cracked Panel
144
Cracked Panel Preparation
144
Hard Top Weatherstrip and Moldings
145
Marking Molding Position
146
Installing Reveal Molding Retainers
146
Panel Replacement
146
Hard Top Window Moldings
146
Applying Sealer to Frame
147
Pulling Cord from Weatherstrip
147
Installing Window Assembly
147
Applying Sealer to Weatherstrip
147
Rear Window Installation
148
Applying Cement to Window
148
Rear Window Removal
148
Hard Top Care and Storage
148
Garnish Moldings and Latches
149
Headlining
150
Weatherstrip and Drip Moldings
150
Vinyl Covering on Removable Hardtop
150
Vinyl Roof Cover Repairs
152
Scuffs or Small Cuts Near Exterior Moldings
152
Hardtop Weatherstrips and Moldings
152
Wrinkles, Blisters and Bubbles
153
Care of Rear Window
153
Care of the Folding Top
153
Folding Top Adjustments
154
Folding Top Trim Installation
154
Trim of Header
155
Rear Bow Retaining Screws
155
Installing Trim and Weatherstrip to Rear Bow
155
Rear Bow Hold-Down Locks
156
Hinge
156
Header
156
Top Assembly Removal and Installation
156
Top Trim and Rear Window Assembly
157
Installing Binding
157
Top Frame and Linkage
157
Side Rail Weatherstrips
158
Hardtop Attachments of Rear Bow
158
Header Weatherstrip
158
Hardtop Attachments of Lock Pillar Area
158
Side Rail Weatherstrip
159
Adding Hardtop (Roof Panel Assembly)
159
Frame and Linkage
159
Corvette Body Special Tools
160
Frame General Description
161
Tramming Sequence
161
Frame Repair Procedures
161
Checking Frame Alignment
161
Frame Dimensions (Chevrolet)
162
Frame Dimensions (Chevelle)
163
Frame Dimensions (Corvette)
164
Front Suspension General Description
165
Front Suspension - Chevrolet
166
Front Suspension - Chevelle & Camaro
166
Front Suspension Maintenance and Adjustments
167
Front Wheel Bearing Adjustment
167
Front Suspension - Corvette
167
Front Suspension - Chevy II
168
Caster and Camber
168
Caster and Camber Adjustment
169
Front End Alignment
169
Steering Axis Inclination Adjustment
170
Toe-In Adjustment
170
Riding Height and Coil Spring Sag
170
Checking Riding Height
171
Front Suspension Repair Procedures
172
Front Brake Drum - Chevrolet, Camaro, Chevelle, Chevy II
172
Front Wheel Hub
172
Steering Knuckle Removal
173
Steering Knuckle Installation
173
Installing Front Hub Inner Bearing
173
Backing Plate Removed - Chevy II
173
Shock Absorber Removal
174
Shock Absorber Installation
174
Upper Control Arm Support Installed - Chevy II
174
Strut Rod Removal
175
Removing Shock Absorber and Bracket - Chevy II
175
Stabilizer Bar Installation
175
Stabilizer Bar Removal
175
Front Spring Removal - Chevrolet
176
Spring Removal Tools
176
Front Spring Removal
176
Compressing Front Spring - Chevy II
178
Removing Spring and Seal Assembly - Chevy II
178
Spring Seat - Exploded View - Chevy II
178
Installing Spring Compressor - Chevy II
178
Lower Control Arm Spherical Joint
180
Removing Lower Ball Joint - Chevelle & Camaro
180
Installing Lower Ball Joint
181
Disassembling Lower Ball Stud
181
Lube Fittings
182
Lower Control Arm Attachment
182
Lower Control Arm Bushing - Chevrolet
183
Lower Control Arm Bushing - Chevelle & Camaro
183
Lower Control Arm Bushing - Small - Chevelle & Camaro
183
Installing Lower Control Arm Cross Shaft Bushing
184
Removing Lower Control Arm Cross Shaft Bushing
184
Removing Lower Control Arm Pivot Bushing - Chevy II
184
Cross Shaft And/On Bushings
185
Upper Control Arm Spherical Joint
185
Upper Control Arm
186
Upper Control Arm Cross Shaft And/Or Bushings
187
Removing Pivot Shaft Bushing - Chevy II
188
Installing Pivot Shaft Bushing - Chevy II
188
Removing Upper Control Arm Cross Shaft Bushings
188
Installing Upper Control Arm Cross Shaft Bushing
