LITHO IN U.S.A.

1962 PASSENGER, CHEVY H, CORVAIR AND TRUCK

ACCESSORIES INSTALLATION 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 contain&d in this literature are based on the latest product information available at the time of

publication approval. The right is reserved to make changes at any time without notice in prices, colors, materials, equipment, specifications and models, and olso fo discontinue models.

CHEVROLET MOTOR DIVISION, GENERAL MOTORS CORPORATION

({J 1961 CHEVROLET MOTOR DIVISION

GENERAL MOTORS CORPORATION

P&A 15 8.7M

ALPHABETICAL INDEX

Description

ADAPTER - Air Conditioner - Power Steering - 6 Cyl.-Pass. ADAPTER - Air Conditioner - Power Steering - V8-Pass •.. ADAPTER - Air Conditioner - Power Steering - 6 Cyl. -Trk. . . ADAPTER - Air Conditioner - Air over Hydraulic Brakes-6 Cyl-Trk. ADAPTER - Air Horns - Tilt Cab Only . . . ADAPTER - Arm Rest - Series 95 Trk. ........ . ADAPTER - Level Floor - Series R1254 ..•....•. AIR CONDITIONER - Deluxe - Series 100-300-Chevy IT AIR CONDITIONER - Deluxe - Series 200-400-Chevy II . AIR CONDITIONER - Deluxe - Corvair - Sedan & Coupes Only AIR CONDITIONER - Cool Pack - V8-Chev. Pass. . . . .• . . AIR CONDITIONER - Cool Pack - 6 Cyl. -Chev. Pass. •. AIR CONDITIONER - Center Mtg. 6 Cyl.-Trk. . •..• AIR CONDITIONER - Right Hand Mtg.-6 Cyl.-Trk .. " ...... . AIR CONDITIONER - Center Mtg. - V8-283 Engine-Trk .. AIR CONDITIONE R - Right Hand Mtg. - V8-283 Engine-Trk. AIR CONDITIONER - Right Hand Mtg. - V8-283-with Air Brakes Trk. AIR CONDITIONER - R~ght Hand Mtg. - V8-348 Engine-Trk ..... AIR CONDITIONER - Right Hand Mtg. - V8-348 with Air Brakes Trk. ANT ENNA - Right Front- Pass. ..... . • . . ANTENNA - Right Rear-Pass ...... . ANTENNA - Left Rear - Dummy-Pass. ANTENNA - Corvette. . . . . ANTENNA - Front .......... . ANTENNA - Front-Chevy II ......•. ANTENNA - Front-All Cabs & Panels-Regular Trks. . • ANTENNA - Tilt Cab Truck . . . . •.. ANTENNA - Front-Series 95 Trk.

BELT - Seat-Front BELT - Seat-Rear .•...... BEZEL - License Plate - Corvair BRACKET - Right Hand Safe ty light- Pass. .... BRACKET - Right Hand Safetylight-Trk. BRACKET - Right Hand Safetylight - Tilt Cab Trk. . . BRACKET - Mirror - All Regular Cabs & Panels . . BRAKE - Power-Pass ... BRAKE - Power-Chevy II. . • . . . . . . . . BRAKE - Power - Truck ......... .

CARRIER - Luggage - Station Wagon-Pass ... CARRIER - Luggage - All Corvair Sedans .•.. CARRIER - Luggage - Corvair & Chevy IT Station Wagons CARRIER - Luggage - Greenbrier - Corvan & CIa Panel Trks. CLOCK - Electric-Pass ....................•. CLOCK - Electric-Corvair-Chevy IT-Series 95 & All Trucks. CLUTCH - Modulated Fan - All Pass. Except Corvair .... COMPASS - All-Except Convertibles ........•......

Part No.

985361 988493 988204 988224 988298 988410 985306 985198 985199 985146 985172 985170 985265 985267 985266 985268 985270 985269 985271 985128 985129 985130 988370 985055 985191 985368 988290 988329

985357 985180 985325 988393 988092 988379 985279 985239 985247 988209

988499 985056 985250 988398 985348 985329 985355 985002

Page No.

60-61-62 58-59

91 91

278-281 386

350-353 8-29 8-29 30-50 51-72 51-72

73-118 73-118 73-118 73-118 73-118 73-118 73-118 119-120 121-122 121-122 123-124 125-126 127-128 129-130

131 132-133

135-139 140-150

151 389 395 397 152

153-157 158-162 163-167

168 169 170 171 172

173-175 176

177-178

ALPHABETICAL INDEX (Continued)

Description

CONTAINER - Litter - All Pass. . . . . . . . . . . CONTROL - Headlamp Beam - Guide:'" Matic- Pass.. . CONTROL - Manual Throttle-Trk. . .... COVER - Plastic Cushion - Two Door-Pass. . .... COVER - Plastic Cushion - Four Door-Pass ......... . COVER - Plastic Cushion - Four Door-Corvair-Except Monza . COVER - Plastic Cushion - Two Door-Corvair-Except Monza COVER - Plastic Cushion - Two Door-Chevy II .. . COV ER - Plastic Cushion - Four Door - Chevy II ...... . COVER - Rear Seat Luggage - Corvair . . . . . . . . . . . . . COVER - Roof Luggage Carrier - Pass. St. Wag. Greenbrier-

Corvan & CIa-Panels .......... . .. . COVER - Roof Luggage Carrier - Corvair Sedan . . . . . COVER - Seat - All Regular Truck Cabs .......... . COVER - Wheel-Pass. . . . . . . . ... . COVER - Wheel-Corvair . . . . . . . . . . . . .. . COVER - Wheel-Chevy II .......... ...... . . COVER - Wire Wheel - Corvair & Chevy II ..... .

DEFROSTER - Rear Window-Pass.-Exc. Sta. Wag. & Convertible . DISPENSER - Tissue-Pass. &. Corvair .............. . DISPENSER - Tissue & Litter Container-All Pass.-Corvair-Chevy II

GUARD - Front Bumper Grille-All Pass ......... . GUARD - Rear Bumper-All Pass. Except Station Wagon ..... GUARD - Front or Rear-All Corvairs . : . .. ... . GUARD - Front Bumper Grille - All Chevy II ..... . GUARD - Rear Bumper-All Chevy II . . . . . . . . . . . GUARD - Bumper - Painted-CIO-20-30-40-K10-20-Trks. GUARD - Bumper - Chrome-C10-20-30-40-K10-20-Trks. GUARD - Bumper - Painted - Series 95 Trk. . . . . . . GUARD - Bumper - Chrome-Series 95 Trk. ...... . GUARD - Grille - Brush Type - C10-20-30-40-Trks ... . GUARD - Grille - Brush Type - All Except - Series C and 95 GUARD - Door Edge - Four Door - All Pass ..•.... GUARD - Door Edge - Two Door - All Pass. .. GUARD - Door Edge - Four Door - All Corvair ..... . GUARD - Door Edge - Two Door - All Corvair .... . GUARD - Door Edge - Four Door - All Chevy IT. . ... GUARD - Door Edge - Two Door - All Chevy II . . . . GUARD - Gasoline Filler Door - All Pass. Except Sta. Wagon GUARD - Gasoline Filler Door - Statioh Wagon - Pass .. . GUARD - Gasoline Filler Door - All Corvair . . ... .

HARNESS - Accessories Wiring - Corvair . -HARNESS - Accessories Wiring - Series 95 Trk. HEATER & DEFROSTER - Gasoline - Corvair HEATER & DEFROSTER - Deluxe - Trk .•...

Part Page No. No.

985276 179-180 988389 181 985328 182-183 988500 184-185 985001 184-185 988288 186 988287 186 985365 186 985366 186 988363 187-18:3

985314 189 985300 189 985370 190-19:~

985142 193 985257 985259 194 985373 195

988382 196-19B 985339 199 985275 200

985165 201 985147 202 988203 203 985331 204 985302 205 988386 206 988387 206 985070 207 988373 207 988155 208-209 985144 210 988427 211 988426 211 988082 212 988422 212 985164 213 985163 213 985119 214 985120 214 988274 215

985086 216 988350 217 985342 218-230 985216 231-237

ALPHABE1'ICAL INDEX (Continued)

Description

HEATER & DEFROSTER - Recirculating-Trk ...... . HEATER & DEFROSTER - Deluxe-Tilt Cab Trk .... . HEATER &; ,DEFROSrrER - Deluxe Air - Series 95 Trk. . ... HEATER &. DEFROSTER - Gasoline - Series 95 Trk. HORN - Air - Trucks with Air Brakes ....... . HORN - Matched - high note - Trk. . . . . . . . . . . . .

LAMP - Back-Up-Pass.-Exc. Impala & Station Wagon ..... . LAMP - Back-Up-Pass.-Station Wagon .......... . LAMP - Back- Up-All Chevy II ............ . LAMP - Back- Up-All Corvair Exc. Sta. Wag. & Four Speed Trans. LAMP - Back- Up-Corvair Sta. Wag.-Exc. Four Speed .... LAMP - Back - Up- Fleet & Stepside Pick- Ups &. Panels~ Trk. LAMP - Courtesy-11-12-13-1400 Series Pass. ..... . LAMP - Courtesy-15-16-17-1800 Series-Exc. Convertible .... LAMP - Courtesy-All Chevy II . . . . . . . . LAMP - Courtesy - Corvair 500 . . . . . . . . LAMP - Courtesy - Corvair 700- 900. . . . . . . . . . . LAMP - Cab Clearance-Trk. . ........ . LAMP - Dome-Series 95 Panel and Greenbrier . . . . . LAMP - Glove Compartment-11-1400-Pass.-All Chevy II-Corv.&Trk. LAMP - Luggage Compartment-All Pass. Chevy IT &. Corvair .. LAMP - Underhood - AU Pass.-Chevy IT and Corvair .... . LIGHTER - Cigarette - Series 95 Trk. . ........ . LIGHTER - Cigarette - Chevy II 100-200 Series . . . . . LIGHTER - Cigarette - All Trucks . . . . . . . . . . . . . LOCK - Rear Door Safety-All Pass.-Chevy II & Corvair LOCK - Station Wagon Compartment-Pass. . . . . . . . . LOCK - Spare Wheel &; Tire-Corvair Exc. Station Wagon

MIRROR - Outside Body Mount-All Pass.-Chevy IT & Corvair MIRROR - Extendable Rear View-Truck. . . . . . . . . . MIRROR - Deluxe Rear View - Truck ........... . MIRROR - Deluxe Rear View - Tilt Cab Truck ...... . MIRROR - Deluxe Rear View - Regular Pick- Ups & Panels MIRROR - Deluxe Rear View - Series 95 Truck ........ . MOULDING - Body Sill-Pass. .... . ..•. MOULDING - Body Sill-Chevy IT ......... . MOULDING - Body Sill - Corvair . . . . . . . .

OPENER - Truck-All Pass.-Except Station Wagon ORNAMENT - Fender Marker - Pass. . . . . . .

PLATFORM - Level Floor - Model 1244 and 1254

Part No.

988101 988354 985340 985344 988252 988114

985261 985262 985293 985183 985184 988170 988396 988397 985294 985298 985299 985341 988346 985273 985246 985217 985237 985362 988072 985295 985351 985113

985169 985278 985281 985283 985284 985285 985148 985297 985084

985137 985324

985305

RADIO & ANTENNA - Manual or Push Button-All Pass. 985124,125,126,127 RADIO & ANTENNA - Corvette ............. . • .. 985139 RADIO & ANTENNA - Manual or Push Button-All Chevy IT . . 985187,188 RADIO & ANTENNA - Manual or Push Button-All Corvairs. 985154,155

Page No.

238-244 245-251 252-265 266-277 278-281

282

283 284-285 286-288 289-291 292-294 295-300

301 301 302

308-309 310-311 303-307 312- 313 314-317 318-319 320-323

324 335

326-328 329

330-331 332

333-334 325

336-338 339-340

341 342 343 344 345

346-348 349

350-353

354-357 358-361 362-365 366-369

ALPHABETICAL INDEX (Continued)

Description Part No.

RADIO & ANTENNA - Manual-All Trks. Except Tilt Cab. . . . .. 985225 RADIO & ANTENNA - Manual - All Tilt Cab Trucks. . . . . . . . 985226 RADIO & ANTENNA - Manual - All Series 95 Trucks ...... 985202

- For Antenna Installation See Pages 121 thru 133 RAILS - Side-All Stepside & Model 1244 Pick-Ups. . . . . 988257 REST - Arm-Rear-Chevy II & Corvalr-985308, 310, 312 985313 REST - Arm-All Cabs & Panels-All Series 95 . . . . 985231

SAFETYLIGHT - All Pass. . . . . . . . . . . . . . . . 985326 SAFETYLIGHT ... All 95 Series Trucks. . . . . . . . . . . . . . 988335

988090 988378

SAFETYLIGHT - All Cabs & Panel Trucks-Except Tilt Cab . . SAFETYLIGHT - All Tilt Cab ......... . Ie •

SCREEN & GRILLE - All Pass. Station Wagon . . . . . SCREEN - Rear Door-All Pass. Station Wagon ..... SCREEN - Radiator Insect-All Pass. Chevy II & Trks. SIGNAL - Parking Brake - All Pass.-Except Impala . . . .

985075 985076 985296 988409

SIGNAL - Parking Brake - All Corvair ....... . . . .. 985333 SIGNAL - Parking Brake - All Chevy II ........ . 985248 SIGNAL - Direction-Conversion from Parking Lamps to Double Face 988116

988402 988403 988404

SPEAKER - Rear Seat - All Pass. Sedans ............ . SPEAKER - Rear Seat - All Pass. Sport Coupe & Convertibles .. SPEAKER - Rear Seat - All Pass. Station Wagons . . . . SPEED & CRUISE CONTROL - All Pass. . . . . . . . . . . SPRING - Auxiliary - All C-L-S-T-50-60-70-80 Series STEP - Side Panel - All Fleetside Pick- Ups . . . . . . . SWITCH - Hazard Flasher-All Pass.-Trks &. Series 95 Trks.

988451,452 988248

. . . 988423

. • . 985327

VENTSHADES - All Two & Four Door Model Pass. .• VENTSHADES - All Two & Four Door Model-Corvalr VENTSHADES - All Two & Four Door-Chevy II VENTSHADES - All Series 95 Trucks . • . . • VENTSHADES - All Truck Cab & Panels . . • . . . . . VISOR - Right Hand Sun - All Regular Cabs & Panels VISOR - Right Hand Sun - All Tilt Cab Trucks VISOR - Right Hand Sun - All 95 Series

WASHER - Windshield - All Pass. • • • . . • .

· 988480,481,482 · 985166,167,168 · 985336,337,338

985025 988127 985235 988339 985238

WASHER - Windshield All Corvair. . • . • • • 985330 985236 985263 985249

WASHER - Windshield - All Chevy II . . . . . . WASHER - Windshield - All Truck Except Tilt Cab WASHER - Windshield - All 95 Series •••..•••••. WASHER - Windshield - All Tilt Cab •• . • . • • • •

GREENBRIER OUTDOOR LIVING EQUIPMENT SCREENS • • • • • • • . • • • ••• CARGO & BAGGAGE NET • CHILD BED

985304 988338

,.. TABLE UNIT ••.••••. \.1:

985100 985104 985359 985107

Page No.

370-378 370-378 379-382

383 384-385

386

387-389 390-392 393-395 396-397

398 399

400-401 402 403 404 405

406-407 408-411 412-414 415-426

427 428

429-435

436 437 438 436 439 440 441 442

443-444 445-446 447-448 449-451 452-454 455-458

459 460 134 461

CABLE ASM. LEAD-IN

\ /' "'\ , A

---------' \, \ \, fI-:,,:,:,' "'111I0Il1 After assembly make sure the \'\ \ ,'.~. antenna cable is positioned AWAY from ' ,-.-existing vehicle wiring. ========---- DRILL 1/2 INL:H \

_ _ _ _ _ _ _ ~~SH PANbL _ -- -':.~'~ HOLE \

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\ L J" -~ . .:JL. -1 BXISTING SCREW GROMMET

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. CABLE ASSY. LEAD-IN

STEP 9 WITH CLIP LOCATED TO DIMENSION SHOWN & ANTENNA ASM. IN VERTICAL POSITION, USE BRACKET AS A TEMPLATE & DRILL A HOLE IN HINGE PILLAR SEE VIEW A.

