1964 CHEVROLET -CHEVELLE-CHEVY II-CORVAIR- CORVAIR SERIES 9S-CHEVROLET TRUCKS ACCESSORIES INSTALLA liON REFERENCE MANUAL
A reference manual to assist dealer service managers in training new car get ready men and mechanics in the proper installation of accessories. Accessories that are installed correctly will fulfill there purpose, function and give satisfactory service to the car owner.
All illustration and specifications contained in this lit.rature ore based on the latest produCt information available at the time of publicatibn approval. The right is reserved to make changes at any time without notic. in prices, colors, materials, equipment, specifications and mod.ls, and also to discontinue models.
CHEVROLET MOTOR DIVISION, GENERAL MOTORS CORPORATION DETROIT MICHIGAN 48202
© 1963 CHEVROLET MOTOR DIVISION GENERAL MOTORS CORPORATION
P&A 15 8.6M LITHO IN U.S.A. ALPHABETICAL INDEX
Flat Part Page Description Rate No. No. Hours
ADAPTER - Air Condo - Truck - without Heater. 986009 96-148 ADAPTER - Air Condo - Pass ....•....• 985750 10-28 ADAPTER - Hazard Flasher Switch - Chevelle 985810 521 ADAPTER - Arm Rest - 95 ....••... 988410 457 ADAPTER - B.U. Lamp - 4 Spd. - Corvair 986004 9 ADAPTER - Radio - Tilt Cab ...... 985673 448-452' AIR CONDITIONING - Custom - Pass. ALL 10-28 7.5 AIR CONDITIONING - Custom - Chevelle ALL 29-45 7.5 AIR CONDITIONING - Deluxe - Chevy II ALL 46-70 7.5 AIR CONDITIONING - Deluxe - Corvair ALL 71-95 10 .0 AIR CONDITIONING - Truck . . . ALL 96-148 7.5 ANTENNA - Right Front - Pass. 985922 149-150 .2 ANTENNA - Right Rear - Pass. 985923 151-152 .•5 ANTENNA - Left Rear Dummy - Pass. 985924 151-152 .3 ANTENNA - Right Front - Chevelle . . 985774 153-154 .3 ANTENNA - Right Rear - Chevelle - Exc. Sta. Wag. Cony. & Cpe...... 985778 155-157 .5 ANTENNA - Left Rear Dummy - Chevelle - Exc. Sta. Wag. Cony. & Cpe. . ••..•...... •..• 985820 155-157 .3 ANTENNA - Right Rear - Chevelle - Cony. & Cpe .•.. 985973 155-157 .5 ANTENNA - Left Rear Dummy - Chevelle Cony. & Cpe. 985974 155-157 .3 ANTENNA - Right Front - Chevy II . • . . 985456 158-159 .3 ANTENNA - Right Rear - Chevy II ..•. 985577 160-163 .5 ANTENNA - Left Rear Dummy - Chevy II 985578 160-163 .3 ANTENNA - Right Front - Corvair .... 985450 164-165 .3 ANTENNA - Right Rear - Corvair . . . . . 985940 166-170 .5 ANTENNA - Left Rear - Dummy - Corvair 985941 166-170 .3 ANTENNA - Left Rear - Corvette . . . . 985687 171-173 .5 ANTENNA - 95 Only ...... 985444 174-175 .3 ANTENNA - All Exc. Tilt & 95 - Truck 985928 176-177 .3 ANTENNA - Tilt Only - TOO - 80, U80 985473 178-179 .3
BELT - Seat - Front ALL 180-185 .4 BELT - Seat - Rear .. ALL 186-195 .5 BEZEL - License Plate - Corvair 985325 196 .2 BRACKET - R.H. SafetyJight used with 985861 Truck 985862 463-465 BRACKET - 1 S.R.V. Mirror •...... •.... 988173 197 BRACKET - Mud Flap - used with 987226 .... 985918 258-261 BRACKET - O.S.R.V. Mirror - used with 985823 985824 393 BRACKET -R.H. SafetyJight - Chevelle 985808 460-462 BRAKE - Power - Pass. .. 985992 198-201 .8 BRAKE - Power - Chevelle •.... 985964 202-204 .8 BRAKE - Power - Chevy II . . • • . 985993 205-206 .8 BRAKE - Power - Truck Cl.Jl-20-30 985936 207-209 1.3
CARRmR - Roof Luggage - 4 Stanch. Pass. & Chevelle • 985690 210 1.4 CARRIER - Roof Luggage - 6 Stanch. - Pass. Sta. Wag. 985691 211 1.4 CARRIER - Roof Luggage - 5 Stanch. Chevelle Sta. Wag. 985806 212-213 1.4 CARRIER - Roof Luggage - Sedans ~ Corvair ...... 985056 210 114
5 ALPHABETICAL INDEX (Continued)
Flat Part Page Description Rate No. No. Hours
CARRIER - Roof Luggage - Sedans - Corvair 985056 210 1.4 CARRIER - Roof Luggage - Panels & Greenbrier. 988398 211 1.4 CLOCK - Electric - Pass. .. 985914 214 .4 CLOCK - Electric - Chevelle ... 985868 215 .5 CLOCK - Electric - Chevy II. . . 985581 216 .5 CLOCK - Electric - Corvair & 95 985865 217-220 .5 CLUTCH - Modulated Fan - Pass. 985355 221 .3 COMPASS - Pass. Exc. Cony. 985002 222-223 .3 CONTROL - Guidematic Headlamp - Pass. 985519 224-225 1.6 COVER - Roof Luggage - Pass. Chevelle & Chevy II 985946,947 226 .3 COVER - Seat - Truck . . 955370 227-228 .4 COVER - Wheel 14" & 13" ...... A~L 229 .4
DEFROSTER - Rear Window - Pass. Chevelle & Chevy II 985758 230-233 .7 DISPENSER - Tissue - All Exc. Trk & Corvette 985827 234 .3
.FRAMES - License - Pass. & Chevelle 985739 235 N/C
GUARD - Bumper - Front - Pass. 985829 236 .4 GUARD - Bumper - Front - Chevelle 985830 237 .4 GUARD - Bumper - Front or Rear - Corvair. 988203 238 .4 GUARD - Bumper - Rear Exc. sta. Wag. - Pass. 985668 239 .2 GUARD - Bumper - Rear Exc. Sta. Wag. - Chevelle 985761 240 .2 GUARD - Bumper - Rear - Chevy II 985302 241 .2 GUARD - Grille - Chevy II 985435 242 .3 GUARD - Grille - Brush Type - Truck 985866 243 1.0 GUARD - Grille - Brush Type - Truck 985867 244-245 1.0 GUARD - Bumper - Front - Truck •• 985501,502 246 .2 GUARD - Bumper - Front or Rear - 95. 985070,988373 247 .2 GUARD - Door Edge - Pass ..• .• 985485,486 248 .2 GUARD - Door Edge - Chevelle .. 985849,850 249 .2 GUARD - Door Edge - Chevy II .. 985163,164 250 .2 GUARD - Door Edge - Corvair . . 988082,988422 251 .2 GUARD - Gasoline Filler Door - Impala & Super Spt. .... 985735,736 252 .2 GUARD - Gasoline Filler Door - Biscayne, Belair & Sta. Wag ...... • 985885,985489 253 .2 • GUARD - Gasoline Filler Door - Corvair 988274 254 .2 GUARD - Mud Flap - Station Wagon - Pass. Chevelle & Chevy II . . . . 985818 255-257 1.0 GUARD - Mud Flap - Truck ...... 987226 258-261 .4
HARNESS - Accessories Wiring - 95 .. 988350 262 HEATER & DEFROSTER - Deluxe Truck 985769 263-269 1.6 HEATER & DEFROSTER - Deluxe Tilt Cab 988354 270-276 4.2 HEATER & DEFROSTER - Thriftair .... 985991 277-283 1.2 HEATER & DEFROSTER - Custom - Deluxe Air 985698 284-298 5.0 HEATER & DEFROSTER - Custom - Gasoline 985648 299-310 3.9 IDTCH - Trailer - Pass. Exc. sta. Wag. 985984 311-313 1.0 HITCH - Trailer - Pass. - Station Wagon. 985766 314-316 1.0
6 ALPHABETICAL INDEX (Continued)
Flat Part Page Description Rate No. No. Hours
HITCH - Trailer - Chevelle Exc. Sta. Wag...... 985744 317-318 1.0 HITCH - Trailer - Chevelle - Station Wagon . . . . . 985745 319-320 1.0 HITCH - Trailer - Except Station Wagon - Chevy II 985988 321-322 1.0 HITCH - Trailer - Station Wagon - Chevy II 985989 323-324 1.0 HITCH - Trailer - Corvair 985985 325-326 1.0 HORN - Air - Truck •. 9.85959 327-330 1.2 HORN - Matched - Truck 985809 331 .3
LAMP - Ash Tray - Pass. & Chevelle 985.926 332-333 .3 LAMP - Back Up - Exc. Sta. Wag. - Pass. 985905 334 .6 LAMP - Back Up - Sta. Wag. Pass. 985906 335-336 1.1 LAMP - Back Up - Exc. Sta. Wag...... ' .. 985907 337-338 .6 LAMP - Back Up - Station Wagon - Chevelle 985908 339-340 1.1 LAMP - Back Up - Chevy II ...... 985969 341-344 .5 LAMP - Back Up - 5 & 700 Series Corvair 985705 345-346 1.4 LAMP - Back Up - Pick Ups & Panels 985970 347-351 .8 LAMP - Cab Clearance - Truck •. 985977 352-356 .8 LAMP - Courtesy - All Exc. Truck .. 985899 357-361 .5 LAMP Dome - 95 ...... 988346 362-363 1.0 LAMP - Glove Compartment - All 985898 364-367 .2 LAMP - Luggage Compartment - All Exc. Trk. 985879 368-373 .3 LAMP - Under hood - All Exc. Truck .. 985880 374-376 .3 LIGHTER - Cigarette - 100 & 200 Series - Chevy II 985999 377 .2 LIGHTER - Cigar ette - Tru ck ...... 985787 378-379 .2 LIGHTER - Cigarette - 95 ...... 985975 380 .2 LOCK - Rear Compartment - Sta. Wag. - Pass ... . 985351 381-382 .5 LOCK - Rear Door Safety - 4 Door - All Exc. Trk. 985295 383 .2 LOCK - Spare Tire - Corvair ...... 985113 384 .2
MIRROR - Outside Rear View - Remote Control - Pass. 985986 385-386 .8 MIRROR - Outside Rear View - Remote Control - Chevelle, Chevy II & Corvair . • ...... 985987 387-388 .8 MIRROR - Outside Rear View - All ...... 985878 389-391 .3 MIRROR - Outside Rear View - 5" x 7" - Truck ... 985823 392-393 .5 MIRROR - Outside Rear View - 7 1/ 2 x 10 1/ 2 - Truck 986014 394-395 .8 MIRROR - Outside Rear View - 6" x 11'; - Truck •.. 985771 396-397 . .8 MIRROR - Outside Rear View - 7" x 16" - Tilt Truck 985283 398-399 .8 MIRROR - Outside Rear View - 7" x 16" - Truck Exc. Tilt 985780 400-401 .8 MOULDING - Body Sill - Chevelle . • . . 985881 402 .7 MOULDING - Hood & Deck Lid - Pass •.. • . • .. •• 985721 403 1.1
OPENER - Automatic Trunk - Pass., Chevelle & Chevy II 985896 404-411 1.0
RADIO & ANTENNA - AM - FM - Pass...... 985873,874 412-415 1.5 RADIO & ANTENNA - Manual & Push Button - Pass. • . ALL 416-419 1.8 RADIO & ANTENNA - Manual & Push Button - Chevelle ALL 420-422 1.8 RADIO & ANTENNA - Manual & Push Button - Chevy II ALL 423-426 1.8 RADIO & ANTENNA - Manual & Push Button - Corvair ALL 427-430 1.8 RADIO & ANTENNA - AM - FM - Corvette ...... 985909 431-438 2.5
7 ALPHABETICAL INDEX (Continued)
Flat Part Page Description Rate No. No. Hours
RADIO & ANTENNA - Manual - Truck Exc. Tilt Cab 985670 437-448 1.6 RADIO & ANTENNA - Manual - Tilt Cabs 985671 449-453 1.6 RADIO & ANTENNA - Manual - Series 95 985814 454-457 1.9 REST - Arm - Truck 985629 458 .2
SAFETYLIGHT - Pass. 985666 459-460 1.0 SAFETYLIGHT - Chevelle 985807 461-463 1.0 SAFETYLIGHT - Truck • . 985861 464-466 1.0 SAFET1ILIGHT - 95 Series 988335 467-469 1.0 SCREEN - Radiator - All Exc. Corvair 985768 470-471 .2 SIGNAL - Parking Brake - Pass. 985994 472 .4 SIGNAL - Parking Brake - Chevelle .. 985901 473 .4 SIGNAL - Parking Brake - Chevy· II .. 985248 474 .3 SIGNAL - Parking Brake - Corvair .. 985333 475 .4 SIGNAL - Direction - Conversion - Truck. 985920 476 .7 SIGNAL - Direction - Conversion - 95 .• 985978 477-478 .7 SIGNAL - Open - Rear Door - Warning - Exc. Truck & Corvette 985591 479-480 .9 SPEAKER - Rear Seat - All Sedans - Pass. . .. 985495 481-482 1.0 SPEAKER - Rear Seat - Spe. Cpe. & Cony. Pass. 985496 483-486 1.0 SPEAKER - Rear Seat - Station Wagon - Pass. 985497 487-489 1.0 SPEAKER - Rear Seat - Chevelle .. 985803 490-492 1.0 SPEAKER - Rear Seat - Pass. & Sta. Wag. Exc. Conv. - Chevy II...... 985493 493-496 .9 SPEAKER - Rear Seat - Exc. Cony. - Corvair 985590 497-499 .7 SPEED & CRUISE CONTROL - 8 Cyl. Pass. 985934 500-507 3.0 SPEED & CRUISE CONTROL - 6 Cyl. Pass. 985933 508-515 2.5 SPRING - Auxiliary - Truck 985767 516-517 1.0 SPRING - Auxiliary - Truck 985515,516 518 1.0 STEP - Side Panel - Truck. 988423 519 .8 STRAP - Luggage - Corvette 985929 520 .8 SWITCH - Hazard, Flasher - All Exc. Corvair 985886 521-528 .5
TABLE - R1206 985107 529
VENTSHADE - Pass. Chevelle Series 95 ALL 530 .3 VENTSHADE - Chevy II . . . • • • • . . • ALL 531 .3 VENTSHADE - Corvair •••...... ALL 532 .3 VENTS HADE - Truck ...... 533 .3 VISOR - R.H. Sun - Truck Exc. Tilt Cab ~:~~~~ 534 .3 VISOR - R.H. Sun - Tilt Cab . 985753 535 .3 VISOR - R.H. Sun - 95 Series • <. 985900 536 .3
WASHER - Windshield - Pass. 985789 537-539 .6 WASHER - Windshield - Chevelle 985788 540-542 .6 WASHER - Windshield - Chevy II 985491 543-544 .6 WASHER - Windshield - Corvair . 985512 545-546 .6 WASHER - Windshield - Truck Exc. Tilt Cab . 985754 547-550 1.0 WASHER - Windshield - Tilt Cab 985755 551-554 1.0 WASHER - Windshield - 95 Series . 985756 555-557 1.0
8 ANTENNA 985444 CORVAIR 95
\\\~. ;~~ ~0\\,c-~ TEMPLATE Ji 'WINDSHIELD OPENING RABBET
II TAPE ""',
o BODY OPENING \ TEMPLATE
RIB ON BEZEL
NOTCH IN OUTER PANEL
RETAINER TUBE
• 136 D1A. HOLE In Hinge Pillar (NO. 29 DRILL) I
CABLE ASM. LEAD-IN
ANTENNA MOUNTING
STEP 1 ALIGN TEMPLATE ON RIGHT HAND BODY FRONT STEP S SUB-ASSEMBLE GASKET & BEZEL. PLACE GAS OUTER PANEL, TAPE IN PLACE,CENTER PUNCH & DRILL KET, BEZEL & CAP ONTO ANTENNA BODY ASM., POSITION AS INDICATED ON TEMPLATE. REMOVE ANY RESULTANT Rm ON BEZEL INTO NOTCH IN OUTER PANEL. SECURE BURRS. SEE FIG. 2. CAP WITH SPANNER WRENCH. SEE FIG. 1 & VIEW A.
STEP 2 REMOVE RIGHT HAND HEADLAMP. STEP 6 INSERT CABLE ASM. LEAD-IN THRU RETAINER TUBE & CAREFULLY TIGHTEN KNURLED NUT TO ANT STEP 3 SLIDE SPACER & GROUND RING OVER ANTENNA ENNA BODY ASM. WITH GAS PLIERS. SCREW RETAINER BODY ASSEMBLY. SEE VIEW A.. TUBE ONTO ANTENNA BODY ASSEMBLY. SEE VIEW A.
