1967 CHEVROLET CAMARO ECO mode

STEERING
9-32

arm on frame and install mounting bolts, washers

and nuts. No washer is used on Corvette.

Install relay rod to idler arm, ^making certain seal

is on stud. Install and tighten nut.

Install cotter pin.

Refer to torque specifications at rear of manual for'

correct torque values.

Chevy II (Fig. 62}

Removal

1.
Remove cotter pin, nut and washer securing idler

arm to relay rod.

2.
Remove relay rod from idler arm.

3.
If equipped with power steering disconnect power

cylinder shaft from idler arm bracket.

4.
Remove three idler bracket to frame bolts and nuts

and remove bracket and idler arm assembly.

5.
Remove cotter pin, nut, washer and bolt securing the

idler arm to the bracket.

6. Press out the idler arm bushing for replacement.

Installation

NOTE: Installation must be done with front

wheels straight ahead or the car will lead to one

side.

1.
Install idler arm bushing, if previously removed.

NOTE: Make certain the outer sleeve of the

bushing does not protrude above surface of idler

arm.

2.
Reverse removal procedure and torque all nuts ac-

cording to specifications.

PITMAN ARM

Removal

1.
Remove cotter pin from pitman arm ball stud and

remove nut.

2.
Remove relay rod from pitman arm by tapping on

side of rod or arm in which the stud mounts with a

hammer while using a heavy hammer or similar tool

as a backing. Pull down on relay rod to remove

from stud.

3.
Remove pitman arm nut from sector shaft and mark

relation of arm position to shaft.

4.
Remove pitman arm with Tool J-6632 as shown in

Figure 2.

Installation

1.
Install pitman arm on sector shaft, lining up the

• marks made upon removal.

2.
Install sector shaft nut.

3.
Position relay rod on to pitman arm. Install nut.

Continue to tighten arm enough to align castellation

with hole in stud and install cotter pin.
STEERING ARM

If, through collision or other damage, it becomes nec-

essary to remove and replace either steering arm, pro-

ceed as follows:

Removal

1.
Remove tie rod from steering arm as outlined in this

section.

2.
Remove front wheel, hub and brake drum as a unit

by removing hub cap and dust cap, cotter pin from

spindle nut and the spindle nut. Pull assembly to-

ward outside of vehicle. If removal is difficult, it

may be necessary to back off brake adjustment to

increase brake shoe-to-drum clearance; see Hy-

draulic Brake Adjustment, Section 5. On models

with disc brakes, remove caliper and disc.

3.
With wheel and drum assembly or caliper and disc

removed, steering arm retaining bolt heads are ac-

cessible and removal of steering arm from vehicle

may be accomplished by removing retaining nuts.

Installation

1.
Place steering arm in position on vehicle and install

retaining bolts*

2.
Install nuts. Use only the special locknut listed for

this use in the Chevrolet Parts Catalog.

3.
Pack wheel bearings using a high quality wheel

bearing lubricant. Install bearings and wheel-hub-

brake drum assembly removed previously. On disc

brake models, install disc and caliper.

4.
Install keyed washer and spindle nut. Proceed as out-

lined under t{ Front Wheel Bearing Adjustment" in

Section 3.

5.
Install tie rod ball stud in steering arm. Be sure that

the dust cover is in place on ball stud.

6. Install castellated nut on ball stud, tighten securely

and install cotter pin.

7.
Following directions given in Section 3 to check cor-

nering wheel relationship and toe-in; correct as

required.

STEERING DAMPER-CORVETTE

Removal

1.
Remove bolt from damper pivot bracket at relay rod.

2.
Remove nut from damper pivot at frame bracket and

withdraw damper assembly.

Damper is serviced as a unit. Replace damper if
3.

damaged or excessively worn.

Installation

1.
Place piston rod end into frame bracket and install

retainers, bushings, and nut.

2.
Insert cylinder end pivot into relay rod bracket and

install through bolt.