188
Front Suspension Special Tools
190
Rear Suspension and Drive Line
191
Rear Suspension General Description
191
Chevrolet Rear Suspension Components
192
Chevelle Rear Suspension Components
192
Chevy II Rear Suspension Components
193
Camaro Rear Suspension Components
193
Rear Suspension Maintenance and Adjustments
194
Corvette Rear Suspension and Driveline Components
194
Measuring Rear Riding Height (Chevrolet and Chevelle)
195
Adjusting Rear Wheel Camber (Corvette)
195
Wheel Alignment (Corvette)
195
Riding Height Check
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 Replacement
197
Coil Spring
197
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 II
199
Rear Spring - Exploded View
199
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 Absorber Mounting - Exploded View (Chevelle)
201
Installing Spring Front Bushing (Camaro)
201
Shock Absorber
201
Control Arm
202
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
Lower Control Arm Front Bushing Installation (Chevrolet)
204
Lower Control Arm Front Bushing Removal (Chevrolet)
204
Upper Control Arm Bushing Installation (Chevrolet)
204
Chevelle Upper and Lower
205
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
Upper and Lower Control Arm Assembly (Chevelle)
207
Rear Suspension Tie Rod - Chevrolet
207
Carrier Mounted Suspension Bushing Removal (Heavy-Duty) (Chevelle)
207
Carrier Mounted Suspension Bushing Installation (Heavy-Duty) (Chevelle)
207
Rear Suspension and Drive Line Component Parts Replacement (Corvette)
208
Wheel Spindle and Support
208
Rear Suspension Tie Rod Attaching Points (Chevrolet)
208
Tie Rod Bushing Replacement (Chevrolet)
208
Wheel Spindle and Support Cross-Section
209
Bearing Cup Removal (Corvette)
209
Installing Spindle Bearing Cup (Corvette)
209
Unseating Drive Spindle Outer Bearing (Corvette)
209
Differential Carrier Support Bracket Replacement
210
Strut Rod and Bracket
210
Shock Absorber Installation (Corvette)
210
Removing Strut Rod Shaft (Corvette)
210
Strut Rod Bushing Replacement
211
Spring Mounting (Corvette)
211
Marking Camber Cam and Bracket (Corvette)
211
Spring
211
Removing Clamp Plate (Corvette)
212
Lowering Spring (Corvette)
212
Removing Center Bolt (Corvette)
212
Aligning Spring Leaves (Corvette)
212
Torque Control Arm
213
Torque Control Arm Bushing Cross-Section (Corvette)
213
Drilling out Retainer Flare (Corvette)
213
Flaring Tool Back-Up Plate (Corvette)
214
Suspension Crossmember
214
Installing Bushings (Corvette)
214
Removing Bushings (Corvette)
214
Stabilizer Shaft Replacement
215
Removing Crossmember (Corvette)
215
Crossmember Mount Cross-Section (Corvette)
215
Stabilizer Shaft Installation (Corvette)
215
Drive Line
216
Rear Axle
216
Axle Bolts and Wheel Nuts
217
Rear Axle Cross-Section
217
Rear Axle Cross-Section (Corvette)
218
Rear Axle Noise Diagnosis
219
Gear Noise
219
Bearing Noise
219
Failure Analysis
219
Component Parts Replacement
220
Axle Assembly
220
Differential Gear Failure
220
Wheel Bearing Removal
221
Axle Shaft
221
Wheel Bolt Replacement
221
Differential Pinion Shaft Removal
221
Pinion Flange, Dust Deflector And/Or Oil Seal
222
Wheel Bearing And/Or Oil Seal Installation
222
Measuring Drive Pinion Bearing Preload
222
Drive Pinion Nut Removal
222
Drive Pinion Flange Installation
223
Drive Pinion Flange Oil Seal Installation
223
Drive Pinion Flange Removal
223
Axle Driveshaft
224
Removing Driveshaft
224
"U" Joint Trunnion Seal Installation
224
Removing Carrier Front Support
225
Removing Companion Flange Nut
225
Removing Companion Flange
225
Pinion Seal Installed
226
Installing Pinion Oil Seal
226
Installing Carrier Assembly
226
Differential Carrier