STEP 4 INSERT ANTENNA BODY ASM. THRU HEADLAMP STEP 7 ASSEMBLE CLIP, BRACKET & "U" NUT TO RETAIN OPENING & UP THRU HOLE IN OUTER PANEL. ALIGN ER TUBE AT DIMENSION SHOWN WITH ONE OF PROVIDED FLAT ON GROUND RING UNDER NOTCH IN OUTER PANEL. SCREWS. USING BRACKET AS A TEMPLATE, DRILL HOLE IN SEE VIEW A. HINGE PILLAR & ATTACH BRACKET TO PILLAR WITH RE MAINING SCREW. SEE FIG. 1 & VIEW A.
CD 1962 Chevr()lel D.vlslon PRINTED IN U. S. A. .~-, General Motou Corp. 174 \\ \
""lIi-i" Aft.r assembly make sure th. '\ anlenna cable Is posltloned AWAY from _ ~\'\ \'7\, existing vehicle wiring. ==::::::::::::: DRILL 1/2 INCH DASH PANEL:t=--'...... --...... DIA. HOLE -- -- ~ ~ \ -\ r~~~ -1 ci-=vy- --r -- -=~ '~~' ~--/ . _~~,~-: ~(( F~__ F~:3dl~~~~~~~ ----:-== ~../~ EXISTING SCREW 2:K~ ~iC' - \ I .~, ,_. 1/ /I \ . : to 'r <:J " -- --- I \d: -_::--1 .1 EXISTING SCREW
\ __~R_~CEIVERJ- r ~ ~------~==~~~
(ABLE ASSY. LEAD-IN
STEP 8 REMOVE INSTRUMENT PANEL COMPARTMENT. PLUG INTO REAR OF RADIO RECEIVER. SEE FIG. 3. LOCATE & DRILL HOLE IN DASH PANEL FROM INNER SIDE THRU INSTRUMENT PANEL COMPARTMENT OPEN STEP 12 REMOVE EXISTING KNOB, WAVE WASHER & ING. SEE FIG. 3. SPACER FROM RIGHT HAND RADIO RECEIVER CONTROL TO GAIN ACCESS TO ANTENNA TRIMMER SCREW. SEE VIEW B. STEP 9 ROUTE PLUG END OF CABLE ASM. TIffiU THE DRILLED HOLE. SEE F1G. 3. ",'i"NI'Do not kink or STEP 13 ADJUST ANTENNA; TUN,E DIAL TO WEAK STAroN bend cable asm. sharply at any time. BETWEEN 800 &. lOOO-KC WITH VOLUME TO OR NEAR MAXIMUM. ADJUST TRIMMER SCREW FOR HIGHEST VOL STEP 10 SLIDE GROMMET OVER PLUG END OF CABLE ASM. UME AT SPEAKER. SEE VIEW B.II!DIAdjust screw thru slot & SNAP INTO HOLE IN DASH PANEL. SEE FIG. 3. in spacer.
STEP 11 ROUTE CABLE ASM. ACROSS TOP OF HEATER STEP 14 REPLACE ALL PARTS PREVIOUSLY REMOVED. HOLE COVER &. SECURE WITH CLIP &. EXISTING SCREW.
175 SEAT BELT -FRONT ALL CHEVROLET -CHEVELLE -CHEVY II-CORVAIR CHEVROLET TRUCK AND CORVAIR SERIES 95
FRONT SEAT CHEVY DRIVER PASS. ALL MODELS ~ lID
PLUG LOCATION TYPICAL
IIIIJ L. H. locanon is symmetrlcally OPPO;/~e. IJ31 ':::::::'---, ~ --.....- ~/\y; . ~1~~:"")'---
--~~~? ..~~ CENTERLINE OF TUNNEL
UNDERBODY
CHEVY (TYPICAL SEAT BELT INSTALLATION)
CI!DI The following steps are for driver && one passenger belt TO HOLE IN PLUG. CUT HOLE IN CARPET OR MAT AROUND installations. For third passenger procure one of the following INSERTED AWL. SEE FIG. 1 VIEW "A"&THE FOLLOWING color matching belt Wlit numbers 985842-3-4-5-6-7-8. For Sub FIGURES WHERE REQumED. urban" Greenbrier use 985842 only. FIG. 1 - CHEVY FIG. 2 - CHEVROLET FIG. 3 - PASSENGER "A" STEP 1 USING DIMENSIONS GIVEN, (FIG. 1 THRU 6)LOCATE FIG. 4 - CORV AIR PLUG BY FEELING CARPET OR RUBBER MAT (SUGHT IN - FIG. 5 - TRUCK R-IO (GREENBRIER) DENTATION). USING AWL, PIERCE MAT & INSERT POINT IN- FIG. 6 - TRUCK (SUBURBAN)
PRINTED IN U. S. A. o 1963 ChevrOlet DIvIsIon General Motors Corp. 180 FRONT SEAT
CHEVROLET
FRONT SEAT
FORWARD
UNDERBODY
181 FRONT SEAT CORVAIR DRIVER PASS. ALL MODElS ~ I~ FRONT SEAT
FO~ ,I Iam.:..l....:C~!::.:· ~~·~;.:E~R.;..;;TIB_L_E__ _ ~~ I '~
. -~ 2-1/2 UNDERBODY 2-1/2
FRONT SEAT DRIVER PASS. GREENBRlER [A] [[] FRONT) ~-' ~ ~ SEAT ~ ~ .... ~~ FORWARD ~.' ''''''.'., ~
REAR OF SEAT TRACK
nr:nw Seat must be in most ~ard position to locate ~ • ~~-":I TRUCK R-IO (GREENBRIER)
182 _ Belt with buckle .' ------y~ FRONT SEAT end installed inboard TRUCK DRIVER I PASS (SUBURBAN) II) I ~ I~ \FRONT SEAT ( )~ .- ·-f / / ,, I ~ , ~~~~~~ ':'" ...... - /~>~-_/
FORWARD
c
• SUBURBAN
STlP 2 BEND SEAT FRAME ASM. FOR LEFT HAND STEP 3 ROUTE PASS. BELTS AROUND SEAT. THREAD DRIV INBOARD BELT. SEE FIG. 6 & VIEW "C". ERS INBOARD BELT UNDER SEAT FRAME ASM., SEAT CUSH ION & SEAT BACK. SEE FIG. 7.
183 SPACi:R NUT CHART EXISTING CLINCH NUT I!IIIII Bracket VEHICLE LOCATION SPACER (ALL EXCEPT PASS "B" ~efree NUT WmCH HAS EXISTING to rotate when HOLES IN REINF.) ALL· EXCEPT OUTBOARD THIN ,-., bolt 1s fully GREENBRIER ~ tightened. & SUBURBAN INBOARD THICK {;!Jr1. _ ' ,,-"\/ ·BISCAYNE, /'-~ L:. Cut--- BEL-Am. miDI OUTBOARD ____ between 100-200, & THIN 500-700 & INBOARD , ---- existing "V" PASS"A"STD. -- slits in fabric TRIM PROTECTOR ~SCREW mill Lift Boot ~lyto ALL EXCEPT BUCKET SEAT, insert bolt GREENBRIER & SUBURBAN
FRONT SEAT BACK _SEAT I ~ -, CUSHION ~"f
SEAT BELT INSTALLATION
2 DOOR MODELS EXCEPT BUCKET GREENBRIER & SUBURBAN
INBOARD O-E-F
-~ II1II On Greenbrier ImIII For Corvair route inboard belt models crisscross between seat back center be Us & cushion : TYPICAL BELT ROUTING (EXCEPT SUBURBAN) BUCKET SEAT ROUTING
II1II Fig. 8 " 9 & Steps 4 thru 6 for all vehicles ex c e p t Sub STEP 7 INSTALL BOor OVER BRACKET, THEN LIFT BOOT urban Truck. PARTIALLY TO EXPOSE HOLE FOR ATTACHMENT. SEE FIG. 8, VIEW "D". STEP 4 ALL MODELS EXCEPT BUCKET SEAT, GREENBRIER & SUBURBAN. LOCATE TWO EXISTING "V" SUTS BY APPLY STEP 8 REMOVE PLUG & INSTALL BOLT, L. WASHER, ING SLIGHT HAND PRESSURE TO FABRIC IN AREA OF BELT BRACKET, SPACER NUT & SEALER. SEE FIG. 1, VIEW A ROUTING. CUT AS SHOWN IN VIEW ttE'~ ON 2 DOOR MODELS & FIG. 8, VIEW D. INSERT BOLT THRU L. WASHER & LOCATE ·'FRONT SLOT" FORWARD OF REAR CUT AS SHOWN BRACKET. INSTALL SPACER NUT ON BOLT, FORCE SEAL IN VIEW "F". ER OVER THREADED POR TION & SEAL TIGHT AGAINST SPACER NUT. (QN GREENBRIER &t SUBURBAN SEAL TIGHT STEP S FOR BELT ROUTING SEE FIG. 8,9. VIEW "E" & "F". AGAINST BRACKET). SEE FIG. 8 & VIEW tiD". STEP 9 INSTALL BOar LIP OVER BRACKET. SEE FIG. 8 STEP 6 INSTALL TRIM PROTECTOR ASSHOWN, SEE VlEW "0" & FIG. 10. VIEW "E". SUP 10 DISCARD ALL REMAINING PARTS. c;. 184 DEALER: PLACE THIS SHEET IN GLOVE COMPARTMENT
PULL TO TIGHTEN BELT
INSERT CATCH TO LATCH BUCKLE
TO LOOSEN BELT TURN BUCKLE OUTWARD TO UNLATCH PULL LEVER OUTWARD
II!III Adjust belt length to suit individual requirement. With belt correctly adjusted, person should not feel the weight of the Buckle a~m. on the abdomen. At no time should the belt allow more than 1 inch forward movement of the body. II1II When not in use belts should be carefully laid on seat &t kept of( the floor.
BOOT UP ImiIDI CLEAN BELTS WITH CLEANER OR Lip must install DETERGENT RECOMMENDED FOR over bracket NYLON.
i'.ii'i!,iI' Do not bleach or redye belts as this may cause severe loss of strength.
BELT ATTACHMENT TO FLOOR OPERATION PROCEDURE & BElT ADjUSTMENT
185 SEAT BELT-REAR ALL CHEVROUT-CHEVELLE-CHEVY II AND CORVAIR
OLT 7/16-20 X 1-1/4 (Unless 13!111 Bdt, Lock & ADJACENT SPACER NUT BELT otherwise i n d i cat e d) Bracket installed EXCEPT GREENBRIER ASM. same as View A. On && SUBURBAN mUCK L. WASHER mID Greenbrier & Suburban // P.WASHER ON SEALER / CHEVROLET, t CHEVY, CORV Am 1\ & PASS. "A" 'I} BRACKET ~ 1/2 INCH. DIA. LOCK ~ HOLE (All Models) UNDERBODY REINFORCEMENT OR NOT USED ON OUT- ~ PLATFO~M (2) WASHER GREENBRIER BOARD ATTACHMENTS SEALER ON CONVENTIONAL & SUBURBAN ONLY ...... ® TRUCK & EXTREME ADJACENT L. WASHER ---""Y' INBOARD POSITIONS ~ GREENBRIER & NUT , , ON SUBURBAN TRUCK SUB URBAN ONLY SEAT BELT INSTALLATION FRONT- CENTER BELT INSTALLATION (EXCEPT PASS. "A") CI!DI Bracket must be free to rotate when Bolt is fully tightened. L. WASHER
FRONT SEAT BELT UNIT ------(CENTER PASS) ! ~~--:::.,,- (2) P. WASHERS 7
BELT ROUTING & BRACKET INSTALLATION (TYPICAL ON ALL VEHICLES)
~ SEAT - CENTER BELT INSTALLATION FIG. 4 TRUCK R-IO (TO INSTALL FRONT CENTER SEATBELT FOR CHEVROLET, CHEVY, PASS. "A", C OR V AIR, ON "PICKUP," BELT UNIT 985835 MUST. BE PROCURED). TRUCK R-I0 (GREENBRIER)&&TRUCK (SUBURBAN). INSTALL FIG. 5 PANEL TRUCK ADJACENT BOLT, WASHER & BRACKET TO CENTER PASS~N FIG. 6 SUBURBAN mUCK (ADAPTER KIT 985952 MUST BE GER WASHERS & BRACKET (SEALER INSTALLED TIGHT A PROCURED TO INSTALL SEAT BELTS). GAINST BRACKET OR ADJACENT SPACER NUT). SEE FIG. 1; FIG. 7 CONV. TRUCK (EXCEPT TILT CAB & LEVEL RID E VIEW B. FOR PASS. itA" EXCEPTION SEE FIG. 11, VIEW s. SEAT) STEP 2 ATTACH SEAT BELTS To BRACKET & ADJUST" TO FIG. 8 TILT CAB TRUCK PROPER LENGTH. SEE FIG. 1 VIEW B & FIG. 12. FlG. 9 CONY. TRUCK (WITH LEVEL RIDE SEAT) FIG. 10 CHEVY REAR SEAT BE LT INSTALLATION FIG. 11 PASSENGER "A" STEP 3 REMOVE SEAT CUSHION && BACK OR FOLD SEAT FOR STEP 5 ATTACH SEAT BELTS TO BRACKET && ADJUST TO ACCESSmllJTY, ALSO TURN BACK FLOOR MAT AT AREA OF .PROPER LENGTH. SEE FIG. 1 VIEW A, C" FIG. 12. INSTALLATION,IF EXISTlNG.PlERCE & SLIT AREA OF MAT AT BRACKET LOCATIONS. STEP 6 INSTALL BRACKET AT EACH DRILLED HOLE BY IN SERTING BOLT THRU WASH~ BRACKET, SEALER & REIN STEP 4 LOCATE DIMPLES IN FLOOR PANEL (EXCEPT SUB FORCEMENT (SEALER INSTALLED TIGHT AGAINST BRAC URBAN TRUCK USE DIMENSIONS ONLy) CENTERPUNCH & KET). SECURE WITH NUT. SEE VIEW A. FeR SUBURBAN DRILL HOLES THRU UNDERBODY OR PLATFORMS. SEE TRUCK EXCEPTION SEE FlG.6&VIEW K.FOR TRUCK R-I0 VIEW A & PICKUP " PANE L RPO A 54 EXCEPTION SEE VIEW c. FIG. 2-CHEVROLET STEP 7 REPLACE SEAT PREVIOUSLY REMOVED. FIG. 3 CORVAIR STEP 8 DISCARD ALL REMAINING PARTS.
