ENGINE-ELECTRICAL-6Y-30
Fig.
2 li—Removing Ignition Switch Nut
4.
Remove heater and/or A/C control panel assembly
retaining screws and push panel assembly from
console.
NOTE: If interference between control panel
and radio is encountered, loosen radio retaining
nuts.
5.
Remove radio control knobs, bezels and retaining
nuts.
6. Disconnect radio wiring harness and antenna lead-in.
7.
Remove radio rear brace attaching screw and re-
move radio from vehicle.
Fig.
231—Switch and Connector Unplugged
8. Remove ignition switch bezel nut using Tool J-7607
and push switch rearward from panel opening.
9. Disconnect wiring connector from rear of switch.
10.
To install, reverse removal procedure.
SPARK PLUGS
CLEANING AND REGAPPING
Clean the spark plugs thoroughly, using an abrasive-
type cleaner. If the porcelains are badly glazed or
blistered, the spark plugs should be replaced. All spark
plugs must be of the same make and number or heat
range. Use a round feeler gauge to adjust the spark plug
gap to specifications (fig. 24i).
Fig.
22i—Unlocking Ignition Switch Connector
Fig.
241—Setting Sfxirk Plug Gap
CHEVROLET CHASSIS SERVICE MANUAL
CHASSIS SHEET METAL 11-4
FENDERS
Fenders are adjustable with shims at the cowl and
rocker panel. To add or remove shims, loosen bolts at
shim locations (fig. 7) and carefully apply force with pry
bar to provide clearance for shim removal or installa-
tion.
SHEET METAL ADJUSTMENTS
For proper operation of doors and hood, and for pre-
sentable appearance, adjust front sheet metal to the tol-
erances shown in Figures
4-
and 5.
COMPONENT PART REPLACEMENT
NOTE: When replacing sheet metal compo-
nents on Chevrolet or Chevelle, note position and
attachment of all seals and dust shielding and
replace as necessary.
BATTERY TRAY
Removal
1.
Disconnect battery cables.
2.
Remove screw retaining battery hold down clamp and
remove battery from vehicle.
3.
Remove screws retaining battery tray to fender skirt
and radiator support.
4.
On Chevrolet, remove headlamp bezel and remove
screw retaining tray to radiator support.
5.
Remove battery tray from vehicle.
Installation
Reverse removal procedure.
RADIATOR SUPPORT
Removal
1.
Remove front bumper (Section 14).
Fig.
3 - Hood Hinge - Chevrolet
2.
Remove grille and related components (Section 13).
3.
Remove battery tray as outlined above.
4.
Remove all electrical connections from radiator
support.
5.
Remove windshield washer bottle from bracket on
radiator support.
6. Remove shroud and radiator (Section 13).
7.
Remove screws and bolts securing support to skirts,
fenders, and frame horns (figs. 8 and 9).
8.. Spread fenders apart enough to allow support move-
ment and remove support from front of vehicle.
Installation
1.
Position the radiator support in vehicle", aligning
mounting screw and bolt holes with drift punch.
2.
install screws and bolts loosely until all are started.
3.
Replace all parts removed following removal proce-
dure in reverse order.
4.
Refer to torque specifications in rear of manual for
correct torque values.
•
5.
Aim headlamps as outlined in Section 12.
FENDER ASSEMBLY
Removal
1.
Remove hood with hinges from vehicle as outlined in
this section.
2.
On Chevrolet models, remove headlamp bezels and
headlamps; on Chevelle models, remove grille ex-
tension panels (fig. 1 or 2 as applicable).
3.
Disconnect wiring harness clips from fender to be
removed.
4.
If applicable, remove horn assembly from fender.
5.
If applicable, remove radio antenna.
6. Remove fender brace (fig. 1 or 2 as applicable).
7.
Remove screws retaining fender to radiator support,
skirt, cowl, filler panel, tie bar, and rocker panel.
Note number and location of shims removed from
locations shown in Figure 7.