STEP 10 FASTEN BRACKET SECURELY TO lflNGE PILLAR WITH SCREW PROVIDED, & TIGHTEN SCREW HOLDING CLIP. SEE VIEW A.

STEP 11 REMOVE THE GLOVE BOX .

STEP 12 LOCATE & DRILL A HOLE IN THE DASH PANEL. SEE F1G. 4.

STEP 13 ROUTE PLUG END OF CABLE ASM. THRU THE

133

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DRILLED HOLK SEE VIEW A. mllll,'11 Do not kink or bend cable sharply at anytime.

STEP 14 SLIDE GROMMET OVER PLUG END OF CABLE ASM. & INSERT INTO DASH, SE E FIG. 4 .

STEP 15 ROUTE CABLE ACROSS TOP OF HEATER HOLE COVER & SECURE WITH CLIP & EXISTING SCREW. SEE FIG. 4.

STEP 16 ADJUST ANTENNA TRIMMER. (SEE RADIO INST­RUCTION SHEET).

STEP 1 7 REP LAC E THE G L 0 V E BOX.

STEP 18 REP LAC E THE H E AD LAM PAS M.

985180 ·CHEVY II SEAT BELT INSTRUCTION SHEET

CHEVROLET, CORV AIR, CORV AIR 95, '" ___ , & TRUCK

NOTE: FOR OPERATING INSTRUCTIONS FOR OWNER, PLACE LAST SHEET IN GLOVE COMPARTMENT

01961 Ch&'n'olBl DIvisIon \V Oeneral MOIOni Corp.

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BRAC

KET

LOCA

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S CO

RVAI

R 95

BR

ACKE

T LO

CA TU

\

985329 INSTRUMENT PANEL CLOCK INSTRUCTION SHEET

CHEVY, CORVAIR, CORVAIR 95 &. TRUCKS

DRILL 1/ 4 INCH DlA. HOLE

-~NCH ~, DIA. HOLES

~- .... ,~\ ~-~ 27/64~:~' ~_ ;;;:-~

REAR OF ASHf- '~- \...-------

TRAY BEZ EL L , OF CAR tfj

.. ....... - '-CENTERLINE

~ - INSTRUMENT A PANEL

STEP 1 LOCATE, CENTER PUNCH &. DRILL HOLES IN INSTRUMENT PANEL. IF INSTRUMENT PANEL IS PADDED, HOLES ARE TO BE DRILLED THRU PAD. (ON CORY AIR 95 &. CHEVy) USE TEMPLATE PROVIDED. SEE FIG. I, 2, OR 3. 11m (ON COaVAIR) Remove Ash Tray Asm. (rom Instrument Panel before drllllng holes .

STEP 2 (ON CORVAlR WITH PADDED DASH) PLACE MOUNT­ING BRACKET IN TRIM PLATE &. LOOSELY INSTALL. SCRIBE AROUND PLATE, REMOVE PLATE & MOUNTING BRACKET & CUT PAD 1/4" INSIDE OF SCRIBED AREA. SEE FIG. 4.

Ii' USI Cl\tvtolt t DI.,1I10ll \!.I o.n .... 1 Motor. Corp.