PRINTED IN U. S. A. CD 1963 Ch.evrolet Division General Motors Corp" 186 .!<-
~ ~
3-1/4
jooool CD -J ~ FLOOR PAN FORWARD
MODEL REAR SEAl: INTER ME DIA TE SEAT I 2 PASS. 3 PASS. 2 PASS. I 3 PASS. i 9 PASS. STATION WAGON OCJ[Q] [j] [AJ~I [£] ' ~lll ...... ~ ~~ I '-'" ~~----: _JJ 4 DOOR SPORT SEDAN IAl[QJ @] 2 DOOR SEDAN IAJ[Q] @] .. '~FORWARD~~ ~-"~\ ...... -:~. ,~~ ...... : .. , CONVERTIBLE ~~ -, ~ H . f'-. SPORT COUPE ~[ID ~-:.-----. ~------~r-F~~....------_ "" ~1-7/8lj\"---..9-1/4 "- \ 6 PASS. STATION WAGON ~~ [£J 4 DOOR SEDAN [!J~ [£] - - ~~;
12-11/16
BRACKn LOCA liONS CHEVRom '" IDII At loci:l.uons IAJ & [£l cut & nest Reinforcements as shown. G
~ FORWARD 1------ ALL MODEUl r I 2 PASS. 3 PASS. 0~ @] 3 -7/8 POSITION ~ 5 POSITION @I - L. H. 5-7/8 POSITION @) - R. H• . BRACKET LOCA liONS CORVAIR ,. ~-~ ,) OWWER EDGE _----I I II :' FSEAT ~ / \ ' I ~~ , i ------6 ",~",~ . 1 ~l2-I!} .------~--<------~("---= @ I~~~ -:)[£]07." . \~------0-1'\'''-2-5/8~ ./ \ \ , 1l_1(8V--~ ------____ ----\ ------CENTERLINE- 5-1/4 OF VEHICLE " FRONT SEAT (REAR MOST POSITION) " ..... ALL I FRONT SEAT ICENTER SEATIREAR SEAT co MODELS 1 I 2 I 3 2 ~ 2 I 3 co PASS. P ASS. PASS. PASS. I PASS. P ASS.LP ASS. SUBURB ~ ~ [!] @] PANEL & , ~D:::--::; PICK-UP 010~1@ I"'-'.~,.£::.... ~/ ~'''''o''~IE-- , / / ~ ~ ~. , ~~."""",~;.-' -- " _ t= "!!o IS ~~r~// - ..-/ ::~;O-/~ /~- / ~ o/:~': ~ /';. _~~;;.-/ . --~ \ ,,~ - -$< $- j ff! H:;' y~~ ~_?_ ; / .,,;-/ " ~ ,,/_Y $'# ~ 3-1J1S ~ j~~ / ./ -,,,--, / - ' . ./ .- ?"'§~~ f' . F~ center" rear seat ' ~ -~c-.. ------//;'/ ~ ~'\~ amlocate hoI e locationmcut floor 3/4 ------~-~- ~"" ~-- ." -, mat with awl. then 1 -~.::.:;;;-;;:;:;:,::- ~~~- fiS-(. " . _,/ circular bole in maL ~- ~~---- -/ / ~'- \\ /' V' "B"will \ ------.• ---- Installation/for Its1eWat existing , - --- ~-~.;;;;.:.- -'-~~- ~ 16 20 X 1..:-3 8 Bo \ ---,~ . use 7 - .' d location, ~~-~) ------,7 I, weld nuts at lnboar #'/ / /~ ----- '-BRACKET LOCATIONS TRUCK R-lO (EXCEPT FRONT SEAT GREENBRIER) DEALER: PLACE THIS SHEET IN GLOVE COMPARTMENT PULL TO TlGHTEN BELT INSERT CATCH TO LATCH BUCKLE TO LOOSEN BELT TURN BUCKLE OUTWARD TO UNLATCH PULL LEVER OUTWARD 13!111 Adjust belt length to suit individual requirement. With belt correctly adjusted. person should not feel the weight of the buckle assembly on the abdomen. At no time should the belt allow more than 1 inch forward movement of the bOdy. EDII When not in use belts should be carefully laid on seat & kept off the floor. Clean belts with cleaner or detergent recommended for nylon. ".""Ni Do not bleach or redye BRACKET belts as nhis may cause severe lOBS of strength. BELT ROUTING ON FRONT CENTER PASS.EXCEPT SUBURBAN TRUCK & TRUCK TYPICAL BELT ROUTING R-l0 ROUTE BELT AS SHOWN IN TYPICAL BELT ROU'I'ING OPERATION PROCEDUR, & BELT ADJUSTMENT ,:. 195 CARRIER-ROOF LUGGAGE 985691-988398 CHEVROLET -STAlION WAGON CHEVROUT-CORVAIR SERIES 9·S PANEl TRUCK ~FWD. 37-1/8 (CORV AIR 95) LUGGAGE CARRIER ASM. -- ~ CAUTION TAG TIIIB DISTAN~ I R~F PANEL MUST BE EQUAL I J ON BOTH SIDES. I j CARRIER A"ACHMENT STEP 1 TAPE SHOULD BE APPLIED TO ROOF PAI:JEL IN B• .','Ilim!i Care must be taken to prevent drlll from pene SUPPORT ATTACHING AREAS TO AVOID MARRING FINISH. trating roof top slde trim panel, use drUl spacer. SEE VIEW A. STEP 6 REMOVE TAPE, PLACE GASKETS OVER HOLES. SUP 2 PLACE LUGGAGE CARRIER ASM. ON ROOF, LO CATING IT TO DIMENSIONS SHOWN. SEE CAUTION NOTE SUP 7 INST ALL SPECIAL SEALING NUTS" LOCATE LUG IN VIEW c. GAGE CARRIER ASM. ON GASKETS. ASSEMBLE ATTACH ING SCREWS PROVIDED MEDIUM TIGHT. SEE FIG. 1" STEP 3 LOOSEN BET SCREW IN EACH SUPPORT " ROT ATE VIEW B. UNTIL BEST FIT IS ATTAINED ON ROOF. SEE FIG. 1. ST£P 8 TIGHTEN TENSION SCREWS PROGRESSIVELY TO STEP 4 USING SUPPORTS AS TEMPLATES, MARK HOLE TENSION RACK BED. SEE VIEW B. CENTERS WITH W AX PENCIL OR SCRmER~ SEE VIEW A. STEP 9 TIGHTEN ALL SCREWS SECURELY. l1li CauUon STEP 5 REMOVE LUGGAGE CARRIER ASM. LIGHTLY CEN tag must be in place for customer information on use of luggage TER PUNCH, PILOT DRILL" ENLARGE HOLES. SEE VIEW carrier. See Fig. 1. PRINTED IN U. S. A. 0111410 Chevrolet Dlvtelon \.V General Motor. Corp. 211 CLOCK-ELECTRIC 985865 CORVAIR, CHEVROLET TRUCK AND CORVAIR 95 5/16 DIA. HOLE _ ------,£/8 DlA. (2) HOLES ~ ~/32 ~ ~~ _ ,-:::.,....-c.. ~ -- ~ "- 27/64~~~ 3/8 /4~ '--CENTERLINE REAR OF ASH r ______OF CAP TR~ABEZEL- . INSTRUMENT PANEL INSTRUMENT PANEL DRJLLING - CCIlVAIR DRlLlJNG - TRUCK R-IO 6/16 DIA. HOLE 1/8 DIA. (2) HOLES DRILLING - TRUCK EXC. TILT • DRILLING - TILT TRUCK STEP 1 REMOVE RADIO R E C E I V E R " SPEAKER FROM STEP 3 (ON CORVAIR WITH PADDED DASH) PLACE VEHICLE. g."",.8/' Removal must precede drilling opera MOUNTING BRACKET IN TRIM PLATE" POSITION ON tion 18 drUl chips will damage receiver " speaker. PAD. SCRIBE AROUND PLATE. REMOVE PLATE" MOUNTING BRACKET. CUT" REMOVE PAD TO DIMEN STEP 2 LOCATE, CENTERPUNCH" DRILL HOLES IN IN SION SHOWN. SEE VIEW At FIG. 5. STRUMENT PANEL. IF PANEL IS PADDED, HOLES ARE TO SliP 4 REINSTALL PREVIOUSLY REMOVED RECEIVER BE DRILLED THRU PAD. ON TRUCK RIO" TRUCK EXC. " SPEAKER. TILT, POSITION TEMPLATES TO CENTERlJNE OF VEHICLE " EOOE OF SPEAKER GRILLE AS SHOWN ON TEMPLATE. SEE FIG. 1, 2, 3 OR 4. " .'1",•• 1. (On Carvair) Remove Ash Tray Asm. from panel before drlWng boles. ~ : (1) lQ63 Chevrolet Olvl,;on PRJNTRO IN U. S. A. General Motors Corp. 217 -~ ------ SCREW 8-15 X 5/8 WIRE ROUTlNG-CORVAIR MOUNTING BRACKET STEP 5 INS ER T SPLIT SECTION OF PAINT MASK AROUND _SCR~ 6-32 X ~ SET STEM OF CLOCK MM. SEE VIEW A- ---- TRIM PLATE-CORVAIR STEP 6 FASTEN MASK TO LE NS BY PLACING MASKING IF PAD EXISTS TAPE 0 V E R HOLE IN MASK.. ALro CO V E R STEM WITH T APE. SEE FIG. 5. STEP 7 PAINT CLOCK MM., MOUNTING BRACKET" TRIM P LA T E (IF REQumED) TO MA TeH INTERIOR. STEP 8 INSERT C L 0 C K WIRES THRU CENTER HOLE IN MOUNTING BRACKET" TRIM PLATE (IF REQUIRED). AT TACH BRACKET TO INSTRUMENT PANEL WITH SCREWS. SEE VIEW A. STEP 9 ATTACH CLOCK TO MOUNTING BRACKET WITH S. SEE VIEW A. • (On Corva.1r) Close cover on Asb Tray "install in t 0 I[ument Panel with bandle next to clock.. Tbia la 180· from previously Ln s tall e d ". position. STEP 10 DRILL HOLE FOR GROUND TERMINAL IN INSTRU MENT PANEL REINFORCEMENT. (LOCATE BOLE AR PROXIMATELY AS SHOWN). SEE VIEW A" FIG. 8, 7 OR 8. 13/64 DIA. HOLE STIP " ATTACH GROUND TERMINAL TO REINFCECEMENT SCREW 8-32 X 7/16 THRU INSTRUMENT m!!,SCREW, LOCKW ASHER" NUT. SEE VIEW A. EXT. TOOTH L. WASHER PANEL PEINFORCEMENT EIiDII Position Lockwasber between termLnal " relnlorcement NUT to ins u r e good ground. A TYPICAL CLOCK ATTACHMENT STIP 12 INSERT CABLE INTO 2-WAY CONNECTOR" PLUG IN CLOCK WIRES, MATCHING COLORS. SEE FIG. 5, 6, 7 OR 8. _ (Truck: RIO 1& Truck bc. Tilt) CoLl excess cable " clamp as sbown. See F1io 6 or 8. STEP 13 ROUTE CABLE WITH EXISTING HARNESS TO FUSE PANEL" ATTACH TO EXISTING HARNESS WITH C LA MPS. STIP 14 (CORVAIR, TRUCK RIO "TILT TRUCK) TAPE SEE FIG. 5. 6. 7 OR 8. GROUND LEAD WIRE TO CLOCK WmEB. SEE FIG. 5, 6 OR 7. ~" 218 EXISTING HARNESS FUSE CLIP ABM. • wmE ROUTING-TRUCK RIO CLOCK ABM. CLAMP GROUND TERMINAL INST. PANEL REINFORCEMENT CABLE ABM. STEP 15 INSTALL FUSE CLIP" FUSE INTO RECEPTACLE IN STEP 16 PLUG GRAY WmE CONNECTOR (LAMP FEED) FUSE PANEL ABM. MARKED "G1.. BOX LP'."" PLUG IN INTO FUSE PANEL ASM. R E C E PTA C L E MARKED RED wmE CONNECTOR (POWER FEED).SEE FIG. 5, 6, 7 OR 8. "PANEL LPS." SEE FIG. 5,6,7 OR 8, _ If Receptacle is occupied, remove existing wire "plug ImI If Receptacle is occupied, remove existing wi r e " 1.nto Jumper. plug into jump er. 219 _CL()CKABM. ORAY WIRE ----, - ----CO-NN-E-C-TOR ::::~~(..--====- HARNESS _fj,.... .iS~-, CI~OC'K LAMP FEED (GRAy) ~, -~= __- -- - mST. --~ - :J' REINFORCEMENT __~ ~~::JUMPERCONNECTOR TERMINAL '\\"'..... -CLOC~K POWER ~~;'Q;?~~ FEED (RED) FUSE CUP ABM. TILT STEP 17 CHECK FOR PROPER OPERATION. STEP II DISCARD REMAINING PARTS. 220 COVER-WHEEL 985828, 985825, 985433, 985963, 985821, 985699, 985757 CHEVROLn-CHEVELLE-CHEVY II-CORVAIR AND CORVAIR SERIES 95 " , \ VALVE STEM ~XTENSION ~\ ~ ~ \ \\ STEP 1 REMOVE EXISTING VALVE CAP " INSTALL PRO STEP 3 PRESS WHEEL TRIM COVER FIRMLY AGAINST VIDED EXTENSION TO VALVE STEM. SEE FIG. 1. WHEEL UNTn. IT SNAPS INTO PLACE. SEE F1G. 1. STEP 2 PLACE WHEEL TRIM COVER AGAINST WHEEL SO THAT VALVE STEM EXTENSION PROTRUDES THRtJ ")PEN ING. SEE FlG. 1. 229 PRlNTBD IN U. B. A. GUARD-BUMPER-FRONT OR REAR 985070-988373 CORVAIR SERIES 95 BOLT 3/8-16 X 1 j LOCK WASHER EXISTING BOLT ~, ~ ) " :~-- ' I "'------~------) ~,------~~ I GUARD ASSY. CENrERLINE OF GUARD FRONT BUMPER-U INCHES (APPROX. ) REAR BUMPER-6 INCHES (APPROX.) GUARD STEP 1 INSTALL GUARD ON FRONT OR REAR BUMPER AT LOCATION SHOWN WITH ATTACHING PARTS PROVIDED. UPPER & LOWER BOLTS SHOULD BE TIGHTENED -PROGRES SIVELY TO INSURE PROPER FIT. SEE FIG. 1. 247 PRINTED IN 11.8. A. HARNESS-ACCESSORIES WIRI NG 985350 TO INSTALL RADIO OR HEATER CORVAIR SERifS 95 HEATER TOTAL SYSTEM CONNECTOR PRODUCTION HARNESS '--:;~ HEA TER CONTROL LAMP (GRAY) RADIO CONNECTOR RADIO HEA TER CONTROL (BLACK) ______LAMP SOCKET HEATER TOTAL SYSTEM (DARK-- GREEN) HARNESS ASSY. snp 1 PLUG LEADS INTO JUNCTION BLOCK ONLY IF CON SEE OTHER ACCESSORY INSTRUCTION SHEETS WHICH ARE CERNED WITH ACCESSORY SPECIFIED. SEE FIG. 1. CONCERNED WITH ACCESSORY REQUIRED. STEP 3 ALL LOOSE LEADS SHOULD BE TAPED TO ACCES STEP 2 ROUTE HARNESS THRU EXISTING CUP. SEE FIG. 1. SORY HARNESS. )0 900 Chevrolet Dlvlelon PRuneD IN U. S. A. ..~ 1 General Motore Corp. 262 HEATER & DEFROSTER-CUSTOM DELUXE AIR 985698 (ORVAIR 95 DEFROOTER : ) 'i/ DEFRQ;TER ~ DUCT ASM. CENTER DUCT EXTENSION CENTER DUCT MM. REAR LOWER DUCT ABM. GINIIAL MOTOIS 'AITS DIVISION GENEtAl MOTOIS COIPOIAnoH DITIOn 2, MICH. PRJNT&D IN U. B. A. (i) 1M2 Chevrolet D\vllion ~. aen.nJ Nolan COI'p. 284 "J"NUT , ~ ~ --~ SCREW 1/4-20 x 5/8 FRONT DUO EXTENSION & DEfROSTER DUCT mill See ad jus t men t && installation procedure summary STEP 5 INSTALL J-NUTS (IN BAG B) ON BRACKET " ~et 15 prior to installation of Control Cables. CEMENT SEALS ON FRONT DUCT EXTENSION. SEE VIEW B. STEP 1 REMOVE COVER &t SCREWS FROM FRONT SEAT STEP 6 SLIP FRONT DUCT EXTENSION THRU OPENING IN RISER" DISCARD. FRONT SEAT RISER && ALIGN WITH OPENING IN SIDE INNER RAIL, &t SECURE WITH SCREWS (IN BAG B). SEE VIEW B. STEP 2 SLIP DEFROSTER CABLE THRU HOLE IN FRONT DUCT EXTENSION. SEE VIEW A. STEP 7 CEMENT SURF ACE OF FRONT DUCT EXTENSION && INSTALL REAR GASKET OVER STUns. INSTALL FRONT STEP 3 ATTACH DEFROSTER CABLE LOOP TO DEFROST GASKET TO OPENING IN TOE PAN. SEE FIG. 1. ER CONTROL ROD WITH CUP (IN BAG B). SEE VIEW A. STEP 8 POSITION DEFROSTER DUCT OVER STUDS ON snp 4 LOOSELY ATTACH DEFROSTER CABLE TO BRAC FRONT DUCT EXTENSION && THRU OPENING IN TOE PAN KET ON FRONT DUCT EXTENSION WITH EXISTING SCREW && SECURE WITH STRAP & ATTACHING PARTS (IN BAG B). && CLAMP. SEE VIEW A. SEE FIG. 1. 