CHEVROLET CHASSIS SERVICE MANUAL

STEERING
9-33

POWER STEERING

INDEX

Page

General Description
. 9-33

Maintenance
and
Adjustments
9-33

Bleeding Hydraulic System
9-33

Fluid Level
. 9-33

Adjustments
. 9-34

Power Steering Gear
. . 9-34

Pump Belt Tension
9-34
Hydraulic System Checks
9-34

Component Replacement
and
Repairs
. 9-35

Power Steering Pump.
. 9-35

Power Steering Gear
9-36

Control Valve
and
Adapter Assembly
9.35

Power Cylinder
9.37

Power Steering Hoses
9.39

GENERAL DESCRIPTION

Two types
of
power steering
are
used
for 1967.
One
is

the conventional linkage type
for
Chevy
n and
Corvette

vehicles
and the
other
is the
integral gear type
for

Chevrolet, Chevelle,
and
Camaro.
For
both types
the

hydraulic pressure
is
provided
by an
engine-driven vane-

type pump.

On
the
Chevy
n and
Corvette linkage type power steer-

ing, hydraulic pressure
is
delivered through
a
hose from

the pump
to a
valve which senses
the
requirement
for

power assistance
and
supplies
the
power cylinder
ac-

cordingly.
The
steering gear used with this power steer-

ing
is the
same basic unit used
on
manually steered

vehicles;
it is
serviced
as
outlined
in the
manual steering

part
of
this section except
for
adjustment, which
is

covered
in the
following pages.
The
steering linkage also

is serviced the same
as
manual counterparts.

The Chevrolet, Chevelle
and
Camaro integral gear type

power steering
has the
hydraulic pressure delivered

from
the
pump through two hoses
to the
steering gear.
In
the power steering gear
the
steering shaft, hydraulic

valve, worm, and rack-piston
nut are all in
line making
a

compact
and
space saving assembly.
All oil
passages
are

internal within
the
gear except
the
pressure
and
return

hoses.

The steering gear
is a
recirculating ball system
in

which steel balls
act as a
rolling thread between
the

steering worm
and
rack-piston
nut. The
rack-piston
nut

is
all one
piece
and is
geared
to the
sector
of
the piston

shaft.
The
valve
is
contained
in the
gear housing elimi-

nating
the
need
of
bolts
or
seals
to
attach
a
separate

valve housing.

The valve
is an
open-center, rotary-type three
way

valve.
The
spool
is
held
in
neutral position by means
of a

torsion
bar. The
spool
is
attached
by
means
of
the stub

shaft
to one end of the
torsion
bar
and
to the
valve body

on
the
other
end.
Twisting
of the
torsion bar allows
the

spool
to
move
in
relation
to the
valve body thereby oper-

ating
the
valve.

MAINTENANCE
AND
ADJUSTMENTS

BLEEDING HYDRAULIC SYSTEM

1.
Fill
oil
reservoir
to
proper level and
let oil
remain

undistrubed
for at
least two minutes.

2.
Start engine
and run
only
for
about
two
seconds.

3.
Add
oil if
necessary.

4.
Repeat above procedure until
oil
level remains
con-

stant after running engine.

5. Raise front
end of
vehicle
so
that wheels
are off
the

ground.

6. Increase engine speed
to
approximately
1500 rpm.

7. Turn
the
wheels
(off
ground) right
and
left, lightly

contacting
the
wheel stops.

8. Add
oil if
necessary.

9. Lower
the car and
turn wheels right and left
on the

ground.

10.
Check
oil
level and refill
as
required.

11.
If oil is
extremely foamy, allow vehicle
to
stand
a

few minutes with engine
off and
repeat above

procedure.
,

a.
Check belt tightness
and
check
for a
bent
or
loose

pulley. (Pulley should
not
wobble with engine

running.)
b.
Check
to
make sure hoses
are not
touching
any

other parts
of the car,
particularly sheet metal.

c. Check
oil
level, filling
to
proper level
if
neces-

sary, following operations
1
through
10.
This

step
and
Step
"D" are
extremely important
as

low
oil
level and/or
air in the oil are the
most

frequent causes
of
objectionable pump noise.

d. Check
the
presence
of air in the oil. If air is

present, attempt
to
bleed system
as
described
in

operations
1
through
10. If it
becomes obvious

that
the
pump will
not
bleed after
a few
trials,

proceed
as
outlined under Hydraulic System

Checks.

