1967 CHEVROLET CAMARO check engine

HEATER AND AIR CONDITIONING 1A-68

Fig.
95—Corvette Four-Season Ducts

5. Connect the various Comfortron harness connectors

to the dash wiring and connect the vacuum hose to

the kick pad valve diaphragm. Push the vacuum hose

harness and wiring harness through the firewall to

the proper location and install their respective

grommets.

6. Raise the control unit into place and install the

mounting screws. Check that all connections are

complete.

7. Replace any radio and/or tape equipment, the ash

tray assembly, and face plate.

8. Replace the glove box assembly.

9. Connect the heater hoses to the core tubes, and

attach the nuts to the case studs through the firewall.

10.
Reconnect the four vacuum hoses as follows: Purple

to the cylinder on the thermo-vacuum valve, yellow

tracer to the body of the thermo-vacuum valve, red

tracer to the vacuum source "Tee" connection, and

white tracer to the vacuum tank inlet.

11.
Connect the wiring harness to the underhood air

conditioning components.

12.
Refill cooling system, connect battery ground cable

and check system performance.

Vacuum Tank

The vacuum tank is mounted on the firewall as shown

in Figure 97. Notice that the two vacuum lines are

clamped to the vacuum tank ports. *

Thermal Vacuum Valve

This heat operated vacuum valve is located in the

heater core input line. Figure 98 illustrates valve instal-

lation with clamps attaching the water hoses as well as

the vacuum hoses in place.
Resistor Assembly

Figure 99 illustrates the location and installation of

the blower speed resistor assembly.

Relays

Two relays are used in the system, both mounted on the

evaporator case as shown in Figure 100. The mounting

bracket forms a common ground for the relays and as a

plug for the hole in the evaporator housing used in the

Four Season system for resistor installation.

Sensors (Thermistors)

Ambient Switch and Sensor

This combination unit, which engages the compressor

clutch at about 40°F and also senses outside air tem-

perature and sun load, is mounted to the firewall within

the engine compartment with its long neck extending

deep into the cowl vent plenum chamber. Figure 98 il-

lustrates this installation,

In-Car Sensor

This sensor is located beneath the lip of the instru-

ment panel overhand just to the right of the driver as

shown in Figure 101.

Removal

1.
Remove glove box assembly.

2.
Disconnect sensor wires connector at harness.

3.
Remove sensor mounting screws, remove sensor

and pull wires and connector through hole in dash.

Installation

1.
Insert connector and

through the dash hole.
wires of replacement sensor

CHEVROLET CHASSIS SERVICE MANUAL

HEATER AND AIR CONDITIONING 1A-77

Compressor Belt Tension Adjustment

Adjust the compressor belt to the specifications shown

in the Tune-Up chart in the Engine section of this manual.

COMPRESSOR FAILURE

If the compressor has failed mechanically to the ex-
tent that metal chips and shavings are found in it, the

system should be checked for foreign material and

cleaned as described under Foreign Material in the

System.

CHEVROLET CHASSIS SERVICE MANUAL

CORVETTE BODY 1B-29

CUSHION

CUSHION ASNi.^ty** ACCESS

#2 BODY BRACKET

( 67 ONLY)
SHIM

( 37 POSITION).

CUSHION ASM.

( 37)

SHIM

( 67 POSITION)

CUSHION

( 37 ONLY)

#1 BODY BRACKET

Fig.
65—Body Mounts

PRECAUTIONS

Creams are available to protect the skin from a con-

dition known as occupational, or contact dermatitis. This

common type of dermatitis is not contagious. Improved

resin formulas in the approved kits have almost elimi-

nated skin irritation. Cream is supplied with the kit for

men who may have a tendency toward skin irritation

from the resins or dust.

The application of these creams is recommended

whenever the Resin Kit materials are used. Generally,

the cream is not required when the plastic solder kit is

being used. Directions for using the cream is as follows:

a. Wash hands clean. Dry thoroughly.

b.
Squeeze about 1/2 inch (or 1/2 teaspoonful) of

#71 cream into palm of hand.

c. Spread evenly and lightly until cream disappears.