285 CENTER DUCT EXTENSION OUTRIGGER f2 I - TAB - ~ CENTER DUCT (PART OF CENTER ABM. DUCT ASM.) FRONT CROSS SILL (UNDERBODy) aNTEI DUO & EXTENSION ASM. STEP 9 INSTALL GASKET ONTO CENTER DUCT EXTENSION. STEP 12 TAPE CENTER DUCT" EXTENSION TOGETHER. SEE VIEW C. SEE FIG. 2. STEP 10 SLIDE CENTER DUCT 'THRU OPENING IN OUTRIGGER STEP 13 SLIDE CENTER DUCT 1& EXTENSION BACKWAR~ f2 ABOUT HALF WAY. SEE VIEW C. THRU OPENING IN FRONT CROSS SILL. SEE FIG. 2. STEP 11 SLIDE CENTER DUCT EXTENSION ONTO TABS && STEP 14 SLIDE SEAL ONTO CENTER DUCT. SEE FlG. 2. FLUSH WITH CENTER DUCT MM. SEE VIEW C. 286 FRONT SEAT RISER 8-15 X 1/2 FORWARD STEP 15 CEMENT GASKET TO SLEEVE & SLIDE SLEEVE FRONT DUCT ASM. INSTALLATION. THRU OPENING IN SEAT RISER & INTO FRONT DUCT EX TENSION. ATTACH WITH SCREWS (IN BAG Al. SEE VIEW D. STEP 18 SLIDE FRONT DUCT THRU OPENING IN SIDE INNER RAIL & ONTO CLIPS OF FRONT DUCT EXTENSION & ATTACH STEP 16 INSTALL DISTRIBUTOR TO SLEEVE WITH SCREW WITH SCREWS & WASHERS (IN BAG~. SEE FIG. 3. (IN BAG A). LOCATE. CENTER PUNCH & DRILL HOLE THRU TOP OF DISTRIBUTOR & SLEEVE ASM. COMPLETE AT SftP 19 ALIGN FRONT DUCT TO OPENING IN OUTRIGGER TACHMENT OF DISTRIBUTOR WITH SCREW (IN BAG A). SEE .2 && ATTACH WITH SCREWS (IN BAG B). A'M'ACH FRONT VIEW D. DUCT TO SEAT RISER WITH SCREW {IN BAG Bl. CEMENT ALL AROUND JOINT OPENING ON FRONT DUCT ABM. SEE STiP 17 REMOVE RIGHT FRONT WHEEL AT TmB TIME FOR FIG. 3. 287 REAR SEAT RISER (Underbody) REAR UPPER DUCT CEMENT (ST ATION WAGON ON REAR SEAT RISER REAR UPPER DUCT • REAR UPPER DUCT & DEFLECTOR ASM. ImII Steps 20,21.22 are for Station Wagon only. ATTACH WITH SCREWS (IN BAG A). SEE VIEW F. STEP 20 REMOV E COVI!:R PLATE" SCREWS FROM REAR STEP 23 (ALL EXCEPT STA. WAGON) CEMENT LIP OF SEAT RISER" DISCARD. REAR UPPER DUCT OPENING" PLACE PLUG OVER OPEN ING. SEE VIEW E. STEP 21 CEMENT SEAL TO OP ENING IN REAR UPPER DUCT. SEE VIEW F. STEP 24 ATTACH J-NUTS (IN BAG C) TO FLANGE OF REAR UPPER DUCT &lSUDE DUCT THRU OPENING IN INTERMEDI- STEP 22 CEMENT GASKET ON REAR DEFLECTOiL SLIDE ATE CRQ:1B SILL ABM. TO ALIGN HOLES" SECURE WITH REAR DEFLECTOR INTO OPENING IN REAR SEAT RISER It SCREWS (IN BAG B). SEE VIEW F. ~ 288 CROSSMEMBER CENTER DUCT ABM. FWD. CROSSMEMBEl( REAR (Underbody) .... -- 1I REAl LOWER ASM. snp 2S DISCONNECT RIGHT HAND BRAKE CABLE BEFORE MEMBER. SEE VIEW H & FlG. 5. INSTALIJNG REAR LOWER' DUCT. STEP 26 SLIDE REAR LOWER DUCT ONTO SEAL OF CENTER SYIP 27 SECURE LOWER DUCT TO INTERMEDIATE" REAR DUCT, INTO PLACE ON INTERMEDIATE &t REAR CROSS- CRCSJMEMBER WITH SCREWS (IN BAG B). SEE FIG. 5. 289 EXISTING FILLER PANEL ASM. INLET DUCT ASM. III!IIII This screw must be assembled from the top as shown. --- PLASTIC SEAM REAR LOWER CEMENT DUCT ASM. (1.40Z) FWD. • REAR LOWER &INLET DUCT ASM. & HO ES STEP 28 REMOVE FILLER PANEL ABM. &£ ATTACHrnG STEP 32 SlJPJ-NUTS (IN BAG C) INTOREAR UPPER DUCT. PARTS &£ RETAIN. CEMENTSEALTOINLETDUCT. SEE FIG. 6. STEP 29 SLIDE CLAMPS (IN BAG D) &£ SLEEVE (L. H. ONLy) STEP 33 LOWER FILLER PANEL IN PLACE & ATTACH IN ONTO HOSES. SEE FIG. 6. LET DUCT TO REAR UPPER DUCT WITH SCREW. WASHER (IN BAG C). SEE FIG. 6. STEP 30 SLIDE HOSES ONTO INLET DUCT & TIGHTEN CLAMPS. SEE FIG. 6. STEP 34 ATTACH J-NUT (IN BAG B) &I CEMENT GASKET TO REAR UPPER DUCT &I CEMENT ALL AROUND JOINT OPENING ON REAR LOWER DUCT. SEE FIG. 6. STEP 31 LOOSELY INSTALL NUT ASM. (IN BAG C) TO FIL LER PANEL, SLIP INLET DUCT ASM. ONTO STUDS & STEP 35 ATTACH REAR LOWER DUCT TO REAR UPPER TIGHTEN. SEE FIG. 6. DUCT WITH SCREWS (IN BAG B). SEE FIG. 6. ~ Position ends of all clamps 3/8 to 1/2 inches away from IBII Tlghten one screw from the bottom &I assemble other '8he'er'meW to avoid conditions which might cause vibration screws loosely as shown. Position rear lower duct asm. " noises & for service. tighten all screws securely. 290 CONNECTOR ASM. CONNECTORS & HOSES STEP 36 REMOVE ,. RETAlN ENGINE COMPARTMENT STEP 40 INSTALL CONNECTOR ASM. ,. SECURE wl'm EXIST COVER. ING SCREWS. SEE VIEW K. StEP 37 REMOVE,. DISCARD AIR INLET DUCT COVER. STEP 41 PLACE CLAMPS ON THE HQJE" INSTALL HQiE. TIGHTEN CLAMPs. SEE nG. 7. STEP 38 REACH THRU OPENING" PULL INLET DUCT THRU, INSTALL CONNECTCB WITH SCR~ BAG 0). ALSO ... Poeitlon ends of all clam.,. 3/8 to 1/2 incbes away from PLACE STICKER ON CONNECTOR ASM. SEE FlG. 7 IJ VIEW J. aheet metal to avoid conditlons which might cause vibl"atlon no.... " fozo service. STEP 39 REMOVE 1& DISCARD COVER FROM UPPER SHROUD ABM. "aETAIN SCREWS. 291 EXISTING CLIP MAIN WIRINCJ HARNESS (Production) HOSE -~~~AB~ CLAMP SEAL - Adhesive side - ~~'6:R to connector. I "BROWN" ) 1-1/2 INCH MINIMUM CLEARANCE - Thld"'" area FWD.~ ~ ~ \ ~~- 'cONN(ECTOR - ASM.-~'H''- . MUFFLER 1& EXHAUST ~ PIPE ASM. : CONNECTORS, WIRING & HOSES STEP 42 REMOVE COVERS FROM FRONT SHROUD ASM. 1& FIG. 8. .. Rotate R. H. hose to obtain clearance shown. DISCARD. RETAIN SCREWS. STEP 4S lNSTALL CLIPS (IN BAG A) TO INTERMEDIATE STEP 43 AT T A C H L. "R. H. CONNECTORS " SEALS TO CROSS SlLL. CONNECT BROWN wntE PROVIDED TO SHROUD ASSEMBLY WITH EXISTING SCREWS. SEE flG. 8. BLOWER MOTOR. THEN ROUTE WmE THRU CLIPS OVER TO MAIN HARNESS & FORWARD!t[G HARNESS THRU EXISTING CLIPS. SEE FIG. 8, I Position ends of all STEP 44 SLIP CLAMPS (IN SAG D) ON HOSES, SLIDE HOSES clamps 3/8 to 1/2 inches away from 8 eet metal to avoid ON CONNECTORS. PQllTION 1& TIGHT EN CLAMPS. S!:E conditions which might cause vibration noises 1& for service. 292 SWITCH ARM \ I !/"CONTROL ASM. rr--1L-\ L _~--~ III~ ---- ~ KNOB RETAINER TABS of switch AUTO TRANSMISSION GROMMET .. -- -.------PARKING BRAKE STEP 46 INSERT LENS INTO SLOT IN CONTROL" POSITION SECURE WITH EXISTING RETAINER. REINSTALL MAIN COVER, DETENT SPRING, SWITCH & SECURE WITH SCREWS HARNESS & BLOWER MOTOR WIRE, ETC. IN NEW GROMMET. (IN BAG A). SEE VIEW M. SEE FIG. 9. STEP 47 RAISE ALL CONTROL LEVERS TO THE TOP OF THEIR SLOTS" ~SERT 1/8 INCH DlA. PIN THRU HOLES STEP 51 WITH SWITCH ARM IN "OFF" POSITION ASSEMBLE IN CONTROL ASSEMBLY, SEE FlG. 9. KNOB (IN BAG A) TO ARM WITH A STRAIGHT PUSH UNTIL KNOB LOCKS ON RETAINER TABS OF SWITCH ARM. A MAXI STEP 48 ATTACH HEAT & AIR CABLES TO CONTROL MUM FORCE OF 40 LBS. WILL ASSEMBLE KNOB IN PLACE. WITH SCREWS (IN BAG A). SECURE WIRE LOOPS OF ALL RETAINER TABS MUST BE_HE CAVITY OF THE CABLES TO RESPECTIVE COl-tTROL LEVERS WITH KNOB. SEE FIG. 9" VIEW L. . • Do not rock kmb ver· SPRING GRIP WASHERS (IN BAG A). SEE FIG. 9 & VIEW M. tically during assembly, as this w en switch arm. ATTACH DEFROSTER CABLE TO CONTROL WITH STEP 49 STEP 52 INSTALL HEATER CONTROL SUPPORT TO INSTRU SCREW (IN BAG A). SECURE WIRE LOOP OF CABLE TO RE MENT PANEL WITH BOLTS, SPACERS & NUTS (IN BAG A). SPECTIVE CONTROL LEVER WITH SPRING GRIP W ASHER(IN SEE FIG. 9. BAG A). SEE FIG. 9" VIEW M. STEP SO REMOVE GROMMET RETAINER FROM TOE STEP 53 INSERT LAMP (IN BAG A) INTO LAMP SOCKET WIRE PANEL" DISCARD EXISTING GROMMET. ROUTE CON (GRAY)" PLUG INTO CONTROL. SEE VIEW M. TROL CABLES THRU OPENING IN TOE PANEL" THRU GROMMET (IN BAG A), POSITION GROMMET & THEN STEP 54 SLIP J-NU'I (IN BAG A) IN PLACE ON SUPPORT" INS'1"ALL REA TER CONTROL TO SUPPORT WITH SCREWS (IN BAG A). SEE FIG. 9. 293 TOE PAN OPENING \ . \ )'-- HEAT CONTROL CABLE ASM. (YELLO~ '~~ '~1 SPECIAL , C~p~ • CONTROL CAllES ~.-- SlIP 55 R 0 UTE DEFROSTER CABLE ALONG RIGHT SIDE TO EXISTING HOLES IN PLENUM PANEL" SIDE RAIL WITH RAIL THRU TOE PAN OPENING, GROMMET " TO HEATER CUPS (IN BAG B). SEE FIG. 10. CONTROL NJ SHOWN IN FlG. 9" 10. AlJGN TAPE OR PAINT MARKS ON THE CABLES DIRECTLY BELOW FLOOR TO TOE STEP 56 ATTACH CLIPS (IN BAG B) TO HEAT" AIR PANEL BREAK LINE BEFORE CLIPPING TO UNDERBODY. CONTROL CABLES" INSERT GLIPS INTO EXISTING ROUTE ALL CABLES ALONG RIGHT SIDE RAIL " ATTACH HOLES IN SIDE RAIL. SEE FIG. 10. 294 AIR VALVE CONTROL Am CONTROL \ CABLE ABM. (BLUE) FWD ~ STEP 57 INSTALL CLIPS (IN BAG B) TO INTERMEDIATE" nIP 60 PULL ON HEAT" AIR CONDurr TO REMOVE REAR CROBSMEMBERS ALONG SIDE DUCT SECURING LASH" CAUSE CONTROL LEVERS TO SEAT AGAINST 1/8 SCREWS. SEE FIG. 11. INCH DIAMETER PIN. TInS.WILL GIVE KNOBS 1/4 INCH CLEARANCE TO TOP OF SLOTS. HOLD IN POSITION" STEP 51 ROUTE HEAT 1& AIR CONTROL CABLES REAR TIGm'EN CABLE CLAMP. SEE VIEW N" FIG. 9. WARD THR U OPENING IN CROOSMEMBER " THRU CLIPS JUST INSTALLED ON INTERMEDIATE" REAR CR~MEM STEP 61 PUSH ON DEFROOTER CONDUIT UNTIL LEVER BERB. SEE FIG. 11. SEATS BACK AGAINST 1/8 INCH DIAMETER PIN. HOLD IN POSITION 1& TJlHTEN CABLE CLAMP. SEE VlEW A " STEP 59 LOOSELY ATTACH HEAT 1& AIR CABLES TO THE IN FIG. 9. LEr DUCT wrrH EXISTING CLAMPS ,. SCREWS. SEC U R E wmE LOOPS OF CABLES TO THEm RESPECTIVE CONTROlS STEP 62 REMOVE l/B INCH DIA. PIN FROM HEATER wrrH SPRING GRIP WASHERB (IN BAG A). SEE VIEW N. CONTROL ASSEMBLY. SEE FIG. 9. 295 DISTRIBUTOR ASM. - DEFROSTER TOE PANEL INSULATOR FLOOR PANEL I: CEMENT INSULATOR" (9.8 OZ.) , CEMENT (13 OZ.) ~ REAR PAn I: CEMENT (13 OZ.) STEP 63 REMOVE EXISTING FLOOR MAT" CEMENT PRO STEP 65 ATTACH RESISTOR (IN BAG A) TO DISTRIBUTOR VIDED PADS TO UNDERSIDE OF FLOOR MAT. CUT OUT WITH SCREWS (IN BAG A). SEE VIEW P. PERFORATED AREA. SEE FIG. 1. STEP 66 INSTALL DISTRIBUTOR WITH SCREWS (IN BAG STEP 64 CEMENT INSULATORS TO TOE PANEL" FLOOR A). SEE FIG. 12. PANEL, "INSTALL FLOOR MAT. SEE FIG. 12. ~ . 