'~~PLATE

~~~;::::N~~ - OF VEillCLE

......---- INSTRUMENT ~-. PANEL

CLOCK ASM.

MOUNTING BRACKET ......-­SCREW -:::::.-<::--~" 6-32 X 1/ 4 --TRIM PLATE-CORVAIR-. .... ..-::J.

IF PAD EXISTS

CUT LINE

--SCREW 6-15 X 5/ 8

(CORVAIR) __ • ',C 1/ 4

SCRIBE LINE --c.:::..:-_::::-~-:::- ;;J.IU-1~~ (CORVAIR) ~:~d~\

~;;;;;§S~._ .. ~vlASH TRAY HAN~LE - ~ ,'~ (CORV AIR) in closed \~~?Siuon.

TYPICAL CLOCK A TV ACHMENT

STEP 3 INSERT CLOCK WIRES THRU CENTER HOLE IN MOUNTING BRACKET & TRIM PLATE (IF REQUIRED) &. AT· TACH BRACKET TO INSTRUMENT PANE L WITH SCREWS. SEE FIG. 4.

STEP 4 AT T A C H CLOCK TO MOUNTING BRACKET WITH SCREWS. SEE FIG. 4. m::ID (ON CORY AIR) Close cover on Ash Tray" installlnto Instrument Panel with handle next tc clock. This ls 180 0 from previously installed position.

NOTE Discard remaining bracket. If instrument pad does not exist, discard trim plate.

PRINTED IN U. s.,

173

JUNCTION BLOCK _ --­/'

r RADIO SPEAKER ASM.

CLOCK ASM.

. r ~ . . ~S ~ . '""~'OO

FUSE CLIP AS~ '"'

FUSE , ~ GRAY WIRE

EXISTING HARNESS

CLOCKASM.

CONNECTOR

-------~-~~-=~

HARNESS CONNECTOR

----------~ --~"-:E:::XISTING HARNESS

STEP 5 INSERT CABLE INTO 2-WAY CONNECTOR" PLUG IN CLOCK WIRES, MATCHING COLORS. SEE FIG. 5, 6, 7 OR 8.

JUNCTION BLOCK" ATTACH TO EXISTING HARNESS WITH PROVIDED CLAMPs. SEE FIG. 5, 6, 7, OR 8. EIlDJI (ON TRUCKS WITH RADIO) Route clock wires over edge or speaker. See Fig. 5 or 8.

STEP 6 ROUTE CABLE WITH EXISTING HARNESS TO

174

•

GRAY WIRE

/ CONNECTOR

/ " HARNESS CONNECTOR

~,'

WIRE ROUTlNG- CHEVY --\""" _--"'I. ~_

L\, \ RADIO

RED WIRE SPEAKER HARNESS 1 __________

D~;,~:::=-~~ $~~ INSTRUMENT - _-~ PANEL

: Ts:.~i?~'!t JUMPER JUMPER WIRE I , ...... t-~ I

I I :~t;.:'1 WIRE CABLE ASM _ RED WIRE t " .Jt~ . t t ~' &.c?'" a / I J .... ~ ~FUSECLIP ASM.

'1!':':"'.f' '~FUSE

WIRE ROUTING-TRUCK EXCEPT TILT) & CORVAIR

STEP 7 (ALL EXCEPT CHEVY) INSTALL FUSE CLIP & FUSE INTO RECEPTACLE IN JUNCTION BLOCK MARKED "GL. BOX LP." & PLUG IN RED WIRE CONNECTOR. SEE FIG. 5, 6 OR 8. ... If receptacle is occupied, remove existing wire " plug into Jumper wIre. Discard fus e & cUp.

STEP 8 (ALL EXCEPT CHEVY) PLUG GRAY WIRE CON ­NECTOR INTO BACK OF JUNCTION BLOCK AT RECEPTACLE MARKED "PANEL LPS." SEE FIG. 5, 6, OR 8. mill If receptacle is occupied, remove exIsting wire & plui""iiit01umper wire.

STEP 9 (CHEVY ONLY) PLUG RED WIRE CONNECTOR INTO RECEPTACLE IN JUNCTION BLOCK MARKED "eLK", SEE FIG. 7. II:DI If receptacle is occupied, remove existing wire " plug into jumper wire.

STEP 10 (CHEVY ONLy) PLUG GRAY WIRE CONNECTOR INTO RECEPT ACLE IN JUNCTION BLOCK MARKED "PNL. LPS", SEE FIG. 7 . .mill If receptacle is occupied, remove existing wire & plug tntO"'jUr'Uper wire.

STEP 11 CHECK FOR PROPER OPERATION.

175

•

985276 LITTER CONTAINER INSTRUCTION SHEET

CHEVROLET. CORVAIR, CORVAIR 95, TRUCK.,. CHEVY

,~~EL

---AINER Part of bracket assembly.

INSTRUMENT PANEL=:\" REINFORCEMENT

bracket aam.

SCREW -Part bracket asm.

INSTRUMENT PANEL INSTRUMENT PANEL COM­PARTMENT

---= =--- ~ __ ~~.ENrn~ I ~ CENTERLINE OF I

1 INSTRUMENT • PANEL COM­

PARTMENT

~JE~·, ... ~~-""

CENTERLINE OF BRACKET

CORY AIR & CHEVROLET

PURCHASED WASHERS

SCREW 8-15 X 3/ 4

STEP I LOOSEN SCREWS IN BRACKET ASSEMBLY.

STEP 2 LOCATE BRACKET ASM. ON INSTRUMENT PANEL & TIGHTEN ATTACHING SCREWS. SEE FIG. I OR 2. IIDI Keep screws c lose as possIble to rolled (lange.

I CORVAIR 95

STEP 3 DISASSEMBLE BRACKET ASM. & DISCARD ALL BUT BRACKET.

STEP 4 LOCATE CENTERLINE OF BRACKET ON CENTER­LINE OF INSTRUMENT PANEL COMPARTMENT OPENING"

fC" lIO Chen-oiet DL"wLon \!,It 1 O,n,nl Moton Corp . 179

- ------ -- ,.: RETAINER-Parto! ~-~ bracket asm. ....--- ROLLED FLANGE \ . \

I INSTRUMENT PANEL REINFORCEMENT

I BRACKET - Part of bracket asm.

L--:~~~I/

SCREW - Part of bracket asm.

CORVAIR

I III /~ ~/~7WINDOW L.H.INNER ~ PANEL -~ -------=

~--------­DRILL (2) .147 INC~~ ~ DlA. HOLES (NO. 26 ________ ..____1

, DRILL) _ ..____

1.--2-3/ 4 i ------I -t . c:::- (71.-----"'"--

2.S ·4....-1

USING BRACKET AS A TEMPLATE, CENTER PUNCH & DRILL HOLES. SEE FIG. 3.

STEP 5 ATTACH BRACKET TO INSTRUMENT PANEL WITH THE PROVIDED SCREWS & PURCHASED WASHERS (USED AS SPACERS). SEE FIG. 3.

CORY AIR 95 ALTERNATE POSITION

STEP 6 L 0 CAT E BRACKET ON INNER PANEL & USE AS A TEMPLATE TO CENTER PUNCH & DRILL HOLES. SEE FIG. 4.

STEP 7 ATTACH BRACKE T TO INNER PANEL WITH THE SCREWS PROVIDED. SEE FIG. 4.

PRINT£D IN U. S. A.

CENTERLINE OF INSTRUMENT PANEL COM­PARTMENT

PANEL /

CENTERUNE OF~ INSTRUMENT

---- ~ ' , -- -~ \ \ ~ \ RETAINER-Part

of Bracket Asm. INSTRUMENT PANEL REINFORCEMENT

\ L--k-- t-\

) /

SCREW - Part of Bracket Asm.

~ LOCATION RADIO OR FLOOR MOUNTED GEAR­SHIFT EXISTS

BRACKET - Part of Bracket AIS m.

TYPICAL TRUCK INSTALLATION

I TRUCKS WITHOUT RADIO OR FLOOR MOUNTED GEARSHIFT

I;STEP 8 LOOSEN SCREWS IN BRACKET ASSEMBLY.

·STEP 9 LOCATE BRACKET ASM. AT CENTERLINE OF IN-.STRUMENT PANEL 8< TIGHTEN ATTACHING SCREWS. SEE

FIG. 5. £I!DI Keep s crews c lose as possible to rolled flange.

I TRUCKS WITH RADIO OR FLOOR MOUNTED GEARSHIFT

STEP 10 LOOSEN SCREWS IN BRACKET ASSEMBLY.

STEP 11 LOCATE CENTERLINE OF INSTRUMENT PANEL COMPARTMENT (SEE FIG. 5) 8< INSTALL BRACKET AS­SEMBLY IN SAME MANNER AS TRUCKS WITHOUT RADIO OR FLOOR MOUNTED TRANSMISSION. SEE FIG. 5.

CHEVY

STEP 12 LOOSEN SCREWS IN BRACKET ASSEMBLY.

STEP 13 LOCATE BRACKET ON INSTRUMENT PANEL 8< TIGHTEN ATTACHING SCREWS. KEEP SCREWS CLOSE AS POSSIBLE TO ROLLED FLANGE. SEE FIG. 6.

ALL MODELS

STEP 14 INSTALL CONTAINER INTO BRACKET. SEE FIG. 7. EImFor Truck & Chevy bend container rods paralle l

with bag before installation. See Fig. 7.

180

INSTRUMENT PANEL~

L---- - """'\-'f --~::::::::::::::::I ---~ .-IlI<Sl'RUME:NT PANEL

COMPARTMENT OPENING

RET AINER - Part of Bracket As m.

~ ~~ - ----:-~-S ~ EL

- - ~ ~ REINFORCEMENT

--\-:-:/8 ~ . ~ ~\ \ .. \

\ \ :!'f \ , \ BRACKET - Part

........ \ 2- 1/8 -- ~ of Bracket A. m.

~ ,,-.,~\ \ L ROLLED FLANGE

\ SCREW - Part of ~ \ Bracket Asm.

---I

\ EXISTING MOUNTING BRACKET (AIR CONDITIONING)

NORMAL POSITION

CONTAINER ASM.

OPUSH T HRU

CONTAINER ATTACHMENT

BENT POSITION

985314·985300 ROOF LUGGAGE CARRIER COVER INSTRUOION SHEET

CHEVROLET ST A. WAG., CORY AIR 4 DOOR & ST A. WAG., CORY AIR 95, TRUCK PANEL & SUBURBAN, CHEVY STATION WAGON

B' B'

A CHEVROLET

STATION WAGON

A

B' B'

B B

A CORVAIR 95 TRUCK

PANEL & SUBURBAN

A

B B

STRAP A 7.00 INCHES

STRAP B 10.00 INCHES

* Cut off excess strap.

SHORT STRAP

A B'

A B'

A B

A B

LONG STRAP ASM.

A A

CORVAIR 4-oooR

A A

A A

CORVAIR & CHEVY

STATION WAGON

A A

B'

B'

B

B

SHORT STRAP ASM.

COVER ASM.

COVER ASM.

FRONT OF VE HICLE

LUGGAGE CARRIER ASM.

:--0::;

SHORT STRAP ASM.

STEP I PLACE COVER ASM. INSIDE ROOF LUGGAGE CARRIER ASM. WITH SHORT 8TAPLED STRAPS (DOWN) ON LOWER HALF & ZIPPER FACING TOWARD REAR & RIGHT SIDE OF VE HICLE. SEE FIG. I.

STEP 2 PLACE TOP END OF SHORT STRAPS ON TOP OF RAIL ASM. & FASTEN WITH BUTTON DESIGNATED. SEE

'i" 18(11 Che\'l'olet DlvLalon \,!.I (leneral Moton Corp. 189

VIEW A.

STEP 3 STRAP8 THAT HAVE TWO BUTTONS ON ONE END & WHEN INSIDE IlUTTON IS USED, CUT OFF OUTSIDE END BUTTON TO DIMENSION SHOWN. SEE VIEW B.

III!III Use short straps to secure cover asm. only, use long straps to hold down load. See Fig. 1.

PRINTED IN U. S. A

EXISTING­VALVE STEM

WHEEL ASM.

985142 WHEEL TRIM COVER INSTRUCTION SHEET

CHEVROLET" CORVAIR 95

WHEEL ASM.

\

/

\

STEP 1 A'TT ACH VALVE STEM EXTENSION TO EXISTING VALVE STEM OF EACH WHEEL. SEE VIEW A.

ING. SEE FIG. 1" VIEW A.

VALVE STEM EXTENSION

WHEEL TRIM COVER

STEP 2 PLACE WHEEL TRIM COVER AGAINST WHEEL SO THAT VALVE STEM EXTENSION PROTRUDES THRU OPEN-

STEP 3 PRESS WHEEL TRIM COVER FIRMLY AGAINST WHEEL UNTIL IT SNAPS INTO PLACE. SEE FIG. 1 " VIEW A.

f'i" IHI ClIl.nolet DL,lllon \V o.n .... 1 Mototl Corp.

PRINTED IN U. S. A.

193

985275 TISSUE DISPENSER & LITTER CONTAINER INSTRUCTION SHEET

CHEVROLET, CORVAffi, CORVAffi 95, & CHEVY (ALL EXCEPT FLOOR MOUNTED SHIFTS)

\ \ ' '\...---' -\~TE~~NE

9~' -~ ~~: ~~NT OF - I~:_

CHALKMARK /

CORVAffi

10- 3/ 4

6-3/ 4

CENTERLINE

CORVAffi 95

~" FRONT OF . >' CAR

- ---------IEI'!DI After first box of tissue is used, remove top (rom tissue box & use as a liner in litter container. ---

--===7) I L-r- --(17 -

- \\ CHALK MARK y-

---- ~ ---- \ '

~A-B

BRACKET

TISSUE DISPENSER

I I

& LITTER CONTAI NER ASM. (FRONT EDGE)

FORWARD EDGE OF SEAT (CHEVROLET &

'~EVY) FLOOR MAT C;:;I!Ji!

~

am Be sure floor mat surface is clean & dry (or marking dimensions when installing container.

STEP 1 USING CHALK, MARK BRACKET LOCATION ON FLOOR '''iliiSE DIMENSIONS SHOWN. SEE FIG. I, VIEW A & B. On Chevrolet & Chevy move seat forward as (ar as poss e before dimensioning.

"?'IHI Churolt'DlTIIILoll W O~n" Motor. COt'p. 200

STEP 2 INSTALL WffiE BRACKET BY PIERCING FLOOR MAT AT CHALK LINE WITH BRACKET ENDS & POSITIONING BETWEEN UNDERBODY & MAT AS SHOWN. SEE FIG. 1. mil Bracket ends must be installed equally distant from "'C"e"ilre"Une of tunnel to maintain a level container condition with floor.

STEP 3 POSITION REAR WALL BOSS OF TISSUE DISPENSER SECURELY ONTO BRACKET AS SHOWN. SEE FIG. I.

PRINTED IN U. S, A.

GUARD ASSY.

GUARD

CENTERLINE OF GUARD

985070-988373 BUMPER GUARD INSTRUCTION SHEET

R-IO SERIES

CLAMP jBOLT 3/B -16 X I LOCK WASHER

FRONT BUMPER-ll INCHES (APPROX. ) REAR BUMPER-6 INCHES (APPROX.)

STEP I INSTALL GUARD ON FRONT OR REAR BUMPER AT LOCATION SHOWN WITH ATTACHING PARTS PROVIDED. UPPER & LOWER BOLTS SHOULD BE TIGHTENED PROGRES­SIVELY TO INSURE PROPER FIT. SEE FIG. I.

207

EXISTING BOLT

PRINTED IN U. S. A.

PRODUCTION HARNESS

./

--- I

HARNESS ASSY.

988350 WIRING HARNESS INSTRUCTION SHEET

R-tO SERIES

HEATER CONTROL LAMP (GRAY)

HEATER TOTAL SYSTEM CONNECTOR

HEATER PURGE SWITCH 1_-- __

RADIO CONNECTOR

RADIO HEATER CONTROL (BLACK) _________ LAMP SOCKET

HEATER TOTAL SYSTEM (DAR;c_GREEN)

STE~ 1 PLUG LEADS INTO JUNCTION BLOCK ONLY IF CON· CERNED WITH ACCESSORY SPECIFIED. SEE FIG. I.

SEE OTHER ACCESSORY INSTRUCTION SHEETS WHICH ARE CONCERNED WITH ACCESSORY REQUIRED.

STE~ 2 ROUTE HARNESS THRU EXISTI NG CLIP. SEE FIG. I.

{;\ Churole! Dlvlalon I.!; 1960 General Moton Corp. 217

STEP 3 ALL LOOSE LEADS SHOULD BE TAPED TO ACCES­SORY HARNESS.

PRINTED IN U. S. A.

, - -~

"''C''litll Chevrolet. Dlvlllion , \!.I Gene""j Moton COrp.

985340 CAR HEATER & DEFROSTER INSTRUCTION SHEET

DEFROSTER

CONTROL ASM.

DEFROSTER DUCT ASM.

CENTER DUCT EXTENSION

CENTER DUCT ASM.

CORVAIR 95

GENERAL MOTORS PAIn DIVISION GENERAL MOtORS (ORPORATION

DnRon 2, MICH.

252

REAR LOWER DUCT ASM.

INLET DUCT ASM.

PRINTED IN U. S. A.

FRONT DUCT EXT­ENS ION ASM.

SCREW 10-12 x 1/2

(Underbody)

(Part of sea t riser)

-mA"~DUCT

ASM.

TOE PAN / BRACKET

FRONT D " GASKET '" <_::.' ~ i~,

SIDE INNER RAIL . (Unde,body) I

/' ~, : " .. .. . :.; '; ~ li4: ' I

v I

SCREW 1/4-20 x 5/8

FWD.

DEFROSTER DUCT ASM.

~ FRONT DUCT EXTENSION & DEFROSTER DUCT

STEP 1 REMOVE COVER & SCREWS FROM FRONT SEAT RISEll & DISCARD.

::

STEP 2 CEMENT SEAL TO FRONT DUCT EXTENSION. SEE VIEW A.

STEP 3 SLIP DEFROSTER CABLE THRU HOLE IN FRONT DUCT EXTENSION & ATTACH WIRE LOOP TO DEFROSTER CONTROL ROD WITH CLIP (IN BAG B). SEE VIEW A.

STEP 4 ATTACH DE FROSTER CABLE & CLAMP TO FRONT DUCT EXTENSION WITH SCREW (IN BAG B) . SEE VIEW A.

STEP 5 INSTALL J-NUTS (IN BAG B) ON BRACKET & CE-

253

GASKET

\ NUT & WASHER \ ASM. 1/4 -20 -----\

ME NT SEALS ON FRONT DUCT EXTENSION. SEE VIEW B.

STEP 6 SLIP FRONT DUCT EXTENSION THRU OPENING IN FRONT SEAT RISER & ALIGN WITH OPENING IN SIDE INNER RAIL, & SECURE WITH SCREWS (IN BAG B). SEE VIEW B.

STEP 7 CEMENT SURFACE OF FRONT DUCT EXTENSION & INSTALL REAR GASKET OVER STUDS. INSTALL FRONT GAS­KET TO OPENING IN TOE PAN. SEE FlG. I,

STEP 8 POSITION DEFROSTER DUCT OVER STUDS ON FRONT DUCT EXTENSION & THHU OPENING IN TOE PAN & SECURE WITH STRAP & ATTACIDNG PARTS (IN BAG B) . SEE FIG. I,

GASKET

IXTINSION ASM.

CENTER DUCT EXTENSION

\

- , -TAB ~ENTER (PART OF CENTER DUCT ASM.)

\

FRONT CROSS SILL (UNDERBODY)

STIP 9 INSTALL GASKET ONTO CENTER DUCT EXTENSION. SEE VIEW C.

STIP 12 TAPE CENTER DUCT & EXTENSION TOGETHER. SEE FIG. 2.

STIP 10 SLIDE CENTER DUCT THRU OPENING IN OUTRIGGER #2 ABOUT HALF WAY. SEE VIEW C.

STIP 11 SLIDE CENTER DUCT EXTENSION ONTO TABS & FLUSH WITH CENTER DUCT ASM. SEE VIEW C.

~. 254

STIP 13 SLIDE CENTER DUCT & EXTENSION BACKWARDS THRU OPENING IN FRONT CROSS SILL. SEE FIG. 2.

STIP 14 SLIDE SEAL ONTO CENTER DUCT. SEE FIG. 2.

~FRON'T DUcr

FRONT S"AT'~ RISER

8-15X 1/2

WASHER X 1/2

1,'1' ~/

SIDE INNER )

. ~L (Underbody I ..... ' K . / ciiiI .,/ // ' FORWARD , I. /1

/

PLASTIC SEAM CEMENT (.80 OZ,)

DUCT ASM,

STEP 15 CEMENT GASKET TO SLEEVE & SLIDE SLEEVE THRU OPENING IN SEAT RISER & INTO FRONT DUCT EX­TENSION. ATTACH WITH SCREWS (IN BAG A). SEE VIEW D.

STEP 16 INSTALL DISTRIBUTOR TO SLEEVE WITH SCREW (IN BAG A). LOCATE, CENTER PUNCH & DRILL HOLE THRU TOP OF DISTRIBUTOR & SLEEVE ASM. COMPLETE AT­TACHMENT OF DISTRIBUTOR WITH SCREW (IN BAG A). SEE VIEW D.

STEP 17 REMOVE RIGHT FRONT WHEEL AT TillS TIME FOR

255

, I ,

FRONT DUCT ASM. INSTALLATION.

STEP 18 SLIDE FRONT DUCT THRU OPENING IN SIDE INNER RAIL & ONTO CLIPS OF FRONT DUCT EXTENSION & ATTACH WITH SCREWS & WASHERS (I N BAG B). SEE FIG. 3.

STEP 19 ALIGN FRONT DUCT TO OPENING IN OUTRIGGER #2 & ATTACH WITH SCREWS (IN BAG B). ATTACH FRONT DUCT TO SEAT RISER WITH SCREW (IN BAG B). CEMENT ALL AROUND JOINT OPENING ON FRONT DUCT ASM. SEE F1G. 3.

REAR UPPER DUCT

REAR SEAT RISER (Underbody)

REAR DEFLECTOR ASM.

SCREW 8-15 X 1/ 2

UPPER DUCT & DEFLECTOR ASM.

STEPS 20. 21 & 22 (STATION WAGON ONLy)

STEP 20 REMOV E COVER PLATE & SCREWS FROM REAR SEAT RISER & DISCARD.

STEP 21 CEMENT SEAL TO OP ENING IN REAR UPPER DUCT. SEE VIEW E.

STEP 22 CEMENT GASKET ON REAR DEFLECTOR. SUDE REAR DEFLECTOR INTO OPENING IN REAR SEAT RISER &

256

(STATION WAGON

ATTACH WITH SCREWS (IN BAG A). SEE VIEW F.

STEP 23 (ALL EXCEPT STA. WAGON) CEMENT uP OF REAR UPPER DUCT OPENING & PLACE PLUG OVER OPEN­ING. SEE VIEW E.

STEP 24 ATTACH J-NUTS (IN BAG C) TO FLANGE OF REAR UPPER DUCT &SUDE DUCT THRU OPENING IN INTERMEDl­ATE CROSS SILL ASM. TO AUGNHOLES& SECURE WITH SCREWS (IN BAG B). SEE VIEW G.

FWD.

REAR LOWER DUCT ASM.

REAR LOWER

------- '\\ FRONT CROSS SILL (Underbody)

xl

STEP 2S DISCONNECT RIGHT HAND BRAKE CABLE BEFORE INSTALLING REAR LOWER DUCT.

STEP 26 SLIDE REAR LOWER DUCT ONTO SEAL OF CEN­TER DUCT & SLIP J-NUTS (IN BAG B) INTO PLACE ON

CENTER DUCT ASM.

CROSS MEMBER INTERMEDIATE (Underbody ) REAR (Underbody)

--

INTERMEDIATE & REAR CROSSMEMBER. SEE VIEW H.

STEP 27 INSTALL STRAPS AT NOTCHES IN REAR LOWER DUCT WITH SCREWS (LOOSELY ASSEMBLED) (IN BAG B). SEE FIG. 5.

257

IIDI This screw must be assembled from the top as shown.

CEMENT (1.4 OZ)

INLET DUCT ASM.

~H"AH LOWER DUCT ASM.

STEP 28 REMOVE FILLER PANEL ASM. & ATTACHING PARTS & RETAIN.

,STEP 29 SLIDE CLAMPS (IN BAG D) & SLEEVE (L.H. ONLy) ONTO HOSES. SEE FIG. 6.

STEP 30 SLIDE HOSES Ol!l:QJNLET DUCT & TIGHTEN CLAMPS. SEE FIG. 6. IlIlIII Short hose must go on R. H. side & long hose on L. H. side.

STEP 31 LOOSELY INSTALL NUT ASM. (IN BAG C) TO FIL­·LER PANEL. SLIP INLET DUCT ASM. ONTO STUDS & TIGHTEN. SEE FlG. 6.

mr. Position ends of all clamps 3/8 to 1/2 inches away from S'he"et metal to avoid conditions which mtght cause vibration noises & for servic e.

258

EXISTING FlLLER PANEL ASM.

"J" NUT

FWD.

NUT & L. WASHER ASM. 5/16-18

SLEEVE -L.H. ONLY (AS SHOWN)

. ----

STEP 32 SLIP J-NUT (IN BAG C) INTO PLACE. CEMENT SEAL TO INLET DUCT. SEE FIG. 6.

STEP 33 LOWER FILLER PANEL IN PLACE & ATTACH IN­LET DUCT TO REAR UPPER DUCT WITH SCREW. WASHER (IN BAG C). SEE FlG. 6.

STEP 34 ATTACH J-NUT (IN BAG B) & CEMENT GASKET TO REAR UPPER DUCT & CEMENT ALL AROUND JOINT OPENING ON REAR LOWER DUCT. SEE FlG. 6.

STEP 3S ATTACH REAR LOWER DUCT TO REAR UPPER DUCT WITH SCREWS (IN BAG B). SEE FlG. 6. III!DI Tighten one screw from the bottom & assemble other screws loosely as shown. Position rear lower duct asm. & tighten all screws securely.

f;-

FWD.

& HOSES

STEP 36 REMOVE" RETAIN ENGINE COMPARTMENT COVER.

STEP 37 REMOVE" DISCARD AIR INLET DUCT COVER.

STEP 38 REACH THRU OPENING" PULL INLET DUCT THRU INSTALL CONNECTOR WITH SCREWS (IN BAG D). SEE FIG. 7" VIEW J.

STEP 39 REMOVE" DISCARD COVER FROM UPPER SHROUD ASM. " RETAIN SCREWS.

/EXlSTING

~. SCREWS

\.

UPPER SRROUD ASM.

~ ~-

~. A.....

J;CI ~- .~ CONNECTOR ASM.

.~ I ,--L;y ' ~

STEP 40 INSTALL CONNECTOR ASM. "SECURE WITH EXIS' ING SCREWS. SEE VIEW K.

"STEP 41 PLACE CLAMPS ON -THE HOllE" INSTALL HOllE, TIGHTEN CLAMPS. SEE FIG. 7.

I11III Position ends of all clamps 3/ 8 to 1/2 lnchee away fron: sheet metal to avoid conditions which might cause vlbratio[ noises" for service.

259

WIRE ASM. BLOWER

)

MOTOR "BROWN"

1-1/2 INCH Ml>nMIUM-" CLEARANCE - Thld

FWD.

~ ... ~

MUFFLER" EXHAUST PIPE ASM.

FRONT SHIWi;ID ~c::7-~/1II

CLIP

MAIN WIRING HARNESS (Production)

ENGINE ASM. ~ WIRING & HOSES

STEP 42 REMOVE COVERS FROM FRONT SHROUD ASM. " DISCARD. RETAIN SCREWS.

STEP 43 INSTALL CONNECTQRS TO FRONT SHROUD ASM. WITH EXISTING SCREWS. SEE FIG. 8.

STEP 44 SLIP CLAMPS (IN BAG D) ON HOSES, SLIDE HOSES ON CONNECTORS. POSITION & T I G H TEN CLAMPS. SEE

260

FIG. 8, II1II Rotate R. H. hose to obtain clearance shown.

STEP 4S INSTALL CLIPS (IN BAG A) TO INTERMEDIATE CROSS SILL. CONNECT BROWN WIRE PROVIDED TO BLOWER MOTOR LEAD, THEN R 0 UTE WIRE THRU CLIPS OVER TO MAIN HARNESS" FORWMeALONG HARNESS THRU EXISTING CLIPS. SEE F1G. 8. I PostHon ends of all clamps 3/ 8 to 1/ 2 inches away from s ee met a 1 to avoid condltions which might cause vlbratLon noises" for service.

~.

_ See Fig. 11 for routing of cables In cab &. attachment to control asm.

CLIP ASM. ill

STEP 46 ALIGN TAPE OR PAINT MARKS ON THE CABLES DIRECTLY BELOW FLOOR TO TOE PANEL BREAK LINE BE­FORE CLIPPING TO UNDERBODY. ROUTE CABLES ALONG. RIGHT SIDE RAIL 8. ATTACH TO EXISTING HOLES IN PLENUM PANEL & SIDE RAIL WITH CLIPS (IN BAG B). SEE FIG. 9.

261

SEE FIG. 10

STEP 47 ATTACH SHUT OFF CABLE TO TEMP. CABLE WITH CLIPS (IN BAG B) 8. INSERT CLIPS INTO EXISTING HOLES IN SIDE RAIL. SEE FIG. 9.

TEMP. CONTROL LEVER

1/4 APPROX. -~;fJ:. (End of metal cap)

EXISTING SCREW CABLE ASM. TEMP.

CONTROL (YELLOW

\ \

\ SEE FIG. 9 '\ .

FWD

~ CABLE ASM. SHUT OFF VALVE (BLUE)

CABLES

am For front installation of cables in vehicles, See Fig. 9.

STEP 4B INSTALL CLIPS (IN BAG B) TO INTERMEDIATE &. REAR CROSS MEMBERS ALONG SIDE DUCT STRAP ATTACH­MENTS. SEE FIG. 10,

STEP 49 ROUTE TEMP. CONTROL&' SHUT OFF VALVE CABLES REARWARD THRU QPENING IN CROSS MEMBEll &.

262

-,

CABLE ASM. SHUT OFF VALVE (BLUE)

LNLET DUCT ASM.

THRU CLIPS JUST INSTALLED ON INTERMEDIATE &. REAR CROSS MEMBERS. SEE FIG. 10.

STEP SO ATTACH THE TWO CONTROL CABLES TO THE IN­LET DUCT WITH EXISTING C LAM P S &. SCREWS. SECURE WIRE LOOPS OF CABLES TO THEIR RESPECTIVE CONTROL WITH RETAINING WASHERS (IN BAG A). SEE VIEW L.

\

SWITCH ARM ~~AB I I n- -~ ~ _~ II II - - ---

n KNOB TENSiON RET AlNER FINGER

V8 FROM CONTROL KNOB

\ \

NUT /

-~-

SCREW 6-8-1 5 X 1/ 2

\ ,

HEATER CON­TROL ASM.

AUTO TRANSMISSION

\ ~OE

STEP 51 REMOVE GROMMET RETAINER FROM TOE PANEL & DISCARD EXISTING GROMMET. ROUTE CONTROL CABLES & BLOWER MOTOR WIRE THRU OPENING IN TOE PANEL & THRU GROMMET (IN BAG A). POSITION GROMMET & THEN SECURE WITH EXISTING RETAINER. SEE FIG. 11. STEP 52 AT T A C H SWITCH TO HEATER CONTROL WITH SCREWS (IN BAG AI. SEE VIEW L. STEP 53 MOVE AIR, HEAT & DEFROSTER KNOBS DOWN SO THAT LEVERS ARE 1/8 INCH FROM TOP OF SLOT. THE CONTROL LEVERS ARE TO BE POSITIONED AS SHOWN WHEN MAKiNG THE ATTACHMENT OF EACH END OF THE CONTROL CABLES. AFTER THE UNIT IS COMPLETELY IN­STALLED IN THE VEHICLE & ALL LEVERS ARE SET IN THE "OFF" OR "UP" POSITION, THE FRICTION IN THE CONTROL & CABLES IS SUFFICIENT TO HOLD THE LEVERS TO WITH­IN 1/8 OF THE TOP OF THE S LOT IN THE CONTROL FACE PLATE. SEE FlG. 11. STEP 54 AT T A C H THE THREE CABLES TO THE HEATER CONTROL WITH EXISTING C LAM P S & SCREWS. SECURE

263

BRAKE

WIRE LOOPS OF CABLES TO THEIR RESPECTIVE CONTROl ~ WITH RETAlNlNG WASHERS (IN BAG AI. SEE FlG. 11. EIlIIII Tighten remaining clamp to prevent rattle. STEP 55 INSTALL KNOB (IN BAG AI ON SWITCH LEVE~ WITH RETAINER (IN BAG AI. SEE FIG. 11 & VIEW M. n!Im Assemble retalner all the way on switch arm witl renslOii fingers resting on edges of arm as shown, prior to as· sembly of knob. With switch arm 1n "OFF" position, assembh knob to arm with a straight push until knob contacts tab on bacl of retainer. A maximum force of 40 Lbs. wlll assemble tab b place. " ·"ii,m! Do not rock knob vertlcally during as· semblyas this wUl bend switch arm. STEP 56 INSTALL HEATER CONTROL SUPPORT TO IN­STRUMENT PANEL WITH BOLTS, SPACERS & NUTS (IN BAC AI. SEE FlG. 11. STEP 57 SLIP J-NUTS (IN BAG A) IN PLACE ON SUPPORT! INSTALL HEATER CONTROL TO SUPPORT WITH SCREWS (ll BAG AI. SEE FIG. 11.

TOE PANEL INSULATOR & CEMENT

DISTIUBUTOR ASM. -DEFROSTER

(9.8 OZ.) --J & DISTRIBUTOR

STEP 58 REMOVE EXISTING FLOOR MAT & CEMENT PRO­VIDED PADS TO UNDERBODY OF FLOOR MAT. CUT OUT PERFORATED AREA. SEE FlG. 1.

STEP 59 CEMENT INSULATORS TO TOE PANEL & FLOOR PANEL, & INSTALL FLOOR MAT. SEE FlG. 12.

264

r DIST1RlB1JTOR ASM. -DEFROSTER

10-12 X 3/4

REAR PAD & CEMENT (13 OZ.)

I

) 1"\~:~~~1;~PAD & .- (4.4 OZ.)

FLOOR PANEL INSULATOR & CEMENT (13 OZ.)

STEP 60 ATTACH RESISTOR (IN BAG A) TO DISTRIBUTOR WITH SCREWS (IN BAG A). SEE VIEW P.

STEP 61 INSTALL DISTRIBUTOR WITH SCREWS (IN BAG A). SEE FlG. 12.

SUPPORT

EXISTING HOLE

TRANSMISSION CONTROL BRACKET

DRILL .169 INCH DIA. HOLE (NO. 18 DRILL)

GRAY ~\...oo...-_--LAMP

F.O.A. INSTRUMENT PANEL HARNESS

r- HE:A 1'ER WIRES "OK. GREEN " OK. BLUE

HARNESS ASM. ACCESSORY

OK, BLUE

(PURGE SWI~rCH!~(n~£~~

JUNCTION BLOCK

BLADE & FUSE CLIP ASM.

WIRE ASM. "BROWN"

MAIN HARNESS

INLET

HOSE

RESISTOR