Work cream into cuticle, between fingers and

around wrists.

d. Apply second coat, repeating Steps b and c.

e. Hold hands briefly under cold running water to

set cream.

2.
Remove resin mixture from hands as soon as possi-

ble and imperatively before mixture starts to gel.

This can be observed by the action of the material

being used. Resin may be removed with lacquer

thinner by washing in soap and water.

3.
Respirators are recommended when grinding. Also

some minor skin irritation from glass and powdered

cured resin may be evident. Washing in cold water

will help to minimize.

4.
Use a belt sander with a vacuum attachment for dust

control if possible.
5. Resin mixtures may produce toxic fumes and should

be used in well ventilated areas.

6. Be careful not to get any resin material on clothing.

7. Use the right materials for the job. It is important

to use the approved kits because Chevrolet's rigid

quality standards assure you the right material to

do the job. Other materials available may not meet

the required engineering and safety standards.

8. Keep the materials, utensils and work area clean

and dry. These repairs involve chemical reactions,

and dirt or moisture may upset the chemical bal-

ances and produce unsatisfactory results.

9. Before starting repair operations, look for hidden

damage by applying pressure around the damaged

area, looking for hairline cracks and other breakage.

Check for minor damage at other points in the vehi-

cle such as around exhaust pipes, grille, headlamps

and points of wear or rub. Early repair of this

minor damage may prevent major repair later.

PLASTIC SOLDER
KIT

The Plastic Solder Repair Kit is used for minor re-

pairs on the Corvette body. These materials will produce

an easy, quick and lasting repair in the case of small

cracks, surface imperfections and small holes.

1.
Use paint remover or power sander, and remove

finish from damaged area. Carefully inspect for

other areas requiring repair.

2.
Mix the materials (fig. 72).

3.
Apply the material, using a putty knife or rubber

squeegee, Figure 73. Work the material into the

repair and build the material up to the desired

CHEVROLET CHASSIS SERVICE

SECTION 2

FRAME

INDEX

Page

General Description 2-1

Chevrolet 2-1

Cheveile '. 2-1

Repair Procedures 2-1
Page

Checking Frame Alignment 2-1

Car Preparation 2-1

Tramming Sequence 2-1

Reference Point Dimensions 2-1

GENERAL DESCRIPTION

CHEVROLET AND CHEVELLE

Frames used on Chevrolet and Cheveile lines are basi-

cally the same, consisting of full length right and left

side members joined laterally by crossmembers. Sev-

eral different frames are used in each line to meet the

various vehicle size and function requirements but the

basic shape for each line remains the same. Differences

between frames in a given line exist only in metal gauge,

part size and numbers of parts necessary to meet the

particular structural requirements of the models

involved.

CORVETTE

The Corvette frame is a rigid perimeter unit, with five
crossmembers. From the rear kick-up forward, trap-

azoidal shaped, closed side members outline and protect

the passenger compartment. At the cowl area, the side

members curve inward in a sweeping "S" shape, to pro-

vide a sturdy foundation for the engine mounts and clear-

ance for front wheel movement. From the kick-up

rearward, box-sectioned side rails provide fore and aft

support for the rear axle and suspension. Lateral sup-

port is provided by five variously shaped welded-in

crossmembers, including the front unit, which formerly

was bolted-in.

CHEVY II AND CAMARO

Underbody alignment checking procedures will be found

in the Body Service Manual.

REPAIR PROCEDURES

CHECKING FRAME ALIGNMENT

Vehicles involved in an accident of any nature which

might result in a "swayed" or "sprung" frame should

always be checked for proper frame alingment in addi-

tion to steering geometry and wheel alignment.

CAR PREPARATION

Preparing the car for the frame alignment check in-

volves the following:

1.
Place the car on level surface.

2.
The weight of the car should be supported at the

wheel locations.

3.
A visual damage inspection should be made to elim-

inate needless measuring. Obviously damaged or

misaligned areas can often be located by sight.