FLUID
LEVEL

1.
Check
oil
level
in the
reservoir
by
checking
the dip

stick when
oil is at
operating temperature.
On

Chevelle models equipped with remote reservoir,

the reservoir should
be
maintained approximately

3/4 full when
oil is at
operating temperature.

2.
Fill,
if
necessary,
to
proper level with
GM
Power

Steering Fluid
or, if
this
is not
available, automatic

CHEVROLET CHASSIS SERVICE MANUAL

STEERING 9-39

4.
Remove cotter pin, nut and ball stud at relay rod.

5. Remove the power cylinder from the vehicle.

Inspection

1.
Inspect the seals for leaks; if leaks are present,

replace the seals using the procedure outlined under

"Disassembly."

2.
Examine the brass fitted hose connection seats for

cracks or damage and replace if necessary.

3.
For service other than ball seat or seal replacement

and ball stud removal, replace the power cylinder.

4.
Check the frame bracket parts for wear.

Disassembly

1.
To remove the piston rod seal remove the snap ring;

then pull out on the rod, being careful not to spray

oil.

2.
Remove the piston rod scraper and scraper element,

back up washer and piston rod seal from the rod.

3.
At the ball stud end of the cylinder, remove the ball

stud seal.

4.
Remove the snap ring retaining the end plug with the

lube fitting.

5. Push on the end of the ball stud and remove the end

plug, spring, spring seat and ball stud.

6. Remove the "O" ring seal from the top lip of the

power cylinder ball stud opening.

7. If the ball seat is to be replaced, it must be pressed

out using Tool J-8937.

Assembly

1.
Reassemble the piston rod seal components by re-

versing the disassembly procedure. Apply a thin
coat of Lubriplate or equivalent on the inner sur-

faces of the seal and scraper before assembly.

2.
Reverse the disassembly procedure when reassem-

bling the ball stud.

3.
In each case be sure that the snap ring is securely,

seated in the ring groove.

Installation

1.
Install the power cylinder on the vehicle by reversing

the removal procedure.

2.
Reconnect the two hydraulic lines, fill the system

with fluid and bleed out air using the procedure out-

lined under "Maintenance and Adjustments." Grease

ball joint.

POWER STEERING HOSES

When servicing the power steering hoses be sure to

align the hoses in their correct position as shown in

Figure 71. On Chevelle models with 396 engine, install

the upper hose so that there is at least .6 inch clearance

between the hose and the Delcotron or the inner fender

skirt.

It is important that the power steering hoses be in-

stalled correctly. Hoses installed out of position may be

subjected to chafing or other abuses during sharp turns.

Always make hose installations with front wheels in

straight ahead position. Do not twist hoses unneces-

sarily during installation.

CAUTION: Do not start engine with any power

steering hose disconnected.

CHEVROLET CHASSIS SERVICE MANUAL

SECTION 10

WHEELS AND TIRES

INDEX

Page

General Description
10-1

Maintenance
and
Adjustments
.............. 10—1

Tires
10-1

Pressures . 10-1

Inspection 10-1

Wear 10-1

Rotation 10-4

Noise 10-4

Cleaning 10-4

Change (W/Wheels) 10-4

Wheels 10-5

Static Balancing (w/Tire) 10-5
Page

Dynamic Balancing (w/Tire) . 10-5

Run Out (w/o Tire) 10-5

Cleaning 10-5

Service Operations 10-5

Tires 10-5

Removal 10-5

Installation 10-5

Repair 10^6

Wheels . 10-6

Valve Assembly 10-6

Repair (Rim) 10-7

GENERAL DESCRIPTION

WHEELS

Chevrolet, Chevelle, Camaro, Chevy n, and Corvette

are base equipped with welded steel wheels. Five studs

with nuts fasten each wheel to the front hub or rear axle

flange. Disc brake equipped vehicles (except Chevrolet

and Corvette) require special 14 inch diameter wheels

with a revised design for clearance, Chevrolet disc brake

equipped vehicles have 15 in. diameter wheels as do all

Corvettes.