~~~~~~~(p~rO~CtiiOnL)~ ________ ~~~::::::~ _____________ ~~:::' ____________ ..J STEP 62 AUTOMATIC TRANSMISSION EXISTS, INSTALL HOSE SUPPORT ON THANSMISSION CONTROL BRACKET WITH SCREW PROVIDED (IN. BAG A). SEE VIEW R.

STEP 63 REMOVE INSTRUMENT PANEL COMPARTMENT. INSTALL DEFROSTER HOSES ON INLETS &. DISTRIBUTOR ASM. SEE FIG. 13. REPLACE INSTRUMENT PANEL COM­PARTMENT. am If automatic transmission exists route L. H. hoses over hose support.

STEP 64 IF NEITHER AN F.O.A. OR ACCESSORY HARNESS EXISTS ON VEIllCLE, PROCURE ACCESSORY HARNESS (UNIT NO. 988350) &. INSTALL.

STEP 6S INSTALL BLADE & FUSE CLIP INTO RECEPTACLE MARKED "HEATER - B. U. LPS." ON JUNCTION BLOCK. SEE FIG. 13.

STEP 66 UNTAPE OK. GREEN W1RE CONNECTOR FROM ACCESSORY OR F.O.A. HARNESS &. PLUG INTO FUSE CLIP PREVIOUSLY INSTALLED. SEE FIG. 13.

265

STEP 67 IF ACCESSORY HARNESS HAS BEEN INSTALLED UNTAPE & PLUG GRAY LEAD CONNECTOR INTO BACK OF JUNCTION BLOCK INTO RECEPTACLE MARKED "PANEL LPS." ' SEE FIG. 13. IIDI If radio exists, wire will always be connected.

STEP 68 PLUG ONE END OF HEATER HARNESS INTO RE­SISTOR ON DISTRIBUTOR & OTHER END INTO SWITCH ON CONTROL. UNTAPE GRAY LEAD. INSERT LAMP (IN BAG A) INTO SOCKET & PLUG INTO CONTROL. SEE FIG. 13 & VIEW s.

STEP 69 CONNECT RED LEAD FROM HEATER HARNESS WITH OK. BLUE &. GREEN WIRE CONNECTOR (FROM F.O.A. OR ACCESSORY HARNESS). ROUTE BROWN LEAD (FROM GROMMET IN TOE PANEL) ALONG EXISTING HARNESS &. CONNECT TO BROWN LEAD OF HEATER HARNESS. SEE FIG. 13.

STEP 70 INSERT FUSE INTO FUSE CLIP ASM. PREVIOUSLY INSTALLED. SEE · FIG. 13.

STEP 71 REPLACE PARTS PREVIOUSLY REMOVED.

985344 CAR HEATER & DEFROSTER INSTRUCTION SHEET

HEATER ASM.

DRAIN HOSE

EXHAUST PIPE ASM.

f'C\ 196 1 Chn ro le t Dlv\alon \!:J Cenllral Motor. Cor p.

CORVAIR 95

GENUIAL MOTORS PARTS DIVISION GENIRAl MOTORS CORPOUnON

OnROIT 2, MICH.

266

DEFROSTER INLET ASM.

CONTROL ASM.

OVERFLOW

F UEL LINE

PRINT J::D I N U. S. A..

~.

HOSE (Part of heater asm. )

LOCK WASHER INT. TOOTH

SCREW 10-24 X 1/ 2

SCREW ~-15 X 3/ 8

HEATER SUPPORT (Part of cover a8m.)

SCREW 10-12 X 1/ 2

COVER & DISTRIBUTOR SUB-ASSEMBLY

mID Vehicle must be equipped with a F. O. A. or accessory harness before heater can be installed. U neither exists, pur­chase accessory harness unit No. 988350 from se"ice &; install.

STEP 1 DISCONNECT BATTERY CABLE.

STEP 2 REMOVE GLOVE BOX, RADIO,HEATER HOLE COVER, FRONT GRILLE & R H. HEADLAMP ASSEMBLY. DISCARD HEATER 1l0LE COVER, BUT RETAIN ATTACHING SCREWS & PLUG LOCATED NEAR UPPER L. H. CORNER

HEATER & DEFROSTER ASM.

CEMENT

HEATER COVER ASM.

~~AI~'-sr.AMI'EDNUT

DISTRIBUTOR CASE ASM.

STEP 3 ATTACH SUPPORT TO HEATER WITH SCREWS PRO­VIDED (IN BAG A). SEE FIG. 1.

STEP 4 CEMENT GASKET TOHEATER, APPLY PLASTIC SEAM CEMENT TO STUDS & ATTACH HEATER TO COVER WITH ATTACHING PARTS PROVIDED (IN BAG B). SEE FIG. 1.

STEP 5 CEMENT GASKET TO DISTRIBUTOR,APPLY PLASTIC SEAM CEMENT TO THREE (3) HOLES IN COVER ASM. & AT­TACH DISTRIBUTOR TO COVER ASM. WITH SCREWS PROVIDED (IN BAG B). SEE FIG. 1.

267

HOSE (Part of heater asm. )

BRACKET ASM.

STUD ("',rt·~ of cover)

VALVE ASM.

SWITCH A~M. 'G, / \ '-

rHL'UWEKASM.

DISTRmUTOR CASE ASM.

rLOCK WASHER INT. TOOTH

SCREW 10-24 X 1/2

~·"OVF.R ASM.

i,-·E~:IS1rlN'G HOLE

~ BLOWER WIRES BLACK & WHITE

".)- RESIS1rOR ASM.

DISTRffiUTOR CASE ASM.

PLASTIC SEAM CEMENT

STEP 6 PLACE BLOWER SWITCH ARM ON VALVE PIN & ATTACH TO DISTRffiUTOR CASE 'WITH ATTACHING SCREWS PROVIDED (IN BAG A). SEE VIEW A.

STEP 7 INSTALL CLIPS PROVIDED (IN BAG A) ON DIS­TRIBUTOR CASE & ATTACH RESISTOR TO CLIPS. SEE VIEW B.

STEP 8 INSTALL BOOT ON BLOWER, SEAL GAP CAUSED BY WIRES LEADING OUT FROM BETWEEN BOOT & MOTOR COVER & ATTACH BLOWER & GROUND WlRE TO BLOWER

268

BRACKET WITH ATTACIflNG PARTS (IN BAG B) . SEE FIG. 2.

STEP 9 ATTACH BLOWER BRACKET TO COVER WITH AT­TACHING PARTS PROVIDED (IN BAG B) & APPLY CEMENT TO BOTH SIDES OF FLANGES. SEE FIG. 2.

STEP 10 ROUTE BLOWER WIRES UNDER BLOWER BRACKET & THRU HOLE IN COVER. SEE FIG. 2. .-. STEP 11 ATTACH HEATER HOSE TO BLOWER WITH CLAMP PROVIDED (IN BAG C). SEE FIG. 2.

~.

WffiING HARNESS ASM.

DARK GREEN wmE

CONNECTOR

POSITIVE TERMINAL

TO EXISTING :HA~R~N~ES:S~9~~~~;;;;;~::~~~~~i:

CONNECTOR

SEE FIG. 4

WffiE FROM COMBUSTION BLACK~ "

WHITE BLOWER MOTOR ~~_ WffiE

STEP 12 PLUG HARNESS CONNECTORS ONTO BLOWER SWITCH & RESISTOR. SEE VIEW c.

STEP 13 PLUG RED & NATURAL WffiE CONNECTORS ONTO THERMOSTAT & SNAP HARNESS INTO EXISTING CLIP UNDER COVER FLANGE. SEE VIEW C.

STEP 14 INSTALL GROMMETS PROVIDED (IN BAG B) IN COVER &. ROUTE BLACK WIRE CONNECTOR FROM HARNESS, THRU GROMMET &. PLUG ONTO BLOWER MaI'OR TERMINAL. SEE FIG. 3 &. VIEW D.

STEP 15 ROUTE BLACK & WHITE COMBUSTION BLOWER MOTOR WIRES THRU GROMMET & ACROSS TOP OF COVER

269

ALONG WITH HARNESS. FIT INTO EXISTING CLIPS ON TOP OF COVER ASM. SEE FIG. 3.

STEP 16 ROUTE EXTENSION HARNESS TRRU GROMMET TO REATER COIL & PLUG WHITE JUMPER WIRE CONNECTOR INTO OVERHEAT SWITCH WIRE CONNECTOR. SEE FIG. 3 & VIEW D.

STEP 17 ATTACH BROWN & BLACK WIRES & SPARK PLUG WIRE, SUPPRESSOR &. S T RAP TO COIL TERMINAlS WITH ATTACHING NUTS PROVIDED. SEE VIEW D.

STEP 18 INSTALL PLUG (RET AlNED FROM DISCARDED HEATER HOLE COVER) & ATTACH ACCESS COVER USING SCREWS & GASKET PROVIDED (IN BAG C). SEE FIG. 3.

GROMMET

HEATER COVER-,

WIRING HARNESS

WHITE WIRE

PURGE SWITCH

EXTENSION HARNESS ASM.