226
Table of Contents
227
Propeller Shaft and Universal Joints General Description
227
Positraction Differential Unit
227
Measuring Positraction Rotating Torque
227
Light-Duty Propeller Shaft Cross-Section (Dana Design)
227
Component Parts Replacement
228
Removing Propeller Shaft from Companion Flange
228
Propeller Shaft Sleeve and Damper Assembly
228
Heavy-Duty Propeller Shaft Cross-Section (Saginaw Design)
228
Propeller Shaft (Dana)
228
Removal
228
Repairs
228
Removing Bearing Caps
229
Installation
229
Pressing Trunnion Bearing from Propeller Shaft
230
Service Kit Trunnion (Saginaw)
230
Propeller Shaft (Saginaw)
230
Removal
230
Repairs
230
Bearing Partially Pressed from Propeller Shaft
231
Removing Bearing from Propeller Shaft
231
Installing Trunnion to Propeller Shaft
231
Installing Snap Ring to Retain Trunnion
231
Installation
231
Rear Suspension Special Tools
232
Brakes
234
Duo-Servo Brakes
234
Brake Pipe Distribution and Switch Assembly
235
Main Cylinder
235
Bleeding Hydraulic System
236
Camaro Pressure Regulator Valve
236
Hydraulic Brake Fluid
236
Pressure Bleeding
236
Bleeding Brakes Using Brake Bleeder Wrench Tool J-21472
237
Brake Bleeder Adapter Tool J-22489-Installed
237
Correct Bleeding Sequence
237
Manual Bleeding
237
Correct Main Cylinder Fluid Level
238
Hydraulic Brake Lines
238
Push Rod to Main Cylinder Clearance
238
Brake Pedal Free Movement
239
Double Lap Flaring
239
Hydraulic Brake Tubing
239
Brake Adjustment
240
Service Brake
240
Parking Brake
241
Parking Brake System - Chevrolet and Chevelle
243
Front Cable
244
Idler Lever
244
Parking Brake System - Camaro
244
Parking Brake System - Chevy II
245
Rear Cable
245
Lever Assembly
246
Parking Brake - Corvette
246
Parking Brake System - Corvette
246
Removing or Installing Cover Lower Mounting Screws
247
Removing or Installing Front Cable
247
Removing or Installing Trim Seal
247
Brake Pedal
248
Brake Shoes
248
Organic Linings
249
Removing Hold-Down Springs and Pins
249
Shoes and Linings
249
Unhooking Pull Back Spring
249
Backing Plate Contact Surfaces
250
Metallic Linings
250
Checking Operation of the Actuating Lever
251
Identification of Warn Metallic Brake Lining
251
Identification of Worn Lining
251
Main Cylinder for Drum Type Brakes - Exploded View
252
Chevelle Wheel Cylinder - Exploded View
254
Anchor Pin
255
Brake Drums
255
Brake Drum Access Hole
256
Disc Brakes General Description
257
Disc Brakes Maintenance and Adjustments
257
Disc Brake - Cutaway View
258
Brake Caliper
259
Pressure Regulator Valve - Chevrolet and Camaro
259
Caliper Assembly - Exploded View
260
Installing Boot Seal in Caliper Bore Using Tool J-22592
261
Installing Piston in Caliper Bore Using Tool J-22591
261
Brake Disc Checking Procedure
262
Dial Indicating Disc Runout
262
Installing Caliper on Disc
262
Parking Brake Shoes
263
Power Brakes Component Replacement
264
Power Brakes General Description
264
Power Brakes Maintenance and Adjustments
264
Brakes Special Tools
265
Engine Mechanical Checks and Adjustments
266
Engine Tune up
266
Spark Plug Removal
266
Test Compression
266
Checking Compression
267
Distributor (in Line)
267
Service and Install Spark Plugs
267
Spark Plug Detail
267
Magnetic Pulse (Breakerless) Distributor
268
Point Alignment
268
Service Ignition System
268
Checking Fan Belt Tension
269
Manifold Heat Control Valve (in Line)
269
Manifold Heat Control Valve (V8)
269
Check and Adjust Accelerator Linkage
271
Remote Choke Adjustment
271
Service Cooling System
271
Service Fuel Lines and Fuel Filter
271
Check and Adjust Dwell
272
Check Dwell Variation
272
Choke Adjustment
272
Instrument Check-Out
272
Additional Checks and Adjustments