TRAMMING SEQUENCE

When checking a frame for alignment in case of dam-

age,
the first step is horizontal "X" checking with a

tram from similar given points on opposite side of the

frame.

Frame alignment checks on all models should be made

with the tram points set at the center of each locating

point indicated and the cross bar level to insure

accuracy.

When "X" checking any section of the frame, the

measurements should agree within 3/16". If they do not,
it means that corrections will have to be made.

If a tram gauge is not available, the "plumb bob"

method of checking may be used. To assure any degree

of accuracy when using this method, the vehicle should

be on a level floor.

By using this method, it is only necessary to have a
#

piece of cord attached to an ordinary surveyor's plumb

bob.
When measuring the distance between two points,

the free end of the cord should be placed on the reference

point allowing the plumb bob to hang on the floor. A check

mark should be made on the floor just under the tip of

the plumb bob. This operation should be repeated at all

reference points. With these points located on the floor,

they may easily be measured with a rule.

The second step is checking the vertical dimensions

from the datum plane to the points to be trammed. With

the proper settings the tram bar will be on a plane

parallel to that of the frame. The exception to this would '

be when one of the reference locations is included in the

misaligned area; then the parallel plane between the

frame and the tram bar may not prevail. After com-

pletion of the repairs, the tram gauge should be set at

the specified dimension to check the accuracy of the re-

pair operation.

ALIGNMENT REFERENCE POINT DIMENSIONS

Dimensions to holes are measured to dead center of

the holes and flush to the adjacent surface metal.

CHEVROLET CHASSIS SERVICE MANUAL

FRONT SUSPENSION 3-3

by means of a lower control arm inner pivot cam; on the

Chevelle, Camaro and Corvette by means of upper control

arm inner support shaft shims.

Caster angle is adjusted, on the Chevrolet and Chevy n

by means of a strut rod which runs from the lower con-

trol arm forward to a frame brace; on the Chevelle,
Camaro and Corvette by means of upper control arm

inner support shaft shims.

A stabilizer bar is used on all Chevelle and Corvette

models. Chevrolet Impalas, station wagons and V-8

engine equipped models are fitted with the stabilizer bar.

UPPER CONTROL ARM

STABILIZER

SPRING
LOWER CONTROL ARM

STEERING KNUCKLE

Fig.
3 - Front Suspension - Corvette

MAINTENANCE AND ADJUSTMENTS

Maintenance intervals recommended for lubrication of

front suspension components have been fully covered in

Section 0 of this manual. Only actual adjustment proce-

dures will be covered here.

NOTE:
Unless otherwise indicated all proce-

dures will apply to all five vehicles covered in

this manual.

FRONT WHEEL BEARING ADJUSTMENT

Proper front wheel bearing adjustment has a definite

bearing on the safe operation of a vehicle. Improperly

adjusted front wheel bearings will result in a lack of

steering stability causing wheel wander, shimmy and ex-

cessive tire wear. Very accurate adjustment is possible

because the spindles are drilled both vertically and hori-

zontally and the adjusting nuts are slotted in all six sides.

NOTE:
Wheel bearings should not
be.
repacked

or adjusted as a part of "New Car Conditioning".
1.
With wheel raised, remove hub cap and dust cap and

then remove the cotter pin from the end of the

spindle.

2.
While rotating wheel, tighten spindle nut to 12 lbs. ft

torque.

3.
Back off adjusting nut one flat and insert cotter pin.

If slot and pin hole do not line up, back off the adjust-

ing nut an additional 1/2 flat or less as required to

insert cotter pin.

4.
Spin the wheel to check that it rolls freely and then

lock the cotter pin by spreading the end and bending

it around.

NOTE:
Bearings should have zero preload and

.001"
to .008" end movement when properly ad-

justed on Chevrolet, Chevelle, Camaro and Cor-

vette; .000" to .004" on Chevy H.

5.
Install dust cap, hub cap or wheel disc and lower

wheel.