BLACK WIRES

~ . \/~

lfi'I~r,~"--:"---~3-WAY CONNECTOR

SCREW 8-15X 3/8

RELAY ASM.

MULTIPLE CONNECTOR ----.... j / ~ , - .H_' ... '" WffiE . _ ---

OK. BLUE WIRE V RED WIRE _ _ .. ..-v. --3-WAY CONNECTOR

& RELAY

STEP 19 SUB ASSEMBLE PURGE SWITCH &. COVER TO ADAPTER WITH SCREWS (IN BAG A). SEE FIG. 4.

STEP 20 ATTACH ADAPTER SUB ASSEMBLY, MULTIPLE CONNECTOR &. RELAY TO EXISTING HOLES IN COVER WITH SCREWS (IN BAG A). SEE FIG. 4.

STEP 21 INSERT TERMINALS OF WHITE &. BLACK WIRES

270

-

INTO HARNESS CONNECTOR. SEE FIG. 4.

.'.i"".tIE White wire to top receptacle on connector.

STEP 22 PLUG HARNESS CONNECTOR TO MULTIPLE CONNECTOR, 3-WAY CONNECTOR (BLACK &. WHITE WIRES) TO RELAY &. REMAINING 3-WAY CONNECTOR (BLACK, OK. BLUE &. RED WIRES) TO PUR G E SWITCH. SEE FlG. 4.

F AN CONTROL LEVER IIDI Valve asm. must close fully when fan knob is 1n off position.

These controls may adjusted by loosening c lamps & repos itioning cables.

EXISTING SET SCREW

mBII Move l ever full forward before tightening set Bcrew. EXISTING

CLAMP" SCREW

CABLE EYE

PUSH-ONNUT-----~~~~~

SCREW

DEFROSTER CO:NTIROIL-' KNOB" CABLE ASM.

FAN CONTROL KN'DB·J "CABLE ASM. SCREW

6- 32 X 3/6

CABll

STEP 23 INSERT FAN, DEFROSTER" HEAT CONTROL KNOB " CABLE ASSEMBLIES INTO SLOTS OF HEATER CONTROL. SLIDE CABLE SHEATHS UP INTO SLOTS" SECURE TO DI­MENSION SHOWN WITH CLAMPS" SCREWS (IN BAG A). SEE FIG. 5.

STEP 24 MOVE HEAT CONTROL KNOB INTO DOWN PO­SITION. WITHIN 1/ 4 INCH OF CABLE SHEATH. ROUTE HEAT CONTROL CABLE THRU LEVER (ON THERMOSTAT). SE­CURE CABLE TO DISTRIBUTOR WITH EXISTING CLAMP & SCREW TO DIMENSION SHOWN. MOVE LEVER (ON THERMO­STAT) FULL FORWARD & TIG HTEN SET SCREW. SEE FIG. 5 & VIEW F.

271

STEP 2S ROUTE FAN & DEFROSTER CONTROL CABLES TO DISTRIBUTOR. ATTACH FAN CONTROL TO LEVER & DE­FROSTER CONTROL TO CRANK WITH PUS H-ON NUTS (IN BAG A). SEE FIG. 5.

STEP 26 SECURE FAN & DEFROSTER CONTROLS TO DISTRffi­UTOR WITH EXISTING CLAMPS & SCREWS TO DIMENSION SHOWN. SEE F IG. 5,

STEP 27 ATTACH INSTRUCTION TAG TO HEAT CONTROL CABLE NEAR CONTROL. SEE FIG. 5.

~lnRI[LL (2) . 136 lNCH DIA. HOLES (NO. 30 DRlLL) AT ----;~[CE:M~:m'_.r DlMPLES (1 HOLE EXISTS WITH wl S WASHER)

ASM,

STEERING COLUMN

CONTROL ASM.

STEP 28 REMOVE EXISTING R. H. Am VENT ROD" TUBE ASM. .. DlSCARD. RETAIN ATTACHlNG PARTS.

STEP 29 CEMENT GASKET TO COVER .. APPLY PLASTIC SEAM CEMENT TO GASKET AT ATTACHING HOLES .. TO DASH AT STUD HOLES. ATTACH COVER TO DASH PANEL WITH EXISTING "J" NUTS, RETAINED SCREWS .. PROVIDED NUTS (IN BAG B). SEE FIG. 6,

STEP 30 APPLY PLASTIC SEAM CEMENT BETWEEN Am VENT ROD" TUBE ABM. .. COVER, THEN ATTACH WITH RETAlNED SCREWS. SEE FIG. 6,

STEP 31 IF W/ SWASHER EXISTS,REMOVE .. RETAIN RESER­yom BRACKET, DISCARD SCREW, LOCATE DIMPLE" DRILL

272

----J:;;;;.......; ~=~~:-El(1S1rING SCREW

" __ """"",,:r:r CEMENT " PLASTIC

I

-~INSTRUMENT PANEL

SUPPORT

__ ~"J"NUT

HOLE. SEE FIG. 6,

~

BOLT 1/ 4-20 X 1

8-15 X 1/ 2

SEAM

STEP 32 IF W/ SWASHER DOES NOT EXIST, LOCATE DlMPLES .. DRILL HOLES. SEE FIG. 6.

STEP 33 APPLY PLASTIC SEAM CEMENT TO HOLES .. AT­TACH CONTROL CABLES TO DABH PANEL WITH CLIP" SCREWS PROVIDED (IN BAG A). IDII U w/s washers exist, attach retained bracket to bottom of clip. SEE FIG. 6.

STEP 34 ATTACH SUPPORT TO INSTRUMENT PANEL WITH SPACERS .. ATTACHING PARTS PROVIDED (IN BAG A). SEE FIG. 7,

. STEP 35 ATTACH CONTROL ASM. TO SUPPORT WITH AT­TACHING PARTS PROVIDED (IN BAG A). SEE FIG, 7.

/ /

PIPE (Part of heater asm. )

\ \

BLOWER I BRACKET

j/ ASM. j ' CLAIilP - 1 -

~ ~ ---------OUTER PANEL

DRAIN HOSEA ASM. 5/ 32 I. D.

~I.D. '-... I I ~ \ \ ~l...J' GRILLE/\

"-_~\ .~, OPENING R.H. SIDE"

~ RAIL "-

'" ..... R. H. BOpy OUT- ____ .-'- .-

-- '-EXISTING HOLE ..... ':..,... ....... ....... j~~ -In Panel ~ _ -:::- ":::'~';"'" ' Jo/ IJI<ILL

~ EXHAUST _~:;._ -:.-PIPE ASM. -

~(r:~~f;-~ :;~~~' ~

& EXHAUST PIPE

STEP 36 INSERT EXHAUST PIPE THRU EXISTING OPENING IN PLENUM PANEL, FIT CLAMP ASM. PROVIDED OVER TOP & SUDE i:XHAUST PIPE OVER HEATER PIPE. SEE FIG. 8.

STEP 37 USING DIMENSIONS SHOWN & PIPE ASM. BRACKET AS A TEMPLATE, CENTER PUNCH & DRILL HOLES IN BODY OUTRIGGER & SIDE RAIL AS SHOWN. SEE FIG. 8.

STEP 38 ATTACH EXHAUST PIPE TO SIDE RAIL USING SCREWS PROVIDED (IN BAG A). SEE FIG. 8.

STEP 39 COMPLETE ATTACHMENT OF EXHAUST PIPE TO HEATER BY SUDING CLAMP ASM. INTO PLACE & TIGHTEN-

273

BRACKET (Part exhaust pipe asm. )

ING. SEE FIG. 8.

SCREW 1/ 4 -14X 1/ 2

STEP 40 ATTACH GASOUNE FRONT PIPE HOSE TOIIEATER PIPE WITH ATT A C HING CLAMP PROVIDED (IN BAG C) & ROUTE THRU EXISTING HOLE IN PLENUM PANEL. SEE FIG~ 8.

STEP 41 ATTACH DRAIN HOSE TO HEATER PIPE & ROUTE TJlRU EXISTING HOLE IN PLENUM PANEL. SEE FIG. 8.

STEP 42 INSTALL PREVIOUSLY REMOV ED HEADLAMP. ROUT E WmES & ATTACH TO CUP ON COVER ASSEMBLY SEE -FIG. 8.

t,.

EXISTING GROMMET

SP. CLIP

TEE PIPE ASM.

GASOLINE PIPE ROUTING

FORWARD

~

STEP 43 REMOVE &. DISCARD 3 WAY TEE CONNECTOR &. REPLACE WITH 4 WAY CONNECTOR PROVIDED (IN BAG C). SEE FIG. 9.

STEP 44 CONNECT TEE PIPE TO 4 WAY CONNECTOR. ROUTE ALONG SIDE EXISTING FUEL LINE &. THRU GROM­MET IN REAR ENGINE SHIELD. SE~ WITH CLIPS PRO­VIDED (IN BAG C). SEE FIG. 9. I11III Proper clearance

274

FAN BELT

REAR PIPE

CROSS SILL

4 WAY TEE CONNECTOR

FUEL PUMP

must be maintalned between fan belt & tee pipe.

STEP 4S FROM UNDERSIDE OF VEmCLE, ROUTE REAR PIPE FORWARD & CLIP TO INTERMEDIATE CROSS SILL &TO SIDE RAIL WITH CLIPS PROVIDED (IN BAG C) . SEE FIG. 10.

STEP46 JOIN REAR PIPE&,TEE PIPE WITH HOSE &. CLAMPS PROVIDED (IN BAG C) . SEE FIG. 10.

\" . ~ .{GASTANK I FRONT R. H. WHEEL- . ~ ASM

J. "OW' .~~Jr~.,~

/ .I ff'-~" .~~

"'---'~/ . j }~~-~~"~--~ II J _ OVERFLOW ' -,

EXISTING OPENING ...... " UPPER PIPE ,~~ . IN SEAT RISER ASM. \ ----~ , ~ ,

.rEXlSTING , CLIP --< . ,~ '-TOE PANEL

FRAME

FORWARD

~ OVERFLOW

.------ LOWER PIPE ~ ASM.

FRONT PIPE ASM.

INTERMEIIIA TE & FRONT ROUTING

G~ HOSE~

STEP 47 ROUTE INTERMEDIATE PIPE FORWARD ALONG EX­ISTING PIPE, ATTACHING TO FRAME WITH EXlSTING " PROVIDED CLIPS (IN BAG C). SEE FIG. 11.

STEP 48 JOIN INTERMEDIATE PIPE TO REAR PIPE WITH HOSE" CLAMPS PROVIDED (IN BAG C). SEE FIG. 11.

STEP 49 ATTACH REGULATOR TO INTERMEDIATE PIPE. SEE FIG. 11.

STEP 50 ROUTE FRONT PIPE FORWARD, ATTACHING TO FRAME WITH CLIPS PROVIDED (IN BAG C) " EXlSTING CUP ON TOE PANEL. SEE FIG. 11.

STEP 51 ATTACH FRONT PIPE TO REGULATOR. SEE FIG. II.

STEP 52 ATTACH FRONT PIPE HOSE TO FRONT PIPE WITH CLAMP PROVIDED (IN BAG C). SEE FIG. 11.

275

, -INTERMEDIATE PIP~~-

GASOLINE TANK

-OVERF~OW UPPER PIPE

_ ASM.

/

EXISTING CUP -<C"":",<: __ ~ --REAR PIPE --- -;;::::

STEP 53 ATTACH OVERFLOW LOWER PIPE TO REGULATUR. SEE FIG. II.

STEP 54 RE MOV E COVER" SCREWS FROM FRONT FACE OF SEAT RISER" THRU OPENING IN SEAT RISER, REMOVE PLUG FROM TAN[{, RET A I N COVER" SCREWS. DISCAR[ PLUG.

STEP 55 S LlDE OVERFLOW UPPER PIPE THRU OPENINC IN SEAT RISER, & THREAD INTO EXISTING HOLE. (FRON WHICH PLUG HAS BEEN REMOVED). SEE VIEW G.

STEP 56 JOIN UPPER" LOWER OVERFLOW PIPES WITH HOSI " CLAMPS PROVIDED (IN BAG C). SEE FIG. 11.

STEP 57 REPLACE ALL EXISTING PARTS PREVIOUSLY RE· MOVED.

/ ACCESSORY HARNESS

/ / EXISTING CLIP

/ F . O. A. HAltNE;SS -~\_

I EXISTING l:LIP '-'

DARK

,VA"" BLUE WIRE

DARK GRE EN WffiE

EXISTING HOLE

TRANSMISSION CONTROL BRACKET

. 08

DRI LL (I) . 169 INCH DIA. HOLE (NO. 18 DRILL)

DARK BLUE WIRE

P ARK GREEN WffiE

DEFROSTER INLET

I ~~~~~.~~~~~~~~ ; GREEN ~~~~~~~~;t:t=t~~~~ 15 AMP ~~~_r

FUSE

10 AMP FUSE

! !

HOSE +r" ~J~~~1::::::~'~' DIA. ) ::-~

'~-DISTRIBUTOR CASE AS M.

F. O. A. HAJRNI~SS·...J

EXISTING CLIP

DEFROSTER HOSES &

GR AY WIRE

STEP 58 IF AUTOMATIC TRANSMISSION EXISTS, DRILL HOLE & INSTALL HOSE SUPPORT ON TRANSMISSION CON ­TROL BRACKET WITH SCREW (IN BAG A). SEE VIEW. H.

STEP 59 REMOVE GLOVE BOX. ASSEMBLE LONG & SHORT DEFROSTER HOSES USING COUPLINGS PROVIDED, INSTALL DEFROSTER HOSES ON INLETS & DISTRI BUTOR CASE. SEE FIG. 12. REPLACE GLOVE BOX. ImDI If automatic trans ­miss ion exis ts route L. H. hose over hos e s upport.

STEP 60 IF ACCESSORY HARNESS HAS BEEN INSTALLED UNT APE &. PLUG GRAY LEAD CONNECTOR INTO BACK OF JUNCTION BLOCK INTO RECEPTACLE MARKED "PANEL LPS. " SEE FIG. 12. EIIIII If radio exists gray wire will always be connected.

STEP 61 UNTAPE GRAY, DARK BLUE & DARK GREEN WIRES

~.

FROM HARNESS. INSERT LAMP INTO SOCKET ON GRAY WIRE &. PLUG INTO BACK OF CONTROL. CONNECT DARK BLUE & DARK GREEN WIRES TO HE ATER HARNESS WIRE. SEE FIG. 12.

STEP 62 INSTALL FUSE CLIP INTO RECEPTAC LE IN JUNCTION BLOCK MARKED "HEATER-B. U. LPS." IN" SERT (15 AMP) FUSE & PLUG IN DARK GREEN WIRE. SEE F IG. 12.

STEP 63 INSTALL FUSE C LIP INTO RECEPTAC LE IN JUNCTION BWCK MARKED "HEAT BLOW - GL. BOX LP. II INSERT (11 AMP) FUSE & PLUG IN DARK BLUE WIRE. SEE FIG. 12.

276

INSPECTION & CHECKING PROCEDURE.

STEP 64 THE CONTROL ASM. FAN KNOB OPERATES THE VENTILATION BLOWER & HAS TWO SPEEDS, LOW-WITH THE KNOB PUSHED HALF WAY IN & HIGH-WITH THE KNOB PUSHED ALL WAY IN. TURN ON IGNITION &'PUSH FAN KNOB IN TO BE SURE VENTILATION BLOWER WORKS AT BOTH SPEEOO.

STEP 65 THE COMBUSTION BLOWER HAS ONLY ONE SPEED (HIGH) & SHOULD WORK WHEN FAN IS IN EITHER LOW OR HIGH POSITION.

STEP 66 WHEN TURNING OFF HEATER OR IGNITION SWITCH, THE COMBUSrION BLOWER SHOULD CONTINUE ro 0 PER ATE FOR APPROX. 30 SECONDS. IF THE COM­BUSTION BLOWER DOES NOT TURN OFF WITHIN TWO MIN­UTES AFTER SHUTTING OFF IGNITION OR HEATER,THE PURGE SWITCH IS DEFECTIVE & MUST BE REPLACED.