Chevrolet station wagons, Chevelle Super Sport 396,

Corvette and Camaro Super Sport 350 are base equipped

with 6 in. width wheels. All other vehicles have 5 in.

width wheels, except Chevy n 100, 300 and 500 Series

Sedans, which have 4 in. width wheels.

Do not install 6 inch width wheels or snow chains on

Chevrolets equipped with rear fender skirts.

TIRES

The factory installed tires on Chevrolet passenger

cars are selected to provide the best all around tire

performance for all normal operation. They are de-

signed to operate satisfactorily with loads up to and in-

cluding the specified full rated load capacity of the
automobile when inflated as recommended in the Vehicle

Capacity Rating and Recommended Tire Inflation Pres-

sures Table (see Specifications).

Optional Oversize and 8-Ply Rating Tires

{Chevrolet and Chevelle Only)

Oversize or 8-ply rating tires are not necessary on

passenger cars for normal requirements. However, an

extra margin of tire service is available when these

options are used at loads up to and including full rated

load.

Optional oversize 4-ply rating and/or 8-ply rating

tires are available on models as indicated in the Tire

Usage Chart (see Specifications). On some models (ex-

ample—Station Wagon), space limitations do not permit

the use of a larger size tire; hence, the 8-ply rating

tire is an available option.

In either case, these tires are applicable to extended

operation at or near full rated load or for trailer towing

when an extra margin of tire service is desired. How-

ever, use of a larger tire or an 8-ply rating tire should

not be construed as permitting an increase in the full

rated vehicle load (see Specifications).

MAINTENANCE AND ADJUSTMENTS

TIRES

Inflation Pressures

To ensure the proper tire inflation pressure for the

owners particular requirements follow the recommenda-

tions in the Vehicle Capacity Rating and Recommended

Tire Inflation Pressures Table (seeSpecifications). Keep

tires properly inflated, and check inflation pressures

periodically. This will ensure the best tire life and riding

comfort, over the full range of driving conditions.
Inspection

Every few thousand miles and at each lubrication, tires

should be checked for sharp objects or stones in the

tread. H tire is punctured, it should be repaired using

one of several repair kits available through tire manu-

facturers1 outlets.

Wear

Misalignment

This is wear due to excessive toe-in or toe-out. In

CHEVROLET CHASSIS SERVICE MANUAL

WHEELS AND TIRES 10-4

the road and it slips, grinding off the tread on the inside

half of the tire at an excessive rate. This type of tire

shows much the same appearance of tread wear as tire

wear caused by negative camber.

Second, the transfer of weight may also over-load the

outside tires so much that they are laterally distorted

resulting in excessive wear on the outside half of the

tire producing a type of wear like that caused by ex-

cessive positive camber.

Cornering wear can be most easily distinguished from

abnormal camber wear by the rounding of the outside

shoulder or edge of the tire and by the roughening of the

tread surface which denotes abrasion.

Cornering wear often produces a fin or raised portion

along the inside edge of each row in the tread pattern.

In some cases this fin is almost as pronounced as a

toe-in fin, and in others, it tapers into a row of tread

blocks to such an extent that the tire has a definite step

wear appearance.

The only remedy for cornering wear is proper in-

struction of owners.

Fig.
5 - Tire Rotatidh

Rotation

To minimize the possibility of tire noise and to equal-

ize tire wear, it is recommended that tires be inter-

changed every 6000 miles as shown in Figure 5 or more

frequently in the case of extremely heavy wear.