296 TRANSMISSION CONTROL BRACKET DEFROSTER INLET STEP 67 (IF AUTOMATIC TRANSMISSION EXISTS) INSTALL STEP 71 IF ACCESSORY HARNESS HAS BEEN INSTALLED. HOSE SUPPORT ON TRANSMISSION CONTROL BRACKET UNT APE &. PLUG GRAY LEAD CONNECTOR INTO RECEPT WITH SCREW PROVIDED (IN BAG A). SEE VIEW R. ACLE IN FUSE PANEL MARKED "PANEL LPS." SEE FIG. 13. II1II U Radio exists, -wire will always be connected. STEP 68 REMOVE INSTRUMENT PANEL COMPARTMENT. INSTALL DEFROSTER HOSES ON INLETS &. DISTRIBUTOR ASM. SEE FIG. 13. REPLACE INSTRUMENT PANEL COM STEP 72 PLUG LOQIE END OF HEATER CONTROL HARN~SS PARTMENT. II1II U automatic transmission exists route ASM. INTO RESISTOR ON DISTRIBUTOR. SEE FIG. 13. L. H. hoses over hose support. STEP 73 CONNECT RED LEAD FROM HEATER HARNESS mp 69 INSTALL FUSE CUP INTO RECEPTACLE MARK WITH DK. BLUE &. GREEN WIRE CONNECTOR (FROM EXISTING ED "HEATER B. U. LPS." ON FUSE PANEL. SEE FIG. 13. OR ACCESSORY HARNESS). ROUTE BROWN LEAD (FROM . GROMMET IN TOE PANEL) ALONG EXISTING HARNESS & CONNECT ro BROWN LEAD OF HEATER HARNESS. SEE mp 70 UNTAPE DK. GREEN WmE CONNECTOR FIG. 13. FROM EXJSI'ING HARNESS &. PLUG INTO FUSE CLIP PREVIOUSLY INgr'ALLED. SEE FIG. 13. STEP 74 INSERT FUSE INTO ruSE ClJP ASM. PREVIOUSLY BI If Dk. Green Connector does not exist procure a INSTALLED. SEE FIG. 13. "Accessory Harn~s8 Unit" from dealer &. install. STEP 7S REPLACE PARTS PREVIOUSLY REMOVED. 1111 Discard any remaining parts, they are used on other models. L~' 297 DETENT SPRING (MTALLED POSI'nON) LOOP KNOB "OFF" I OR "CLOSEO" , J POSITION :\ I,-' " - J KNOB "ON" POSITION CONTROL ASM. INSTALLATION" ADJUSTMENT SliP 77 INSTALLATION" ADJUSTMENT SUMMARY PROCEDURE 1. ATTACH DEFROSTER CABLE LOOP TO FRONT DUCT EXTENSION CONTROL ROD. SEE STEP 3. 2. LOOSELY ATTACH DEFROSI'm TO FRONT DUCT EXTENSION. SEE STEP 4. 3. RAISE ALL CONTROL LEVERS TO THE TOP OF SLOTS. SEE STEP 4'1. 4. INSERT PIN THRU HOLES IN CONTROL ASSEMBLY. SEE STEP 47. 5. ATTACH HEAT" Am CABLES TO CONTROL" LEVER PIN&. SEE STEP 48. 6. ATTACH DEFRQiTER CABLE TO CONTROL" LEVER PIN. SEE STEP 49. 7. INSTALL CONTROL" CABLE ASSEMBLY INTO VEHICLE. SEE STEP 64. 8. ATTACH HEAT" AIR CABLES TO INLET DUCT ASSEMBLY. SEE STEPS 59 "60. 9. TIGHTEN CLAMPS ON CABL1i8. SEE STEPS 60 " 61. 10. REMOVE PIN FROM CONTROL ASSEMBLY. SEE STEP 62. ~. 298 HlATER & DlFROSTER-CUSTOM GASOLlNl 985648 CORVAIR SERIES 95 CONTROL ASM. DRAIN HOSE OVERFLOW EXHAUST PIPE ASM. GENlRAl MOTORS PARTS DIVISION GENERAL MOlORS CORPORAlION DETROIT I, MICH. 299 PIUM1'I:D IN U. 8. A. HOSE (Part of heater asm. ) HEATER & DEFROSTER ASM. LOCK WASHER INT. TOOTH HEATER SUPPORT HEA TER COVER ASM. (Part of cover asm.) CEMENT-PLASTIC SEAM CEMENT DISTRIBUTOR CASE ASM. HEATER, (OVER & DISTRIBUTOR SU8-ASSEMBl Y ImID Vehicle must be equipped with a F. O. A. or accessory STEP 3 ATTACH SUPPORT TO HEATER WITH SCREWS PRO harness before heater can be installed. H neither exists, pur VIDED (IN BAG A). SEE FIG. 1. chase accessory harness unit No. 988350 from service & install. STEP 4 CEMENT GASKET TO HEATER, APPLY PLASTIC STEP 1 DISCONNECT BATTERY CABLE. SEAM CEMENT TO STUDS & ATTACH HEATER TO COVER WITJi ATTACHING PARTS PROVIDED (IN BAG B). SEE FIG. 1. STEP 2 REMOVE GLOVE BOX, RADIO, HEATER HOLE COVER, STEP 5 CEMEN1'GASKET TO DISTRIBUTOR, APPLY PLASTIC FRONT GRILLE & R. H. HEADLAMP ASSEMBLY. DISCARD SEAM CEMENT TO THREE (3) HOLES IN COVER ASM. & AT HEATER HOLE COVER, BUT RETAIN ATTACHING SCREWS & TACH DISTRIBUTOR TO COVER ASM. WITH SCRE!WS PROVIDED PLUG LOCATED NEAR UPPER L. H. CORNER (IN BAG B). SEE FIG.- 1. 300 DISTRmUTOR CASE ASM. BLOWER ASM. SCREW 10-24 X 1/2 HOSE (Part of heater asro. ) BRACKET ASM. STUD (Part of cover) PLASTIC SEAM CEMENT COMBUSTION BLOWER STEP 6 PLACE BLOWER SWITCH ARM ON VALVE PIN & BRACKET WITH ATTACmNG PARTS (IN BAG B). SEE FIG. 2. ATTACH TO DISTRIBUTOR CASE WITH ATTACHING SCREWS PROVIDED (IN BAG A). SEE VIEW A. STEP 9 ATTACH BLOWER BRACKET TO COVER WITH AT STEP 7 INS TAL L CLIPS PROVIDED (IN BAG A) ON DIS- TACHING PARTS PROVIDED (IN BAG B) & APPLY CEMENT TRIBUTOR CASE & ATTACH RESISTOR TO CLIPS. SEE~ TO BOTH SIDES OF FLANGES. SEE FIG. 2. VIEW B. STEP 10 ROUTE BLOWER WIRES UNDER BLOWER BRACKET & THRU HOLE IN COVER. SEE FIG. 2. STEP 8 INSTALL BOOT ON BLOWER, SEAL GAP CAUSED BY WIRES LEADING. OUT FROM BETWEEN BOOT & MOTOR STlP 11 ATTACH HEATER HOSE TO BLOWER WITH CLAMP COVER & ATTACH BLOWER & GROUND WIRE TO BLOWER PROVIDED (IN BAG C). SEE FIG. 2. 301 WIRING HARNESS ASM. POSITIVE /1// TERMINAL CONNECTOR \ ~ARK GREEN WIRE ,,0 EXISTING HARNESS COVER SEE FIG. 4 STEP 12 PLUG HARNESS CONNE CTORS ONTO BLOWER ALONG WITH HARNESS. FIT INTO EXISTING CLIPS ON TOP SWITCH & RESISTOR. SEE VIEW c. OF COVER ASM~ SEE FIG. 3. STEP 13 PLUG RED & NATURAL WIRE CONNECTo.RS ONTO STEP 16 ROUTE EXTENSION HARNESS THRU GROMMET TO THERMOSTAT & SNAP HARNESS INTO EXISTING CLIP UNDER HEATER COIL & PLUG WHITE JUMPER WIRE CONNECTOR COVER 1fLANGE. SEE VIEW C. INTO OVERHEAT SWITCH WIRE CONNECTOR. SEE FIG. 3 & VIEW D. STEP 14 INSTALL GROMMETS PROVIDED (IN BAG B) IN COVER & ROUTE BLACK WIRE CONNECTOR'FROM HARNESS, STEP 17 ATTACH BROWN & BLACK WIRES & SPARK PLUG THaU GROMMET & P LUG ONTO BLOWER MOTOR TERMINAL. WIRE, SUPPRESSOR & STRAP TO COIL TERMINAlS WITH SEE FIG. 3 & VIEW D. ATT ACHING NUTS PROVIDED. SEE VIEW D. STEP 18 INSTALL PLUG (RET AINED FROM DISCARDED STEP lS ROUTE BLACK & WHITE COMBUSTION BLOWER HEATER HOLE COVER) & ATTACH ACCESS COVER USING MOTOR WIRES THRU GROMMET & ACROSS TOP OF CO V E R SCREWS & GASKET PROVIDED (IN. BAG C). SEE FIG. 3. ,~. 302 GROMMET WHITE WIRE MULTIPLE CONNECTOR ""--.... ~. J / / BLACK WIRE ___ ~ DK.. BLUE WIRE V / "" , PURGE SWITCH, MULTIPLE CONNECTOR & RELAY STEP 19 SUB ASSEMBLE PURGE SWITCH & COVER TO INTO HARNESS CONNECTOR. SEE FlG. 4. ADAPTER WITH SCREWS (IN BAG A). SEE FIG. 4. _!.'.IINII White wire to top receptacle on connector. STEP 20 ATTACH ADAPTER SUB ASSEMBLY\ MULTIPLE CONNECTOR & RELAY TO EXISTING HOLES IN COVER WITH STEP 22 PL UG H A R N E S S CONNECTOR TO MULTIPLE SC.REWS (IN BAG A). SEE FIG. 4. CONNECTOR. 3-WAY CONNECTOR (BLACK & WHITE WIRES) TO RELAY & REMAINING 3-WAY CONNECTOR (BLACK. DK. STEP 21 INSERT TERMINALS OF WHITE & BLACK WillES BLUE & RED WIRES) TO PU RGE SWITCH. SEE FIG. 4. 303 FAN CONTROL LEVER mil Valve asm. must close fully when fan knob is in off position. ImID Move lever full forward before mil These controls may be tightening set screw. EXISTING adjusted by loosening clamps & CLAMP & repositioning cables. SCREW PUSH-ON NUT DEFROSTER CONTROL KNOB & CABLE ASM. FAN CONTROL KNOB ~CLAMP & CABLE ASM. SCREW 8-32 X 3/8 CONTROL CABLE STEP 23 INSERT FAN, DEFROSTER 8& HEAT CONTROL KNOB STEP 25 ROUTE FAN & DEFROSTER CONTROL CABLES TO 8& CABLE ASSEMBLIES INTO SLOTS OF HEATER CONTROL. DISTRIBUTOR. ATTACH FAN CONTROL TO LEVER & DE SLIDE CABLE SHEATHS UP INTO SLOTS &; SECURE TO DI FROSTER CONTROL TO CRANK WITH PUSH-ON NUTS (IN BAG MENSION SHOWN WITH CLAMPS" SCREWS (IN BAG A). SEE A). SEE FIG. 5. FIG. 5. STEP 24 MOVE HEAT CONTROL KNOB INTO DOWN PO STEP 26 SECURE FAN& DEFROSTER CONTROLS TO DISTRIB SITION, WITHIN 1/4 INCH OF CABLE SHEATH. ROUTE HEAT UTOR WITH EXISTING CLAMpS & SCREWS TO DIMENSION CONTROL CABLE THRU LEVER (ON THERMOSTAT). SE SHOWN. SEE FIG. 5. CURE CABLE TO DISTRIBUTOR WITH EXISTING CLAMP & SCREW TO DIMENSION SHOWN. MOVE LEVER (ON THERMO STAT) FULL FORWARD & rIGHrEN SET SCREW. SEE FIG. -STEP 27 ATTACH INSTRUCTION TAG TO HEAT CONTROL 5 & VIEW F. CABLE NEAR CONTROL. SEE FIG. 5. 304 I \ CEMENT PLASTIC SEAM '-EXlSTING SCREW PLASTIC L 1\ \\ CONTROL CABLES I SEAM ~ '. \1 I ....,...._.. ~'~ EXISTING BRACKET(WITH Wls WASHER) • HEATER &COVER \ \ 1 I I . . j--- , ----- "'-J/ ,'-STEERING COLUMN SCREW 8-15 X 1/2 CONTROL ASM. ATTACHMENT STEP 28 REMOVE EXISTING R. H. AIR VENT ROD & TUBE HOLE. SEE FIG .. 6. ASM. & DlBCARD. RETAIN ATTACHING PARTS. STEP 32 IF W/SWASHER DOES NOT EXIST, LOCATE DIMPLES SUP 29 CEMENT GASKET TO COVER & APPLY PLASTIC && DRILL HOLES. SEE FIG. 6. SEAM CEMENT TO GASKET AT ATTACHING HOLES & TO DASH AT STUD HOLES. ATTACH COVER TO DASH PANEL STEP 33 APPLY PLASTIC SEAM CEMENT TO HOLES & AT WITH EXISTING "JtI NUTS. RETAINED SCREWS & PROVIDED TACH CONTROL CABLES TO DASH PANEL WITH CLIP & NUTS (IN BAG B). SEE FIG. 6. SCREWS PROVIDED (rn BAG A). mill If W/S washers exist, attach retained bracket to bottom of clip. SEE FIG. 6. snp 30 APPLY PLASTIC SEAM CEMENT BETWEEN AIR STEP 34 ATTACH SUPPORT TO INSTRUMENT PANEL WITH VENT ROD & TUBE ABM. & COVER, THEN ,ATTACH WITH SPACERS & ATTACHING PARTS PROVIDED (IN BAG A). SEE RETAINED SCREWS. SEE FIG. 6. FIG. 7. STEP 31 IF W/SWASHER EXISTS, REMOVE & RETAIN RESER STEP 35 ATTACH CONTROL ABM. TO SUPPORT WITH AT vom BRACKET, DISCARD SCREW, LOCATE DIMPLE & DRILL TACHING PARTS PROVIDED (IN BAG A). SEE FIG. 7. 305 / / ...... / -c: --...... /' / ...... I __ HEATER AS]...... "- ...... / -- ~ - ...... / ...... ,,- "-...... \ ...... \ PIPE (Part of \ heater asm.) \ \ \ \ ,~ \ /~,~ \ ~~ :-, I 1/ ~~ili-I / 'i //' / // /1// - .,//// .::..~-"':~~'::~-1 BLOWER BRACKET ASM. OUTER PANEL ----" --- BRACKET (Part of exhaust pipe asm. ) : HOSES & EXHAUST PIPE 1/4-14X1J2 STEP 36 INSERT EXHAUST PIPE THRU EXISTING OPENING ING. SEE FIG. 8. IN PLENUM PANEL, FIT CLAMP ASM. PROVIDED OVER TOP &. SLIDE EXHAUST PIPE OVER HEATER PIPE. SEE FIG. 8. STEP 40 ATTACH GASOLINE FRONT PIPE HOOE TO HEATER PIPE WITH ATT ACHING CLAMP PROVIDED (IN BAG C) & STEP 37 USING DIMENSIONS SHOWN &. PIPE ASM. BRACKET ROUTE THRU EXISTING HOLE IN PLENUM PANEL. SEE AS A TEMPLATE, CENTER PUNCH &. DRILL HOLES IN BODY FIG. 8. OUTRIGGER &. SIDE RAIL AS SHOWN. SEE FIG. 8. STEP 41 ATTACH DRAIN HOOE TO HEATER PIPE &. ROUTE STEP 38 ATT ACH EX H A US T PIPE TO SIDE RAIL USING THRU EXISTING HOLE IN PLENUM PANEL. SEE FIG. 8. SCREWS PROVIDED (IN BAG A). SEE FIG. 8. STEP 42 INSTALL PREVIOUSLY REMOV ED HEADLAMP. STEP 39 COMPLETE ATTACHMENT OF EXHAUST PIPE TO ROUTE WIRES &. ATTACH TO CLIP ON COVER ASSEMBLY. HEATER BY SLIDING CLAMP ASM. INTO PLACE&'TIGHTEN- SEE FIG. 8. 306 ..... - FAN BELT EXISTING GROMMET SP. CLIP TEE PIPE ASM. • TEE GASOLINE PIPE ROUTING ...... -. HOSE 5/32 Y. D. CROSS SILL UNDERBODY • REAR GASOLINE PIPE ROUTING STEP 43 RE MOVE & DISCARD 3 WAY TEE CONNECTOR & must be maintained between fan belt &. tee pipe. REPLACE WITH 4 WAY CONNECTOR PROVIDED (IN BAG C). SEE FIG. 9, STEP 4S FROM UN DE RS IDE OF VEHICLE, ROUTE REAR PIPE FORWARD&. CLIP TO INTERMEDIATE CROSS SILL &TO STEP 44 CON N E C T TEE PIPE TO 4 WAY CONNECTOR. SIDE RAIL WITH CLIPS PROVIDED (IN BAG C). SEE FIG. 10, ROUTE ALONG SIDE EXISTING FUEL LINE &. THRU GROM MET IN REAR ENGINE SHIELD. SE~ WITH CLIPS PRO STEP 46 JOIN REAR PIPE &. TEE PIPE WITH HOSE &. VIDED (IN BAG C). SEE FIG. 9. liliiii Proper clearance CLAMPS PROVIDED (IN BAG C). SEE FIG. 10, 307 (' -, , FRONT R. H. WHEEL- ' ~ r GAS TANK I HOUSE - - ~ ASM. ' "'(i-~~·J -~~~ , ~-~->- ~ _,__ / ~~-I ',, ':.~~~r~,_. .''