1960 Chevrolet Corvair Repair Service Manual

Description

This 400 + page, 1960 Chevrolet Corvair Shop Manual is a reproduction of the original, out of print manual. This service manual provides service, repair, and maintenance information for 1960 Chevrolet Corvair automobiles.

Table of Contents

General Information
Vehicle Dimensions
Model Identification
Engine Data
Gear and Control Ratios
Capacities
Tire Information
Vehicle and Component Weights
Unit and Serial Number Locations
Selection of Gasoline and Engine Oil
Keys and Locks
Pushing Car to Start
Emergency Towing
Lifting Corvair with Drive-on Hoist
Standard Torque Table

Lubrication and General Maintenance
Lubrication and Maintenance Guide
Lubrication
Engine Crankcase Oil
Crankcase Capacity
First 1000 Miles
After 1000 Miles
SAE Viscosity Oils
Types of Oils
Maintaining Oil Level
When to Change Crankcase Oil
Favorable Conditions
Dust Area Operation
Low Temperature Operation
Crankcase Dilution
Automatic Control Devices to Minimize Crankcase Dilution
Oil Filter
Changing of Oil Filter Cartridge
Front Suspension
Steering Linkage
Clutch Control Cross Shaft
Steering Gear
Generator
Distributor
Air Cleaner Maintenance
Oil Cooler Cleaning
Front Wheel Bearings
Universal Joints
Transmission
Rear Axle
Battery
Carburetor Fuel Filter Service
Hydraulic Brake Cylinder Fluid Level
Parking Brake and Clutch Cable Pulleys and
Cables
General Maintenance
Body Lubrication
Tire Pressures and Inspection
Engine Tune-Up
Blower Belt Adjustment
Brake Adjustment
Tire Rotation
Spark Plug Service
Complete Dealer Inspection

Suspension
General Description
Maintenance and Adjustments
Lubrication
Adjustment of Front Wheel Bearings
Wheel Alignment
Preliminary Steps
Front Wheel Alignment
Camber Adjustment
Caster Adjustment
Steering Axis Inclination
Toe-in Adjustment
Cornering Wheel Relationship
Rear Wheel Alignment
Toe-in Adjustment
Camber
Service Operations
Front Suspension
Front Hub and Drum
Shock Absorbers
Inspection of Spherical Joints
Riding Height and Coil Spring Sag
Coil Springs, Lower Control Arms, Spherical Joints and/or Bushings
Upper Control Arms, Spherical Joints, Cross-Shafts and/or Bushings
Strut Rod
Suspension Cross Member
Rear Suspension
Shock Absorbers
Riding Height and Rear Coil Spring Sag
Coil Springs
Lower Control Arm
Suspension Cross Member
Front and Rear Suspension to Body Alignment
Cage Nut Repair
Specifications
Special Tools

Wheels and Tires
General Description
Maintenance
Testing Tire Pressures
Puncture Inspection
Changing Road Wheels
Interchanging Tires
Cleaning Whitewall Tires
Service Operations
Correction of Irregular Tire Wear
Dismounting and Mounting Tires
Tire and Rim Repair
Balancing Wheels and Tires
Static Balance
Dynamic Balance
Wheel Runout and Eccentricity
Testing for Tire Noise
Troubles and Remedies
Specifications

Steering
General Description
Maintenance and Adjustments
Lubrication
Adjustments
Steering Gear
Steering Wheel Alignment and High
Point Centering
Steering Shaft and Mast Jacket Relationship
and Alignment
Turn Signal Housing to Steering Wheel
Clearance
Toe-in Adjustment
Service Operations
Steering Wheel
Removal
Installation
Steering Gear
Removal
Disassembly
Ball Nut Disassembly
Inspection
Repairs
Pitman Shaft Bushing Replacement
Side Cover Bushing Replacement
Assembly
Ball Nut
Steering Gear
Adjustment on Bench
Installation
Mast Jacket
Removal
Repairs
Upper Bearing Replacement
Ixiwer Seal Replacement
Installation
Steering Linkage
Tie Rods
Removal
Installation
Relay Rod
Removal
Cleaning and Inspection
Repairs
Bushing Removal
Bushing Replacement
Installation
Idler Arm
Removal
Bushing Replacement
Installation
Troubles and Remedies
Specifications
Special Tools

