1967 CHEVROLET CAMARO fuel tank removal

FUEL TANK
AND
EXHAUST SYSTEMS
8-13

CHEVY II

FUEL TANKS

INDEX

Page

Page

General Description.
8-13

Component Part Replacement
8-13

Fuel Tanks
8-13

Fuel Lines
8-14
Metering Units (Gauge Sending Unit)
8-13

Fuel Tank Filler- Neck Caps.
. . 8-14

Fuel Tank Vent Lines .......
8-14

GENERAL DESCRIPTION

ANTI-SQUEAK

MA'
ANTI-SQUEAK

MATERIAL

SEDANS

STATION WAGON

Fig.
15-Chevy
II
Fuel Tanks

All Chevy
II
Models have
16
gallon capacity (approx.)

fuel tanks mounted between
the
frame rails
to the
rear
of

the rear axle
(fig. 15). The
fuel tanks
are
basically
the

same
for the
passenger
car
and two-seat,
six
passenger

station wagon models. The tanks
are
held
in
place
by two

metal straps attached individually
to the
underbody
at

each
end. The
straps hinge
at the
forward
end
and secure

the tank
at the
rear with
an
adjustable bolt and nut
ad-

sembly. The tank rests against the rear compartment
pan

reinforcement.
The
two-seat station wagon
gas
tank
is

secured
to the
contour
of
forward
and
rear underbody
brackets.
The
filler neck
is
accessible
by
removal
of a

fender
gas cap at the
rear left fender location.

A fine mesh screen
is
located
at the end of the
fuel

pickup pipe
to
prevent
the
entrance
of
dirt into
the sys-

tem.
The
tank
can be
drained
by
siphoning
at the
filler

neck
or by
removing
the
gauge sending unit and siphon-

ing
at the
tank opening.

CAUTION: Care should
be
exercised
to
avoid

denting
or
puncturing
the
fuel tank when
in-

stalling
or
removing.
~

COMPONENT PART REPLACEMENT

FUEL TANKS

Draining Tank

The absence
of a
drain plug
in
the Chevy
n
Model
gas

tanks makes
it
necessary
to
siphon fuel from
the
tank

when draining
is
needed. Refer
to the
recommended

draining procedures previously outlined under Chevrolet

Models
in
this section.

Removal
and
Installation

1.
Drain fuel tank.

2.
Raise
and
support vehicle.

3.
Disconnect
the
filler neck inlet hose
and the
vent

connection
(fig. 15).

4.
Remove
the gas
tank sending gauge unit access hole

cover
on
station wagons.
5. Disconnect fuel tank gauge sending unit with special

spanner Tool J-8950, detach wire
and
fuel pickup

line
at the gas
tank.

6. Remove tank support straps and lower tank carefully.

7. Reverse procedure
to
install.

The sending units
are
located on
the top
forward
end of

the
gas
tanks.
The
fuel strainer
is
located
at the end of

these sending units.

FUEL TANK GAUGE SENDING UNIT

AND FUEL STRAINER
(Fig. 16)

Replacement

1.
Drain tank
to a
level below
the
unit.

2.
Disconnect fuel pickup line
and
gauge unit wire.

3.
Use
special Tool J-8950
to
remove
cam
lock.
Re-

move unit and rubber gasket.