. J " J IL ~~- '-: ''-'-" 1/''~"-- ,- ~~, FRONT PIPE HOSE /"II , OVERFLOW~- - ___.. - -. ~ [ EXISTING OPENING -'-" UPPER PIPE \~___--.... _____ --.... ~, CLAMP IN SEAT RISER ---.; ~ ASM. \ ~ ___ fEXlSTlNG _ , CLIP <'" . ~~ "-TOE PANEL GASOLINE TANK FRONT PIPE ASM. FORWARD UNDERBODY INTERMEDIATE & FRONT PIPE ROUTING STEP 47 ROUTE INTERMEDIATE PIPE FORWARD ALONG EX STEP 53 ATTACH OVERFLOW LOWER PIPE TO REGULATOR. ISTING PIPE, ATTACHlNG TO FRAME WITH EXISTING 8& SEE FIG. 11. PROVIDED CLIPS (IN BAG C). SEE FIG. 11. STEP S4 REM 0 V E COVER & SCREWS FROM FRONT FACE STEP 48 JOIN INTERMEDIATE PIPE TO REAR PIPE WITH OF SEAT RISER & THRU OPENING IN SEAT RISER, REMOVE HOSE 8& CLAMPS PROVIDED (IN BAG C). SEE FIG. 11. PLUG FROM TANK, RETAIN COVER & SCREWS. DISCARD PLUG. STEP .9 ATTACH REGULATOR TO INTERMEDIATE PIPE. SEE FIG. 11. STEP S5 SLIDE OVERFLOW UPPER PIPE THRU OPENiNG STEP SO ROUTE FRONT PIPE FORWARD, ATTACHING TO IN SEAT RISER, & THREAD INTO EXISTING HOLE. (FROM FItAME WITH CLIPS PROVIDED (IN BAG C) 8& EXISTING CLIP WHICH PLUG HAS BEEN REMOVED). SEE VIEW G. ON TOE PANEL. SEE FIG. 11. STEP S6 JOIN UPPER &: LOWER OVERFLOW PIPES WITH HOSE & CLAMpS PROVIDED (IN BAG C). SEE FIG. 11. STEP 51 ATTACH FRONT PIPE TO REGULATOR. SEE FIG. 11. STEP 52 ATTACH FRONT PIPE HOSE TO FRONT PIPE WITH STEP 57 REPLACE ALL EXISTING PARTS PREVIOUSLY RE CLAMP PROVIDED (IN BAG C). SEE FIG. H. MOVED. ,:. 308 TRANSMISSION CONTROL BRACKET .08 EXISTING HOLE DEFROSTER INLET / ACCESSORY HARNESS / / EXISTING CLIP / .---. F. O. A. HARNESS EXISTING/ CLIP -- DARK/ / GREEN / 15 AMP FUSE EXISTING CLIP DEFROSTER HOSES & WIRING STEP 58 IF AUTOMATIC TRANSMISSION EXISTS, DRILL FROM HARNESS. INSERT LAMP INTO SOCKET ON GRAY HOLE & INSTA LL HOSE SUPPORT -ON TRANSMISSION CON WIRE & PLUG INTO BACK OF CONTROL. CONNECT DARK TROL BRACKET WITH SCREW (IN BAG A). SEE VIEW. H. BLUE & DARK GREEN WIRES TO HEATER HARNESS WIRE. SEE FIG. 12. STEP S9 REMOVE GLOVE BOX. ASSEMBLE LONG & SHORT DEFROSTER HOSES USING COUPLINGS PROVIDED. INSTALL STEP 62 INSTALL FUSE CLIP INTO RECEPTACLE IN DEFROSTER HOSES ON INLETS & DISTRIBUTOR CASE. SEE JUNCTION BLOCK MARKED "HEATER- B. U. LPS. II IN FIG. 12. REPLACE GLOVE BOX. ImDI U automatic _trans sERT (15 AMP) FUSE & PLUG IN DARK GREEN WIRE. SEE mission exJsts route L. H. hose over hose support. FIG. 12. STEP 60 IF ACCESSORY HARNESS HAS BEEN INSTALLED STEP 63 INSTALL FUSE CUP INTO RECEPTACLE IN UNTAPE & PLUG GRA Y LEAD CONNECTOR INTO BACK OF JUNCTION BLOCK MARKED "HEAT BLOW- GL. BOX LP." JUNCTION BLOCK INTO RECEPTACLE MARKED "PANEL INSERT (11 AMP) FUSE & PLUG IN DARK BLUE WIRE. LPS." SEE FIG. 12. IDII If radio exists gray wire will SEE FIG. 12. always be connected. STEP 61 UNTAPE GRAY, DARK BLUE & DARK GREEN WIRES 309 INSPECTION & CHECKING PROCEDURE. STEP 64 THE CONTROL ASM. FAN KNOB OPERATES THE STEP 69 INSPECT ALL GASOLINE LINES TO BE SURE THERE VENTILATION BLOWER & HAS TWO SPEEDS, LOW-WITH AR:E: NO LEAKS. THE KNOB PUSHED HALF WAY IN & HIGH-WITH THE KNOB PUSHED ALL WAY 'IN. TURN ON IGNITION &'PUSH FAN KNOB STEP 70 HEATER MUST PRODUCE 150° !-5° OUTLET TEM IN TO BE SURE VENTILATION BLOWER WORKS AT BOTH PERATURE WITHIN 3 MINUTES WITH ENGINE AT IDLE. IF SPEEm. THE OUTLET TEMPERATURE REACHES 160° THIS INDICATES A FAULTY THERMOSTAT, IF THE OUTLET TEMPERATURE STEP 6S THE COMBUSTION BLOWER HAS ONLYONE SPEED FAIlS TO REACH 135° THIS INDICATES INADEQUATE GASO (HIGH) & SHOULD WORK WHEN FAN IS IN EITHER LOW OR LINE FLOW & MAY BE CAUSED BY BENT PIPES, PLUGGED HIGH POSITION. PIPES. NOZZLES, FITTINGS, OR A FAULTY FUEL PUMP, STEP 66 WHEN TURNING OFF HE ATE R OR IGNITION STEP 71 GASOLINE PRESSURE AT THE HEATER SHOULD BE SWITCH, THE COMBliS nON BLOWER SHOULD CONTINUE WITHlN THE RANGE OF 4. 5 TO 5 P. S. 1. IF THE PRESSURE TO 0 PER ATE FOR APPROX. 30 SE CONDS. IF THE COM IS HIGHER THAN 5 P. S.I. THE OVERFLOW REGULATO~ IS BUSTION BLOWER DOES NOT TURN OFF WITHIN TWO MIN FAULTY. IF THE PRESSURE IS LOWER THAN 4. 5 P. S, L THE UTES AFTER SHUTTING OFF IGNITION OR HEATER,THE ENGINE FUEL' PUMP 18 FAULTY. THE PRESSURE RANGE OF PURGE SWITCH IS 0 E F E C T I V E & MUST BE REPLACED. THE FUEL PUMP SijOULD BE WITHIN 6 TO 8 P. S. L STEP 67 IF EITHER OR BOTH BLOWERS 00 NOT WORK, IN STEP 72 REFER TO SHOP MANUAL FOR CORRECT HEATER SPECT ALL WIRING CONNECTIONS, ESPECIALLY THE FIYE MAINTENANCE &. REPAIR. WAY CONNECTOR ON THE COVER. IT IS ESSENTIAL THAT THE WHITE WIRE LEADING FROM THE COMBUSrION BLOW ER ASM. BE INS E R TEO INTO THE CONNECTOR IN THE PROPER SLOT. STEP 68 START ENGINE & LET IT IOLE. PUSH CONTROL ASM. HEAT KNOB ALL WAY IN. HEATER Musr IGNITE & OPERATE WITHOUT RUMBLING, POPPING, OR HAVING A SMOKY EXHAUST. ~. 310 LAMP-COURTESY 985899 CHfVROUT-CHEVEU(-CHEVY II-CORVAIR-CORVAIR SERIES 95 SUPPORT-B~nd to clear Instrument Panel. ) I --- I REINFORCEMENT ~ CHEVROLET I I I HARNESS TERMINAL (2 WIRE) .// HARNESS TERMINAL 17/64 DlA. HOLE (2- WIRE) OR KNOCK EXISTING OUT PLUG SWITCH ,• ~ , walE (EXISTING SWITCH) TYPICAL I CHEVROLET STEP 1 PLACE L. H. LAMP IN ITS APPROXlMA TE INST ALL CURELY (EACH SIDE). SEE FIG. 2. ED POSITION. ROUTE R. H. LAMP OVER STEERING COLUMN SUP 5 (WITHOUT JAMB SWITCHES) TAPE CONNECTOR ON TO R. H. SIDE. WHEN RADIO IS PRESENT,REMOVE LOWER SHOOT wmE TO HARNESS.PLUG LAMP HARNESS TERMINAL MOUNTING BRACKET BOLT" PLACE WIRE BE1WEENBRAC INTO SWITCH (EACH SIDE). SEE FIG. 2. KET 1& INSTRUMENT PANEL. REATTACH BOLT. ATTACH WmE TO REINFOOCEMENT WITH PROVlDED CUPS 1& TAPE STEP 6 (WITH JAMB SWrrCHES) DISCONNECT EXJSTING TO EXISTING HARNESS. SEE FIG. 1 1& VIEW B. WIRING FROM JAMB SWITCH" PLUG INTO ROUND CONNEC TOR ON LAMP HARNESS. PLUG LAMP HARNESS TERMINAL STEP 2 PLACE "U" NUT ON LAMP " ATTACH TO INSTRU INTO JAMB SWITCH (EACH SIDE). SEE FIG. 3. MENT PANELTHRU EXISTING HOLE WITH SCREW PROVID ED (EACH SIDE). SEE FIG. 1 1& VIEW A. STEP 7 REPLACE KICK PANEL 1& VENTILATOR SCREWS. 3 REMOVE EXISTING SCREWS ONVENTILATORGRILLE, BEND TABS UP 1& REPLACE DABH " FLOOR MATS. BE E snp FIG. 1. Dis c ar d any remaining parts. ROLL BACK FLOOR MAT 1& DASH MAT 1& REMOVE KICK PANEL IZmI BY BENDING TABS DOWN. SEE FIG. 1. STIP. PLUG CONNECTOO INTO RECEPT AC LE IN STEP 4 (WITHOUT JAMB SWITCHES) KNOCK OUT PLUG IN FUSE PANEL MARKED "BATT." SEE FIG. 1. _ If Re FRONT DOOR HINGE PILLAR" SCREW JAMB SWITCH INSE- ceptacle is occupied remove " plug into Jumper Wire. o 1i63 Cllevrolet Dlvlillion PRINTBD IN U. S. A. 04ln4lnl Moto,.. Corp. 357 SUPPORT-(WITHOUT GAS HEATER) SUPPORT-(WITH GAS HEATER) II ALTERATION- TRUCK R-lO '/ ,J C SEE FIG. 4 R. H. LAMP INSTALLATION WITH GAB HEATER TRUCK R-10 TRUCK R-lO STEP 1 REMOVE BULB" SOCKET FR OM EACH SUPPOOT STEP 4 DRILL HOLE THRU EXISTING DIMPLE IN FRONT " ALTER SUPPORT AS SHOWN, REASSEMBLE SOCKETS,SUP. DOOR HINGE PILLAR & SCREW JAMB SWITCH IN SECURE- PORTS" BULBS. SEE FIG. 6. EmIl n Gasoline Heater exists, LY (EACH SIDE). SEE FIG. 2. lamp support must be atr aightened to e 11 m in ate bend. STEP 5 TAPE CONNECTOR ON SHORT WffiE TO HARNESS. STlP 2 PLACE L. H. LAMP IN ITS APPROXIMATE'INSTALL PLUG LAMP HARNESS TERMINAL INTO SWITCH (EACH ED pa;ITION " ROUTE WmE THRU EXISTING CLIP UNTIL SIDE). SEE FIG. 2. R. H. LAMP IS IN ITS APPROXIMATE INSTALLED POSITION. SEE FIG. 7. STEP 6 ATrACH WmES TO REINFORCEMENT EXTENSION, BOTH SIDES, WITH CLIPS PROVlDED.SEE FIG. 'I & VIEW H. STEP 3 REMOVE EXISTING OUTBOARD SCREW THAT AT TACHES VENT CONTROL KNOB BRACKET. SLIDE LAMP ABM. STEP 7 INSERT FUSE" CLIP INTO RECEPT ACLE ON FUSE BRACKET BETWEEN VENT CONTROL KNOB BRACKET" IN PANEL MARKED "HEAT BLOW -GL.BOX LP. It & PLUG IN STRUMENT PANEL" SECURE WITH PREVIOUSLY REMOVED CONNECTOR. SEE FIG. 7. _11 Receptacle ia occupied, SCREW. SEE VIEW C (FIG. 4) B!DII If Gasoline Heater exists, remove exiating wire" connector to Jwnper Wire. attach R. H. lamp support to instrument panel thru inboard hole STEP 8 LOOP 1& TAPE EXCESS WmE. SEE FIG. 7." with screw provided. See Fig. 7" View J. Remaining parts may be di 8 car de d. 36.0 LAMP-DOME 988346 CORYAIR SERIES 9S PANfL TRUCKS DRILL (2) 5/8 INCH DlA. HOLES IN LINE (Use a hole saw) JAMB SWITCH ASM. DRILL '1/8 [NCH DIA. HOLE // ~ . _. --I /~ _:-~' ,'//-- ROOF TRIM PANEL IS-GAUGE~ BLACK ---. - WIRING ---- STEP 1 REMOVE REAR TRIM PANELS FIRSt IF VEHICLE STlP 4 CRIMP & SOLDER BARE END OF WIRE TO CLIP. RE IS MODEL 1206. MOVE LENS FROM LAMP ASM. INSERT CLIP INTO BASE. IN SERT LAMP INTO CLIPS. REPLACE LENS. SEE FIG. 2 " STlP 2 LOCATE, CENTER PUNCH, "DRILL HOLE IN L. H. VIEW A. REAR DOOR HINGE PILLAR REINFORCEMENT. SEE FIG. 1. STEP 3 PUSH BARE END OF WIRE ASM. THRU GROMMET STEP 5 LOCATE, CENTER PUNCH. & DRILL HOLES IN R. H. " SLIDE GROMMET ALONG WIRE TO A POINT ABOUT (12) FRONr LOAD DOOR & R.H. REAR DOOR HINGE PILLARS. [NCHES FROM FUSE HOLDER. THREAD BARE END OF SEE FIG. 1. WIRE THRU DRILLED HOLE FROM UNDER REINFORCEMENT. THEN CLIP WIRE TO PILLAR" ROUTE TO FRONT OF STEP 6 FROM INSIDE OF VEHICLE LOCATE, CENTER SECOND ROOF BOW FROM REAR. SEE FIG. 1. USE STIFF PUNCH, & CUT HOLES IN R. H. CORNER TRIM PANEL & WffiE TO ASSIST ROUTING THRU HOLES & AROUND CORNERS. ROOF RAIL, IF ACCESS HOLES 00 NOr EXISt. LOCATE SYMMETRICALLY OPPOSITE TO HOLES ON L. H. SIDE. SEE U customer desires to change location in vehlcle, pro II1II FIG. 1. ".!llIlm. Do not drlll thru roof panel. cure same gauge wire as spect11ed "spllce, solder" tape. 'r01960 CIIevrolet DlVlaloD PRINTED IN U. 8. A. '\!:..I Qeneral Motor. Corp. 362 LAMP-GLOVE COMPARTMENT 985898 ALL PASSENGER CARS AND TRUCKS ,-INSTRUMENT PANEL -- rf-~2~P'~s~~::- INSTRUMENT PANEL COMPARTMENT - --- :-- --~ TERMINAL ; l r--J r \\ \y . I 'i.. -- SWITCH ASM. CHEVROLET EXISTING WIRING HARNESS TAPE (PASS "A") I CHEVROLET &: PASS "A'I I STEP 1 ROUTE WIRE TERMINAL THRU NOTCH IN UPPER RECEPTACLE MARKED "BATT. II SEE FIG. 1. LEFT HAND CORNER OF INSTRUMENT PANEL COMPART- II1II U receptacle is occupied, remove existing wire MENT&: THRU HOLE IN UPPER LEFT SIDE OFCOMPART- &: connect to jumper wire. Discard Clip &: Blade Asm. MENT OPENING. SEE FIG. 1 && 2. && F U 8 e • STEP 5 (PASS .tA") ROUT E WIRE DOWN TO REINFORCEMENT STEP 2 ASSEMBLE WIRE TERMINAL TO SWITCH. INSERT && ATTACH WIRE WITH PROVIDED C LIP. ROUTE WIRE LAMP &: PRESS SWITCH INTO POSITION. SEE VIEW A. ALONG EXISTING HARNESS TO FUSE PAN E L. TAPE WIRE TO HARNESS AS SHOWN. SEE FIG. 2. STEP 3 (CHEVROLET) ROUTE WIRE ALONG E X 1ST I N G STEP 6 (PASS "A")PLUG WIRE CONNECTOR INTO RECEP HARNESS &: THRU EXISTING RETAINER TO FUSE PANEL. TACLE MARKED "BAT. FUSED". SEE FIG. 2.... If re TAPE WIRE TO HARNESS AB SHOWN. SEE FIG. 1. ceptacle Is occupied, remove existing wire && connect to jumper wire. D i 8 C ar d Cllp & Blade Asrn.. && Fuse. STEP 4 (CHEVROLET) PLUG WIRE CONNECTOR INTO @' 1963 Chevrolet Dtvlslon , Oeneral Motors Corp. 364 PRINTED IN U. S. A. WIRE ASM. \ \ \ , EXISTING WIRE 'r:-- A :/--;£, -~ 1C....