273
Adjust Idle Speed and Mixture
273
Check and Adjust Ignition Timing
273
Testing Crankcase Ventilation Valve
273
Idle Speed and Mixture Screws
274
Distributor Resistance
275
Ignition Output and Secondary Leakage
275
Ignition Switch
275
Secondary Resistance
275
Carburetor
276
Cooling System
276
Cylinder Head Torque and Valve Adjustment
276
Fuel Pump
276
Engine Mechanical Component Replacement and Adjustment
277
Engine Mechanical General Description
277
In Line Engines (Typical)
278
Synchromesh Transmission
278
Manifold Assembly
279
Rocker Arm Cover
279
Valve Mechanism
279
Valve Adjustment
280
Valve Lifters
280
Air Adapter Tool
281
Compressing Valve Spring
281
Cylinder Head Assembly
281
Valve Stem Oil Seal And/Or Valve Spring
281
Engine Blocked for Pan Removal
282
Oil Pan
282
Pan Gaskets and Seals
282
Oil Pump
283
Removing Oil Seal (Lower Half)
283
Removing Oil Seal (Upper Half)
283
Crankshaft Pulley and Hub
284
Oil Seal (Rear Main)
284
Torsional Damper
284
Crankcase Front Cover
285
Oil Seal (Front Cover)
285
Camshaft
286
Checking Camshaft Gear Runout
286
Measuring Lobe Lift
286
Timing Gear Marks
286
Checking Timing Gear Backlash
287
Flywheel
287
Installing/Removing Crankshaft Gear
287
Timing Gears
287
Engine Mounts
288
Front Mount Replacement
288
Rear Mount Replacement
288
Engine Mechanical (V8) General Description
289
Engine Mechanical (V8) Component Replacement and Adjustment
290
Exhaust Manifold
291
Intake Manifold
291
Cylinder Head Torque Sequence
304
Intake Manifold Torque Sequence
304
Engine Special Tools
305
Coolant Level
306
Coolant System Checks
306
Engine Cooling General Description
306
Engine Cooling Maintenance and Adjustments
306
Carburetors
309
Engine Fuel
309
Service Procedures
309
Float Adjustment
312
Fuel Level Sight Plug
312
Choke Coil Replacement
313
Fuel Filter Maintenance
313
Throttle Linkage Adjustment
314
Air Cleaners General Description
315
Air Cleaners Service Procedures
316
Oil Bath Maintenance
316
Polyurethane Element Maintenance
316
Oil Wetted Paper Element Replacement
317
Oil Wetted Paper Element Testing
317
Testing Air Cleaner
317
Filling Tool with Oil
318
Fuel Pump General Description
318
Fuel Pump Service Procedures
318
Engine Fuel Special Tools
320
Air Injection Reactor System General Description
321
Air Injection Reactor System Maintenance Procedures
321
Drive Belt
321
Drive Pulley
321
Air Injection Pump
322
Air Manifold, Hose and Tube
322
Mixture Control Valve
322
Air Manifold Hose and Tube Routing (Typical)
323
Check Valve
323
Air Injection Tube
324
Air Injector Reactor System Special Tools
325
Installing Pressure Relief Valve
325
Pressure Setting Plug
325
Battery
326
Engine Electrical
326
Types of Batteries
326
Activating Dry Charged Batteries
327
Dry Charged Batteries
327
Wet Charged Batteries
327
Common Causes of Failure
328
Electrolyte Level
328
Level Indicator
328
Water Usage
328
12 Volt Battery Suggested Charging Rates
329
Battery Charging Procedures
329
Battery Safety Precautions
329
Carrier and Hold-Down
329
Battery Testing Procedures
330
Battery Visual Inspection
330
Full Charge Hydrometer Test
330
Installing Batteries
330
Testing Specific Gravity
331
Charging System General Description
332
Delcotron Cross-Section View
332
Circuity - Voltage Regulator Assemblies (Except Corvette)
333
Voltage Regulator Assemblies
333
Circuitry - Voltage Regulator Assemblies (Corvette)
334
Typical Wiring Diagram Showing Lead Connections
334
Adjusting Voltage Setting
335
Battery System Condition Test
335
Delcotron Diode and Field Test
337
Indicator Lamp/Initial Field Excitation Circuit Tests
337
Field Circuit Resistance Wire Checks
338
