SECTION
IB
CORVETTE BODY
INDEX
Page
General Description . . * • •.
•
^"i1
Maintenance and Replacements 1B-1
Front End 1B-1
Adjustments IBri
Hood 1B-1
Hood Catch 1B-2
Hood Assembly . 1B-2
Front Emblems 1B-2
Vent Grilles 1B-2
Instrument Panel Tray . 1B-2
Cowl Area Trim
....................
1B-4
Rear View Mirror 1B-4
Outside 1B-4
Inside . 1B-4
Sun Visor . 1B-4
Cowl Ventilator Assembly 1B-4
Windshield ; 1B-5
Doors 1B-7
Adjustments 1B-7
Door Lock Striker 1B-7
Door Window and Vent 1B-7
Door Hinges 1B-7
Trim Panel and Inside Handles IB-11
Weatherstrip 1B-11
Door Ventilator Assembly 1B-12
19437 Model 1B-12
19467 Model 1B-13
Window Glass 1B-13
Glass Run Channel—Upper 1B-14
Window Outer Seal Assembly 1B-14
Window Inner Seal Assembly 1B-14
Glass Run Channel—Rear 1B-15
Window Regulator—Manual 1B-15
Window Regulator—Power 1B-15
Door Lock and Remote Controls 1B-16
Outer Handle . 1B-16
Lock Cylinder 1B-17
Hinges—Door Assembly . 1B-17
Rear Quarter .. . 1B-19
Door Sill and Molding . . 1B-19
Rear End . . r 1B-19
Folding Top Compartment Lid 1B-19
Adjustments . . 1B-19
1B-19
Page
Lock 1B-19
Control 1B-19
Rear Window—19437 Model 1B-21
Gas Tank Door and Rear Trim Plate.,. . . . . . . . 1B-23
Rear Filler Panel 1B-23
Spare Tire Mount 1B-23
Rugs and Interior Trim 1B-25
Cleaning Soft Trim 1B-25
Carpets and Covers—All Models 1B-26
Rear Body Trim , . 1B-26
Soft Covers 1B-26
Rigid Plastic Trim 1B-26
Garnish Moldings Plus-Headliner-19437 Model . . 1B-27
Seats 1B-27
Body Mounting 1B-27
Body Repairs . 1B-27
General Instructions . . . 1B-27
Repair Panels. 1B-28
Precautions 1B-29
Plastic Solder Kit 1B-29
Resin Kit 1B-30
Specific Repairs 1B-32
Scratched Panels-Spot Refinishing 1B-32
Dents in Panels-Surface Cracks !B-33
Cracked Panels . . 1B-35
Fractures 1B-37
Panel Replacement 1B-39
Hard Top . . 1B-41
Care and Storage 1B-41
Rear Window 1B-41
Garnish Moldings and Latches 1B-42
Headlining 1B-43
Weatherstrips and Drip Molding 1B-43
Vinyl Covering . 1B-43
Folding Top 1B-46
Care of Folding Top 1B-46
Care of Rear Window 1B-46
Adjustments 1B-48
Top Assembly, Removal and Installation 1B-49
Top Trim and Rear Window Assembly 1B-50
Frame and Linkage 1B-52
Weatherstrip 1B-52
Adding Hardtop 1B-52
Special Tools 1B-53
GENERAL DESCRIPTION
.
A
structural network
of
steel forms the backbone
of
the
Corvette body. When combined with
the
fiber-glass
re-
inforced plastic body panels,
the
steel-plastic marriage
results
in a
body with increased torsional rigidity
and
greater beaming strength.
Convertible models continue with two roof styles:
the
folding
top
and the removable hardtop. In operation, both
tops function similar to those
of
previous models. Either
top
is
standard and both
are
optional
as
determined by
the top selected
as
base equipment.
MAINTENANCE
&
REPLACEMENTS
FRONT
END
ADJUSTMENTS
(Refer to Figure
2)
Adjustments should
be
made
in
order
-
hood position
first, then catch adjustments.
Hood
The position
of the
hood
in
relation
to
the hood body
opening and the fender surfaces
is
controlled by the posi-
tion
of the
hinges and position
and
adjustment
of
catch
and bumpers.
