GENERAL INFORMATION 0-4
Fig.
1—Vehicle
Serial Number
Located on Left Front Hinge
Pillar—Chevrolet Shown
Fig.
2—Vehicle Serial Number and
Body Style, Body Number Trim and
Paint Combination Located on
Instrument Panel Brace
Under Glove Box—Corvette
Fig. 3—Four and Six Cylinder
Engine Unit Number Located on
Pad at Right Hand Side of Cylinder
Block at Rear of Distributor
Fig.
4—Eight Cylinder Engine Unit
Number Located on Pad at Front,
Right Hand Side of Cylinder Block
Fig.
5—Rear Axle Unit Number
Located Bottom Surface of Carrier
at Cover Mounting Flange—Corvette
Fig.
6—Rear Axle Unit Number
Located on Right or Left Axle
Tube Adjacent to Carrier
BSHfi^;^
PAINT
HRIKI5"tM>
fIHIsS
HE|St.>MfT*
^^ * *•'"
•<"'
Fig.
7—Body Style, Body Number
Trim Type and Paint Combination
Located on Upper Right Hand Side
of the Dash Panel—Chevrol et
Fig.
8—Body Style, Body Number
Trim Type and Paint Combination
Located on the Upper Left Hand
Side of the Dash Panel—Chevelle
and Camaro
Fig.
9—Body Style, Body Number
Trim Type and Paint Combination
Located on the Upper Right Hand
Part of the Dash Panel—Chevy II
1. Manufacturers identity number assigned to all
Chevrolet built vehicles.
2.
See Model Identification in this section.
3.
Last number of model year (1967).
4.
F-Flint
5.
Unit numbering will start at 100,001 at all plants.
KEYS AND LOCKS
Four keys (two hexagonal head and two round head) are
provided with each vehicle. The hexagonal-head key
operates the ignition switch and front door locks. The
round-head key operates the locks for the glove box and
rear compartment lid.
' Lock cylinders (except trunk) are furnished for service
uncoded, this necessitates the coding of these replace-
ment lock cylinders.
NOTE: In service, the trunk and glove box
lock cylinders are provided together with the
trunk lock cylinder coded and the glove box
cylinder uncoded.
The side bar type lock (fig. 18) is used for the ignition,
front doors and trunk. The glove box lock is of the wafer
CHEVROLET CHASSIS SERVICE MANUAL
GENERAL INFORMATION
0-6
Once the code number of the lock is obtained look up
this number in a key cutting book.
All side bar locks (except trunk) furnished to the field
by the Parts' Department are uncoded, that is, they are
furnished without tumblers, springs or spring retainers,
these parts are serviced separately. The tumblers come
in five different depths, indicated by numbers.
The side bar locks have six tumbler positions, and in
looking up the cutting code, the following may be used as
an example. After key code number is determined, either
from key or from number stamped on lock cylinder refer
to your code book and record the key cutting information
as follows:
Key of Lock
Code Number
0V11
Cutting or Tumbler
position from head
of lock
Key Cutting
Code Numerical
545431
123456
NOTE:
Key blanks used for ignition and door
locks are stamped with an "A" while rear com-
partment and glove box blanks are stamped with
a "B".
The number that is written above the cutting or tumbler
position indicates each different tumbler which is to be
dropped into each tumbier slot of the lock.
In cases where a code book is not available, the dia-
gram shown on Figure 19 may be used to determine the
tumblers required to assemble an uncoded lock cylinder.
1.
Lay the key on the diagram (fig. 19) with bottom of
key flush with edge of the drawing, head and point
carefully lined up.
2.
Read the code in numbers 12345 from the head of the
key to the end from positions 1 to 6 inclusive. As
each depth is determined write that number in the
blank space provided above the position numbers
(1-2-3-4-5-6).
3.
With key properly lined up on diagram, all cuts that
show in the first section are marked
"1"
J
4.
Cuts that fall in the first black section, mark "2".
5. Cuts that fall in the first white section, mark "3".
6. Cuts that fall in second black section, mark "4".
7. Cuts that fall in the second white section, mark "5".
After the numbers have been determined and written
above the cutting positions the lock cylinder should be
assembled as follows.
Lock Cylinder Assembly—Refer to Figure 20
1.
Hold cylinder with head of cylinder away and starting
•... at the head of the cylinder, insert the tumblers in
their proper slots in the order called for by the
code, ribbed side toward you and long point down.
2.
After all tumblers are in place, check for correct-
ness with the code. Then press tumblers down with
one finger.
3.
Insert one tumbler spring in the space provided
above each tumbler.