Closing Voltage Adjustment
339
Field Relay Checks and Adjustment
339
Generator Removal and Installation
339
Other Harness Checks
339
Brush Replacement
340
Double Contact Regulator
341
Field Relay Adjustment
342
Ignition Pulse Amplifier Unit
343
Ignition Systems General Description
343
Magnetic Pulse Distributor
343
Breaker Point System
344
Breakerless System
344
Distributor Contact Points
344
Ignition Coil Check (Breakerless)
344
Breaker Plate and Attaching Parts
345
Checking Breaker Arm Spring Tension
345
Distributor Lead Arrangements
346
Inaccurate Gauging of Rough Points
346
Setting Dwell Angle
346
Top View of Distributor
346
Adjusting Dwell Angle
347
Distributor Condenser
347
Eight Cylinder Engine Distributor
347
Setting Point Opening
347
Distributor (Breaker Point Type)
348
Distributor - Exploded View
348
Breakerless (Magnetic Pulse) Distributor Disassembly
352
Breakerless (Magnetic Pulse) Distributor Installation
352
Breakerless (Magnetic Pulse) Distributor Removal
352
Distributor Off-Engine Test
352
Ignition Pulse Amplifier Component Checks
353
Ignition Pulse Amplifier Disassembly
353
Pulse Amplifier Component Checks
353
Pulse Amplifier Panel Board
353
Ignition Switch Replacement
354
Pulse Amplifier Internal Circuitry
354
Transistor Checking
354
Removing Ignition Switch Nut
355
Setting Spark Plug Gap
355
Spark Plugs Cleaning and Regapping
355
Unlocking Ignition Switch Connector
355
Resistance Checks
357
Starter Circuit General Description
357
Starter Circuit Maintenance and Adjustments
357
Starting Motor Cross Section
357
Starter Mounting
358
Starting Circuit Diagram
358
Starting Motor and Solenoid Check
358
Starting Motor Removal and Installation
358
Clutch and Transmissions
360
Clutch General Description
360
Clutch Maintenance and Adjustments
360
Linkage Inspection
360
Chevelle Clutch Pedal Free Travel Adjustment
361
Clutch Linkage Adjustment
361
Chevy II Clutch Pedal Free Travel Adjustment
362
Clutch Assembly
362
Clutch Component Parts Replacement
362
Clutch Pedal Free Travel Adjustment
362
Clutch Cross Shaft
363
Clutch Pedal
363
Release Bearing Lubrication and Comparison
363
Lower Linkage Details
364
Corvette Lower Linkage Details
365
Three-Speed (Saginaw Fully Synchronized) Transmission
365
Chevrolet, Chevelle, Chevy II, Camaro Shift Linkage Adjustment
366
Clutch and Transmissions Maintenance and Adjustments
366
Extension Oil Seal Replacement
366
Floor Shift Linkage Adjustment
366
Shift Control Lever and Bracket Assembly
366
Speedometer Driven Gear
366
Component Part Replacement
367
Transmission Replacement (Exc. Corvette)
367
Transmission Side Cover
367
Corvette Transmission Replacement
368
Transmission Overdrive
368
Case Rear Oil Seal
369
General Description
369
Governor Switch and Pinion
369
Servicing the Overdrive
369
Sun Gear Solenoid, Oil Seal and Control Cable Bracket
369
Adjusting Relay Point Opening
370
Electrical Unit Checks
370
Ignition Grounding Contact
370
Overdrive Relay
370
Diagnosis - Overdrive
371
Overdrive Electrical Circuit Wiring Diagram
372
Side Cover Assembly
373
Three-Speed Heavy Duty Transmission (Warner Model T 16)
373
Side Cover Assembly - Layout
374
Warner T-16 3-Speed Lever and Linkage Adjustment
374
Corvette and Camaro Shift Linkage Adjustment
375
Four-Speed Transmission (Muncie)
375
Shift Linkage Adjustment
375
Four-Speed (Muncie) Transmission Gearshift Linkage
376
Gear Shift Lever Reverse Blocker Cable
376
Extension Oil Seal
378
Speedometer Driven Gear and Oil Seal
378
Four-Speed (Saginaw) Transmission
379
Transmission Replacement
379
Shift Linkage Adjustment (Camaro and Corvette)
380
Shift Linkage Adjustment (Chevrolet & Chevelle)
380