6. Perform the same operation on each front wheel.

CHEVROLET CHASSIS SERVICE MANUAL

BRAKES 5-9

COMPONENT REPLACEMENT AND REPAIRS

PARKING BRAKE-CHEVROLET, CHEVELLE AND

CAMARO (Figs. 19 and 20)

Pedal Assembly

Removal

NOTE:
Remove positive cable from battery to

eliminate the possibility of creating short cir-

cuits under dash.

1.
Place parking brake pedal in released position.

2.
Remove equalizer check nut, and separate cable

stud from equalizer.

3.
Remove two attaching nuts from mounting studs

located in engine compartment.

4.
Remove front cable .ball end from pedal assembly

swivel.

5. Remove pedal assembly to dash brace attaching

screw.

6. Remove pedal assembly by lowering rear slightly

to avoid scratching dash, and pulling, it out of the

firewall.

Installation

1.
Place pedal assembly in position with the two mount-

ing studs protruding through the holes provided in

the firewall.

2.
Install and tighten pedal assembly to dash brace

attaching screw.

3.
Position front cable ball end into pedal assembly

swivel.

4.
Install and tighten two attaching nuts on mounting

studs located in engine compartment.

5. Place
,
equalizer in position on center cable and

insert front cable stud through equalizer and secure

with check nut.

6. Adjust parking brake as outlined under Maintenance

and Adjustments in this section.

7. Connect positive battery cable.

Front Cable

Removal

NOTE:
Remove positive cable from battery to

eliminate the possibility of creating short cir-

cuits under dash.

1.
Place parking brake pedal in released position.

2.
Remove equalizer check nut, and separate cable

, stud from equalizer.

3.
Remove retainer from cable assembly at inner side

of frame rail.

4.
Remove ball end of cable from pedal assembly

swivel.

5. Compress expanded conduit locking fingers at toe

pan arid withdraw cable from car.

6. On Chevelle, if necessary, remove rubber tube

from front cable.

Installation

1.
On Chevelle, if necessary, replace rubber tube

over front cable.

2.
Position cable ball and conduit tip through cutout

in firewall. Make sure conduit locking fingers are

fully expanded and secured in cutout, then position

cable ball into pedal assembly swivel.
3.
Feed stud end of cable through frame rail and se-

cure with retainer on inner side of frame.

4.
Place one check nut on cable stud and insert stud

through equalizer, (make sure center cable is in

position), then place second check nut on stud.

5. Adjust parking brake as outlined in this section.

6. Connect positive battery cable.

Center Cable

Removal

1.
Place parking brake pedal in released position.

2.
Remove equalizer check nut and remove equalizer

from cable.

3.
Remove cable from cable guides.

4.
Disconnect center cable from rear cables at

connectors.

Installation

1.
Install cable ends into rear cable connectors.

2.
Place cable through equalizer and install equalizer

on to front cable stud, secure with check nut. (Do

not tighten.)

3.
Install cable in cable guides (figs. 19 and 20),

4.
Adjust parking brake as outlined in this section.

Rear Cables

Removal

1.
Place parking brake pedal in released position.

2.
Remove equalizer check nut and remove equalizer

from cable.

3.
Remove rear cable from connector.

4.
Remove retainer from rear cable at frame bracket.

Pull cable out of bracket.

5. Remove rear brake drum as outlined in this section.

6. Remove rear brake shoes as outlined in this section.

7. Remove cable end from parking brake actuating

lever.

8. Compress expanded conduit locking fingers at flange

plate entry hole and withdraw cable.

Installation

1.
Pass end of cable and conduit tip through flange

plate entry hole, making sure that conduit locking

fingers all expand fully.

2.
Connect cable end to actuating lever.

3.
Install rear brake shoes, drum and wheel as out-

lined in this section.

4.
Pass cable through frame bracket and install

retainer.

5. Install cable end into cable connector.

6. Position equalizer on center cable and place on

front cable stud, secure with check nut.

7. Make sure all center cable guides are in place

and adjust parking brake as outlined in this section.