The fore
and aft
position
of the
hood may be adjusted
CHEVROLET CHASSIS SERVICE MANUAL
CORVETTE BODY 1B-4
Fig.
3-Hood Spacing
vehicle as a unit by removing six screws around the
outer edge of opening, two screws retaining striker plate
and four screws which fasten compartment support to
cowl cross brace under dash. For parts identification
refer to Figure 6.
COWL AREA TRIM
Figure 7 illustrates instrument panel pads, cowl
"kick'.' panels, radio grille cover and console-to-dash
trim panel.
Figure 8 illustrates trim and moldings which are in-
stalled in the console area.
When installing instrument panel pads, it is advisable
to use new clips. Position of these clips upon installation
is illustrated in Figure 9.
REAR VIEW MIRROR
Outside
Removal
The outside rear view mirror may be removed from
the'
door by removing the set screw, located on the in-
board side of the mirror support, with an alien wrench.
Installation
Mirror may be installed by following the removal
procedures in reverse order. ,
Inside
Installation of inside mirror may be seen in Figure 10.
Tension of mirror stud may be adjusted by loosening or
tightening adjusting screw.
SUN VISOR
Attachment of sun visor assembly to windshield header
is made as shown in Figure 10. Turning adjusting screw
in increases friction.
COWL VENTILATOR ASSEMBLY
The following outline covers either the right of left
hand side. Refer to Figure 11.
Removal
1.
Disconnect positive cable from battery.
CHEVROLET CHASSIS SERVICE MANUAL
CORVETTE BODY
1B-6
ASH TRAY
SET SCREW
(PART
OF
KNOB)
TENSION
ADJUSTING
SCREWS
Fig.
8—Console Trim
cracks",
the
windshield opening must
be
carefully
checked
for
irregularities
and
deformation.
To
check
windshield opening proceed
as
follows:
1.
With weatherstrip
and all
foreign material removed
from perimeter
of
opening and with molding clips
in
place, install windshield checking blocks (Special
Tool J-8942)
as
shown in Figure 17. Note that check-
ing blocks must
be
placed over molding clips
to
obtain proper alignment.
2.
Place
a new
windshield glass
in
opening, resting on
J-8942 blocks
as
shown in Figure
18.
3.
Check
fit of
glass carefully. Space between glass
and frame should not vary more than 1/8".
4.
Mark
and
repair
any
imperfections. Recheck
fit as
required.
Fig.
9—Special Clip
Fig.
10—Sun Visor and Inside Rear View Mirror
Installation
1.
Carefully clean
all
loose material
out of
windshield
frame
(fig. 19).
2.
Install
new
molding clips (Item
9, fig. 12).
Both
models
use 13
type
B
clips equally spaced on lower
frame section.
37
Models use 11 type A clips equally
spaced on the top frame section.
3.
Apply
a
bead
of gun
grade body sealer such
as
3M-1170
in
apex
of
windshield frame
as
shown
in
Figure
20.
4.
Install weatherstrip on windshield glass.
5. Starting
at
bottom center
of
glass, insert
a
piece
of
heavy cord such
as
chalk line,
etc. in
groove
of
weatherstrip.
Cut
cord long enough so that about 10"
of free length exists after going around windshield.
Knot ends
of
cord together where they meet at bot-
tom center
of
glass
and
draw knot into groove
(fig.
21).
Tape loose ends
to
inside surface
of
glass
as
shown.
6. Place weatherstrip windshield assembly
in
wind-
shield frame. From inside
of
vehicle grasp ends
of
cord and pull toward you.
It is
wise to have an assis-
tant exert gentle
but
firm pressure
on
outside sur-
face
of
glass
in the
area where string
is
emerging
from weatherstrip. Figure
22
illustrates action
of
string
on
weatherstrip.
Lip of
seal
is
pulled out of
frame apex and over pinchweld flange.
7. When string
has
been removed, carefully inspect
seating
of lip
over entire perimeter
of
windshield,
paying particular attention to corners.
8. Apply
2
beads
of
sealer on outer surface
of
weather-
strip
as
shown
in
Figure
23.
Inject
a
moderate
quantity
of
windshield cement such
as
3M-6699B
between windshield glass
and
weatherstrip using
pressure gun
as
shown
in
Figure
23.