NOTE:
Rotate Corvette tires at 4000 miles or

sooner.

Interchanging tires will effectively prevent undue wear

on any particular tire. II tire interchanging is followed

as recommended above, all tires will have the same

number of miles in each wheel position at the end of the

fourth change. When interchanging tires, inspect for

signs of abnormal wear, bulging, etc., stones, glass, and

nails should be removed before reinstallation.

Noise

Noise caused by the normal action of tire treads on

various road surfaces is often confused with rear axle
gears or other noises in the car.

The determination of whether tires are causing the

noise complained of is relatively simple. The car should

be driven at various speeds and note taken of part

throttle, and sudden acceleration and deceleration. Axle

and exhaust noises show definite variations under these

conditions, while tire noise will remain constant. Tire

noise is, however, most pronounced at speeds of approx-

imately twenty or thirty miles per hour.

The tires may be further checked by driving the ear

over smooth pavement with the tires at normal pressure

and again over the same stretch of pavement when the

tires have been inflated to fifty pounds pressure. Reduce

the tires to normal pressure one at a time to determine

the faulty tire or tires. This high inflation pressure

should immediately be reduced to normal after test. If

the noise for which the test is being made is caused by

tires,.
it will noticeably decrease when the tire pressure

is increased, whereas axle noise should show no change

in volume.

If, on inspection, the tires on the front wheels are

found to be creating most of the noise the alignment of

the front wheels should be checked. Excessive tire noise

usually results from lower than recommended tire pres-

sure, incorrect alignment, uneven tire wear, or defective

(thumper) tire.

Cleaning

A great deal of ordinary road dirt which collects on

white sidewall tires may be sponged off with clear water

or a mild soap solution.

A good brand of whitewall tire cleaner, however, is

a quicker and more effective cleaner for removing dirt

and stains from whitewall tires and in many cases it

will remove stains and discoloration that the simpler

method of soap and water will not remove.

Under no circumstances should gasoline, kerosene or

any cleaning fluid containing a solvent derived from oil

be used to clean whitewall tires. Oil in any form is

detrimental to tire rubber and a cleaner with an oil base

will discolor or injure whitewall tires.

Change (W/Wheels)

To change the road wheels using the jack that comes

with the car, observe the following procedure:

1.
Set hand brake and block front wheels if rear wheel

is being changed.

2.
Remove hub cap or wheel disc and break wheel

mounting nuts loose.

3.
Place the jack as directed tinder, General Informa-

tion,
Section 0 and raise car until wheel clears

ground.

4.
Remove wheel mounting nuts and remove wheel from

hub or drum.

5. To replace road wheel, reverse the above instrue-

. tions. Proper torque on nuts is 55-75 ft. lbs.

torque (70-85 ft. lbs. for Corvette aluminum wheel

nuts).

CAUTION: On models equipped with discs, in-

dex the pilot hole in the disc on the valve stem.

(To insure that the anti-rotation notches in wheel

disc register on lugs in wheel rim.)

CHEVROLET CHASSIS SERVICE MANUAL

CHASSIS SHEET METAL 11-18

b.
Check and adjust front wheel alignment as out-

lined in Section 3.

c. Check and adjust headlamp aiming as outlined in

Section 12.

HOOD ASSEMBLY

Hood may be removed either with or without hinges.

To shorten aligning time, hood hinge plates may be lo-

cated by scribing a mark on hood and/or body which

outlines entire plate. See Maintenance and Adjustments -

Hood Hinge for hood adjustment procedure. Hood hinge

springs may be easily and safely removed and installed.

through the use of Tool J-9559 as follows:

1.
With hood opened only far enough to allow passage of

mechanic's arm between hood and fender, insert ends

of J-9559 (through bolt removed) between coils of

spring until barrel of tool contacts outer diameter

of spring.

2.
Open hood fully while still holding spring (with tool

installed) in hand; when hood is near fully opened

position, spring may be removed as shown in Figure

28.