Shift Linkage Adjustment (Chevy II)
380
Aluminum Powerglide
382
Manual Shift Linkage Check & Adjust
383
Periodic Low Band Adjustment
383
Periodic Oil Change
383
Chevrolet Shift Linkage Adjustments
384
Floor Shift Linkage
384
Camaro Linkage Adjustment
386
Camaro Shift Linkage Adjustment
386
Chevy II Linkage Adjustment
386
Corvette Powerglide Control Lever and Bracket Assembly
388
Floor Mounted Control Lever and Bracket Assembly
388
Throttle Valve Linkage Adjustment
388
Neutral Safety Switch Adjustment
389
Throttle Return Check Valve Adjustment
389
Converter Holding Tool
390
Corvette Powerglide Transmission
390
Checking Fluid Level and Condition
391
Diagnosis
391
Manual Linkage
391
Warming up Transmission
391
Basic Pressure Checks
392
Oil Leaks
392
Pressure Test Plug
392
Powerglide Basic Pressure (Mainline) Check Chart
393
1967 Shift Points - Powerglide
394
Turbo Hydra-Matic Transmission
395
Turbo Hydra-Matic Diagnosis Procedure
400
Case Porosity - Repair
401
Oil Pressure Check
401
Turbo Hydra-Matic Shift Points
401
Clutch Special Tools
402
Manual Transmission Special Tools
403
Aluminum Powerglide Special Tools
404
Turbo Hydra-Matic Special Tools
405
Fuel Tank and Exhaust Systems
407
Draining Fuel Tank
408
Fuel Lines
408
Siphon Construction
408
Fuel Tank Removal and Installation
409
Gauge Unit Assembly
409
Fuel Tank Vent Line
410
Gauge Unit and Fuel Strainer
410
Exhaust Pipe
411
Exhaust Systems
411
Muffler Assembly
411
Tail Pipe And/Or Resonator
411
Single Exhaust Systems
412
Dual Exhaust Systems
413
Fuel Pipe Retainer Clip
414
Fuel Tanks Component Part Replacement
414
Fuel Tanks General Description
414
Filler Neck and Vent Assemblies
415
Installing Fuel Line Retainer Clip
415
Fuel Tank Gauge Unit Removal
416
Chevy II Fuel Tanks
419
Corvette Fuel Tank
424
Camaro
433
Standard Steering
441
Steering
441
Steering Gear Adjustment Points
442
Adjusting Steering Ratio - Corvette
443
Checking Wheel Pull - Corvette
443
Steering Wheel Alignment
443
Regular Wheel and Horn Attachments
444
Steering Wheel Regular Production
444
Corvette Telescoping
445
Removing Steering Wheel with J-2927
445
Simulated Wood
445
Steering Column Wiring Connector
445
Corvette Telescoping Wheel Option
446
Steering Coupling
446
Removing or Installing Dash Panel Covers and Seal
447
Steering Column Escutcheon
447
Powerglide Indicator Connection
448
Steering Coupling Clearance Adjustment
448
Steering Gear - Chevrolet, Chevelle, Camaro and Corvette
449
Mast Jacket Cover Attachments - Chevy II
450
Sector Shaft Seal Replacement
450
Steering Column
450
Steering Column to Dash Panel
451
Synchromesh Steering Column - Exploded View
452
Column Secured in Bench Vice
453
Removing or Installing "C" Ring Retainer
453
Removing Wiring Protector
453
Upper Bearing Preload Spring and Cancelling Cam
453
Bottoming Shift Levers Using Spanner Wrench J-22568
454
Removing Turn Signal Switch Cover from Column
454
Upper Shift Lever Spring and Bowl Washer
454
Column Mounted Powerglide Lever or Floor Shift Column - Exploded View
455
Disassembly - Column Mounted Powerglide Lever or Floor Shift Column
456
Powerglide Dial Indicator Assembly
456
Assembly - Column Mounted Powerglide Lever or Floor Shift Column
457
Shift Tube and Steering Shaft
457
Tolerance Ring Kit - First and Final Adjustment
457
Tilt Steering Column - Exploded View
458
Disassembly - Tilt Column
459
Assembly - Tilt Column
461
Disassembly - Standard Corvette Column
463
Standard Corvette Column - Exploded View
464
Assembly - Standard Corvette Column
465
Corvette Telescoping Column - Exploded View
466
Disassembly - Corvette Telescoping Column
466
Assembly - Corvette Telescoping Column
467