-0~- INSTR UMENT PANEL SLI:J COMPARTMENT L _------' - . -- 1--_ -- " ' ----..::;;;.=:::~---.~-"'~ - ~ / -7r-..:=.::::~ II ' ------'"'":7=-,...--::::.. . ---:::-... / -=---:....--:""- TERMINAL V -,..p( r:.:::-----=.: / /ll~~~" I " ''7"...--.---T) ' ;1 .:-- L EXISTING HOLE II / II LAMP tl: SWITCH ASM. II I TYPICAL (CORVAIR, TRUCK R-IO & TRUCK) ICORVAIRI STEP 1 ROUTE WIRE TERMINAL THRU SLIT IN UPPER FUSE PANEL. SEE FIG. 3. LEFT HAND CORNER OF INSTRUMENT PANEL COMPART MENT & THRU HOLE IN UPPER LEFT SIDE OF COMPART STEP 4 PRESS CLIP & BLADE INTO RECEPTACLE MARK MENT OPENING. SEE FIG. 3 & VIEW c. ED "GL. !MP' '1, INSERT FUSE & CONNECT WIRE. SEE VIEW B.. If receptacle i8 occupied, remove existing STEP 2 ASSEMBLE WIRE TERMINAL TO SWITCH. INSERT wire & connec 0 jumper wire. Discard cUp & blade asm. & fuse. LAMP & PRESS SWITCH INTO POSITION. SEE VIEW c. STEP 5 LOOP & TAPE EXCESS WIRE. SEE FIG. 3. STEP 3 ROU:rE WIRE THRU EXISTING C LIPS (ON DASH) TO mI Discard remaining part8. 365 INSTRUMENT PANEL INSTRUMENT PANEL REINFORCEMENT COMPARTMENT \ J 1iIr'T"'--'II TRUCK R-I0 ITRUCK R-IO & TRUCK I STEP 1 ROUTE WIRE TERMINAL THRU SLIT IN UPPER STEP 4 (TRUCK) MOUNT CLIPS ON FORWARD FLANGE OF LEFT HAND CORNER OF INSTRUMENT PANEL COMPART INSTRUMENT PANEL REINFORCEMENT & ROUTE WIRE MENT & THRU HOLE IN UPPER LEFT SIDE OF COMPART THRU THESE CLIPS TO FUSE PANEL. SEE FIG. 4 & VIEW D. MENT OPENING. SEE FIG. 4 OR 5 & VIEW C, FIG. 3. STEP 5 PRESS CLIP & BLADE INTO RECEPTACLE MARK- SUP 2 ASSEMBLE WIRE TERMINAL TO SWITCH. INSERT ED "GL BOX LP. II !IT FUSE & CONNECT WIRE. SEE LAMP & PRESS SWITCH INTO POSITION. SEE FIG. 4 OR 5 VIEW B & FIG. 3. • If receptacle is occupied, remove & VlEW C, FIG. 3. existing wire & connec · 0 jumper wire. STEP 3 (TRUCK R-IO) ROUTE WIRE TO FUSE PANEL BY STEP 6 LOOP & TAPE EXCESS WIRE. SEE FIG. 4 OR 5. LOOPING AROUND R. H. DEFROSTER DUCT, PASS OVER IIIl!DI Discard remaining parts. L. H. DEFROSTER DUCT, LOOP AROU~ EXISTING WIR ING HARNESS ALONGSIDE OF EXISTING CLIP. SEE FIG. 5. ~. 366 LIGHTER -CIGARETTE 985975 CORVAIR SERIES 95 TRUCK ------ HOUSING ·ASM. JUNCTION BLOCK SUP 1 REMOVE PLUG FROM HOLE IN INSTRUMENT PANEL. STEP 4 LOOP WffiES AROUND HARNESS &a ROUTE TO JUNCTION BLOCK. SEE FIG. 1. STEP 2 INSERT HOUSING THRU BEZEL && HOLE IN INSTRU MENT PANEL && SECURE' WITH RETAINER. 'PLUG HEATING STEP 5 PLUG BLACK WIRE CONNECTOR lNTO OPEN- UNIT INTO HOUSING. SEE FIG. 1. ING IN JUNCTION BLOCK MARKED "CIG. LTR .... && CONNECTOR WITH JUMPER INTO OPENING MARKED STEP 3 ATTACH CONNECTOR TO TERMINAL ON HOUSING && "PANEL LPS." ... If receptacle is occupted, remove ex INSERT LAMP INTO RETAINER. SEE FIG. 1. lBting wire 1& connect to jumper wire. ~ . fC\ 1161 ct.ewoltt Ohi.IOll PRINTED IN U. S. A. , \!I Gee.l WolQU Corp. 380 MIRROR-OUTSIDE REAR VIEW 6" x 11" 985771 CORVAIR SERIES 9S BOLT 3/8-16X 5/8 BOLT 3/B-16X 5/8 TEE BOLT INT. TOOTH INTERNAL. TOOTH 1/4-28X 1/2 LOCK WASHER LOCK WASHER INT. TOOTH NUT NUT LOCK WASHER NUT 5/32 I r "I \ ::{~~~gt DIA.' It- ~ MOUNTING BRACKET && GASKET BOLT 3/B-16X 3/4 INT. TOOTH FRONT EDGE ii;"!! \ \ LOCK WASHER NUT FRO~AA i !{I ~~:KETf____ l ~,~ ~7i~ - - ~~ ~~ ~~::-,J_1:#-- 0\ e BRACKET *2 \, G .191 INCH DIA. (4) HOLES ", _ &\~ (NO. 11 DRILL) mIIIFor proper mirror adjustment, mirror can ~~ be positioned in slots in Iilirror support. SCREW For additional in & out adjustment Mounting 5/16 - 18 X 3/8 bracket can be positioned inside of arm. TRUCK INSTALLATION\ PLAIN WASHER STEP 1 ON L. H. SIDE ONLY, REMOVE & DISCARD EXIST STEP 6 ATTACH UPPER PART OF ARM TO UNDER SIDE OF ING MIRROR && ATTACHING PARTS. PLUG HOLES WITH TOP BRACKET WITH ATTACHING PARTS PROVIDED. SEE P ARTS PROVIDED. SEE FIG. 1. FIG. 1. STEP 2 MARK HOLE CENTER AT TOP OF DOOR && VERTI STEP 7 LINE UP LOWER BRACKETS WITH CENTERLINE CAL CENTERIJNE AT BOTTOM FROM FRONT EDGE OF PREVIOUSLY MARKED, USE BRACKETS AS TEMPLATE. C. V. PILLAR, USE DIMENSIONS SHOWN. USING TOP BRACK MARK HOLE CENTERS, CENTEflPUNCH && DRILL ET (STAMPED 1# 1) AS TEMPLATE, MARK REMAINING TOP BOTTOM HOLES. SEE FIG. 1. flOLE. SEE FIG. 1. STEP 8 ATTACH BOTTOM BRACKETS && GASKETS WITH SHP 3 CENTERPUNCH && DRILL TOP HOLES IE ATTACH ATTACHING PARTS PROVIDED. SEE FIG. 1. TOP BRACKET (STAMPED It 1) && GASKET WI'I'H ATTACH ING pARTS PROVIDED. SEE FIG. 1. STEP 9 ASSEMBUo: MlRROR SUPPORTS TO MIRROR WITH ATTACHING PARTS PROVIDED. SEEi FIG. 1. SHP 4 ASSEMBLE MOUNTING BRACKETS IE GASKETS TO ARM. SEE FIG. 1. mill Do not spread brackets over tube, STEP 10 INSTALL MIRROR BY ATTACHING MIRROR SUp· but assemble from arm end. PORTS TO MOUNTING BRACKET WITH AT T A CHI N G . \ PARTS PROVIDED. SEE FIG. 1. STEP 5 ASSEMBLE BRACKET (STAMPED *1) TO TOP SIDE OF LOWER PART OF ARM, IE BRACKET (STAMPED *2) TO Slip 11 FOa R. H. REAR VIEW M I R R 0 R INSTALLATION BOTTOM SIDE OF LOWER P ART OF ARM WITH ATTACHING REPEAT STEPS 2 THRU 10. PART PROVIDED. SEE FIG. 1. i1'j. CD 1901 Chevrol,t DlvlalOD PRINTED IN U. 8. A. . General Motors Corp. 396 BOLT 3/B-16X 5/8 NUT 3/8-16 BOLT 3/B-16X 5/8 INT. TOOTH INT. TOOTH INT. TOOTH TEE-BOLT LOCK WASHER LOCK WASHER LOCK WASHER 1/4 - 28X 1/2 NUT PLAIN WASHER NUT INT. TOOTH LOCK WASHER NUT ~l.~~r~~ -~- . -- ~>\\\ ) " \ 1:{~~~'s1 .\ , i I 1/ \\ ;'1/' Ii 'i \"~ / / /;' FRONT EDGE~\\ ~_ '~ // OF c. V. PILLAR \\ ____ ,j / I SCREW 14-10X3/4 /~I ~_-d~.0~ INT. TOOTH I __ y-- J - ~.-J / _____ .191 DIA. (4) HOLES &--- LOCK WASHER -- (NO. 11 DRILL) .1m:\ _~SCREW 5/16-18X3/B ( For proper mirror adjustment. mirror can ~ ~ PLAIN WASHER II1II be positioned in slots in mirror support. ~ For additional in " out adjustment mounting bracket can be positioned inside of arm. CORVAIR 95 INSTALLATION STEP lOON L. H. SIDE ONLY. REMOVE & DISCARD EXIST STEP 6a ATTACH UPPER PART OF ARM TO TOP SIDE OF ING MmROR && ATTACHING PARTS. P LUG HOLES WITH TOP BRACKET WITH ATTACHING PARTS PROVIDED. SEE P ARTS PROVIDED. SEE FIG. 2. FIG. 2. STEP 20 MARK HOLE CENTER AT TOP OF DOOR" VER STEP 7a LINE UP LOWER BRACKETS WITH CENTERLINE TICAL CENTERLINE AT BOTTOM FROM FRONT EDGE 0 F PREVIOUSLY MARKED. USE BRACKETS AS TEMPLATE, C. V. PILLAR, USE DIMENSIONS SHOW N. USING TOP MARK HOLE CENTERS, CENTERPUNCH" DRILL BOTTOM BRACKET (sTAMPED *1) AS TEMPLATE, MARK REMAIN HOLES. SEE FIG. 2. ING TOP HOLE. SEE FIG. 2. STEP 8a ATTACH BOTTOM BRACKETS" GASKETS WITH STEP 30 CENTERPUNCH & DRILL TOP HOLES" ATTACH ATTACHING PARTS PROVIDED. SEE FIG. 2. TOP BRACKET (STAMPED * 1) && GAsKET WITH ATT ACH ING PARTS PROVIDED. SEE FIG. 2. STEP 9a ASSEMBLE MIRROR SUPPORTS TO MmROR WITH ATTACHING PARTS PROVIDED. SEE FIG. 2. STEP 40 ASSEMB_NTING BRACKETS" GASKETS TO ARM. SEE FIG. ~~Do not spread brackets over tube, SlEP lOa INSTALL MlRROR BY ATTACHING MIRROR SUP but assemble from arm end. POR TS TO MOUNTING BRACKETS WITH ATTACHING PARTS PROVIDED. SEE FIG. 2. STEP Sa ASSEMBLE BRACKET (STAMPED * 2) TO TOP SIDE OF LOWER PART OF ARM. && BRACKET (STAMPED * 1) TO BOTTOM SIDE OF LOWER PART OF ARM WITH STEP 110 FOR R. H. REAR VIEW MIRROR INSTALLATION ATTACHING PARTS PROVlDED. SEE FIG. 2. REPEAT STEPS 2a THRU lOa. 397 985238 SUNSHADE INSTRUCTION SHEET CORVAIR 95 DRILL 1-1/8 INCH DlA. HOLE DRILL (3) .136 INCH DlA. HOLES (#29 DRILL) _ ___ ------ SCREW 10-8-12 X 3/4 / R. H. SUNSHADE & SUPPORT ASSY. ------iI R.H. SUNSHADE STEP 1 LOCATE EXISTING DIMPLE & DRILL LARGE HOLE metrically opposite to L. H. bracket before drilling holes. IN TRIM PANEL. SEE FIG. 1. STEP 3 USING SUPPORT AS TEMPLATE CENTERPUNCH & DRILL HOLES. SEE FIG. 1. STEP 2 INSERT SUNSHADE & SUPPORT INTO HOLE & LINE UP WITH TOP OF WINDSHIELD OPENING & L. H. SUNSHADE. STEP 4 INSTALL SUNSHADE WITH ATTACHING PARTS PRO SEE FIG.!. 1.·lInNi. Be sure bracket ls located sym- VIDED. SEE flG. 1. 01960 Chevrolet Dlvtslon \V OeoeraJ Motors Corp. 464 SAFETYLIGHT -LEFT OR RIGHT HAND 988335 CORVAIR SERIES 9S / DOOR EDGE , Install Shaft\\ with \ \ st.mped "T~::~: up, '\ \ \ \ l.P~TLAMPASM. \ \ TEMPLATE '--- SCREW HANDLE 8-15 X 1/2 WEDGE DRILLING & INSTALLATION ... L. H. installation shown. R. H. typical except template STEP 5 INSERT SPOT LAM P SHAFT T H R U BRACKET & faces down. ROTATE TO ENGAGE TONGUES IN OUTSIDE BRACKET WITH SLOTS ON SHAFT. TIGHTEN SET SCREW. SEE FIG. 2. STEP 1 TAPE TEMPLATE, CENTER PUNCH & DRILL HOLES AS INDICATED ON TEMPLATE. SEE FIG. 1. SUP 6 PLACE RUBBER SPACER ON SHAFT & ROTATE TO MATCH CONTOUR OF DOOR. POSITION INN ER BRACKET STlP 2 AT T A C H OUTSIDE BRACKET &I GAS K E T WITH SUPPORT INTO THE INSIDE BRACKET & SUDE ONTO SHAFT, SCREWS. SEE FIG. 2. PRESS TIGHT TO DOOR & TIGHTEN SET SCREW. SEE FIG. 2. SUP 3 INSERT DRILL BUSHING IN BRACKET &I TIGHTEN STEP 7 USING SUPPORT AS A TEMPLATE,CENTER PUNCH SET SCREW. CENTER PUNCH &I DRILL HOLE THRU DOOR. & DRILL HOLE IN DOOR. ATTACH SUPPORT TO DOOR LOCATE, CENTER PUNCH, &I DRI L L GROMMET HOLE ON WITH PROVIDED SCREW. SEE FIG. 2. INSID~ OF DOOR. SEE FIG. 2. STEP 8 WITH SPOTLAMP IN NORMAL UPRIGHT PQSITION STEP 4 REMOVE & DISCARD DRILL BUSHING. DISMANTLE REINSTALL HANDLE TO FACE 30° TO THE REAR & SECURE NUT, WEDGE, &I HANDLE FROM SPOTLAMP. WITH WEDGE & NUT. SEE FIG. 2. PRINTED IN U. S. A. 01"1 Chevrolet DI,lIlon 467 \!.I c.neral MolDn Corp. WEATHER STRIP I • * I I ...... ·r ~ ZON . . I i SURFACE / \ ------ DRILL.098 INCH DIA. HOLE (No. 40 Drill) (L. H. SHOWN - R. H. SYM WIRING L.H. SPOTLAMP METRICALLY OPPOSITE) STEP 9 LOCATE, CENTER PUNCH &. DRlLL HOLES ON STEP 12 INS TAL L CUPS WITH PROVIDED SCREWS. SEE FORWARD EDGE OF DOOR & FRONT BODY HINGE PILLAR. FIG. 3 &. VIEW A. SEE FIG. 3 &. VIEW A. STEP 13 INSERT CLIP &. BLADE INTO RECEPTACLE ON STEP 10 THREAD SparLAMP WIRE THRU DOOR &. ROUTE JUNCTION BLOCK MARKED "HEATER· B. U. LPS." PLACE THRU HOLE IN HINGE PILLAR. SEE FIG. 3. CONNECTOR ON WIRE TERMINAL. SEE FIG. 3. STEP 11 PLACE GROMMETS ON WIRE &. PRESS IN PLACE. STlP 14 (L. H. SPOTLAMP) PLUG CONNECTOR INTO CLIP ADJUSTWIRE FOR SWING CLEARANCE OF DOOR. SEE FIG. 3. &. BLADE &. INSERT FUSE. SEE FIG. 3. 