3.
As soon as spring is removed, insert long bolt sup-

plied with J-9559 through holes in end of tool, pass-

ing it through spring, and install nut on bolt.

Spring may be removed from J-9559 or J-9559 may be

installed in a new spring by the following method:

1.
Place a closed 6 or 8 inch "C" clamp in a vise or

fasten it to a heavy bench top (bench should be fas-

tened to floor).

2.
Hook one end of spring in clamp and the other end

in hook of a hoist as shown in Figure 29.

3.
Stretch the spring enough to allow insertion of

J-9559. Install through bolt if spring is not to be

installed on hinge at once.

HOOD CATCH AMD LOCK (Fig. 19)

Removal

1.
Remove catch assembly as follows:

a. Remove screws retaining catch assembly to radi-

ator support.

b.
Remove screws retaining catch assembly to catch

support assembly.

c* Remove screws retaining catch assembly to grille

upper bar.

2.
Before removing hood lock plate from hood, locate

position on hood by scribing around base of lock

plate. Remove screws retaining lock plate to hood

and remove lock plate from vehicle.

Installation

1.
Install both catch and lock assemblies in reverse

order of removal procedure.

2.
Align as outlined under Maintenance and Adjust-

ments - Hood Catch.

HOOD TRIM

Crown Molding

Hood crown molding is retained by clips installed on

underside of hood. Clips may be removed by carefully

pressing them off molding mounting studs with screw

driver.
When installing a new molding, force clips onto mount-

ing studs as far as possible and then clench clips with

long-nosed pliers to eliminate gap between molding and

hood, as shown in Figure 30.

Emblem

The hood emblem is retained by four nuts which are

accessible from under the hood.

COWL VENT GRILLE

The cowl vent grille replacement procedure for Chevy

U is the same as for Chevrolet and Chevelle. Refer to

Chevrolet and Chevelle Cowl Vent Grille replacement

procedure and see Figure 16.

FRONT END ASSEMBLY

The Chevy n front end body design allows for removal

of the entire front end of the vehicle without disassembly

of front suspension of sheet metal. One man may remove

and transport the front end assembly using only a floor

jack placed under the crossmember and the vehicle front

wheels. Figure 31 illustrates the assembly in process

of removal with jack stand in position under rocker panel.

Proceed with removal
as.
follows:

Removal

1.
Remove hood assembly as outlined in this section.

2.
Remove engine assembly as outlined in Section 6.

On 4 cylinder models, replace crossmember.

3.
Raise car from floor and install jack stands as

shown in Figure 31.

4.
Remove pitman arm from steering gear as outlined

in Section 9.

5.
Remove steering gear mounting bolts from skirt

assembly.

6. Remove 4 bolts securing each skirt assembly to

lower dash brace.

7.
Remove fender-to-rocker extension mounting screws

and record shimming.

8. Remove brake hydraulic line and fuel line from right

hand skirt.

9. Position floor jack or equivalent under front cross-

member.

10.
Remove hydraulic line from main cylinder.

11.
Remove fender-to-cowl mounting screws and record

shimming.

12.
Remove upper skirt-to-dash mounting screws and

record shimming.

13.
Remove front end from vehicle as shown in Figure

31.

Inspection

If car has been involved in a collision, it is advisable

to carefully inspect cowl and dash area for damage. Pay

particular attention to welds, cage nuts, weld nuts and

skirt mounting surfaces. Cage and weld nuts may be

repaired by outright replacement (the best method), or

by the installation of spiral thread inserts. If the spiral

inserts are used, follow the instructions furnished by the

manufacturer. -

Installation

%, position front end assembly at upper dash mounts

and lower dash support, align screw holes with drift

punch and install all mounting screws and bolts

loosely; do not tighten until all screws and bolts are

started. Replace original shimming.