CAUTION: If the springs are tangled, do not
pull them apart—unscrew them.
4.
Reverse the lock cylinder so that the head of the
cylinder is now toward you. Insert the spring re-
tainer so that one of its six prongs enters into each
of the springs and the two large end prongs slide into
the slots at either end of the cylinder. Press the
retainer down with one finger.
5. To check, insert proper key and if tumblers are in-
stalled properly the side bar will be allowed to drop
down. If bar does not drop down, remove the key,
spring retainer, springs and tumblers and reas-
semble correctly.
NOTE:
If the tumblers have not been assembled
correctly and not according to the code, the
tumblers can be removed from the cylinder by
holding it with the tumbler slots down, pulling
the side bar out with the fingers and jarring the
cylinder to shake the tumblers out. This pro-
cedure is necessary because after the tumblers
have been pressed down into the cylinder they
are held in their slots by the cross bar.
6. If after checking it is found that the lock is as-
sembled properly, remove key and place cylinder in
INSERTING
TUMBLER
CHECKING
WITH CODE
STAKING
POINTS
NSERTING
TUMBLER SPRINGS
INSERTING
SPRING RETAINER
Fig.
19—Tumbler Requirement Diagram
Fig.
20—Assembling Lock Cylinder
CHEVROLET CHASSIS SERVICE MANUAL
HEATER AND AIR CONDITIONING 1A-56
BLACK & RED
IGNITION—-y^****
SWITCH -"A
/
BLOWER LEAD—^^^
RESISTOR—-" \^<
ASM.
f'
i
'fu^^^^A^^^^^r"G^OUH£>
WIRE
^^
k4
^EVAPORATOR HARNESS
' EVAPORATOR & BLOWER ASM.
Fig.
73—Underdash Wiring—Universal System (Typical)
evaporator outlet pipes. Locate the bracket about
1/2" from the dash panel.
12.
Replace the inlet and outlet hoses and hose clamp
connections.
13.
Evacuate and charge the system. Add three fluid oz.
refrigerent oil after installing a new core.
14.
Check system performance.
Corvette
Replacement (Fig. 78)
1.
Purge the system of refrigerant.
2.
Drain the engine radiator. Then remove the radiator
supply tank from its brackets, the heater water
valve and vacuum line from the firewall, and the
heater hoses from the core pipes. Carefully fold the
hoses,
valve and tank away from the evaporator
case.
3.
Remove the right hand hood lock support.
SCREW DRIVER
(NARROW BLADE) T£
GROOVE
A. Insert screw driver in
tang toward terminal
B. Pry tang back out to
when reinstalled into
RMINAL
\ CONNECTOR
TANG
groove & press
to release.
insure locking
connector.
Fig.
74—Terminal Removal—Universal System
4.
Disconnect the expansion valve equalizer line con-
nection and the evaporator oil bleed line from the
POA.
5.
Disconnect the evaporator outlet to POA inlet
connector.
6. Remove the POA bracket to evaporator case attach-
ing bolts. Then carefully move the valve and its
outlet hose away from the evaporator case.
Fig.
75-Cable Removal-All Weather
CHEVROLET CHASSIS SERVICE MANUAL
HEATER AND AIR CONDITIONING 1A-73
Fig.
105—Comfortron Control Head
10.
Introduce R-12 vapor at cylinder (room) temperature
and pressure.
11.
Leak test all fittings and connections and give partic-
ular attention to a leak test at the compressor shaft
seal if compressor has not been leak tested on the
bench.
12.
Complete system processing and charge system.
FUSES
A fuse, located in the junction block protects the entire
air conditioning system except for the blower when op-
erating at high speed.
A second fuse, to protect the high speed blower circuit,
is located in the electrical wiring between the horn relay
and the Air Conditioner relay (except Universal). The
Universal unit has a fuse in the line between the ignition
switch and the Air Conditioner blower switch. See the
specification page for the proper replacement fuse.
FOUR SEASON HEATER COMPONENTS
Corvette
The heater components of the system are, in general,
much the same as those of the standard Corvette heater.
Heater hoses carry the engine coolant to the heater core,
located in the air distributor duct beneath the instrument
panel.
A significant difference is that in the Corvette Air
Conditioning System there is no flow through the heater
core until the COOL IN-HOT PULL knob is pulled out.
This movement opens the vacuum switch on the air
distributor assembly and allows vacuum to be applied
to the water valve mounted in the engine compartment,
opening the valve. Thus the heater core is unheated
until needed, at which time it receives full flow of the
engine coolant. Air passing through the core receives
maximum heat which is tempered by mixing with un-
heated air before entering the passenger compartment.