Brakes
General Description
Maintenance and Adjustments
Hydraulic Brake Fluid
Bleeding Hydraulic System
Pressure Bleeding
Manual Bleeding
Push Rod to Main Cylinder Clearance
Hydraulic Brake Lines
Hydraulic Brake Hose
Hydraulic Brake Tubing
Double Lap Flaring
Hydraulic Brake Adjustment
Parking Brake
Adjustment
Inspection
Service Operations
Forward Parking Brake Cable
Removal
Installation
Rear Parking Brake Cable
Removal
Installation
Brake Pedal
Removal
Inspection
Installation
Brake Shoes
Removal
Inspection
Installation
Main Cylinder
Removal
Disassembly
Inspection
Assembly
Installation
Wheel Cylinder
Removal
Disassembly
Inspection
Assembly
Installation
Brake Drums
Removal
Inspecting and Reconditioning
Cleaning
Installation
Troubles and Remedies
Special Tools

Power Train
General Description
Service Operations
Introduction
Removal of Power Train from Vehicle
Separation of Power Train Major Components
Three Speed Transaxle
Removal of Transaxle from Engine
Separation of Three Speed Transmission
from Differential Carrier
Repair Procedures
Automatic (Powerglide) Transaxle
Removal of Transaxle from Engine
Separation of Automatic Transmission
from Differential Carrier
Repair Procedures
Powerglide Selective Thrust Washer
Determination
Assembly of Power Train Major Components
Three Speed Transaxle
Assembly of Three Speed Transmission
and Differential Carrier
Assembly of Three Speed Transaxle
to Engine
Automatic (Powerglide) Transaxle
Assembly of Automatic Transmission
and Differential Carrier (Includes Rear
Selective Thrust Washer Determination)
Assembly of Automatic Transaxle to
Engine
Installation of Power Train in Vehicle
Special Tools