CHEVROLET CHASSIS SERVICE MANUAL

SECTION 12

ELECTRICAL-BODY AND CHASSIS

CONTENTS
OF
THIS
SECTION

Page
Page

System 12-1

Instruments and Gauges 12-21

Directional Signal 12r40
Windshield Wipers and Washers 12-44

Wiring Diagrams 12-56

Special Tools 12-60

LIGHTING SYSTEM

INDEX

Page

General Description
!2-i

Maintenance and Adjustments
•.................. 12-2

Headlamp Adjustment......................
12-3

Headlamp Panel Travel Adjustment.
12-5

Service Operations.
. . .. 12-5

Front Lighting
12-5

Headlamp
. 12_5

Parking Lamp
12-5

Fender Lamp
. 12_^

Headlamp Panel
12-8

Headlamp Panel Motor
^2-9

Rear Lighting
l2-10

Tail, Stop and Directional Lamps
12-10
Page

Backing Lamps
12-14

License Plate Lamp
12-14

Automatic Transmission Quadrant Lamp
12-14

Seat Separator Console Lamps
. 12-15

Lighting Switch
. . 12-15

Wiper Switch.
12-15

Stoplight Switch
12-15

Dimmer Switch
12-15

Backing Lamp Switches
12-15

Neutral Safety Switches
12-17

Parking Brake Alarm Switch
................. 12-19

Instrument Panel Compartment Lamp/Switch
12-19

Cirgarette Lighter
12-19

GENERAL DESCRIPTION

.
The lighting system includes: the main lighting switch,

stop light, dimmer, and backing lamp switches, head-

lamps, parking lamps, stop, tail and directional lamps,

instrument illumination and indicator lamps, and the

necessary wiring to complete the various circuits. A

fuse panel provides convenient power take offs and fuse

clips for the appropriate circuits (fig. 1).

Chevrolet and Chevelle headlamp installation is all

new in that the headlamps are located in the radiator

support with adjusting screws and springs. Eliminating

the need for having separate headlamp housings. Chev-

rolet and Chevelle headlamp retainers and springs are

interchangeable.

Chevy n headlamp housings are new because of revised

front end styling and Corvette front end lighting is basi-

cally carryover.

Front fender lamps have been added as an option for

Chevrolet models and as standard equipment on Caprice

series.

Camaro models use single headlamps and the Rally

Sport model headlamps are covered by a retractable

section of the grille when lamps are not used. The sec-

tion of the grille covering the headlamps folds back when

lights are required; the headlamps are stationary. The

covering is retracted by a small electric motor mounted

to the headlamp housing. The headlamps are automat-

ically uncovered when the headlight switch is pulled "ON"

for illumination. If at any time the electrical circuit

becomes inoperative, the lamps can be uncovered manu-

ally. The ignition switch must be
"ON"
in order to close

the headlamp doors.

Parking lamp for Chevelle and Chevrolet models are
new due to revised front end sheet metal and bumper

styling. Parking lamps are located in the bumper on

Chevrolet, Chevelle and Chevy n models

Camaro parking lamps are located in the radiator

grille except for the Rally Sport models on which the

parking lamps are in the valance panel. For styling

reasons, the lens is white and an amber glass bulb is

used. All Camaro parking lamps require a separate

ground wire to assure a good ground contact because of

the plastic grille and painted contact surfaces.

The Chevrolet tail, stop, and directional lamps are in

one housing with a three section lens design on Impala

and Caprice sedans. The center lens for Impala series

is the back-up lamp. The center lens on the Caprice is

a tail lamp with the back-up lamps being located in the

rear bumper. Chevrolet station wagons have three indi-

vidual housings with three lenses, the center lamp being

the back-up. Biscayne and Bel-Air sedans have a single

housing and lens for tail, stop, and directional lamp with

a similarly constructed back-up lamp inboard and adja-

cent to it.

Chevelle tail, stop, and directional lamps are a single

lens design that follows through with the rear fender

styling. The back-up lamp is located in r.ear bumper.

Camaro models except Rally Sport have tail lamps

with integral back-up lamps mounted inboard of the rear

fenders between the trunk opening and bumper. The

Rally Sport model has dual tail lamps in the rear housing

and valance mounted back-up lamps.