CHEVROLET CHASSIS SERVICE MANUAL

FUEL TANK
AND
EXHAUST SYSTEMS
8-18

CORVETTE

FUEL TANK

INDEX

Page

General Description.
. 8-18

Service Operations
8-18

Fuel Tank
8-18

Gauge Sending Unit
8-20

Fuel Lines.
8-20

GENERAL DESCRIPTION

20 GALLON TANK

Fig.
21
—Corvette Fuel Tanks

The Corvette
is
equipped with
a
standard
20
gallon

(approx.) tank
or an RPO 36
gallon (approx.) fiberglass

tank
(fig. 21). The
tanks
are
installed
at the
very rear

of
the
vehicle, convenient
for
direct fuel filling into
the

tank.
The
tanks
are
held
in
place
by
two metal straps
at-

tached individually
to a
removable
gas
tank frame
sup-

port.
Two
guides
at the end of
the straps
are
adjustable

for securing
the
straps onto
the
tank support. The tank

support
is
secured
to the
frame rail with flat washers,

lockwashers, bolts
and
nuts.
The
tanks' rest
on six
felt

anti-squeak pads.
One pad
centers
on the
rear frame

crossmember
and one at
each side
on the
same cross-

member.
At the
same rear location two pads
are
placed

on
the
tank
at the
metal support strap (rear) attachment
location
and
another anti-squeak
pad
cemented
on the

support
at
the front
of
the tank.

The fuel tanks
are
equipped with
a gas
gauge metering

unit,
a
fuel pickup, fuel strainer
and
vent line.
If it be-

comes necessary,
the
tank
can be
completely drained
by

removing
the
fuel pickup hose which
is
located
at
the
bot-

tom
of the
tank,
or
by removing the metering
for
quicker

draining.

A pressure vacuum type, positive vented design
cap,

conforming
to
I.C.C. regulations,
is
used on both regular

production
and
optional fuel tanks.
The cap is
inter-

changeable with past model tanks
for
service replace-

ment purposes.

SERVICE OPERATIONS

FUEL TANK

CAUTION:
IF THE GAS
TANK SHOULD
BE

REMOVED
AND
INSTALLED, CARE SHOULD

BE EXERCISED
TO
AVOID PUNCTURING,

DROPPING
OR
DENTING
THE GAS
TANK.

Removal
(20
Gallon Tank)

WARNING: FIRST REMOVE BATTERY

CABLE.
1.
Remove
the
spare tire from tire carrier.

2.
Remove spare tire carrier bolted attachments
and

carrier
(fig. 22).

3.
Remove
the "U"
bolt attachments
at
both rear tail

pipe
(See
Figure
23).

4.
Separate
the
exhaust system
at
the transmission sup-

port crossmember
by
loosening
the "U"
bolt nuts.

5. Remove both rear muffler brackets from
the
frame

and slide
the
muffler system rearward.

CHEVROLET CHASSIS SERVICE MANUAL

FUEL TANK AND EXHAUST SYSTEMS 8-20

4.
Attach the retaining straps with strap guide attached

to the fuel tank support, and secure with-the nut and

lockwasher assembly.

5. Connect the filler neck boot to the drain hose of the

tank and install boot around filler neck,

6. Connect the fuel pickup line, ground wire and make

certain that the fuel drain line is flush to 1/2" in-

board of the rear bumper opening.

7. Attach tank metering unit wires (fig. 25).

8. Replace fuel in tank. Replace gas cap.

9. Check for possible leaks.

10.
Reconnect the exhaust system by reversing the above

removal procedures (see "Exhaust System").

11.
Install spare tire carrier by securing the bolt

attachment.

12.
Install the spare tire in the tire carrier.

Removal (36 Gallon Tank)

1.
Remove cover (fig. 26).

2.
Disconnect hoses and drain tank and remove two

fittings at bottom of tank.

3.
Disconnect fuel and vent lines and wires at tank

(fig. 27).

4.
Remove straps.

installation (36 Gallon Tank)

Reverse removal procedure to install.

FUEL TANK METERING UNIT OR GAUGE

SENDING UNIT AND STRAINER

The fuel tank metering unit is located at the bottom of

the fuel tank. The fuel strainer is attached at the end of

the sending unit inside the tank.

Replacement (20 Gallon Tank)

1.
Follow fuel tank removal procedure through Step 2.

2.
Drain the tank. Disconnect the attaching wires.

3.
Remove metering unit with a fuel tank gauge unit

Spanner J-8950 (revised).

4.
'Remove metering unit and gasket.

CAUTION: Carefully remove unit so as not to

damage screen on the end of the pipe.