Engine
General Description
Engine Mounting
Cylinder Numbering
Lubrication System
Crankcase Venting
Cooling System
Air Induction System
Maintenance and Adjustments
Engine Oil
Engine Oil Level
Fan Belt or Blower Belt
Ignition Timing
Compression Check
Valve Adjustment (Engine Running)
Air Cleaner and Carburetion
Engine Electrical Components
Engine Tune-Up
Engine Cleanliness
Cleaning Oil Cooler
Cooling System Thermostat Adjustment
Service Operations
General Service Information
Engine Service Reference Guide
Component Service Procedures – In Vehicle
Engine Sheet Metal Components
Upper Shroud
Front Shield
Side Shield (Left Side)
Side Shield (Right Side)
Lower Shrouds
Front Shrouds
Rear Shroud (Left Side)
Rear Shroud (Right Side)
Exhaust Duct Assembly
Engine Mountings
Front Mounts
Rear Mount
Oil Filter and Generator Adapter
Blower Bearing, Blower and Crankcase
Cover
Oil Cooler
Oil Pan
Oil Pump Pick Up Tube and Screen
Crankcase Vent Tube and Gasket
Cylinder Head and Component Parts
Cylinder Head (Left Bank)
Cylinder Head (Right Bank)
Valve Rocker Arms, Balls and Nuts
Valve Springs
Push Rods
Hydraulic Lifters
Oil Pump Gears
Oil Pump Pressure Regulator
Connecting Rod Bearings
Crankshaft Pulley and Engine Rear Housing
Seal
Piston Ring Replacement
Checking Camshaft Lobe Lift
Generator
Distributor
Coil
Spark Plugs
Carburetor
Fuel Pump
Air Cleaner
Exhaust Muffler
Oil Filter
Pulley Belt
Off the Vehicle Service Operations
Engine Disassembly (Engine Removed)
Fuel Pump
Oil Pan
Exhaust Manifold
Cylinder Head
Hydraulic Lifters
Piston and Connecting Rod Assemblies
Cylinder Air Baffle
Piston and Cylinder
Crankshaft Pulley
Camshaft and Crankshaft
Main Bearings
Repairs – Engine Components
Cylinder Heads
Disassembly
Cleaning
Inspection
Reseating Valve Seats
Refacing Valves
Exhaust Valve Seat Inserts
Exhaust Manifold Sleeves
Assembly
Piston and Connecting Rods
Piston Pin Fit
Pistons, Rings and Cylinder Assembly
Cylinders
Piston Rings
Piston and Connecting Rod Assembly
Engine Rear Housing
Oil Pump
Rear Housing Seal
Housing Replacement
Oil Cooler By-Pass Valve
Oil Filter By-Pass Valve
Crankcase
Cleaning, Inspection and Repairs
Stud and Thread Repairs
Oil Level Gauge Tube
Blower Bearing
Main Bearings
Bearing and Journal Inspection
Main Bearing Clearance
Connecting Rod Bearings
Valve Lifters
Flywheel Housing Seal
Engine Assembly (Engine Removed)
Crankshaft
Camshaft
Timing Gear Marks
Camshaft End Play
Timing Gear Backlash
Pistons, Cylinders and Connecting Rods
Crankcase Cover and Blower Bearing
Oil Pump Screen and Tube Assembly
Cylinder Head
Push Rod Oil Drain Tube
Engine Rear Housing
Crankshaft Pulley
Oil Cooler
Exhaust Manifolds
Valve Lash Adjustment
Oil Filter and Generator Adapter
Spark Plugs
Fuel Pump
Engine Oil
Troubles and Remedies
Specifications
Special Tools

Clutch
General Description
Maintenance and Adjustments
Clutch Linkage Adjustment
Service Operations
Clutch Assembly
Removal from the Vehicle
Disassembly
Inspection
Repairs
Pilot Bearing
Assembly
Installation to the Engine
Installation in the Vehicle
Clutch Pedal Assist Spring
Removal and Installation
Clutch Pedal and Sleeve Bushing
Removal
Installation
Clutch Cable and Pulley Assembty
Removal
Installation
Clutch Lever Control Cable Cross-Shaft
Removal
Installation
Specifications
Special Tools

Rear Axle
General Description
Periodic Maintenance
Lubricant
Differential Carrier
Universal Joints
Hub Nuts
Service Operations
Service Reference Guide
Differential Carrier in Vehicle
Axle Shaft – Bearing – Universal Joint
Side Bearing Adjusting Sleeve
Seal Replacement
Speedometer Driven Gear
Assembly Replacement
Differential Carrier – Removal and
Installation from Vehicle-
Differential Carrier Removed from Vehicle
Differential Carrier Disassembly
Inspection
Repairs – Three-Speed and
Automatic Transmission Axles
Pinion and/or Bearing Replacement
Including Pinion Depth Shim
Determination
Pinion Front Bearing
Race Replacement
Side Bearing Adjusting
Sleeve Seal Replacement
Side Bearing Adjusting Sleeve
Bearing Race Replacement
Ring Gear Replacement, Differential
Side Bearing Replacement and
Differential Overhaul
Repair – Three-Speed Axles Only
Clutch Release Bearing Shaft
Seal Replacement
Clutch Release Bearing Shaft and/or
Pinion Rear Bearing Race Replacement
Repairs – Automatic Transmission
Rear Axles Only
Pinion Shaft Front Oil Seal and/or
Converter Hub Oil Seal Replacement
Pinion Shaft Rear Oil Seal Replacement
Pinion Shaft Bushing Replacement
Stator Shaft and/or Pinion
Rear Bearing Race Replacement
Differential Carrier Assembly
Ring Gear and Pinion Bearing Adjustments
Ring Gear-to-Pinion
Backlash Adjustment
Ring Gear and Pinion Contact Pattern
Troubles and Remedies
Rear Axle Noise Diagnosis
Specifications
Special Tools

