SECTION O
INFORMATION AND LUBRICATION
CONTENTS OF THIS SECTION
Page
General Information o-l
Lubrication 0-13
GENERAL INFORMATION
Model Identification and Vehicle Dimensions
Chevrolet
Chevelle
Chevy n
Corvette
Camaro
Page
0-1
0-1
0-2
0-2
0-3
0-3
Page
Unit and Serial Numbers o-3
Engine Number o-3
Vehicle Serial Number 0r3
Keys and Locks 0-4
Pushing,Towing and Lifting 0-7
Series
Biscayne
Bel Air
Tmpala.
Impala
Super Sport
Caprice
MODEL IDENTIFICATION-CHEVROLET
Model Number
6-Cyl
15311
15369
15335
15511,
15569
15535
15545
16387
16367
16369
16339
16335
16345
16787
16767
—
—
—
—
V-8
15411
15469
15435
15611
15669
15635
15645
16487
16467
16469
16439
16435
16445
16887
16867
16647
16639
16635
16645
Description
2-Door Sedan, 6-Passenger
4-Door Sedan, 6-Passenger
4-Door Station Wagon, 2-Seat
2-Door Sedan, 6-Passenger
4-Door Sedan, 6-Passenger
4-Door Station Wagon, 2-Seat
4-Door Station Wagon, 3-Seat
2-Door Sport Coupe, 5-Passenger
2-Door Convertible, 5-Passenger
4-Door Sedan, 6-Passenger
4-Door Sport Sedan, 6-Passenger
4-Door Station Wagon, 2-Seat
4-Door Station Wagon, 3-Seat
2-Door Sport Coupe, 4-Passenger
2-Door Convertible, 4-Passenger
2-Door Custom Coupe, 5-Passenger*
4-Door Custpm Sedan, 6-Passenger
4-Door Custom Wagon, 2-Seat
4-Door Custom Wagon, 3-Seat
*4-Passenger when optional bucket front seats are specified.
VEHICLE DIMENSIONS-CHEVROLET
Pertinent dimensions for the different models are shown in the following chart.
Model
Length Overall . .
Width Overall (Body)
Height Overall
Wheelbase
Tread-Front
Tread-Rear
Curb Weight: Approximately 3543 lbs.
Sedan
213.2"
79.6"
55.4"
119.0"
62.5"
62.4"
4-Door Sedan with
2-Door
Sport Coupe
213.2"
79.6"
54.4"
119.0"
62.5"
62.4"
L-6 Engine; 3685 lbs
Convertible
Coupe
213.2"
79.6"
55.3"
119.0"
62.5"
62.4"
. with V-8 Engine.
Station
Wagon
212.4"
79.6"
56.7"
119.0"
63.5"
63.4"
CHEVROLET CHASSIS SERVICE MANUAL
GENERAL INFORMATION 0-2
MODEL IDENTIFICATION-CHEVELLE
Series
Chevelle 300
Chevelle 300
Deluxe
Malibu
Super Sport
396
Concours
Model Number
6-Cyl
13111
13169
13311
13369
13335
13569
13539
13517
13567
13535
—
13735
V-8
13211
13269
13411
13469
13435
13669
13639
13617
13667
13635
13817
13867
13835
Description
2-Door -Sedan, 6-Passenger
4-Door Sedan, 6-Passenger
2-Door Sedan, 6-Passenger
4-Door Sedan, 6-Passenger
4-Door Station Wagon, 2-Seat
4-Door Sedan, 6-Passenger
4-Door Sport Sedan, 6-Passenger
2-Door Sport Coupe, 5-Passenger*
2-Door Convertible, 5-Passenger*
4-Door Station Wagon, 2-Seat
2-tooor Sport Coupe, 5-Passenger*
2-Door Convertible, 5-Passenger*
4-Door Station Wagon, 2-Seat
*4-Passenger when optional bucket seats are specified.
EL CAMINO
13380
13580
13480
13680
2-Door
Sedan
Pickup,
3-Passenger Reg.
2-Door
Sedan
Pickup,
3-Pass. Deluxe
VEHICLE DIMENSIONS-CHEVELLE
Pertinent dimensions for the different models are shown in, the following chart.