5. Clean strainer screen by blowing out with com-

pressed air.

6. Reverse procedure to install.

Replacement (36 Gallon Tank)

1.
Remove cover.

2.
Follow Steps 2 thru 6 as outlined under replacement

for 20 gallon tank.

FUEL LINES

20 Gallon Tank

The fuel lines are conveniently located along the out-

side of the right frame rail (fig. 28). The lines extend
Fig.
26—Gasoline Tank (36 Gallon) Compartment Cover

from the fuel tank pickup at the bottom of the tank, along

the rear frame crossmember to the right frame rail,

extending through the rail at the kickup area and along the

top inside edge of the frame to the fuel pump, Flexible

hoses are located at the fuel tank pickup and at the fuel

pump.

36 Gallon Tank

The 36 gallon tank fuel lines are routed from the bot-

tom of both sides of the tank to the right frame rail

(fig. 20).

Maintenance

CAUTION: Always drain gasoline from the

complete fuel system including carburetor, fuel

pump and all fuel lines and fuel tank if the vehi-

cle is to be stored for any great length of time.

This precaution will prevent accumulation~ol

gum formation and resultant poor engine

performance.

. The fuel lines should occasionally be inspected for

leaks,
kinks or dents, especially when work has been

done on the underside of car or after the car has been

traveling over rough or stone roads at higher speeds.

If evidence of dirt is found in the carburetor or fuel pump

at disassembly, the lines should be disconnected and

blown put. Check the fuel tank strainer for damage or

omission.

Fuel lines are beaded-type ends for connection to

hoses and flared ends for secure metal-to-metal line

connections.

CHEVROLET CHASSIS SERVICE MANUAL

FUEL TANK AND EXHAUST SYSTEMS 8-28

assembly is mounted on top of the tank and cannot be

removed for service without lowering the tank. The

upper filler neck assembly is routed through an opening

in the rear panel above the bumper and through the trunk

floor pan (fig. 33). The filler neck is not centered in the

rear panel but offset to the right to obtain the proper fill

rate.

The fuel pickup pipe is an integral part of the tank

meter unit^ located at the top front center of the tank. A

fine mesh screen is located at the bottom end of the fuel

pickup pipe to prevent the entrance of foreign material

into the fuel system.

Fig.
33—Filler Neck Assembly

COMPONENT PART REPLACEMENT

FUEL TANK

Draining Tank

Refer to Chevrolet page 8-2.

Removal and Installation

1.
Drain fuel tank. .'...' .

2.
Raise vehicle.

3.
Disconnect fuel pickup line, gauge wire and ground

lead from tank unit.

4.
Loosen filler neck inlet hose clamp.

5. Remove tank support strap bolts and straps, then

lower tank carefully.

6. Reverse procedure to install.

FUEL TANK GAUGE SENDING UNIT (Fig. 34)

Replacement

1.
Remove fuel tank.

2.
Remove cam lock using special Tool J-8950.

3.
Remove meter unit and rubber gasket.

CAUTION: Carefully remove unit so as not to

damage screen on end of pipe.

4.
Clean screen by blowing out with compressed air.

5. Reverse removal procedure to install.
FUEL LINES (Fig. 35)

The gasoline lines extending from fuel tank to fuel

pump,
are routed on the underside of the underbody, on

the right side, opposite the single exhaust system. The

lines extend from the fuel tank to the right side of the

engine to the fuel pump and over the front of the engine

to the carburetor.

Maintenance

CAUTION:

plete fuel
Always drain gasoline from corn-

including carburetor, fuel

pump and
fuel lines and fuel tank if the

vehicle is to be stored for any
eciable

length of time. This precaution will prevent

accumulation of gum formation and resultant

poor engine performance.

The fuel lines should occasionally be inspected for

leaks,
kinks, or dents. If evidence of dirt is found in the

carburetor or fuel pump disassembly, the lines should be

disconnected and blown out. Check the fuel tank strainer

for damage or omission. Fuel lines are of 5/16" diameter

tubing for regular installation with beaded-type ends for

connections to hoses and flared ends for secure line

connections.