Corvette, Chevy n, and Corvair tail and directional

signal lights are carryover. The Corvette has new back-

up lamps center mounted above the license plate opening.

CHEVROLET CHASSIS SERVICE

ELECTRICAL-BODY AND CHASSIS 12-2

FJg.
1 - Fuse Panel Assembly

All power window and tailgate circuits require the igni-

tion switch to be "ON" to open or close the windows un-

like past model designs which were operated independ-

ently of the ignition switch.

The windshield wiper and washer switch is new in that

washer button in the center of the knob has been deleted
and its function will be accomplished by pushing the knob.

A set screw is used to retain the knob to the shaft.

In addition to fuses, the wiring harness incorporates

fusible links to protect the wiring. Links are used rather

than a fuse in wiring circuits that are not normally fused,

such as the ignition circuit. Fusible links in the Chevro-

let wiring are four gauge sizes smaller than the cable it

is designed to protect. The links are marked on the

insulation with wire gauge size because of the heavy insu-

lation which makes the link appear a heavier gauge than it

actually is.

Engine compartment wiring harness incorporate sev-

eral fusible links. Each link is identified with its gauge

size.
A fusible link is a length of special wire (normally

four wire gauges smaller than the circuit it is protecting)

used in wiring circuits that are not normally fused, such

as the ignition circuit. The same size wire with a spe-

cial hypalon insulation must be used when replacing a

fusible link.

The links are:

1.
The pigtail lead at the battery positive cable (except

Corvette) is a 14 gauge, brown fusible link protecting

the 10 gange battery charging circuit. This wire is

an integral part of the battery cable assembly and

servicing requires replacing the complete battery

cable assembly. On Corvette models this link is

installed as a molded splice at the solenoid "Bat"

terminal and servicing requires splicing in a new

link.

2.
A 16 gauge black fusible link is located at horn relay

to protect all unfused wiring of 12 gauge or larger.

It is a serviceable piece with an in-line connector

and is not integral with the wiring harness.

3.
The generator warning light and field circuitry (16

gauge wire) is protected by a fusible link (20 gauge

orange wire) used in the "battery feed to voltage

regulator #3 terminal" wire. The link is installed

as a molded splice in the generator and forward lamp

harness and is serviced by splicing in a new 20 gauge

wire as required.

4.
The ammeter circuit on all models is protected by

two orange, 20 gauge wire fusible links installed as

molded splices in the circuit at the junction block or

the solenoid "Bat" terminal (Corvette only) and at the

horn relay. Each link is serviced by splicing in a

new 20 gauge wire as required.

The wiring harnesses use a standarized. color code

common to all Chevrolet vehicles. Under the color code,

the color of the wire designates a particular circuit. The

harness title indicates the type of harness, single of mul-

tiple wire, and also describe the location of the harness.

The body harness is a flat, solid wire assembly and is

routed through the vehicle near the center of the body.

Composite wiring diagrams (figs. 104 thru 124) are in-

cluded at the end of this section.

MAINTENANCE AND ADJUSTMENTS

Maintenance of the lighting units and wiring system

consists of an occasional check to see that all wiring

connections are tight and clean, that the lighting units are

tightly mounted to provide good ground and that the head-

lamps are properly adjusted. Loose or corroded con-

nections may cause a discharged battery, difficult start-

ing, dim lights, and possible damage to generator and

regulator. Wire harnesses must be replaced if insulation

becomes burned, cracked, or deteriorated. Whenever it
is necessary to splice a wire or repair one that is bro-

ken, always use solder to bond the splice. Always use

rosin flux solder on electrical connections. Use insulat-

ing tape to cover all splices or bare wires.

When replacing wires, it is important that the correct

size be used. Never replace a wire with one of a smaller

size.

Each harness and wire must be held securely in place

by clips or other holding devices to prevent chafing or

CHEVROLET CHASSIS SERVICE MANUAL