STEP 67 IF EITHER OR HOTH BLOWERS DO NOT WORK, IN­SPECT ALL WIRING CONNECTIONS, ESPECIALLY THE FIVE WAY CONNECTOR ON THE COVER. IT IS ESSENrIAL THAT THE WHITE WIRE LEADING FROM THE COMBUSriON BLOW­ER ASM. BE INSERTED INTO THE CONNECTOR IN THE PROPER SLOT.

STEP 68 START ENGINE & LET IT IDLE. PUSH CONTROL ASM. HEAT KNOB ALL W,AY IN. HEATER Musr IGNITE & OPERATE WITHOUT RUMBLING, POPPING, OR HAVING A SMOKY EXHAUST.

277

STEP 69 INSPECT ALL GASOLINE LINES TO BE SURE THERE AR~ NO LEAKS.

STEP 70 HEATER MUST PRODUCE I50'! 5' OUTLET TEM­PERATURE WITHIN 3 MINUTES WITH ENGINE AT IDLE. IF THE OUTLET TEMPERATURE REACHES lSO'THIS INDICATES A FAULTY THERMOSTAT. IF THE OUTLET TEMPERATURE FAILS TO REACH 135' THIS INDICATES INADEQUATE GASO­LINE FLOW & MAYBE CAUSED BY BENT PIPES, PLUGGED PIPES, NOZZLES, FITTINGS, OR A FAULTY FUEL PUMP.

STEP 71 GASOLINE PRESSURE AT THE HEATER SHOULD !;lE. WITHIN THE RANGE OF 4. 5 TO 5 P. S. I. IF THE PRESSURE IS HIGHER THAN 5 P. S. I. THE OVERFLOW REGULATOR IS. FAULTY. IF THE PRESSURE IS LOWER THAN 4. 5 P. S. L THE' ENGINE FUEL PUMP IS FAULTY. THE PRESSURE RANGE OF THE FUEL PUMP SHOULD BE WITHIN 6 TO 8 P. S. L

STEP 72 REFER TO SHOP MANUAL FOR CORRECT HEATER MAINTENANCE & REPAIR.

·~ e '! w

to> o CD

• • f ~

JUMPER I~E

swr -_____ ~ ~6 X 7/ 16! 'I SWITCH

t---: 7 I ~

\.CO~~- ~ TMENr ' ,~ EXISTlNG i~. CLIP CLIPS ~:;::::> .-= _----~- ----- _~·ANH. KICK . _- • I'i:. ---- EL <, t;;. '7".- ~~ .......... - '

/ ',pP'~' ,'~'~' -T"(d .~ ... " ~'I' -~:\'-'. • . w, ,~' " .~' ,,""".-.~

I"'TAPE -~ I -I ":'\~~ DRILL 7/ 8 INCH

DlA. HOLE

I f'-mNGE I PILLAR

, Ii .C

,~~~-tl;~c~~-~~CH ',l-r ... ' ' ~ .--,.-Jr -.,~~ " \~ ., ~,J~'-='~ c_~~'-' , -=""_:. 7' ~ ~~? LOCK WA NT BLACK

, I " "- "~.

1/

' . ' -' l' ' c~';::'=~ .= =:,,"", ~~<-ORANGE

wmTE NUT

r ~~co ,~" ~~ . . ,,, ' ~"c='oo, ~, ~_ 7"/U~MK , ' _, .rn~

A

WIRE ROUTING & LAMP ASM. MOUNTING

500 SERIES CORV AIR

STEP 1 LOCATE" CUT SLOT ON BACK WALL OF INSTRUMENT PANEL COMPARTMENT" INSTALL CLIP THRU swr. SEE VIEW B.

STEP 2 REMOVE L. "R. H. KICK ~ " INSTALL CLIP ON TOP EDGE OF R. H. KICK PANEL. SEE FlG. 1.II1II Clip is existing on L. H. kick panel.

CONTROL KNOB

~"'" ' ,\ CENTER

OF CAR

STEP S DRILL HOLES THRU EXISTING DIMP LES IN EACH FRONT DOOR HINGE PILLAR. SEE VIEW A.

~ STEP 3 PLACE LAMP WITH WmTE WIRE IN ITS APPROXIMATE INSTALLED Z POSITION" ROUTE LAMP WITH BLACK LEAD THRU EXISTING" PROVIDED

CLIPS TO R. H. SIDE OF VEmCLE. SEE FIG. 1.

STEP 6 TAPE JUMPER WIRE" CONNECTOR TO TERMINAL WIRE " ROUTE THRU DRILLED ·HOLE IN PILLAR. THEN INSERT TERMINAL END INTO JAMB SWITCH" PRESS JAMB SWITCH INTO POSITION. SEE FIG •. I" VIEW A. STEP 7 REP LAC E KICK PANELS" HOOK WIRES INTO CLIPS ON TOP OF KICK PANELS. SEE FIG. I.

STEP 4 REMOVE EXISTING INBOARD SCREW THAT ATTACHES L. "R.H. CONTROL " INSTALL PROVIDED SCREW. AT T A C H LAMPS TO THESE SCREWS WITH WASHERS" NUTS. SEE VIEW C.

STEP 8 INSERT FUSE CLIP" FUSE INTO RECEPTACLE ON JUNCTION BLOCK MARKED "HEAT BLOW -GL. BOX LP. " "PLUG IN CONNECTOR. SEE FIG.!. mil U receptacle is occupied, remove existing wire" connect to jumper wire. Discard fuse & clip .

,... 0 C ~ ...

" '" !il-< <-

~; ... ." -.0 " _ CD o Z '" '" '" N < ... -.0 > :011 CD $C ~ ,...

~ ... 0 Z

'" :z: ... ... ...

AlTERATION

" ~-;;:;;:- -- \~ -- /. - - ~EINFORCiMENT

DRILL 7/ 8 INCH (

(

DlA. HOLE

JUMPER ~~~~~::"'TERMINAL I / """"----

N ,

~: I

(.

SUPPORT

L.H. CONTROL ' i W:~~'~~WASHER

, VENT BRACKET , EXISTING 0""""" I

J II 'ASM.

SCREW ASM."\.. fa ' 10-24 X 3/ 4 _ ~ ~~

INSTRUMENT PANEL COMPARTMENT

EXTENSION LAMP ASM. II '/ TAPE

CORVAIR 95

STEP la REMOVE BULB I< SOCKET FROM EACH SUPPORT I< ALTER SUPPORT AS SHOWN. REASSEMBLE SOCKETS, SUP­PORTS" BULBS. SEE FlG. 2. EIIII U gasol1ne heater exists, Lamp support must be stralghtened to eliminate bend. STEP 2a PLACE LAMP WITH WHITE WIRE IN ITS APPROXl­MATE INSTALLED POSITION I< ROUTE LAMP WITH BLACK WIRE THRU EXISTING CLIP TO R.H. SIDE OF VEHICLE. lEE FIG. 4, STEP 3a REM 0 V E EXlSTING SCREWS THAT ATTACH 1. I< R. H. CONTROL I< RETAIN (2). PLACE LAMP SUPPORT ON OUTBOARD SIDE I< WAS HER ON INBOARD SIDE BETWEEN cONTROL I< INSTRUMENT PANEL I< REATTACH CONTROLS NITH RETAINED I< PROVIDED SCREWS. SEE FIG. 3, _ l gasollne heater exists, attach R. H. lamp support to existlng inboard weld nut with provlded screw.

--I

~./)

STEP 4a DRILL HOLES THRU EXISTING DIMPLES IN EACH FRONT DOOR HINGE PILLAR. SEE FlG, 3. '

STEP Sa TAPE JUMPER WIRE I< CONNECTOR TO TERMINAL WIRE I< ROUTE THRU DRILLED HOLE IN PILLAR. INSERT TERMINAL END INTO JAMB SWITCH I< PRESS SWITCH INTO POSITION. SEE FIG. 3. IIiIII Terminal must face inboard. STEP 6a ATTACH WIRES TO REINFORCEMENT EXTENSION, BOTH SIDES, WITH CLIPS. SEE FIG. I I< VIEW D. STEP 7a INSERT FUSE I< CLIP INTO RECEPTACLE ON JUNC­TION BLOCK MARKED "HEAT BLOW - GL. BOX LP. " I< PLUG IN CONNECTOR. SEE FIG. 4. lID If receptacle Ls oc­cupied, remove existing wire & connect to jumper wire, Dis­card (use &: clip.

STEP 8a LOOP I< TAPE ANY EXCESS WIRE. SEE FlG. 4.

309

988346 DOME LAMP INSTRUCTION SHEET

R-1205 & 1206

~FR'ONr LOAD DOOR

r-1WOIF TRIM PANEL

HINGE PILLAR

.~.

WIRING

ROOF TRIM PANEL

1

.. ~~

HINGE PILLAR

.. ~

STEP I REMOVE REAR TRIM PANELS FIRST IF VEHICLE IS MODEL 1206.

STEP 2 LOCATE, CENTER PUNCH, & DRILL HOLE IN L. H. REAR DOOR HINGE PILLAR REINFORCEMENT. SEE FIG. 1.

STEP 3 PUSH BARE END OF WIRE ASM. THRU GROMMET & SLIDE GROMMET ALONG WIRE TO A POINT ABOUT (12) INCHES FROM FUSE HOLDER. THREAD BARE END OF WIRE THRU DRILLED HOLE FROM UNDER REINFORCEMENT. THEN CLIP WmE TO PILLAR & ROUTE TO FRONT OF SECOND ROOF BOW FROM REAR. SEE FIG. 1. USE STIFF WmE TO ASSIST ROUTING THRU HOLES & AROUND CORNERS. mil If customer desires to change location 1n vehicle, pro­cure same gauge wire as speciUed "splice, solder" tape. fC) Chevrolet Dlvt,lon l( 1960 General Moton Corp. 312

DRILL (2) 5/8 INCH DIA. HOLES IN LINE (Use a

RAIL hole saw)

. \ DRILL 7/8 INCH DlA. HOLE

PILLAR

GROMMET ,/

~ DRILL 1/2 INCH DIA. HOLE

STEP 4 CRIMP & SOLDER BARE END OF WIRE TO CLIP. RE­MOVE LENS FROM LAMP ASM. INSERT CLIP INTO BASE. IN­SERT LAMP INTO CLIPS. REPLACE LENS. SEE FIG. 2 & VIEW A.

STEP 5 LOCATE, CENTER PUNCH, & DRILL HOLES IN R. H. FRONr LOAD DOOR & R. H. REAR DOOR HINGE PILLARS. SEE FIG. 1.

STEP 6 FROM INSIDE OF VEHICLE LOCATE, CENTER PUNCH, & CUT HOLES IN R. H. CORNER TRIM PANEL & ROOF RAIL, IF ACCESS HOLES DO NOr EXIST. LOCATE SYMMETRICALLY OPPOSITE TO HOLES ON L. H. SIDE. SEE FIG. 1. ",lIii"'il Do not drlll thru roof panel.

PRINTED IN U. S. A.

CRIMP & SOLDER .04 MINIMUM CRIMP

WIRE ASM.

____ JJI;;:;.:~5-- LAMP

WIRE CONNECTION TO LAMP

ROOF BOW _~"'Y

M,~ ,.:5l~~ :t DIA. HOLES

<31 DRILL ~f\::L_~~;.,.",~R_ETAINER

LAMP ASM.

FORWARD

& LAMP

STEP 7 POSITION RETAINER ON CENrER OF REAR ROOF BOW & USE IT AS A TEMPLATE TO DRILL HOLES. SEE F IG. 3. " ,If"Nt! Do not drill thru roof panel.

STEP 8 PASS LAMP ASM. T HRU RErA INER & ATTACH RETAINE R TO BOW WITH SCREWS. SEE FIG. 3.

ST!P 9 DRAW LAMP ASM. UP ro REr AINER BY PULL-ING OUT WIRE LEADS rHEN PRESS LAMP ASM. TO RE ­TAINER UNTIL PRONGS SNAP INTO PLACE. SEE FIG. 3.

STEP 10 P USH WIRES OVER BEHIND FLANGES OF ROOF BOW. ROUTE BROWN & GRAY WIRES BEHIND R. H. ROOF TRIM PANEL T HRU ACCESS HOLES TO DOOR HINGE P IL­LARS. SEE FIG. 1, SHEET 1. am Use s Uff wire to

313

------

, CLIP

FUSE l HOLDER

I~-~ , REGULATOR CONNEC110N

assist r outing thru holes & aroun d corners.

STEP 11 PULL rERMINA LS OF BROWN & GRAY WIRES our THRU DRILLED HOLES. INSERT THEM IN ro METAL CON­NECTORS ON END OF JAMB SWITCHES & PUSH SWITCHES INTO PLACE . SEE FIG. 1.

STEP 12 ROUTE TERMlNAL END OF WIRE ASM. TO FRONT OF REGULATOR, CLIP FUSE HOLDER TO HINGE PILLAR & CONNE CT WIRE TO BATrERY TERMINAL ON REGULATOR. SEE F IG. 4 & VIEW B, & ALSO CLIP WI RE TO HINGE PILLAR. SEE FIG. I. STEP 13 INSERT GROMMET, PLACED ON WIRE ASM. IN STEP 3, INTO DRILLED HOLE IN REAR PILLAR REIN­FORCEMENT. REPLACE REAR TRIM PANELS IF RE ­MOVED IN STEP 1.

985273 INSTRUMENT PANEL COMPARTMENT LIGHT SWITCH INSTRUCTION SHEET

CHEVROLET - CORV AIR - CORV AIR 95 - TRUCK & CHEVY

. JUMPER WIRE

WIRE CONNECTOR

CHEVROLET

STEP 1 R 0 UTE WIRE TERMINAL T H R U SLIT IN UPPER LEFT HAND CORNER OF INSTRUMENT PANEL C;OMPART­MENT & THRU HOLE IN UPPER LEFT SIDE OF COMPART­MENT OPENING. SEE FIG. 1 & VIEW A.

STEP 2 ASSE~LE WIRE T!i:RMINAL TO SWITCH. INSERT LAMP & PRESS SWITCH INTO POSITION. SEE VIEW A.

STEP 3 ROUTE WffiE ALONG REINFORCEMENT & ATTACH WITH" THREE OF PROVIDED CLIPS. ROUTE WIRE WITH EXISTING HARNESS TO JUNCTION BLOCK. TAPE WIRE TO

314

REINFORCEMENT

HARNESS CLOSE TO JUNCTION BLOCK. SEE FIG. 1.

STEP 4 PLUG wmE CONNECTOR INTO EITHER RECEPTA­CLE MARKED "CTSY." SEE FIG. 1. EIiDI If receptacle is occupied. remove existing wire & connect to jumper wire.

STEP 5 INSERT FUSE INTO RECEPTACLE MARKED "TAIL­LPS." SEE FIG. 1.

STEP 6 LOOP EXCESS WIRE & TAPE. SEE FIG. 1. mil Discard remaining parts.

PRINTED IN U. S. A.

EXISTING CLIPS

DASH

EXlSTING CLIP

[

EXISTING WIRE 'L-.----i-/- -:):,bd _ -/

/ "'----{;- -JUMPERWffiE

STEP la ROUTE WIRE TERMINAL THRU SLIT IN UPPER LEFT HAND CORNER OF INSl'RUMENT PANEL COMPART­MENT & THRU HOLE IN UPPER LEFT SIDE OF COMPART­MENT OPENING. SE E FIG. 2 & VIEW C.

STEP 2a ASSEMBLE WIRE TERMINAL TO SWITCH. INSERT LAMP & PRESS SWITCH INTO POSITION. SEE VIEW C.

STEP 3a ROUTE WIRE THRU EXISTING ClJPS (ON DASH) TO

315

JUNCTION BLOCK. SEE FIG. 2.

STEP 4a PRESS CLIP & BLADE INTO RECEPTACLE MARK­ED "GL. BOX LP. ", INSERT FUSE & CONNECT wmE. SEE VIEW D. ImIII If receptacle is occupied, remove existing wire& connect"tojumper wire. Discard clip & blade asm. &fuse.