CHEVROLET CHASSIS SERVICE MANUAL

ELECTRICAL-BODY AND CHASSIS 12-35

SERVICE OPERATIONS

INSTRUMENT CLUSTER

REMOVAL AND INSTALLATION (Fig. 49)

1.
Remove mast jacket assembly. Refer to Section 9

for removal procedures.

2.
Disconnect tachometer drive cable at distributor.

3.
Disconnect the headlamp panel control switch from

instrument cluster.

4.
Remove lighting switch as outlined in this section.

10 10-A 1112 13

14
15 16 17 18 19

Fig.
49- Instrument Cluster Connections

1.
Cluster Illuminating

Bulbs

2.
Direction Signal Indicator

Bulb L.H.

3. Direction Signal Indicator

BulbR.H.

4.
Headlamp Actuating Motor

Indicator

5. Headlamp Hi Beam

Indicator

6. Parking Brake Alarm

Indicator

7. Ground Lead Attaching

Point

8. Temperature Indicator
"1"

Terminal
9.

10.

10A.

11.

12.

13.

14.

]5.

16.

17.

18.

19.

20.

21.
Temperature Indicator "S"

Terminal

Ignition Switch Receptacle

ignition Switch Illuminating

Bulb

Oil Pressure Indicator

Tachometer

Lighter Receptacle

Trip Odometer

Wiper Switch Receptacle

Speedometer

Ammeter "Gen" Terminal

Ammeter "Battery" Terminal

Lighting Switch Receptacle

Fuel Gauge
"1"
Terminal

Fuel Gauge "S" Terminal

5. Remove the ignition switch. Refer to Section 6Y

for removal procedure. Then disconnect ignition

switch lamp support at instrument panel.

6. Disconnect oil pressure line at oil pressure gauge

then remove the lead wires from ammeter, wiper

switch and cigarette lighter. Disconnect trip odom-

eter at mast jacket support.

7. Remove the instrument cluster-to-dash retaining

screws and pull cluster assembly slightly forward

to obtain clearance for removal of speedometer

cable, tachometer cable, cluster ground wire, fuel

gauge lead wires and remaining indicator and cluster

illuminating lamps.

8. To install cluster in dash panel, reverse removal

procedure.

FUEL GAUGE

The gasoline fuel gauge circuit consists of an electri-
cal indicator in the instrument cluster and a float-

controlled rheostat in the fuel tank.

Since the fuel gauge consists of two remotely located

units and connecting wires, it is sometimes difficult to

determine which unit is at fault when the gauge fails to

operate properly. Cluster removal is necessary to re-

place the fuel gauge.

NOTE:
Be sure to check gas gauge fuse in fuse

panel before attempting to trouble shoot for

inoperative gauge or tank sending unit.

SPEEDOMETER AND/OR TACHOMETER

Removal and Installation

Cluster must be removed from vehicle to service

speedometer head assembly (see Cluster Removal pro-

cedure)
.
With cluster removed from vehicle:

1.
Remove five screws securing cluster back panel to

cluster assembly; separate the parts carefully.

CAUTION: Care must be used to avoid marring

instrument cluster face.

2.
Remove two screws securing speedometer or ta-

chometer head to cluster back panel; carefully re-

move speedometer or tachometer head.

NOTE:
Servicing of speedometer or tachom-

eter head should be performed by an authorized

AC service station.

3.
Reverse above procedure to install speedometer.

Cable Replacement or Lubrication

1.
Disconnect the. cable from the speedometer or ta-

chometer head. Remove the old cable by pulling it

out from speedometer end of conduit.

NOTE:
If old cable is broken it may be nec-

essary to remove lower piece from transmission

or distributor end of conduit as applicable.

2.
Lubricate the lower 3/4 of cable with
AC
speedom-

eter cable lubricant and push the cable into the con-

duit. Connect the upper end to the speedometer or

tachometer head and road test vehicle for proper

operation.