468 INSTRUMENT ~ PANEL REIN- FORCEMENT ~ " " ' 1' --:::----- "" " ' I r ----- • I I ----- / WIRING I.H. SPOTlAMP STEP 15 (R. H. SPOT LAMP) P LUG TERMINA L INTO CON STEP 16 (R. H. SPOT LAMP) PLUG CONNECTOR INTO CUP NECTOR ON WIRE ASM. INST ALL CLIPS ON INSTRUMENT " BLADE & INSERT FUSE. SEE FIG. 3. IEI!DII U receptacle PANEL REINFORCEMENT AT CONVENIENT LOCATIONS. 1a occupied remove & plug into jumper wire. R 0 UTE WIRE ASM. THRU C UPS. SEE FIG. 4 & VIEW A. 469 SIGNAl-DIRECTION-CONVERSION 985978 CORVAIR SERIES 9S EXJSTING LOWER MULTIPLE CONNECTOR HOLE aB. ~~ -F~ GRILLE OPENING HEADLAMP ~-~ OPENING~~ FRONT INSTALLATION STEP 1 READ DBlECTlONS ON TEMPLATE FC8 LOCATION" wmE " PLACE GROMMET IN HOLE PREVlOUSLY DRILLED. DRILLING, ON 1..B. SIDE TAPE TEMPLATE SECURELY IN USE BODY SEALER TO SEAL WATERTIGHT. SEE FIG. 1. PLACE. SEE VIEW itA". Fa:t R. B. SIDE USE SAME TEM PLATE EXCEPT 1'0 PLACE TEMPLATE REVERSE SIDE UP. SIEP 8 (R.H. INSIDE OF VEHlCLE) DISCONNECT LOW ER CONNECTOR BODY, REMOVE DARK BLUE WIRE ..!!I!....wNAL STEP 2 LIGHTLY CENTERPUHCH AT HOLE LOCATIONS L.B. " RECONNECT CONNECTOR BODY. SEE FIG. 1...... 1'01' "R..H. SIDE, REMOVE TEMPLATE, DRILL BOLES DESIGNAT Terminal removaJ. see View "F", Fig. 2. ED. STEP 9 (L. H. INSIDE OF VEHICLE) DISCONNECT LOWER snp 3 REMOVE HE A D LAM P S " FRONT GRILLE. CONNECTOR B 477 PfUNTEO IN U. B. A. · 136 DIA. (3) HOLES ,-~iOU~-~-~~~EC~:i-~-g~j (NO. 29 DRILL) -----JINSERT SCREW DRIVER & ~PRESS TANG TOWARD -_'-".-.-~-'" TERMINAL. /"",_~I -~~-....."':!"'::...- 2. PRY TANG BACK OUT TO . DmECTION SIGNAL LAMP ASM. ;..;;..;,,~-----.--.. '- EXISTING REAR ~ MAIN HARNESS ___ ~ " CONNECTOR BODY ENGINE ACCESS DOOR o ' '~ REAR INST ALLA nON ,~~ STEP 13 LOCATE, CENTERPUNCH & DRILL HOLE TO DIM- STEP 17 PLACE CONNECTOR BODY, wmES," DIRECTION ENSION SHOWN, SEE VIEW D. II!III H hole saw is used, SIGNA L LAMP BACK THRU DRILLED HOLE. SEE FIG. 2. set saw to 4-1/4 Dia. STEP 14 REACH IN THRU "JUST BELOW HOLE PREVIOUSLY DRILLED, DISCONNECT STOP" TAIL LAMP CONNECTOR SUP 18 USE LAMP AS TEMPLATE, DRILL HOi..ES" AT- BODY FROM REAR MAIN HARNESS CONNECTOR BODY, SEE TACH LAMP WITH PARTS PROVIDED. SEE FIG. 2. VIEW "D". STEP 15 REMOVE TERMINAL END OF STOP LAMP W IR E STEP 19 OPEN REAR ENGINE COMPARTMENT DOOR, REACH (VIOLET) FROM LOWER HOLE ·IN CONNECTOR BODY, LOOP INSIDE AROUND CORNER, RECONNECT STOP" T A I L LAMP " TAPE WmE TO TAIL LAMP wmE (LIGHT BLUE).SEE FIG. CONNECTOR BODY INTO REAR MAIN HARNESS CONNECTOR 2 " VIEW "F". BODY. SEE VIEW "E". STEP 16 INSERT TERMINAL END OF DmECTION SIGNAL LAMP WIRE (BLACK) Tlnw GASKET" INTO LOWER HOLE STEP 20 FORR.H. SIGNAL LAMP INSTALLATION, REPEAT IN CONNECTOR BODY. SEE FIG. 2. STEPS 13 THRU 19. 478 SWITCH-HAZARD FLASHER 985886 CORVAIR SERIES 95 EXISTING CLIP EXISTING SLOT (IN BRACE ASM. OLD LOCATION) STEERING COLUMN EXISTING DlHECTION BRACE ASM. SIGNAL CONNECTORS EXISTING HARNESS CONNECTOR (NEW LOCATION) STEERING COLUMN BRACE ASM. JUMPER WIRE ORANGE WIRE TAPE EXISTING CHASSIS HARNESS TRAF FIC HAZARD SWITCH & HARNESS ASM. ~ BRACE ASM. \~ E STEP 1 DISCONNECT POSITIVE BATTERY CABLE. ORS TO TRAFFIC HAZARD _LAMP CONNECTOR, SNUG TRAF FIC HAZARD LAMP HARNESS & ORANGE WIRE UP INTO COR STEP 2 LOCATE, CENTERPUNCH " DRILL HOLE TJmU NER OF BRACE ASM. & SNAP TRAFFIC HAZARD LAMP CON STEERING COLUMN BRACE. SEE VIEW D. NECTOR INTO PLACE. SEE FIG. 4 &. VIEW E. STEP 3 INSTALL SWITCH" HARNESS ASM. WITH ROUN 0 STEP 5 ROUTE ORANGE WIRE FROM SWITCH &. HARNESS NUT. ATTACH LAMP, KNOB &. FLASHER ASM. SEE FIG. 4. ASM. UNDER BRACE & UP THRU OPENING IN BRACE TO FUSE pANEL. INSERT FUSE CLIP & FUSE INTO RECEP STEP 4 REMOVE EXISTING HARNESS CONNECTOR FROM TACLE IN FUSE PANEL MARKED "HTR" OR "B. U. LPS." BRACE ASM. " DISCONNECT DIRECTION-SIGNAL CQNNEC PLUG ORANGE WIRE CONNECTOR 2li!2,CLIP. LOOP & TORS. ATTACH TRAFFIC HAZARD LAMP CONNECTE1RS TO TAPE EXCESS wmE. SEE FIG. 4. EIiDI If receptacle is EXISTING VACATED HARNESS CONNECTOR. ROUTE TRAF occupied, remove &. plug into Jumper Wire. FIC HAZARD LAMP HARNESS BEHIND EXISTING HARNESS CONNECTOR &I.,ATTACH CONNECTOR TO BRACE ASM. IN STEP 6 CONNECT POSITIVE BATTERY CABLE & SEE LAST NEW LOCATION. ATTACH DIRECTION-SIGNAL CONNECT- SHEET FOR CHECKING'OPERATION. 525 TABLE 985107 R 1206 --- REINFORCEMENT SCREW RETAINING BLOCK mp 1 L 0 CAT E POINT" A" & DRILL HOLE THRU SOFT STfP 4 REMOVE WING BOLTS & RETAINING BLOCK FROM TRIM PANEL (IF EXISTING) & METAL SIDE TRIM PANEL. UNDERSIDE OF TABLE. REMOVE (1) TABLE LEG FROM HOLE IS TO BE IN ALIGNMENT WITH EXISTING SCREWS. STOWAGE POSITION. REPLACE RETAINING BLOCK & WING SEE FIG. 1. BOLTS TO SECURE REMAINING (2) LEGS. SEE FIG. l. SliP 2 ATTACH REINFORCEMENT & AUGN WITH ROO F STEP 5 SCREW TABLE LEG INTO CENTER ANCHOR PLATE TRIM PANEL LOWER EDGE. DRILL REMAINING HOLES US ON BOTTOM OF TABLE & ATTACH TABLE TO REINFORCE ING REINFORCEMENT AS A TEMPLATE. SEE FIG. 1. MENT WITH (2) SPECIAL WING BOLTS. SEE FIG.!. IIDI Exerciae care to avoid damage to reinforcement. STfP 6 TABLE MAY BE USED OUTSIDE THE VEHICLE BY STEP 3 SECURE REINFORCEMENT TO SIDE TRIM PANEL INSTALLING THE ADDITIONAL LEGS PROVIDED & PLACING WITH REMAINING SCREWS. SEE FIG. 1. SPECIAL WING BOLTS IN STOWAGE POOlTION. SEE VIEW A. ; PRINTED IN U. S. A. 529 VENTSHADE 985527, 985528, 985529, 985995, 985996 985997, 985998, 985025 CHEVROLET-CHEVELU & CORVAIR 95 CLIPS - Equally spaced 2 DR. - 4 Clips as shown 4 DR. - 3 Cllps FRONT DEFLECTOR -~ ·~; t,·~~· ~ f1.~:~ ~~~!i: • ___---~ I I 'i ~~~~~~~-': -----~~--<-~! ~~ --- WEATHERST~J ~ I C. V. PILLAR ./ I ~ ./ 1,.~, ~ ~~NTO~ TYPICAL FRONT DOOR INSTAllATION & REAR QUARTER WINDOW INSl AlLA TION 2.. DOOR MODELS FRONT OF ~CAR ... WAGONS ~ liliiii Deflectors are stampedtosbow position LF for ALL WINDOWS LeTt'Front, RF for Right Front, etc. STEP 3 PUSH UP DEFLECTOR UNTIL "0" CHANNEL OF DE FRONT DOOR WINnow FLECTOR TOUCHES DC:>al FRAME. SEE VIEW A. snp 1 INSERT FRONT FLANGE OF DEFLECTOR BET STEP 4 FROM INBOARD SIDE OF DOOR. USE PUTTY KNIFE WEEN WEATHERSTRIP Iz CV PILLAR. SEE FIG. 1. OR SIMILAR TOOL TO PRY BACK. RUBBER CHANNEL. AT OPENING PUSH CLIP STRAIGHT UP UNTIL IT SNAPS 0 V E R I REAR QUARTER WINDOW OR REAR POOR WINDOW LEOOE OF DOa\ FRAME. CLIP IS THEN LOCKED IN PLACE SEE VIEW A. STEP 2 INSERT FRONT FLANGE OF DEFLECTOR BETWEEN STEP 5 REPEAT ABOVE STEPS Fat DEFLECTORS ON OP RUBBER CHANNEL" WJNDOW FRAME. SEE FlG~'S 1,2 OR 3. POSITE SIDE OF VEmCLE. PalNTaD IN U. 8. A. t;j'\ lM~ CbrtroJet Diwt.loo ~ a.a.-I.I MWlt. Corp. 530 VISOR R.H. SUN 985900 CORVAIR SERifS 95 DRILL 1-1/8 INCH DIA. HOLE DRILL (3) .136 INCH DIA. HOLES (#29 DRILL) SCREW 10-8-12 X 3/4 I R. H. SUNSHADE & -d SUPPORT ASSY. I.H. SUNSHADE STEP 1 LOCATE EXISTING DIMPLE & DRILL LARGE HOLE metrically opposite to L. H. bracket before drilling holes. IN TRIM PANEL. SEE FIG.!. STEP 3 USING SUPPORT AS TEMPLATE CENTERPUNCH & DRILL HOLES. SEE FIG. 1. STEP 2 INSERT SUNSHADE & SUP z>ORT INTO HOLE && l.JNE UP WITH TOP OF WlNn:;HIELD OPENING & L.H. ·SUNSHADE. STEP 4 INSTALL SUNSHAD€ WITH ATTACHING PARTS PRO SEE FIG. 1. i'.""",:' Be sure bracket \.s located sym- VIDED. SEE FlG. 1. o Chevrolet Dhillon PRINTED IN u. S. A. \!:V ~~.eo Genera. Moton Corp. 536 WASHER-WINDSHIELD 985756 CORVAIR SERIES 95 11/32 DlA. 'H) 3-5/8 INT. -EXT. TOOTH LOCK WASHER SEALING WASHER • 144 DlA. (5) HOLES (NO. 27 DRILL) )__ @D-~_ I LOWER BRACKET~~ \ ,- -~ BRACKETS & NOZZLE ------STEP 1 LOCATE EXISTING DIMPLES IN DASH PANEL & PANEL. SEE VIEW A. IIJ!IDml Before drllling procedure is DRILL HOLES FOR UPPER R. H. & L. H. & LOWER BRACKETS started, It is suggested that mask Lng tape be applled to outer & GROMMET. SEE FIG. 1. Imm If heater exists, U.3e lower panel in drilllng area to avold marring the finish . hole of heater control cables clip for attachlng lower bracket. STEP 4 REMOVE FRONT GRILLE & ORNAMENT ASSEMBLY. STEP 2 INSTALL RESERVOIR UPPER & LOWER MOUNTING BRACKETS WITH ATTAClnNG PARTS PROVIDED. SEE FIG. l. STEP S INSTALL NOZZLE ASM. WlTH ATrACIDNG PARTS STEP 3 LOCATE, CENTER PUNCH & DRILL HOLES IN OUTER PROVIDED. SEE VIEW A. CD 1062 Chevrolet DIvision PRINTED IN U. S. A. General MolOl'8 Corp. 555 KNOB ASM. ~TJNGNUT ~. -{Q;-(, ~SCREW J\ / EXISTINGBEZEL SWITCHi'l WASHER ASM. CONNECTOR INSTRUMENT PANEL ~ NOZZLE ASM.~ / \ ~_ ~ _------?-;::.:- \~ HOSE (LONG) / , ~-~ \ l------:X-- ~ ~ ~ \ ~ \\ /~~) \ ~~ // (~ ~) PU~P ASM. _~ ~ SPECIAL GROMMENT ((, \J 2 - WIRE ,- / \ ( '::' (l)~ ----- ' CONNECTOR " I ' / EXISTING WIPER \ ~ -- ,~--< ')\\ ~ < ~ MOTO~ HARNESS CONNECTOR \ -:;:::::::::-- \ \ ' ~ - ' ~~~~~: ~ ,EXISTING _ ~. '-' ) \ V HARNESS \ .- .~~ \ .) \ " .. , .:~:~ r " \ \ . ~ - -;,!- -...;;;:.:::::::::::~U 3-WIRE CONNECTOR lJ~ ;HARNESS I 1 _",-, ,ASM. E,kTING ..J) RESERVOIR ASM. I ( / ~ , ''' "\ CLIP / _~ i-- - - I ! 1~~-~_ /- WIRE & HOSE ROUTING ~TEP 6 PLACE WIPER MOTOR IN PARK POSITION, RE- TANG TO BE POSITIONED UPW ARD) INSTALL KNOB. MOVE PLASTIC COVER FROM DRIVE SHAFT OF WIPER ATTACH EXISTING WIPER CONNECTOR (SLOTTED) TO MOTOR & POSITION CAM ON SHAFT. DISCONNECT UPPER TERMINAL. SEE VIEW B. MOTOR HARNESS CONNECTOR. SECURE PUMP ASM . TO WIPER MOTOR ASM. WITH SCREWS PROVIDED. SEE STEP 9 ATTACH PROVIDED PLUG TO PUMP OUTLET & CON- FIG. 2 ,,'il~'I:IC'am follower on Pump must ride on NECT (LONG) HOSE TO REMAINING OUTLET, THEN ROUTE outer surface alam ~ may require that Cam be rotated HOSE THRU GROMMET & HOLE, & CONNECT TO PREVIOUSLY slightly to allow proper alignment. INSTALLED NOZZLE. INSERT GROMMET. SEE FIG. 3. STEP 7 INSTALL HOSE & FILTER ASM. INTO RESERVOm & ATTACH RESERVOm TO BRACKETS. FASTEN HOSE TO STEP 10 ROUTE PROVIDED HARNESS THRU EXISTING CENTER OUTLET ON PUMP. SEE FIG. 3 CLIP ON DASH UNDER INSTRUMENT PANEL. ATTACH (2 WIRE) CONNECTOR TO PUMP, (3 WIRE) CONNECTOR STEP 8 DISCONNECT EXISTING WIPER CONNECTOR FROM TO WIPER MOTOR & EXISTING CONNECTOR PREVIOUSLY SWITCH. REMOVE WIPER KNOB & SWITCH ASM. & DIS DISCONNECTED TO REMAINING CONNECTOR. ATTACH CARD BUT RETAIN BEZEL & NUT. INSTALL PROVIDED (1) WffiE CONNECTOR TO SWITCH. SEE FIG. 3. SWITCH'WITH RETAINED BEZEL & NUT. (TERMINAL WITH 556 R.H. CENTERLINE OF WINDSHIELD L. H. 8-3/8 APPROX. POINT OF CONTACT CENTERUNE OF WATER STREAM / ( STEP 11 TEST SYSTEM TO INSURE CORRECT INSTALLA CONTACT, BALL OF NOZZLE MM. SHOULD BE ADJUSTED. TION & DETERMINE LOCATION OF POINT OF CONTACT FOR ADJUSTMENT MAY BE MADE BY INSERTING STRAIGHT PIN WATER STREAM. SEE FIG. 4. IN BALL OF NOZZLE & TURNING BALL. SEE VIEW C. STEP 13 REP LAC E FRO NT G R ILL E & 0 RNA' MEN T STEP 12 IF WATER STREAM DOES NOT REACH POINT OF ASSEMBLY. 557