8. Remove fender from vehicle.
Installation
Refer to disassembly procedure for location of screws
and install screws loosely. Install the shimmed screws
at rocker panel and cowl and adjust fender (figs. 4 and 5)
before tightening other screws. Always start adjustment
with original amount of shims, then add or remove shims
as required.
FENDER SKIRT
Removal
CAUTION: Chevelle air conditioned models
have condenser hoses routed through the right
front fender skirt. Cut skirt and bend as neces-
sary to move hoses clear of skirt. If necessary,
refer to Section 1A for air conditioning compo-
nents and procedures.
CHEVROLET CHASSIS SERVICE MANUAL
ELECTRICAL-BODY AND CHASSIS 12-21
2.
Remove ash tray, retainer attaching screws and
retainer.
3.
Remove Air Conditioning distributor
duct'
retaining
screws and duct.
4.
Remove heater and/or Air Conditioning control panel
assembly retaining screws and push panel assembly
from console.
NOTE:
If interference between control panel
and radio is encountered, loosen radio retaining
nuts.
5. Remove radio control knobs, bezels and retaining
nuts.
6. Disconnect radio wiring harness and antenna lead-in.
7. Remove radio rear brace attaching screw and re-
move ra(Jio from vehicle.
8. Remove ignition switch bezel nut using Tool J-7607
and push switch rearward.
9. Disconnect cigarette wiring connector.
10.
Remove cigarette lighter retainer and lighter as-
sembly from console.
11.
To install, reverse removal procedure.
Fig.
35 - Cigarette Lighter — Chevelle
CHEVROLET INSTRUMENTS AND GAUGES
INDEX
Page
General Description 12-21
Service Operations 12-22
Instrument Cluster........................ 12-22
Instrument Cluster Lamps 12-22
Printed Circuit .
* •
12-22
Speedometer 12-22
Speedometer Cable 12-23
Fuel Gauge 12-23
Page
Clock 12-24
Tachometer 12-24
Ammeter . . 12-24
Temperature Gauge 12-24
Oil Pressure Gauge 12-24
Oil Pressure Indicator 12-24
Generator Indicator 12-26
Temperature Indicator 12-26
GENERAL DESCRIPTION
The standard instrument cluster on all models contains
seven circular housings consisting of: a speedometer;
fuel gauge; oil pressure, generator and temperature indi-
cators; right and left directional signal indicators; brake
warning and high beam indicators; and includes a clock
on deluxe models. An optionally available instrument
cluster provides special instrumentation which includes
in addition to the speedometer and clock: a tachometer;
fuel, oil pressure, ammeter and engine temperature
gauges; which replace the standard fuel gauge and indi-
cator lights. The brake warning indicator is relocated
to the tachometer dial face and the high beam and direc-
tional indicators are positioned in the speedometer dial
face.
Instrument cluster removal is recommended before at-
tempting to service the printed circuit and gauges even
though some units may be accessible from behind the
cluster. Limited working space under the instrument
panel increases the possibility of electrical malfunctions
due to poor connections, and damaged or improperly in-
stalled printed circuit. The printed circuit is service-
able but not repairable and requires complete
replacement.
The brake warning light serves a dual purpose. It
functions as an indicator when the parking brake is ap-
plied and also warns if a malfunction (loss of hydraulic
pressure) should occur in the brake system. The two
separate switches, which provide the signal to operate the
indicator, are located at the parking brake support and in
the hydraulic brake line at the master cylinder. Service
of the brake pressure, differential switch unit at the
master cylinder is described in Section 5 of this manual.
All indicator and cluster illumihating lamps may be
replaced without removing the cluster from the vehicle.
The bulbs are installed in plastic holders which lock into
the cluster housing and make contact with the printed
circuit. An instrument lamp is used to illuminate the
ignition switch. A special fibre optic lucite wiring
transmits light from the lamp to the switch.
Regular maintenance is not required on the instrument
cluster or its components other than maintaining clean,
tight electrical connections, replacing defective parts and
keeping the speedometer cable properly lubricated.
CHEVROLET CHASSIS SERVICE MANUAL