TEMPERATURE GAUGE

The temperature indicator requires very little service

other than testing for malfunctioning and replacing de-

fective units. Cluster must be removed to service tem-

perature gauge.

Do not attempt to repair either the engine unit or the

gauge. When installing new engine unit, do not use

thread compound on unit threads, as this will increase

electrical resistance of unit and cause faulty reading

on gauge.

AMMETER OR OIL PRESSURE GAUGE

The ammeter or oil pressure gauge requires very

little attention other than keeping ammeter terminals

clean and tight. If the oil pressure control line should

become restricted it should be blown out or replaced.

Cluster must be removed to service these gauges.

HftVKI MANUAL

SECTION 14

INDEX

Page

General Description—Chevrolet 14-1

Service Operations 14-1

Front Bumper Assembly 14-1

Removal 14-1

Disassembly . 14-1

Assembly „ 14-1

Installation . . 14-1

Bear Bumper Assembly 14-2

Removal .' 14-2

Disassembly . 14-2

Assembly 14-2

Installation 14-2

General Description—Chevelle 14-2

Service Operations 14-2

Front Bumper Assembly 14-2

Removal 14-2

Disassembly 14-3

Assembly 14-3

Installation 14-3

Rear Bumper Assembly 14-3

Removal . . 14-3

Disassembly 14-3

Assembly . . . . 14-3

Installation 14-3

General Description—Chevy II 14-3

Service Operations 14-3

Front Bumper Assembly 14-3

Removal 14-3
Page

Disassembly 14-4

Assembly 14-4

Installation . 14-4

Rear Bumper Assembly . 14-4

Removal 14-4

Disassembly 14-4

Assembly ..................... 14-4

Installation 14-4

General Description—Corvette 14-4

Service Operations . 14-4

Front Bumper Assembly . . 14-4

Removal 14-4

Installation . . 14-5

Rear Bumper Assembly 14-5

Removal 14-5

Installation 14-5

General Description—Camaro 14-6

Service Operations . 14-6

Front Bumper Assembly 14-6

Removal. . 14-6

Disassembly 14-6

Assembly 14-6

Installation 14-6

Rear Bumper Assembly 14-6

Removal . 14-6

Disassembly 14-6

Assembly 14-6

Installation 14-7

GENERAL DESCRIPTION-CHEVROLET

The front bumper is a new, full width, three-piece

design consisting of a center and two end face bars.

Two holes are pierced in the center face bar for the

parking lamps. The bumper attaching brackets are

lengthened to attach in common with new front bumper

diagonal braces.

The rear bumper is a new three-piece design similar
in general appearance to the 1966 design. Caprice mod-

els have pierced holes in the center portion of the bumper

for the back-up lamps with the other models incorporat-

ing the back-up, lamps with the tail lamps. The fuel tank

filler door assembly remains the same as the 1966

models.

SERVICE OPERATIONS

FRONT BUMPER ASSEMBLY (Fig. 1)

Removal

1.
Raise and support front end of vehicle.

2.
Disconnect parking lamp wiring.

3.
Remove bolts attaching bumper brackets and braces

to frame.

4.
Remove bumper from vehicle.

Disassembly

1.
Remove bolts attaching brackets and braces to

bumper.

2.
Separate face bar sections by removing two bolts at

each joint.

3.
Remove screws attaching each parking lamp assem-
bly to center face bar and remove parking lamps.

Assembly

Attach both parking lamps to center face bar and

tighten bolts firmly. Assemble the front bumper follow-

ing the disassembly procedure in reverse order. Except

for parking lamp attachments, install all bolts loosely; do

not tighten any bolts until all bolts are installed.

Installation

1.
Position assembled bumper on frame horns aligning

holes in bumper brackets and braces with those in

frame.

2.
Install bolts, lock washers, and nuts; do not tighten.

Note that eight sided adjustment washers (fig. 1) are

CHEVROLET O-
SERVICE