STEP 5a LOOP &I TAPE EXCESS wmE. SEE FIG. 2. _ DlBcard remaining parts.

TRUCK

, CORVAIR 95

WIRE ASM.

~ ~

B SEE FIG. 2

STEP 1 b ROUTE WIRE TERMINAL THRU S LIT IN UP PER LEFT HAND CORNER OF INSTRUMENT PANEL COMPART­MENT & THRU HOLE IN UPPER LEFT SIDE OF COMP ART­MENT OPENING. SEE FIG. 3 OR 4 & VIEW C, F1G-. 2.

,STEP 2b ASSEMBLE WIRE TERMINAL TO SWITCH. INSERT LAMP & PRESS SWITCH INTO POSITION. SEE FIG. 3 OR ~ & VIEW C, FIG. 2.

STEP 3b (CORVAIR 95) ROUTE WIRE TO JUNCTION BLOCK BY LOOPING AROUND R. H. DEFROSTER DUCT, PASS OVER J... H. DEFROSTER DUCT, LOOP AROUND EXISTING WIRING HARNESS ALONGSIDE OF EXISTING CLIP. SEE FIG. 4.

316

SWITCH ABM.

STEP 4b (TRUCK) MOUNT CLIPS ON FORWARD FLANGE OF INSTRUMENT PANEL REINFORCEMENT & ROUTE WIRE THRU THESE CLIPS TO JUNCTION BLOCK. SEE FIG. 3, & VIEW D.

STEP 5b PRESS CLIP & BLADE INTO RECEPTACLE MARKED "GL. BOX LP." INSERT FUSE & CONNECT WIRE. SEE VIEW D & FIG. 2. ImDI If receptacle I.a occupied, remove existing wire & connect to jumper , wlre.

STEP 6b LOOP & T APE EXCESS WIRE. SEE FIG. 3 OR 4. IIiDI DiBcard remaining parts.

985237 CIGARETTE LIGHTER INSTRUCTION SHEET

CORVAm 95

-----~-

LAMP ASM.

HOUSING ASM.

INSTRUMENT PANEL

/-

1 HEAT~WmE(BLACK)--~ ~

---- -- HEA T1NG UNIT "KNOB ASM.

JUNCTION BLOCK

STEP 1 REMOVE PLUG FROM HOLE IN INSTRUMENT PANEL,

STEP 2 INSERT HOUSING THRU BEZEL" HOLE IN INSTRU­MENT PANEL" SECURE WITH RETAINER. "LUG REA T1NG UNIT INTO HOUSING. SEE FIG. I.

STEP 3 ATTACH CONNECTOR TO TERMINAL ON HOUSING" INSERT LAMP INTO RETAINER. SEE FIG. I.

tC" Chevroltt D1NIoII ~. \!.I1"l a.,eral Motora Corp. 324

STEP 4 LOOP wmES AROUND HARNESS" ROUTE TO JUNC TION BLOC K. SEE FIG. I.

STEP 5 PLUG BLACK wmE CONNECTOR INTO OPEN-ING IN JUNCTION BLOCK MARKED "eIG. LTR.". & CONNECTOR WITH JUMPER INTO OPENING MARKED "PANEL LPS." DiDI If receptacle 18 occupted, remove ex­istlng wire & connect to jumper wire.

PRINTED IN U. S. A.

985169 OUTSIDE REAR VIEW MIRROR INSTRUCTION SHEET

CHEVROLET. CORVAIR, COR VAlR 95, TRUCK (PANEL" SUBURBAN) & .

1/1/ \\ '

? \ 1 SCREW "B"~ _

~3M

A TRUCK & CORV AIR 95

:~~::g~

WRON:j.f. •• ANGLE

'---"---_ ____ -,0'--_

..

-: . ~~-TAPE

C. V. PILLAR

SCREW ' CHROME

~T"M'" LAT" - To be located in this position Cor R. H. Truck Installation on ly.

SHOULDER SCREW "A" 8-U X 5/ 8

/

OF CAR , DRlLL.120 IN(:H '--

~ ?!'" HOLE ~31 DRILL ) LMARKED~' ~~

PASS., CORVAIR, TRUCK (PANEL & SUBURBAN) & •

'-,mG'E OF C. V. PILLAR

STEP 1 FOLLOW DIRECTIONS ON TEMPLATE FOR MODEL DESIGNATION" LOCATION. TAPE TEMPLATE IN PLACE. SEE FIG. I OR FIG. 2.

STEP 2 L I GHTLY CENTER PUNCH AT REAR HOLE LO­CATION, & MARKCENTERLlNEWITH CHALK ORGREASE PENCIL ON DOOR SURFACE FORWARD OF TEMPLATE. SEE FIG. I OR FIG. 2.

STEP 3 DRlLL R EAR HOLE AS DESIGNATEO ON TEMPLATE, REMOVE TEMPLATE.

STEP 4 INSERT SCREW PROVIDED INTO REAR HOLE, SCR EW "A" FOR CHEVROLET, CORVAIR ". . SCREW "B" FOR TRUCKS" CORY AIR 95. mil Utie dimen­sion in View "A" for Trucks" Corvalr 95. Adjust screw "Btl so mirror wHl be tlght .

'C'liU CheYl'oL't DLv'-Lon \!) oeneul Mototl Corp.

333

STEP 5 PLACE GASKET ON MIRROR BASE &. PLACE MIRROR OVER SCREW "A" OR "B", SLJDE MIRROR FORWARD TO LOCK IN PLACE. SEE FIG. I OR F IG. 2.

STEP 6 LINE UP FORWARD TIP OF MIRROR BASE WITH LINE PREVIOUSLY MARKED ON DOOR. SEE FIG. 1 OR FIG. 2.

STEP 7 DRILL FRONT HOLE THRU EXISTING HOLE IN MIR­ROR BASE AT ANGLE AS SHOWN IN VIEW B. INSERT SCREW "C" PROVIDED, TIGHTEN SECURELY. SEE FIG. l OR FIG. 2. mD Care should be taken not to mar chrome.

EI!ID L. H. installation shown, R. H. installation same except to p I ace template face down on Chevr olet, Corvair, Truck" • . For R. H. Truck Installation a lso use dimension shown In Fig. 1. For R.H. install a ti on on Corvair 95 use dimensions in Fig. 3.

PRINTED IN u.s. A.

';

FRONT

t;;P0F CAR

L.H. DOOR EDGE

TAPE

334

MIRROR ASM.

REAR n,. __ .

Hole slze shown on mn L H door. temjjl'ate lor . . R DRILLING

CORVAIR 9S·RH DOO

985285 REAR VIEW MIRROR INSTRUCTION SHEET

R-IO SERIES

FRONT OF VEHICLE

~

OUTER ARM ASM.

GASKET

9/16

DRILL (3) 7/ 16 INCH DIA. HOLES

REINFORCEMENT ASM.

STEP 1 REMOVE & RETAIN THE SIDE DOOR INNER TRIM PANEL.

STEP 2 ASSEMBLE UPPER & LOWER BRACKET TO SU P­PORT WITH ATTACHING PARTS PROVIDED. SEE VIEW A. mil L. H. & R. H. upper brackets are provided. Be sure bracket s lants forward on L. H. side. SEE FIG. 1.

STIP 3 USING LOWER BJ;tACKET AS TEMPLATE, LOCATE, CENTERPUNCH & DRILL HOLES IN OOOR. SEE FIG. 1.

STEP 4 FROM INSIDE OF DOOR, POSITION REINFORCE­MENT THRU ACCESS HOLE & INTO DRILLED HOLES, FROM OUTSIDE OF DOOR ATTACH GASKET & LOWER BRACKET WITH ATTACHING PARTS PROVIDED. SEE FIG. 1. REPLACE TRIM PANEL.

STlP 5 USING UPPER BRACKET AS TEMPLATE, LOCATE,

m CIIe .... ole iDLylILon ~ 1960 Ge ner ilL Motorl Corp. 342

UPPER BRACKET

INNER ARM ASM.

LOWER--. ...... 1;Joi'\" BRACKET

BOLT 3/8 -16 X 5/ B INT. TOOTH­LOCK WASHER NUT

MmRORASM.

J MOUNTING BRACKET & GASKET

NUT 1/4 -28 INT. TOOTH­LOCK WASHER PLAIN WASHER

CENTERPUNCH & DRILL HOLES. SEE FIG. 1.

STIP 6 ATTACH UPPER BRACKET WITH UPPER GASKET & ATTACHING PARTS PROVIDED. SEE FIG. l.

STEP 7 LOCATE ALONG CONTOUR, CENTERPUNCH & DRILL FORWARD HOLE FOR OUTER ARM. SEE FIG. 1.

STEP 8 ASSEMBLE INNER & OUTER ARM WITH NUT PRO­VIDED, & ATTACH OUTER ARM & GASKET TO DOOR WITH ATTACHING PARTS PROVIDED. SEE FIG. 1.

STEP 9 ATTACH INNER ARM TO SUPPORT WITH GASKET & BRACKET & ATTACHING PARTS PROVIDED. SEE FIG. 1 & VIEW A.

STEP 10 INSTALL MIRROR TO SUPPORT WITH GASKET & BRACKET & ATTACHING PARTS PROVIDED, SEE VIEW A.

PRINTED IN U. S. A.

985305

LEVEL PLATFORM INSTRUCTION SHEET 1244.54 MODELS

DRILL (2) 3/4 INCH DIA. HOLES

~ 2-5/16R .>...,

3 :A.~2-5/8 ""

2-3/~- ~ ""

PLATFORM CUTTING

STEP 1 PURCHASE LOCALLY ENOUGH 3/4 INCH (5-PLY EX­TERIOR GRADE "AB ttl PLY WOO D TO MAKE (3) EQUAL PARTS.

STEP 2 CUT (3) EQUAL PARTS OF PLYWOOD TO DIMENSION SHOWN. SEE FIG. 1.

STEP 3 CUT GROOVE IN ALL (3) PARTS ON "Btl SIDE SEE FIG. 1.

350

~:3A'?/':4 F" ~R~ ~~ ~ ~ $ Sf$$5ti. 1/~

FRONT PLATFORM

STEP 4 DRILL (2) HOLES & CUT SLOT IN (1) PART DESIG­NATED "REAR PLATFORM". SEE VIEW A.

STEP 5 CUT GROOVES & CHAMFER ALONG EDGES O~ OP­POSITE SIDE OF GROOVE ON (1) PART DESIGNATED I CEN­TER PLATFORM". SEE VIEW B.

STEP 6 CUT OUT AREA ON REMAINING PART DESIGNATED "FRONT PLATFORM". SEE FIG. 1. & VIEW C.

PRINTeD IN U. 8. A.

DRILL 3/4 INCH DIA. HOLE 3/8 INCH DEEP ( 12~4 ONLY)

REINFORCEMENTS & SUPPORTS

STEP 7 USING REINFORCEMENTS PROVIDED AS A TEM-PLATE, LOCATE &. DRILL HOLES IN UNDERSIDE OF PLAT­FORMS. mil Do not drill thru plywood with $"32 inch drill. SEE FIG.~

STEP 8 USING SUPPORTS PROVIDED AS A TEMPLATE, LOCATE & DRILL HOLES IN TOP OF CENTER PLATFORM.

351

DRILL (7) 3/32 INCH DIA. HOLES

SEE FIG. 2. II1II Drill thru permissible.

STEP 9 ATTACH REINFORCEMENTS &. SUPPORTS TO PLATFORMS WITH SCREWS PROVIDED. SEE FIG. 2.

STEP 10 (ON 1254 MODELS ONLy) LOCATE &. DRILL HOLE IN R. H. CORNER OF FRONT PLATFORM. SEE FIG. 2.

SCREW 1/4-20-5/8

------- ...-

~ . BRACKET

ASM.

SILL ASM. -R. H.

REAR BRACKET ASM. ______

/~~ SCREW

~ ~VCAB .-::::--~ ,

~ ~-~'-~. "--./ --------~- I -... _

DRILL (4) 21/64 : _ ===----- _______ INCH DIA. HOLES I I - _____ - --- _ - ----------

.2-31/32 ~ - ~ --- nu"u __________

L ~ DRILL (6) .152 INCH

~ OF VEHICLE, -... DIA. HOLES _____ ~

/2CREW

SCREW -~ (NO. 24 DRILL) -__________ ----=:. lO-16xl/2--. ~;.::(16 - --.L~_&~DE _______ Ill-

lV------=:: ---- - ! I ,~ SILL ASM. -... _ - --____=_ ____=__ 1--

/~ ~~

~20X5/8

WASH~E ;:::;-~ ---~

~1: -~~- --~

-~FLOORPANEL SCREW 10-16 x 1/2

, o Sill ASSEMBLIES-DRILLING

STEP 11 REMOVE & RETAIN SPARE TIRE & ATTACHING PARTS.

STEP 12 ON..\LL MODELS, LOC1.TE CENTER PUNCH & DRILL TWO INSIDE HOLES FOR FRONT & REAR SILL AS­SEMBLIES & USING THEM AS A TEMPLATE, LOCATE, CEN­TER PUNCH" mm .. L REMAINING HOLES. SEE FIG. 3

STEP 13 LOCATE. CENTER PUNCH & DRILL FORWARD HOLES IN SIDE SILL ASSEMBLIES & USING THEM AS A

352

TEMPLATE LOCATE. CENTER PUNCH & DRILL REMAIN­ING HOLES. SEE FIG. 3.

STEP 14 INSTALL ALL SILL ASSEMBLIES WITH ATTACH-ING PARTS PROVIDED. SEE FIG. 3.

STEP 15 ON 1254 MODELS ONLY, REMOVE EXISTING SC~EWS ON R. H. SIDE PANEL & INSTALL BRACKETS PRO­VIDED WITH EXISTING SCREWS. SEE FIG. 3 & VIEW D.

.----------SCREW 1/4-20 X 1-1/2 ---

------

, PLATFORMS

STEP 16 REINSTALL SPARE TIRE.

STEP 17 INSTALL PLATFORMS && SECURE WITH ATTACH-ING PARTS PROVIDED. SEE FIG. 4.

353

FRONT PLATFORM ASM.

REAR PLATFORM ASM.

STEP 18 TO REMOVE PLATFORMS, REMOVE SCREWS & START BY LIFTING REAR PLATFORM, USING ACCESS HOLE ON R. H. SIDE. SEE FIG. 4.

985202 RADIO INSTRUCTION SHEET

CORVAIR 95

RECEIVER & SPEAKER ASM.

Preliminary: Check all items against the packing sUp. If any items are miss­ing, mark them on the packing slip. Fill ip the dealerts name. &. forward sUp to the zone office attention of the zone parts &. accessories manager. Alter checking tubes for tightness in their sockets. connect the radio receiver to a 12 volt power supply &. play the radio. A new radio that plays properly for 15 minutes can be assumed an acceptable product.

STEP 1 PUSH CUSHIONONTO TANG OF MOUNTING PLATE. DROP MAGNET END OF SPEAKER THRU HOLE IN MOUNTING PLATE" Po:IITION MOUNTING ~LATE CAREFULLY UNDER INSTRUMENT PANEL, NESTING CUSHIONED END OF PLATE INTO PANEL "EYE BROW". SEE FIG. 1.

STEP 2 ALIGN SPEAKER PARALLEL TO INSTRUMENT

01981 Chevroltit Division \V General Motor8 Corp.

.... -----

SCREW 10 - 32X 1-1/4

V7-28 ~ KNOB ASM.

TONE CONTROL KNOB ~ ~

379

PANEL &. ATTACH FORWARD END OF MOUNTING PLATE &. MOUNTING BRACKET TO EXISTING BRACKET ON DASH PAN­EL WITH "U" NUTS &. SCREWS. SEE FIG. 1.

STEP 3 ATTACH COVER BRACKET TO INSTRUMENT PAN­EL REINFORCEMENT WITH "J" NUTS & SCREWS. SEE FIG. 1.

STEP 4 SLIDE RECEIVER INTO COVER &. ATTACH TRIM PLATE WITH NUTS. SEE FIG. 1.