Removing Bumper Key Strap
467
Removing Lower Bearing Retaining Ring
467
Steering Linkage
469
Tie Rods
469
Freeing Ball Stud
471
Idler Arm
471
Relay Rod - All Models Except Corvette
471
Relay Rod - Corvette
471
Pitman Arm
472
Steering Arm
472
Steering Damper - Corvette
472
Power Steering General Description
473
Power Steering Maintenance and Adjustments
473
Hydraulic System Checks
474
Power Steering Gear
474
Pump Belt Tension
474
Power Steering Pump
475
Steering Component Replacement and Repairs
475
Control Valve and Adapter Assembly
476
Power Cylinder - Exploded View
477
Power Steering Hose Installation
478
Steering Special Tools
480
Wheels and Tires General Description
481
Wheels and Tires Maintenance and Adjustments
481
Tire Rotation
484
Tires Service Operations
485
Wheels Dynamic Balancing (W/Tire)
485
Wheels Run out (W/O Tire)
485
Wheels Static Balancing (W/Tire)
485
Tire Installation Safety Precautions
486
Valve Assembly
486
Wheels Service Operations
486
Chassis Sheet Metal
488
Hood Adjustment
488
Hood Bumpers
488
Hood Hinge
488
Front End Sheet Metal - Chevrolet
489
Front End Sheet Metal - Chevelle
490
Chassis Sheet Metal Component Part Replacement
491
Fenders
491
Radiator Support
491
Sheet Metal Adjustments
491
Fender Trim
492
Sheet Metal Adjustments - Chevrolet
492
Sheet Metal Adjustments - Chevelle
493
Cowl Vent Grille
494
Hood Catch and Lock
494
Hood Trim and Insulation
494
Rear Wheel Cover
494
Chevy II
498
Sheet Metal Adjustment - Chevy II
499
Front End Sheet Metal - Camaro
506
Electrical-Body and Chassis
513
Lighting System
513
Fuse Panel Assembly
514
Headlamp Adjustment - T-3 Headlamps
515
Horizontal Adjustment
515
How to Select a Level Aiming Area
516
To Compensate for Unlevel Floors
516
Vertical Adjustment
516
Electrical-Body and Chassis Service Operations
517
Front Lighting
517
Headlamp Panel Travel Adjustment
517
Parking Lamp Replacement
517
Fender Lamp Service
518
Headlamp Assemblies
518
Headlamp Panel Replacement - Corvette
520
Headlamp Motor Replacement
521
Headlamp Panel Motor
521
Bulb Replacement
522
Rear Lighting Service
522
Tail, Stop and Directional Lamps
522
Rear Lighting Composite
523
Backing and License Lamps
525
Cigarette Lighter Replacement
531
Instrument Panel Compartment Lamp/Switch Replacement
531
Parking Brake Alarm Switch Replacement
531
Chevrolet Instruments and Gauges General Description
533
Chevrolet Instruments and Gauges Service Operations
534
Instrument Cluster Lamp Replacement
534
Instrument Cluster Removal and Installation
534
Printed Circuit Replacement
534
Fuel Gauge Replacement
535
Instrument Cluster Connections
535
Speedometer Cable Replacement or Lubrication
535
Ammeter Temperature and Oil Pressure Gauges Replacement
536
Clock or Tachometer Replacement
536
Oil Pressure Indicator
536
Optional Gauge Cluster
536
Instrument Panel Wiring
537
Chevelle Instruments and Gauges General Description
538
Chevelle Instruments and Gauges Service Operations
538
Generator Indicator
538
Temperature (Cooling System) Indicator
538
Clock Replacement
539
Fuel Gauge And/Or Ammeter Replacement
539
Speedometer Cable
539
Speedometer Replacement
539
Instrument Cluster Assembly
540
Chevy II Instruments and Gauges
543
4. Gen Indicator
544
5. Temp Indicator
544
O I L " Indicator
544
Corvette Instruments and Gauges
546
Fuel Gauge Connector
546
Parking Brake Alarm Indicator
547
Camaro Instruments and Gauges
548
Cover
555
Windshield Wipers and Washers
556
Wiper Transmission Assembly
556
Wiper Motor Assembly
557
Non-Depressed Park Wiper
558
Wiper Motor and Gear Box Assembly
558
Windshield Washer Pump
560
Depressed Park 2-Speed Wiper Chevrolet General Description
561