9. Install lower reveal molding, aligning
it
with mark
made upon disassembly. Refer
to
Figure
12,
View
A, before attempting installation; note that flange
of
molding
and
clips (item
9) at
ends
of
molding must
pass between molding retaining clips and windshield
frame.
li
difficulty
is met in
engaging molding
flange with retaining clips,
a
piece
of
shim stock
may
be
used
as a
"shoe horn"
to
place flange be-
hind clips.
10.
Install
in
order named: Upper reveal molding (align-
ing marks made
at
disassembly); side weatherstrip
CHEVROLET CHASSIS SERVICE MANUAL
CORVETTE BODY
1B-7
HEAT
CONTROL
€P-
CABLE
VIEW A
HOOD RELEASE
Fig.
11—Cowl Ventilator
and
Controls
and reveal moldings; upper garnish molding; lower
garnish molding; side garnish molding; header latch
plates on 19467 Models and rear view mirror.
11.
Clean
up
excess sealer
and
cement with rag damp-
ened with oleum spirits, prep-sol
or
kerosene;
in-
stall wiper arm assemblies.
DOORS
ADJUSTMENTS
Door Lock Striker
Door lock strikers incorporate
an
inter-lock feature
consisting
of a
notch
in the
striker into which the lock
bolt housing extension engages. With
the
inter-lock
feature
it is
very important that
the
lock extension en-
gages properly
in the
striker notch
and
that, where
necessary,
the
correct striker emergency spacers
are
used to obtain proper engagement.
1.
To
adjust striker
up,
down,
in, or
out loosen striker
plate screws and shift striker and adjusting plates
as
required, then tighten screws.
2.
To determine
if
door lock striker emergency spacers
are required, apply modeling clay
or
body caulking
compound
in the
door lock striker notch where
the
lock extension engages,
and
then close
the
door
to
form
a
measurable impression in the clay
or
caulk-
ing compound,
as
shown
in
Figure
24.
Remove
all
clay
or
compound when adjustment
is
completed.
When dimension
"A"
from inside face
of
striker teeth
to center
of
lock extension
is
less than 3/16", install
emergency spacers
and
proper length striker attaching
screws.
NOTE:
Dimension
"B"
from center
of
lock
extension
to
inside face
of
striker notch should
.
never be less than 1/8".
If check indicates need
for
emergency spacers,
pro-
ceed
as
follows:
1.
With pencil, scribe position
of
striker on body pillar.
2.
Remove three door lock striker attaching screws and
remove striker
and
adjusting plates from pillar.
3.
To
install, place striker, shims and adjusting plates
within scribe marks
on
pillar
and
tighten screws.
IMPORTANT: Whenever
a
door
has
been
re-
moved
and
installed,
or
realigned,
the
door
SHOULD NOT be closed completely until
a
visual
check
is
made to determine
if
the lock extension/
will engage
in the
striker notch. Where
re-
quired, door lock striker emergency spacers
should
be
installed
so
that door
can be
closed
and
an
accurate check made to determine emer-
gency spacer requirements.
Door Window and Vent Adjustment
To move
the top of the
window
in or
out, the bottom
ends
of
both
run
channels
are
adjustable.
The
rear
channel
is
adjusted
by
loosening
the
lower
of
the two
screws
on the
rear face
of
door, "C" Figure 25, and
moving channel
as
necessary.
The
front channel
is ad-
justed
by
removing
the
trim pad and moving the Channel
in
or out by a
stud
and nut
adjustment, "B" Figure 25.
The
top end of the
rear channel
is
not adjustable in
or
out.
On 19467 models
an
adjustment
may be
made
to the
closed-door relationship
of the
vent assembly
to the
windshield frame. This adjustment
is
controlled
by the
stud-nut assembly "B" Figure
25.
The closed position
of the
window
is
controlled
by
bumper assemblies located
at
each end
of
window frame
as shown
in
Figure
26.
^
Access
to
bumper retaining
screw
may be
gained through holes
"D" and
"E"
in
Figure
25.
Door Hinges
The position
of the
door assembly in the body opening
is adjusted
by the
striker plate position covered
pre-
viously
and the
position
of the
door
on
the hinge rear
CHEVROLET
a
SERVICE