Heater Core
Replacement
The heater core in the Corvette Air Conditioning
System is removed in the same manner as the core in
the Corvette heater. The distributor assembly must first
be removed from under the dash as covered previously
in this section before the core can be removed and
replaced.
Water Valve
Installation of the water valve is illustrated in Figure
113.
An inoperative valve must be replaced.
Chevrolet
Heater Core
Removal
1.
Disconnect battery ground cable.
2.
Drain radiator
3.
Remove right front fender and skirt assembly.
Fig.
106—Comfortron Temperature Dial Adjustment
Fig.
107—Amplifier Removal
CHEVROLET CHASSIS SERVICE MANUAL
HEATER AND AIR CONDITIONING 1A-81
HORN RELAY
r
CONN.-
14 BROWN
(TO FUSE
PANEL)
BATTERY
1
—I ^ COMPR
ESSOR
DASH y
V-^ PANEL \
GROMMET—%
1 \
_ J~ ") "^
>14 BLACK/RED STRIPE-
FUSE .20 AMP.
•WIRE ASM. BLOWER-
MOTOR
14 BLACK 1
IGNITION SWITCH1
(ACCESSORY
TERMINAL)
CONTROL SWITCH
-RESISTOR
CONN.
•14 TAN
•16 BLACK
LIGHT BLUE STRIPE
•THERMOSTAT CONTROL
EVAPORATOR & BLOWER ASM.
Fig.
117—Universal System Wiring Diagram (Typical)
CHEVROLET CHASSI
HEATER AND AIR CONDITIONING 1A-82
•BATTERY
(POS)
CABLE
NOTE
When
control
switch*
is !TOFF"
&
Air
Cond
is
"ON"
(Control
knob
pulled
but) the
blower
fan'will
run at low
speed.
CONTROL
SWITCH
CONNECTIONS
OFF
LOW
MED
HIGH
B
TO
NONE
B
TO L
BTOL&M
B
TO L
&
H
COMPRESSOR
GROUND
WIRE
ASM
BATTERY
(NEGATIVE)
CABLE
COMPRESSOR
ASM
DASHPAJSTEL
GROMMET
16DG
CONTROL
SWITCH
RESISTOR
ASM
14LBL
14BRN
CLUTCH
COIL
EXTENSION
WIRE
ASM
-14BRN--N
JUNC
BLOCKi
OSTATIC
SWITCH
CONTACTS
NORMALLY
CLOSED
STARTING
MOTOR
SOLENOID
BLOWER
MOTOR
AIR
COND
CONTROL
(PUSH-PULL)
KNOB
DOOR
SWITCH
(PUSH
BUTTON
NORMALLY
CLOSED)
RELAY
ASM
HORN
RELAY
DIVERTER
DOOR CABLE
FUSE
PANEL
EVAPORATOR
ASM
IGNITION SWITCH-
ACCESSORY TERMINAL)
Fig. 118—All Weather Wiring Diagram (Chevy II)
CHEVROLET CHASSIS SERVICE MANUAL
HEATER AND AIR CONDITIONING 1A-83
DIVERTER DOOR
CRANK POSITIONS:
AIR COND "ON"
AIR COND "OFF*
AIR COND SWITCH
(PUSH BUTTON,
NORMALLY CLOSED
CONTACTS)
BLOWER MOTOR
CONTACTS
NORMALLY
4D
16
16B/Y
COMPRESSOR
GROUND WIRE
ASM
BAT.
TERMINAL
ON STARTING
MOTOR SOLENOID
' BATTERY
CABLE ASM:
NEGATIVE
POSITIVE—*
- CONTROL SWITCH
SET AT:
•OFF
LOW
MED
HIGH
CONTACTS:
BTOBL
BTOL
BTOM
BT0M6B,
CLUTCH
HOUSING
liOli: WHEN CONTROL
SWITCH IS AT "OFF" &
AIR COND. IS "ON", FAN
WILL RUN AT LOW SPEED.
"AIR COND-PULL"
KNOB (SHOWN IN "ON"
POSITION)
TO REGULATOR
HORN
RELAY
16 BRN-BODY WIRING
HARNESS-837
14BRN
I
^
IA^RN
* IGNITION SWITCH
« 12R ACCESSORY TERMINAL
12R f
AMMETER
LEGEND:
AIR COND WIRING (PART OF
ENGINE WIRING HARNESS)
WIRING IS PART OF EQUIP
REG PRODUCTION WIRING
Fig.
119—Corvette—Four-Season Wiring Diagram
CHEVROLET CHASSIS SERVICE MANUAL
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