PARKING BRAKE-CHEVY II (Fig. 21)

Lever Assembly

Removal

NOTE:
Remove positive cable from battery

to eliminate possibility of creating short cir-

cuits under dash.

CHEVROLET CHASSIS SERVICE MANUAL

BRAKES
5-31

POWER BRAKES

INDEX

General Description 5-31

Maintenance
and"
Adjustments 5-31

Inspection . ... 5_31

Lubrication 5-31

Bleeding Instructions . . . 5.31

Air Cleaner Service . . . , 5.31
Page

Component Replacement 5-31

Power Brake Cylinder ......* 5-31

Removal . . 5-31

Disassembly and Assembly See Overhaul Manual

Installation . . . . 5-31

GENERAL DESCRIPTION

The Power Brake Unit is a self-contained hydraulic

and vacuum unit, utilizing manifold vacuum and atmos-

phere pressure for its power.

This unit permits the use of a low brake pedal as well

as less pedal effort than is required with the conventional

(nonpower) hydraulic brake system. Only two external
line connections are necessary -
one
a vacuum connection

from manifold to check valve located on front shell; the

other, a hydraulic connection from the main cylinder

outlet directly into the hydraulic system. The unit is

mounted on the engine side of the fire wall and directly

connected to the brake pedal.

MAINTENANCE AND ADJUSTMENTS

INSPECTIONS

1.
Check vacuum line and vacuum line connections as

well as vacuum check valve in front shell of power

unit for possible vacuum loss.

2.
Inspect all hydraulic lines and connections at the

wheel cylinders and main cylinder for possible

hydraulic leaks.

3.
Check brake assemblies for scored drums, grease

or brake fluid on linings, worn or glazed linings,

and make necessary adjustments.

4.
Check brake fluid level in the hydraulic reser-

voirs.
The reservoirs should be filled to the levels

shown in Figure 8.

5. Check for loose mounting bolts at main cylinder and

at power section.

6. Check air cleaner filter in power piston extension

and replace filter if necessary.

7. Check brake pedal for binding and misalignment

between pedal
-and
push rod.

LUBRICATION

The power brake unit is lubricated at assembly and
needs no further lubrication other than maintaining

normal reservoir fluid level. The reservoir should be

filled as described in this section.

BLEEDING INSTRUCTIONS

The power system may be bled manually or with a

pressure bleeder as outlined in this section. Use only

GM
Supreme 11 Brake Fluid or equivalent. Do not use the

power assist while bleeding. The engine should not be

running and the vacuum reserve should be reduced to

zero by applying the brake several times before starting

the bleeding procedure.

AIR CLEANER SERVICE

Servicing of the air cleaner is recommended and the

element replaced when restriction becomes severe

enough to affect power brake response. At any other

time, if cleaning of the filter is felt necessary, it should

be shaken free of dirt or washed in soap and water and

thoroughly dried.

COMPONENT REPLACEMENT

POWER BRAKE CYLINDER

Removal

1.
Remove vacuum hose from vacuum check valve.

2.
Disconnect hydraulic lines at main cylinder.

Disconnect push rod at brake pedal assembly.

Remove nuts and lock washers securing power unit

to fire wall, and remove power unit from engine

compartment.
3.

4.

NOTE:
Chevy

to fire wall.
has a three stud attachment

Repair procedures for the power cylinder are outlined

in the Brake Section of the Overhaul Manual-for service
of the main cylinder refer to applicable portion of

"Standard Brakes" in this manual.

Installation

1.
Mount the power brake assembly in place and install

the attaching nuts and lock washers.

2.
Attach vacuum line to check valve.

3.
Secure hydraulic lines to main cylinder.

4.
Attach push rod to brake pedal assembly, and check

operation of stop light.

5. Bleed brakes as outlined in this section.

CAUTION: After replacing the unit on the vehi-

cle,
start the engine and allow vacuum to build

up before applying the brake.