Model
Sedan
197.0"
75.0"
54.1"
115.0"
58.0"
58.0"
2-Door
Sport Coupe
197.0"
75.0"
53.2"
115.0"
58.0"
58J0"
Convertible
Coupe
197.0"
75.0"
53.9"
115.0"
58.0"
58.0"
Station
Wagon
199.9"
75.0"
56.7"
115.0"
58.0"
58.0"
Sedan
Pickup
199.9"
75.0"
56.7"
115.0"
58.0"
58.0"
Length Overall .
Width Overall (Body)
Height Overall . . .
Wheelbase. .
Tread-Front
Tread-Rear .
Curb Weight: Approximately 3104 lbs. 4-Door Sedan with L-6 Engine 3258 lbs. with V-8 Engine.
MODEL IDENTIFICATION-CHEVY II
Series
100
NOVA
NOVA SS
Model Number
L-4
11111
11169
mmm.
—
6 Cyl.
11311
11369
11335
11569
11537
11535
11737
V-8
11411
11469
11435
11669
11637
11635
11837
Description
2-Door Sedan, 6-Passenger
4-Door Sedan, 6-Passenger
4-Door Station Wagon, 2-Seat
4-Door Sedan, 6-Passenger
2-Door Sport Coupe, 5-Passenger
4-Door Station Wagon, 2-Seat
2-Door Sport Coupe, 4-Passenger
CHEVROLET CHASSIS SERVICE MANUAL
GENERAL INFORMATION 0-3
VEHICLE DIMENSIONS-CHEVY II
Model
Length Overall
Width Overall (Body) . . . .
Height Overall
Wheelbase
Tread-Front
Tread-Rear . . .
Sedan
183.0"
71.3"
56.7"
110.0"
56.8"
56.3"
2-Door
Sport Coupe
183.0"
71.3"
54.4"
110.0"
56.8"
56.3"
Station
Wagon
187.4"
71.3"
57.6"
110.0"
56.3"
55.8"
Curb Weight: Approximately 2668 lbs. 4-Door Sedan with L-4 Engine; 2767
lbs.
with L-6 Engine; 2959lbs.
with V-8 Engine.
MODEL IDENTIFICATION-CAMARO
VEHICLE DIMENSIONS-CORVEnE
Model Number
6-Cyl
12337
12367
V-8
12437
12467
Description
2-Door Sport Coupe, 4-Passenger
2-Door Convertible, 4-Passenger
VEHICLE DIMENSIONS-CAMARO
Model
Length Overall .....
Width Overall (Body) . .
Height Overall
Wheelbase
Tread-Front
Tread-Rear
Sport Coupe
Convertible
184.7"
72.6"
50:8"
108.0"
59.0"
58.88"
Weight: Sport Coupe with L6 Engine 2908 lbs.; with
V-8 Engine 3063 lbs.
MODEL IDENTIFICATION-CORVETTE
Model
Number
19437
19467
Description
2-Door Sport Coupe, 2-Passenger
2-Door Convertible, 2-Passenger
UNIT AND SERIAL NUMBER LOCATIONS
For the convenience of servicemen when writing up
certain business papers, such as L. & M.R.'s Product
Information Reports, or reporting product failures in
any way, we are showing below the location of various
unit numbers. These unit numbers and their prefixes
and suffixes are necessary on these papers for various
reasons—such as accounting, follow-up on production,
etc.
Model
Length Overall
Width Overall (Body). . .
Height Overall.
Wheelbase
Tread-Front
Tread-Rear .
Convertible
Sport
Coupe
175.1"
69.6"
49.8"
49.6"
98.0"
56.8"
57.6"
Curb Weight: 3145 lbs. Convertible
3135 lbs. Sport Coupe
with Base V-8
The prefixes on certain units identify the plant in which
the unit was manufactured, and thereby permits proper
follow-up of the plant involved to get corrections made
when necessary.
Engine Unit Number
The engine unit number (figs. 3 and 4) shows manu-
facturing plant, month and day of manufacture, and
transmission type. A typical engine number would be
F1210FA, which would breakdown thus:
F~Manufacturing Plant (F—Flint, T—Tonawanda)
12—Month of manufacture (December)
10—Day of manufacture (tenth)
FA—Transmission and engine type
Vehicle Serial Number
A typical vehicle serial number tag (fig. 1) yields
manufacturers identity, vehicle type, model year, as-
sembly plant and production unit number when broken
down as shown in the following chart.