STEP 5 SLIP SPACERS ONTO R. H. CONTROL SHAFT, & TONE CONTROL KNOB" SPACER ONTO L.H. CONTROL SHAFT. PRESS A KNOB ONTO EACH SHAFT END. SEE FIG. 1.

STEP 6 POSITION GASKET ON COVER & ATTACH COVER TO COVER BRACKET WITH SCREWS. ATTACH MOUNTING BRACKET TO RECEIVER WITH SCREW. SEE FIG. 1.

PRINTED IN U. S. A.

~.

CONNECTORS

FUSE & CLIP

STEP 7 CONNECT SPEAKER CONNECTOR TO PLUG AT BACK OF RECEIVER. INSERT CABLE ASM. LEA~IN PLUG INTO SOCKET ON R. H. SIDE OF RECEIVER. SEE FIG. 2.

STEP 8 UNT APE RADIO CONNECTOR FROM INSTRUMENT PANEL wmING HARNESS & CONNECT IT TO PLUG ON RE­CEIVER. IF ~TING HARNESS HAS NO RADIO CONNECTOR, PROCURE ACC ESSORY HARNESS UNIT NO. 988850 FROM STOCK 8& INSTALL IN VEHICLE. SEE FIG. 2.

380

, BOTTOM VIEW-RECEIVER ASM.

STEP 9 PRESS FUSE CLIP ASM. INTO RECEPTACLE ON JUNCTION BLOCK MARKED "RADIO" UNTIL LOCKED IN PLACE, THEN INSERT FUSE .INTO CLIPS. SEE FIG. 3.

STEP 10 PLUG CONNECTOR OF EXISTING HARNESS, OR ACCESSORY HARNESS IF USED, INTO JUNCTION BLOCK SLOT. SEE FIG. 3.

STEP 11 COVER HOLE IN RECEIVER BOTTOM WITH TAPE, TO ELIMINATE EXCESSIVE LIGHT .. SEE FIG. 4 • .

EXISTING NUT &. LOCK WASHER

ARMATURE TERMINAL

GENERATOR CAPACITOR

BOLT 1/4-28 X 7/16 LOCK WASHER

CAPACITOR (1911095)

TAPPED HOLE

EXISTING LOCK CLIP & NUT

POSITIVE (+) TERMINAL

ENGINE INGNITION COIL-CAPACITOR

STEP 12 ATTACH CAPACITOR TO GENERATOR SECURELY WITH PROVIDED BOLT & WASHER. CONNECT CAPACITOR LEAD TO ARMATURE TERMINAL SECURELYWITH EXlSTING LOCK WASHER &. NUT. SEE FIG. 5.

STEP 13 ATTACH CAPACITOR TO REGULATOR SECURELY WITH EXISTlNG SCREW. CONNECT CAPACITOR LEAD TO BATTERY TERMINAL ON REGULATOR SECURELY WITH EX­ISTING CLAMP &. SCREW. SEE FIG. 6.

381

BATTERY TERMINAL

• REGULATOR CAPACITOR

ST ATIC COLLECTOR ~-- FRONT WHEEL HUB

STATIC COLLECTOR

STEP 14 ATTACH CAPACITOR TO IGNITION COIL SECURE­LY WITH PROVIDED SCREW" WASHER. CONNECT CAPACI- , TOR LEAD TO COIL POSITIVE TERMINAL SECURELY WITH EXlSTlNG LOCK CLIP" NUT. SEE FIG. 7.

STEP lS REMOVE FRONT WHEEL BEARING GREASE RE­TAINERS. REMOVE ALL GREASE FROM RETAINERS &. LATHE HOLES. INSERT STATIC COLLECTORS INTO GREASE RETAINERS. BEND BACK COTTER PINS FOR CLEARANCE &. REPLACE RETAINERS. SEE FIG. 8.

• R.H. SIDE GROUND STRAPS

STEP 16 LOCATE, CENTER PUNCH, &. DRILL HOLES IN EN­GINE SIDE SIDELDS " ENGINE COMPARTMENT UNDERBODY SHIELDS. SEE FIG. 9 •

STEP 17 ATTACH GROUND STRAPS TO SIDELDS WITH PRO­VIDED WASHERS &. SCREWS. SEE FIG. 9 • 1'.liIo.,:, All lock washers must be placed first, directly against shields,

GROUND STRAP

ENGINE SIDE SHIELD

otherwise poor grounding may result.

STEP 18 EXTEND ANTENNA TO FULL HEIGHT, TURN RE­CEWER liON", SET CONTROLS TO MAXIMUM VOLUME, &. TUNE-IN A WEAK STATION BETWEEN 800 &. 1000 KILOCY­CLES. ADJUST ANTENNA TRIMMER FOR MAXIMUM VOLUME (FOR LOCATION OF TRIMMER ADJUSTING SCREWSEE FlG.4).

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988335 SPOTLAMP INSTRUCTION SHEET

DRILLING & INST AltA nON

IEIlDII L. H. lnstallation shown. R. H. typical except template faces down.

STEP 1 TAPE TEMPLATE, CENTER PU~CH & DRILL HOLES AS INDICATED ON TEMPLATE. SEE FIG. 1.

STEP 2 A T T A C H OUTSIDE BRACKET & GAS K E T WITH SCREWS. SEE FIG. 2.

STEP 3 INSERT DRILL BUSHING IN BRACKET & TIGHTEN SET SCREW. CENTER PUNCH & DRILL HOLE THRU DOOR. LOCATE, CENTER PUNCH, & DRI L L GROMMET HOLE ON INSIDE OF DOOR. SEE FIG. 2.

SUP 4 REMOVE & DISCARD DRILL BUSHING. DISMANTLE NUT, WEDGE, & HANDLE FROM SPOTLAMP.

TEMPLATE

-'-----

BRACKET SUPPORT

390

SCREW HANDLE

8-15 X 1/2

WEDGE

STEP 5 INSERT SPOT LAM P SHAFT T HR U BRACKET & ROTATE TO ENGAGE TONGUES IN OUTSIDE BRACKET WITH SLOTS ON SHAFT. TIGHTEN SET SCREW. SEE FIG. 2.

STEP 6 PLACE RUBBER SPACER ON SHAFT & ROTATE TO MATCH CONTOUR OF DOOR. POSITION INN E R BRACKET SUPPORT INTO THE INSIDE BRACKET & SLIDE ONTO SHAFT, PRESS TIGHT TO DOOR & TIGHTEN SET SCREW. SEE FIG. 2.

STEP 7 USING SUPPORT AS A TEMPLATE)CENTER PUNCH & DRILL HOLE IN DOOR. ATTACH SUPPORT TO DOOR WITH PROVIDED SCREW. SEE FIG. 2.

STEP 8 WITH SPOTLAMP IN NORMAL UPRIGHT POSITION REINSTALL HANDLE TO FACE 30° TO THE REAR & SECURE WITH WEDGE & NUT. SEE FIG. 2.

PRINTED IN U. S. A.

ON SURFACE OF DOOR

(L. H. SHOWN - R. H. SYM­WIRING L.H. SPOTLAMP METRICALLY OPPOSITE)

STEP 9 LOCATE, CENTER PUNCH & DRILL HOLES ON FORWARD EDGE OF DOOR & FRONT BODY IDNGE PILLAR. SEE FIG. 3 & VIEW A.

STEP 10 THREAD SPOTLAMP WIRE THRU DOOR & ROUTE THRU HOLE IN HINGE PILLAR. SEE FIG. 3.

STEP 11 PLACE GROMMETS ON WIRE & PRESS IN PLACE. ADJUST WIRE FOR SWING CLEARANCE OF DOOR. SEE FIG. 3.

391

\ \ \ I 1-1 1 I

1- ~ r JUNCTION , I BLOCK I I I I

,=~~~~~~~~~_.~.CI:~}~~~~ -- ~ - , --'- -.'":

':::.

STEP 12 INS TAL L CLIPS WITH PROVIDED SCREWS, SEE FIG. 3 & VIEW ~

STEP 13 INS E R T CLIP & BLADE INTO RECEPTACLE ON JUNCTION BLOCK MARKED "HEATER - B. U. LPS." PLACE CONNECTOR ON WIRE TERMINAL. SEE FIG. 3,

SUP 14 (L. H. SPOTLAMP) PLUG CONNECTOR INTO CLIP & BLADE & INSERT FUSE. SEE FIG. 3.

SPOT LAMP ASM.

INSTRUMENT ~ PANEL REIN~ FORCEMENT ~ '\:, ""r

WIRING R.H. SPOTLAMP

STEP lS (R.H. SPOl'LAMP) PLUG TERMINAL INTO CON­NECTOR ON WIRE ASM. lNST ALL CLIPS ON INSTRUMENT PANEL REINFORCEMENT AT CONVENIENT LOCATIONS. ROUT E WIRE ASM. THRU CLIPS. SEE FIG. 4 It VIEW A.

INSTRUMENT PANEL REINFORCEMENT

STEP 16 (R.H. SPOTLAMP) PLUG CONNECTOR INTO CLIP It BLADE & INSERT FUSE. SEE FIG. 3. EmIl· If receptacle La occupied remove &,plug into jumper wire.

392

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988480-988481-988482-985025

/ /

f------- - -- . ---._,. ... - - - .. - - -- - - - - --.---

INSTALLATION INSTRUCTIONS FOR RAIN DEFLECTORS

1. Rain Deflectors will fit only the models, shown on the carton label.

2. Rain Deflectors ar-e stamped to show their position - RF for right front door; LF for left front, etc.

3. Insert flange between the weatherstrip and door frame. Flange should disap­pear and curves fit properly.

4. If weatherstrip bead overlaps the vent wing division post, clip off overlapping portion.

5. Centerpunch and drill the front screw hole fil'st, using a #43 or .OB9 drill. Drill through door frame as shown be­low. (See sketch.) Insert screw.

6. Holding shade in position, centerpunch and drill remaining hole. Insert screw.

'1. Operate Window. If window binds spread glass channel to allow complete closing.

WEA TIl ERSTRIP

~/~l~t:._ WEATHERSTRIP BEAD

GLASS

4-24xl/4 TAPPING SCREW

INSTRUCTION NO. 3755'122 2-11-58

1~~------3 liB ------~~I

436

5 1/2

~.

985238 SUNSHADE INSTRUCTION SHEET

CORVAIR 95

DRILL 1-1/8 INCH DIA. HOLE

I

-JI ---R.H. SUNSHADE

SUP 1 LOCATE EXISTING DIMPLE & DRILL LARGE HOLE iN TRIM PANEL. SEE FIG. 1.

SUP 2 INSERT SUNSHADE & SUPPORT INTO HOLE & LINE UP WITH TOP OF W1ND3HIELD OPENING & L. H. SUNSHADE. SEE F1G. 1. ,.,'iiiim. Be sure bracket is located sym-

01960 Chevrolet Dln.lon ~ OeneMll Motors Corp,

DRILL (3) . 136 INCH DIA. HOLES (#29 DRILL)

442

---SCREW 10-8-12 X 3/4

R. H. SUNSHADE & SUPPORT ASSY.

metrically opposite to L. H. bracket before drilling holes.

STEP 3 USING SUPPORT AS TEMPLATE 9ENTERPUNCH & DRILL HOLES. SEE FIG. L

STEP 4 INSTALL SUNSHADE WITH ATTACHING PARTS PRO~ VIDEO. SEE FIG. 1.

PRtNTEO IN U. S. A,

985304 WINDSHIELD WASHER INSTRUCTION SHEET

CORVAIR 95

EXISTING WINDSHIE LD""--:) WIPER MOTOR

~i J ~ L.B. BRACKET

INT. -EXT. TOOTH LOCK WASHER

SEALING WASHER

DRILL (5) .144 INCH DIA. HOLES (NO. 27 DRILL)

@-~ LOWER BRACKET - ----

STEP 1 LOCATE EXISTING DIMPLES IN DASH PANEL & DRILL HOLES FOR UPPER R. H. & L. H. & LOWER BRACKETS

.& GROMMET. SEE FIG.!. ImID U heater exlsts, use lower hole of heater control cables clip [or attaching lower bracket.

STEP 2 INSTALL RESERVOIR UPPER & LOWER MOUNTING BRACKETS WITH ATTACIflNG PARTS PROVIDED. SEE FIG. 1.

STEP 3 LOCATE, CENTER PUNCH & DRILL HOLES IN OUTER

452

PANEL. SEE VIEW A. 11·111111.11 Before drilling procedure is started, it is suggested that masking tape be appUed to outer panel1n drllling area to aVOid marring the finish.

STEP 4 REMOVE FRONT GRILLE & ORNAMENT ASSEMBLY •.

STEP 5 INSTALL NOZZLE ASM. WITH ATTAcmNG PARTS PROVIDED. SEE VIEW A.

PRlNTEO IN U. S. A.

10-32 x 1/4

PUMP & RESERVOIR

\

I

)

STEP 6 PLACE WIPER MOTOR IN PARK POSITION, RE-MOVE PLASTIC COVER FROM DRlVE SHAFT OF WIPER MOTOR & POSITION GEAR ON SHAFT. INSTALL PUMP SO THAT GEAR ALIGNS WITH SLOT IN PUMP & SECURE WITH SCREWS. SEE FIG. 2.

STEP 7 INSTALL HOSE & FILTER ASM. INTO RESERVOIR & ATTACH RESERVOIR TO BRACKETS. FASTEN HOSE TO CENTER OUTLET ON PUMP. SEE FIG. 3 & HOSE CHART.

STEP 8 DISCONNECT EXISTING WIPER CONNECTOR FROM SWITCH. REMOVE WIPER KNOB & SWITCH ABM. & DISCARD BUT RETAIN BEZEL & NUT, INSTALL PROVIDED SWITCH WITH RETAINED BEZEL & NUT. (TERMINAL WITH TANG TO BE POSITIONED UPWARD). INSTALL KNOB. ATTACH EX­ISTING WIPER CONNECTOR (SLOTTED) TO UPPER TERMIN-

453

BEZEL { SWITCH WASHER

EXISTING i{( ASM. CONNECTOR

INSTRUMENT PANEL

HOSE CHART

HOSE DrA. LENGTH

A-NOZZLE 5/32I.D. B INCHES 5/32 I. D. 4 INCHES 5/32I.D. 6 INCHES

EXISTING WIPER MOTOR HARNESS CONNECTOR

3-WIRE CONNECTOR

RESERVOIR ASM.

AL. SEE VIEW B.

srEP 9 CUT PROVIDED HOSE INTO LENGTHS SHOWN (HOSE CHART) & ATTACH TO TEE. CONNECT "B & C" TO PUMP OUTLETS, THEN ROUTE "A"THRU GROMMET & HOLE. CON­NECT TO NOZZLE. INSERT GROMMET INTO POSITION. SEE FIG. 3.

STEP 10 ROUTE HARNESS ASM. THRU EXISTING CLIP ON DASH UNDER INSTRUMENT PANEL. ATTACH HARNESS ASM. (2 WIRE) CONNECTOR TO PUMP. DISCONNECT EXISTING WIPER CONNECTOR FROM MOTOR & ATTACH HARNESS (3 WIRE) CONNECTOR TO WIPER MOTOR. ATTACH EXISTING WIPER CONNECTOR TO REMAINING HARNESS ABM. MOTOR CONNECTOR. SEE FIG. 3.

~.

STRA1GHT~' PIN

BALL

R.H.

STEP 11 TEST SYSTEM TO INSURE CORRECT INSTALLA­TION & DETERMINE LOCATION OF POINT OF CONTACT FOR WATER STREAM. SEE FIG. 4.

STEP 12 IF WATER STREAM DOES NOT REACH POINT OF

454

8-3/8 APPROX.

POINT OF CONTACT

( /

CONTACT, BALL OF NOZZLE ASSY. SHOULD BE ADJUSTED. ADJUSTMENT MAY BE MADE BY INSERTING STRAIGHT PIN IN BALL OF NOZZLE & TURNING BALL. SEE VIEW c.

STEP 13 REP LAC E FRO NT GRI LLE & ORNAME NT ASSEMBLY.