Armature Removal
562
Brush Plate and Circuit Breaker Removal
562
Motor Section Disassembly
562
Case and Field Assembly Removal
563
Gear Box Section
566
B-Drive Gear Disassembly
567
Drive Gear - Assembly
567
Relay Switch - Latch and Terminal Board Assembly
567
Washer Pump Unit Removal and Installation
567
Depressed Park 2-Speed Wiper and Washer
568
Wiper Motor and Washer Pump Assembly
568
Wiper Assembly Repairs
569
Wiper Transmission Removal and Installation
569
Wiper Assembly Exploded View
570
B-Drive Gear Mechanism
571
Relay Control and Latching Mechanism
571
Washer Pump Assembly
572
Washer Pump Section
572
Front Lighting & Engine Compartment - Chevrolet
573
Fuse Panel - Chevrolet
574
Instrument Panel Cluster - Chevrolet
575
Body and Rear End Lighting (Exc Wagon) - Chevrolet
576
Body and Rear End Lighting (Wagon)
577
Front Lighting and Engine Compartment
578
Fuse Panel - Chevelle
579
Instrument Panel and Cluster - Chevelle
580
Body and Rear Lighting - Chevelle
581
Front Lighting & Engine Compartment - Chevy II
582
Fuse Panel - Chevy II
583
Instrument Panel and Cluster - Chevy II
584
Body and Rear Lighting - Chevy II
585
Front Lighting & Engine Compt - Corvette
586
Fuse Panel - Corvette
587
Instrument Panel and Cluster - Corvette
588
Body and Rear Lighting - Corvette
589
Front Lighting & Engine Compt - Camaro
590
Fuse Panel - Camaro
591
Instrument Panel and Cluster - Camaro
592
Body and Rear Lighting - Camaro
593
Radiator and Fan Shroud - Corvette
594
Radiator and Grille General Description
594
Radiator and Grille Service Operations
594
Radiator and Shroud - All Vehicles
594
Grille Assembly - Chevrolet
595
Plate
595
Radiator and Shroud - Chevrolet
595
Radiator and Shroud - Chevelle
596
Grille Assembly - Chevelle
596
Grille Assembly - Chevy II
597
Grille Assembly - Corvette
598
Grille Assembly - Camaro
598
Bumpers
602
Front Bumper Assembly
602
Rear Bumper Assembly
603
Rear License Plate Housing
608
Cruise Master System
610
Accessories
610
Component Operation
611
Engagement Switch
611
Brake Release Switches
612
Servo Unit
612
Regulator
613
Magnetic Speed Sensing Assembly
613
Vacuum Switch, Air Bleed and Filter, and Low Limit Speed Switch
614
Regulator Cross Section
614
Regulator Exploded View
615
Servo
617
Electrical System Check out
618
Engagement Switch Test
618
Servo and Vacuum System Check out
618
Cruise Master System Checks
619
Automatic Level Control General Description
620
Vacuum and Electrical Diagram
620
Heating and Air Conditioning Specifications
628
Front Suspension Specifications
628
Wheel Alignment Specifications
628
Bolt Torques
629
Riding Height Measurement
629
Rear Suspension Specifications
630
Brakes Specifications
632
Brakes Torque Chart
632
Engine Specifications
633
Engine Torques
638
Engine Mount Torque Chart
638
Tune up Chart
639
Generator Specifications
640
Engine Electrical Specifications
640
Battery Specifications
640
Regulator Specifications
641
Starting Motor Specifications
641
Distributors Specifications
642
Coil Specifications
643
Transmission and Clutch Specifications
644
Steering Specifications
646
Steering Torque Chart
647
Wheels and Tires Specifications
648
Tire Usage and Recommended Tire Inflation Pressures
648
Body and Chassis Electrical Specifications
652
Fuses and Circuit Breaker
653
Bumpers Specifications
655
Decimal Equivalents
657
Drill Sizes
658
Gages
659
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CHEVROLET 1962 Chevy II Wiring Diagram (50 pages)
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CHEVROLET
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Automobile
| Size: 17.46 MB
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