Manufacturer
Identity1
1
Body
Style2
5645
Model
Year8
7
Assembly
Plant*
F
Unit
Number5
100025
CHEVROLET CHASSIS SERVICE /MANUAL
CORVETTE BODY 1B-27
CUT OFF PAINTED
PORTION OF CARTRIDGE NOZZLE
ALONG EDGE-OF PAINT LINE
ADHESIVE CAULKING
MATERIAL
Fig.
60—Applying Caulking Material to Glass
GARNISH MOLDINGS PLUS HEADLINER-
19437 MODEL
Figure 64 illustrates installation details of garnish
moldings and headlining.
Headlining is not cemented in place.
Removal of dome lamp and garnish moldings is
necessary.
J-NUT
FILLER PANEL
BODY REAR
Fig.
61—Installing Rear Glass
Fig.
62—Gas Tank Door and Rear Trim Plate
SEATS
Removal
1.
Remove bolt retaining each forward support to floor.
2.
Fold seat back forward.
3.
Loosen two bolts retaining each seat hold-down
bracket.
4.
Move seat forward and out of brackets.
Adjustments
Height of seats is adjustable at both front and rear by
means of shims or washers.
Angle of seat backrest may be changed by adjusting
stops located on lower edge of seat back.
BODY MOUNTING
Figure 65 illustrates underbody attachment-to-frame
body mounting brackets. Shims which are shown on
rear crossmember are cemented in place.
The torque of all body mounting bolts should be checked
periodically as an aid to preventing annoying squeaks
and rattles. AH bolts shown in Figure 65 should be
torqued to 45 lbs. ft.
BODY REPAIRS
GENERAL INSTRUCTIONS
The following gives information necessary for repair
of collision damage and performance of general main-
tenance on both the 19437 and 19467 Corvette bodies.
Included here is information dealing with availability of
repair panels, general installation procedures for in-
staUing panels and repairing damage to the body.
Repair of fiber glass reinforced plastic bodies is a
relatively easy matter if a few simple precautions are
observed.
In cases where welding must be done on steel parts
which are stiU installed on body, do not allow flame or
direct welding heat to come into direct contact with
CHEVROLET CHASSIS SERVICE MANUAL
FRONT SUSPENSION 3-5
FRONT END ALIGNMENT
Front end alignment, that is alignment of the inter-
related steering components of the front suspension sys-
tem, must be correctly maintained to assure ease and
stability of steering and satisfactory tire life.
Alignment Preliminary Steps
Several different types of machines are available for
checking all the factors of front end alignment. The in-
structions furnished with each particular machine should
be followed. In all cases, however, checks should be
made with the vehicle level and at curb weight.
Since steering complaints are not always the result of
improper alignment a check should be made to see if any
of the following conditions exist. Any such conditions
should be corrected before proceeding further.
1.
Steering gear loose or improperly adjusted.
2.
Steering gear housing loose at frame.
3.
Excessive wear or play in spherical joints or steer-
ing shaft coupling.
4.
Tie rod or steering connections loose.
5.
Improper front spring heights.
6. Unbalanced or underinflated tires.
7.
Improperly adjusted wheel bearings.
8. Shock absorbers not operating properly.
Wheel alignment should always be made with the vehi-
cle rolled forward taking out any slack in the same man-
ner as when the vehicle is traveling forward.
Caster and Camber Adjustment
NOTE: Before adjusting caster and camber
angles, the front bumper should be raised and
quickly released to allow car to return to its
normal height.
Chevelle, Camaro and Corvette
Caster and camber adjustments are made by means of
shims inserted between the upper control arm inner sup-
port shaft and the support bracket attached to the frame
(fig. 6). Shims may be added, subtracted or transferred
to change the readings as follows:
Fig.
6 - Caster and Camber Adjustment - Chevelle
Typical of Corvette and Camaro
Caster - change shims at either the front or rear of
the shaft.
The addition of shims at the front bolt or removal
of shims at the rear bolt will decrease positive
caster. One shim (1/3 2") will change caster (ap-
prox.) 1/4°.
Camber - change shims at both the front and rear of
the shaft.