Transmission-Manual
General Description
Maintenance and Adjustments
Lubrication
Shift Linkage Adjustment
Service Operations
Service Reference Guide
Service Operations – Transmission in Vehicle
Gearshift Lever Assembly
Shift Control Rod
Transmission Removal and Installation
Service Operations – Power Train Removed
from Vehicle
Disassembly of Transmission
Inspection and Repair
Bearings
Transmission Case
Gears
Reverse Idler Gear Bushings
Countergear Needle Bearings
Clutch Gear Bearing Replacement
Clutch Sleeve & Synchronizer Rings
Synchronizer Energizing Springs
Assembly of Transmission
Troubles and Remedies
Specifications
Special Tools

Transmission-Automatic
General Description
Maintenance and Adjustments
Oil Requirements
Oil Level
Draining and Refilling
Shift Linkage Adjustment
Neutral Safety Switch Adjustment
Throttle Valve Linkage Adjustment
Low Band Adjustment
Service Operations
Service Reference Guide
Service Operations – Transmission in Vehicle
Range Selector Assembly
Control Cable Assembly
Vacuum Modulator
Governor
Valve Body and Low Servo
Transmission Removal and Installation
Service Operations – Power Train
Removed from Vehicle
Disassembly of Transmission
Inspection and Repair of
Transmission Components
Front Pump
Clutch Drum
Planet Carrier
Turbine Shaft
Pump Shaft
Rear Pump and
Reverse Piston Assembly
Converter
Assembly of Transmission
Front Pump
Thrust Washer Determination
Trouble Shooting
Hydraulic Pressure Data
Diagnosis Guide
Specifications
Special Tools

Engine Tune Up
Introduction
Mechanical Checks and Adjustments
Remove Spark Plugs and Test Compression
Clean, Service and Install Spark Plugs
Service Ignition System and Make Necessary
Repairs
Service Battery and Battery Cables
Service Blower Belt and Generator
Check Operation of Cooling Air Throttle Valve
Check Fuel Lines
Clean and Service Air Cleaner
Check Carburetor Linkage and External
Adjustments
Inspect and Service Cooling System
Check Lubricant Level and Inspect for Oil
Leaks
Normalize Engine
Perform Cleaning and Checking Operations
During Warmup
Cylinder Head Bolts
Instrument Check-out
Test Cranking Voltage
Test Ignition Resistance By-pass
Test Distributor Resistance
Test Dwell and Dwell Variation
Test Ignition Timing and Advance
Test Secondary Resistance and Polarity
Test Ignition Output and Secondary Leakage
Test Charging Voltage
Adjust Idle Speed and Mixture and Check
Vacuum
Additional Checks and Adjustments
Road Test Vehicle
Cylinder Balance Test
Battery Test
Starting Circuit Checks
Generating Circuit Checks
Ignition Circuit Checks
Fuel Pump Test

Engine Electrical
General Trouble Shooting
Battery
Generator
Regulator
Starting Motor and Solenoid
Ignition System
Generating Circuit
Periodic Servicing
Battery
Generator
Regulator
Checks and Adjustments on the Vehicle
Generator Telltale Light
Wiring
Battery
Regulator
Generator
Servicing of Units Off the Vehicle
Battery
Generator
Removal
Brush Replacement
Disassembly
Cleaning and Inspection
Testing Generator Parts
Repairs
Assembly
Installation
Regulator
Removal
Inspection and Adjustment
Cleaning Regulator Contact Points
Contact Support Brackets
Cutout Relay Air Gap and Point Opening
Voltage Regulator Air Gap
Current Regulator Air Gap
Replacing Springs
Installation
Radio By-pass Condensers
Polarizing the Generator
Starting Circuit
Periodic Servicing
Checks and Adjustments on the Vehicle