CHEVROLET CHASSIS SERVICE

SECTION 6

ENGINE

CONTENTS
OF
THIS SECTION

Page

Engine Tune Up
6-1
Torque Sequence

Engine Mechanical
(In
Line)
6-12
Special Tools
. .

Engine Mechanical (V8)
6-24
Page

6-39

6-40

ENGINE TUNE UP

INDEX

Page

General Description
. 6-1

Mechanical Checks and Adjustments
6-1

Spark Plug Removal
6-1

Test Compression
6-1

Service and Install Spark Plugs
6-2

Service Ignition System
6-3

Service Battery
and
Battery Cables
6-5

Service Delcotron
and
Regulator
6-5

Service
Fan
Belt
6-5

Service Manifold Heat Valve
6-5

Tighten Manifold
6-5

Service Fuel Lines
and
Fuel Filter ..........
6-6

Service Cooling System
6-6

Check and Adjust Accelerator Linkage
6-6

Service Crankcase Ventilation
6-6

Service
Air
Injection Reactor System
6-6

Choke Adjustment
6-7
Page

Instrument Cheek-Out
6-7

Instrument Hook-Up.
. 6*7

Check and Adjust Dwell
6-7

Check Dwell Variation
6-7

Check and Adjust Timing
6-8

Adjust Idle Speed
and
Mixture
6-8

Additional Checks and Adjustments
. 6-8

Testing Crankcase Ventilation Valve
. 6-8

Testing Cranking Voltage
6-8

Cylinder Balance Test
. 6-8

Battery
6-8

Ignition
; 6-8

Carburetor
6-11

Fuel Pump
6-11

Cooling System
. 6-11

Cylinder Head Torque and Valve Adjustment
..... 6-11

GENERAL DESCRIPTION

The engine tune up
is
important
to the
modern automo-

tive engine with
its
vastly improved power and perform-

ance.
The
higher compression ratios, improved electri-

cal systems
and
other advances
in
design, make today1 s

engines more sensitive
and
have
a
decided effect
on

power, performance and fuel consumption.

It
is
seldom advisable
to
attempt
a
tune up
by
correc-

tion
of one or two
items only. Time will normally
be

saved
and
more lasting results assured
if the
technician

will follow
a
definite
and
thorough procedure
of
analysis

and correction
of all
items affecting power, performance

and economy.

The tune
up
will
be
performed
in
two parts.
The
first

part will consist
of
visual and mechanical checks and
ad-

justments;
the
second part will consist
of
an instrument

checkout that
can be
performed with
any one of the
units
of service equipment available
for
this purpose. Always

follow
the
instructions provided
by the
manufacturer
of

the particular equipment
to be
used.

Additional checks
and
adjustments
are
included
in the

latter part
of
this section
for use as
required. Many
of

these operations
can be
used
to
isolate and correct trou-

ble located during
the
tune up. Where conditions
are
UB-

covered requiring major corrective action, refer
to the

appropriate section
of
this manual
or the
Passenger

Chassis Overhaul Manual
for
detailed service informa-

tion.

Typical illustrations
and
procedures
are
used except

where specific illustrations
or
procedures
are
necessary

to clarify
the
operation. Illustrations showing bench
op-

erations
are
used
for
clarification however
all
operations

can
be
performed
on the
vehicle.

MECHANICAL CHECKS
AND
ADJUSTMENTS

Spark Plug Removal

Remove any foreign matter from around spark plugs
by

blowing
out
with compressed
air,
then disconnect wires

and remove plugs.

Test Compression
(Fig. 1)

The compression check
is
important because
an
engine

with
low or
uneven compression cannot
be
tuned success-
fully.
It is
essential that improper compression
be cor-

rected before proceeding with
the
engine tune
up.

1.
Remove
air
cleaner
and
block throttle
and
choke
in

wide open position.

2.
Hook
up
starter remote control cable
and
insert

compression gauge firmly
in
spark plug port.

CAUTION: Whenever
the
engine
is
cranked

CHEVROLET
C*
IS SERVICE MANUAL