Adding an equal number of shims at both front and
rear of the support shaft will decrease positive cam-
ber. One shim (1/32") at each location will move
camber (approx.) 1/5° (Chevelle and Camaro); 1/6°
(Corvette).
TIGHTEN TO LOCK
ADJUSTMENT
Fig.
7 - Caster and Camber Adjustment Points - Chevrolet
CHEVROLET CHASSIS SERVICE MANUAL
FRONT SUSPENSION 3-6
Fig.
8 - Caster and Camber Adjustments - Chevy
To adjust for caster and camber, loosen the upper sup-
port shaft to crossmember nuts, add or subtract shims as
required and retighten nuts.
NOTE:
Caster and camber can be adjusted in
one operation.
Caster and camber specifications will be found in the
last section of this book.
Chevrolet and Chevy II
The caster angle is adjusted by turning the two niits at
the front of the lower control arm strut rod (figs. 7 and
8).
Shortening this rod will increase caster. Lengthen-
ing will decrease caster.
Camber angle is adjusted by loosening the lower con-
trol arm pivot bolt and rotating the cam located on this
pivot. This eccentric cam action will move lower control
arm in or out, thereby varying camber.
Steering Axis Inclination Adjustment
"Camber" is the outward tilt of the wheel and "steering
axis inclination" is the inward tilt of the knuckle. Cam-
ber cannot be changed without changing steering axis
inclination. Correct specifications willbe found at the
end of this section. If, with the camber correctly ad-
justed, the steering axis inclination does not fall within
the specified limits the knuckle is bent and should be
replaced.
If a new knuckle is installed, caster, camber and toe-in
must be readjusted.
Toe-In Adjustment
Toe-in, the inward pointing of both front wheels, is
checked with the wheels in the straight ahead position. It
is the difference of the distance measured between the
extreme front and the distance measured between the ex-
treme rear of both front wheels. Correct toe-in specifi-
cations will be found at the end of this section.
NOTE:
Toe-in must be adjusted after caster
and camber adjustment.
A. If the equipment being used measures the toe-in of
each wheel individually:
1.
Set the steering gear on the high point, mark 12
o'clock position on the steering shaft and position
the steering wheel for straight ahead driving.
2.
Loosen the clamp bolt at each end of each tie rod
and adjust to the total toe-in as given in the speci-
fications at the end of this book.
B.
If a tram gauge is being used, proceed as follows:
1.
Set the front wheels in the straight ahead position.
2.
Loosen the clamp bolts on one tie rod and adjust
for the proper toe-in as given in the specifications
at the end of this book.
3.
Loosen the clamp bolts on the other tie rod. Turn
both rods the same amount and in the same direc-
tion to place the steering gear on its high point and
position the steering wheel in its straight ahead
position.
C.
After the adjustment has been made:
1.
a. Chevrolet—Position inner tie rod clamp bosses
forward to 90° down to avoid stabilizer link bolt
interference.
b.
Chevelle—Position the tie rod clamp bosses
down to 45?° forward to avoid interference.
c. Chevy II--Position the outer tie rod clamp
bosses forward and not more than 45° up or
down from horizontal to avoid interference.
Inner clamps forward and vertical.
d. Corvette--Position inner tie rod clamps with
bolt horizontal and down. Position outer clamps
with bolt vertical and to the rear.
e. Camaro—Position inner tie rod clamps with
open end of clamp and slot in line. Position
relative to ground unimportant. Position outer
clamps with bolt top and 30° either side of ver-
tical. Position relative to slot unimportant.
RIDING HEIGHT AND COIL SPRING SAG
The following check will quickly determine whether or
CHEVROLET CHASSIS SERVICE MANUAL
FRONT SUSPENSION 3-7
CAMARO
CHEVROLET
AND
CORVETTE
LOWER
CONTROL
ARM
CHEVELLE
CHEVY
II
Fig.
9- Checking Riding Height
not the vehicle riding height is correct.
1.
Place the vehicle on a smooth, level floor and bounce
and rock the front end several times. Raise vehicle,
then allow it to settle to a normal height.
2.
Measure the following two distances (fig. 9):
a. From the floor to the center of the inner pivot of
the lower control arm. (On the Chevrolet and
Camaro, this measurement must be made at the
rear end of the pivot.)
b.