Wiring Diagrams
Introduction
Ignition – Starting Circuit Energized
Primary Circuit
Positive and Negative Circuit
Charging and Generating Circuit
Oil Temperature and Oil Pressure Sender Circuit
Fuel Gauge Circuit
Panel Lighting Circuit
Interior Lighting Circuit
Parking Lamp Circuit
Direction Signal Circuit
Headlamp Circuit
Tail Lamp Circuit
Horn Circuit
Windshield Wiper Circuit
Cigarette Lighter Circuit
Glove Compartment Lamp Circuit
Backing Lamp Circuit
Courtesy Lamp Circuit
Radio Circuit
Heater Circuit
Windshield Washer Circuit

Chassis Electrical
Lighting System
Headlamps
Replacement
Adjustment
T-3 Aimers
Aiming Screen Method
Lighting Switch Replacement
Stoplight Switch Replacement
Dimmer Switch Replacement
Windshield Wiper Switch Replacement
Neutral Safety Switch Replacement
Back-Up Lamp Switch Replacement (3-Speed only)
Instrument Panel Compartment Lamp Switch Replacement
Bulb and Lamp Body Service
Parking Lamp
Tail, Stop and Back-Up Lamp
Instruments and Gages
Instrument Cluster
Generator Telltale Indicator
Oil Pressure and Temperature Telltale Indicator
Fuel Gauge
Speedometer Service
Horn and Horn Relay
Direction Signal
Windshield Wiper and Washer
Windshield Wiper
Description and Operation
Removal and Installation
Disassembly
Inspection
Assembly
Trouble Shooting
Specifications
Windshield Washer (optional)
Description and Operation
Overhaul Procedures
Trouble Shooting
Troubles and Remedies
Specifications
Special Tools

Fuel and Exhaust System
Model H Carburetor Air Horn Assembly
General Description
Maintenance and Adjustments
Accelerator Pedal
Accelerator Control Linkage Adjustments
Synchronizing Carburetors
Idle Speed and Mixture Adjustments
Float Level and Drop Adjustments
Pump Rod Adjustment
Fast Idle Adjustment
Automatic Choke Adjustment
Choke Unloader Adjustment
Inlet Fuel Filter
Service Operations
Removal
Disassembly
Inspection
Assembly
Installation
Special Tools

Fuel Pump
General Description
Maintenance and Adjustments – Trouble Diagnosis and Testing
Inspection and Test
Service Operations
Removal
Disassembly
Cleaning and Inspection
Assembly
Installation
Troubles and Remedies

Air Cleaner
Inspections and Cleaning

Fuel Tank
General Description
Service Operations
Fuel Lines
Gauge Unit or Fuel Strainer
Replacement
Fuel Tank
Removal and Installation
Filler Neck Replacement