Chevrolet--Measure the distance from the floor
to the lower face of the lower steering knuckle
boss for the spherical joint on the same side of
the vehicle.
Chevelle—From the floor to the outer pivot
which is located 1/8" (.12) inboard from the ball
stud boss at the lower surface of the arm.
Chevy II--Measure the distance from the floor
to the lower ball joint seat.
Corvette—Measure the distance from the floor
to the lower face of the lower steering knuckle
boss for the spherical joint on the same side of
the vehicle.
Camaro—From the floor to the lower inboard
edge of ball seat.
3.
The difference between these two measurements
should be as outlined in the Specifications given at
the end of the book with the vehicle at curb weight
(full tank of gas, spare tire and jack in trunk, no
passengers).
4.
Measure the opposite side of the vehicle in the same
manner. The measurements for both sides should
differ no more than 1/2".
5. To correct the height, springs must be replaced.
These springs do not have flat ends and shims should
not be used.
CHEVROLET CHASSIS SERVICE MANUAL
FRONT SUSPENSION 3-9
Inspection
1.
Check bearings for cracked separators or worn or
pitted rollers and races.
2.
Check brake drum for
out-of-
round or scoring.
3.
Check fit of bearing outer cups in hub.
Repairs
Replacement of Bearing Cups
1.
Using steel bar stock, make press-out tools shown in
Figure 11.
2.
Insert removers through hub, indexing ends into slots
in hub shoulder behind bearing cup.
3.
Using a suitable extension pipe or rod, press bearing
cups from hub.
4.
Install new bearing cup in hub using Tool J-8849 on
the outer and Tool J-8850 on the inner cup (fig. 12).
Use Driver Handle J-8092 with the installers. Make
sure that the bearing cups are not cocked and are
fully seated against shoulder in hub.
Installation
1.
Pack both inner and. outer bearings using a high
melting point wheel bearing lubricant.
2.
Place inner bearing in hub, then install a new inner
bearing lip seal assembly. Seal flange should face
bearing cup.
3.
Carefully install wheel hub over steering spindle.
4.
Install outer bearing, pressing it firmly into the hub
by hand.
5.
Install spindle washer and adjusting nut. Draw up
tight and adjust wheel bearings as outlined under
"Front Wheel Bearing Adjustment".
STEERING KNUCKLE
Chevrolet, Chevelle, Camaro and Corvette—It is rec-
ommended that vehicle be raised and supported on a
twin-post hoist so that the front coil spring remains com-
pressed, yet the wheel and steering knuckle assembly re-
main accessible. If a frame hoist is used, support lower
control arm with an adjustable jackstand to safely retain
spring in its curb height position.
Chevy n— While vehicle weight is still on front wheels,
position support between upper control arm and frame
side rail (fig. 13), then raise vehicle and position adjust-
able jackstand under lower control arm.
Removal
1.
Raise vehicle and support lower control arm as noted
above.
2.
Remove hub cap, wheel hub dust cover, cotter pin,
adjusting nut and washer. Withdraw wheel and tire,
brake drum, (or, on Corvette--brake caliper and disc
and hub assembly, See Section 5) and wheel hub and
bearing assembly from steering knuckle spindle.
3.
Remove brake shoes from backing plate (except
Corvette, See Section 5) and clamp wheel cylinder.
CAUTION: Keep brake shoes clean and dry.
4.
Remove brake anchor pin and two bolts securing
brake backing plate and steering arm to steering
knuckle.
5.
Withdraw steering arm and brake backing plate from
steering knuckle. Wire backing plate to frame (fig.
13).
Do not disconnect brake line.
NOTE: Refer to Section 9 - Steering Linkage -
Tie Rod, for further steering arm service
operations.
6. Remove upper and lower ball stud cotter pins and re-
move ball stud nuts. Free steering knuckle from
ball studs by rapping steering knuckle bosses. With-
draw steering knuckle.
Installation
1.
Place steering knuckle in position and insert upper
and lower ball studs into knuckle bosses.
2.
Install ball stud nuts and tighten nut as shown in the
specifications at the end of this section.
Fig.
12 - Installing Front Hub Inner Bearing
Fig.
13 - Backing Plate Removed - Chevy II
CHEVROLET CHASSIS SERVICE MANUAL