Exhaust System

Body
Four Door Models/Two Door Models
General Information
Body Name Plate
Body Lubrication
Body Wiring
Body Shell
General Body Construction
Underbody
General Service Information
Underbody Alignment Checking Procedure
Repairs
Rear Suspension Crossmember Attaching Bolt
Locations
Outer Mounting Weld Nuts
Inner Mounting Tapped Plates
Front Suspension Crossmember Cage Nuts
Front Fender Outer Panel
Front End Panel Assembly
Front End
Front Compartment
Lid
Lid Torque Rods
Lid Lock Cylinder Assembly
Lid Lock Assembly
Lid Lock Striker
Gas Tank Filler Door Assembly
Body Ventilating System
Cowl Top Ventilator Grille
Cowl Trim Pad
Cowl Side Duct Air Outlet
Cowl Side Duct Air Outlet Door
Windshield Wiper Components
Windshield Wiper Link and Transmission
Assembly
Windshield Wiper Motor
Windshield Assembly
Rear View Mirror Support
Windshield Garnish Mouldings
Sunshade Support Assembly
Windshield Pillar Drip Moulding
Windshield Glass
Windshield Reveal Mouldings
Instrument Panel Components
Instrument Panel Compartment Door
Instrument Panel Compartment Door Knob
Instrument Panel Compartment Door Hinge Stop
Instrument Panel Finishing Moulding
Doors
Front and Rear Doors
Inside Handles
Trim Assembly
Lock Striker
Water Deflector
Bottom Drain Hole Sealing Strip
Weatherstrip Assembly
Pinchweld Finishing Strip
Front Doors
Front Door Assembly and Hinges
Ventilator Assembly
Window Assembly
Window Glass Run Channel
Window Regulator Assembly
Lock Spring Clips
Lock Cylinder Assembly
Lock Remote Control Assembly
Lock and Remote Control Connecting Link
Outside Handle
Outside Handle Push Button
Rear Doors
Rear Door Assembly and Hinges
Window Assembly
Window Vertical Guide Roller Assembly
Window Vertical Guide Assembly
Window Glass Run Channel
Window Regulator
Lock Remote Control Assembly
Lock Assembly
Outside Handle
Outside Handle Push Button
Headlining
Seats and Seat Compartment Trim
Front Seat
Front Seat Assembly
Seat Adjusters
Seat Back
Seat Side Protector Cover
Repositioning Front Seat Assembly
Rearward Adjustment of Seat
Seat Height Adjustment
Seat Tilt
Stationary Rear Seat
Cushion
Seat Back
Seat Back Support
Station Sedan Folding Rear Seat
Seat Back Catch Plate
Seat Back Finishing Mouldings
Rear Floor Filler Panel and Hinge
Seat Back Panel Locking Pin
Seat Back Mounting Support Link
Seat Back Assembly
Rear Seat Compartment Trim
Side Trim Replacement
Rear Trim and Insulation Replacement
Front Trim and Insulation Replacement
(with Folding Seats)
Division Panel Trim and Insulation Replacement
Wheelhouse Trim Replacement
Rear End
Back Window Assembly
Engine Compartment
Lid
Lid Hinge
Lid Support
Lid Latch
Lower Gutter Sealing Strip
Exterior Mouldings – 700 Models
Front Compartment Lid Outer Panel Moulding
Front Fender Lower Outer Panel Moulding
Front Door Lower Outer Panel Moulding
Rear Door Lower Outer Panel Moulding
Rear Fender Lower Outer Panel Moulding
Engine Compartment Lid Outer Panel Moulding
Front Roof Drip Scalp Moulding
Rear Roof Drip Scalp Moulding
Bumpers
Front Bumper
Rear Bumper
Special Tools

Heater
General Description
Heating System Components
Cycle of Operation
Service Diagnosis
Introduction
Diagnosis Guide
Wiring
Ventilator Blower
Combustion Blower
Thermostat
Breaker Points
Ignition Coil
Spark Plug
Overheat Switch
Purge Switch
Heater Control Switch
Fuel Supply
Inspection of Burner
Checking the Nozzle and Fuel Solenoid
Solenoid Coil Check
Valve Check
Nozzle and Spray Pattern Check
Exhaust Tube
Heat Exchanger
Relay
Service Operations
Ventilator Blower Motor Replacement
Combustion Blower Motor Replacement
Thermostat Replacement
Heater Control Switch Replacement
Ignition Unit Base Assembly (Breaker
Points) Replacement
Ignition Coil Replacement
Overheat Switch Replacement
Purge Switch Replacement
Relay Replacement
Burner Assembly
Removal
Disassembly
Assembly
Installation
Spark Plug Replacement
Nozzle Replacement
Solenoid Coil Replacement
Heat Exchanger Replacement
Heater Unit (Complete)
Removal and Installation
Air Distributor Case Replacement
Controls
Control Knob and Cable Replacement
Control Assembly Replacement
Control Adjustments
Specifications
Special Tools

Specifications

Index of Topics