1969 Fisher Body Service Manual

GENERAL INFORMATION 1-1 SECTION 1 GENERAL INFORMATION INDEX Subject Page Manual Description 1-1 Introduction 1-1 Index 1-1 Page and Figure Numbers 1-1 Reference Tabs 1-1 Text 1-1 Illustrations 1-1 Model Identification Chart 1-2 Model Identification 1-3 Introduction 1-3 Body Series Number 1-3 Body Style Identification 1-3 Body Style Name 1-3 Body Number Plate 1-4 Vehicle Identification Number 1-4 Lock Cylinder Coding 1-5 Five Bitting Level Lock Cylinder and Key .... 1-5 Cutting Keys 1-6 Replacement Lock Cylinders 1-6 Assembly and Coding Lock Cylinders 1-6 Assembly and Coding Glove and Console Compartment Lock Cylinders 1-7 Glass Polishing 1-8 Description 1-8 Glass Polishing Procedure 1-8 Wood Grain Transfer 1-9 Description 1-9 Subject Page Removal 1-10 Installation 1-10 Paint Conditions 1-11 Introduction 1-11 Blistering 1-11 Blushing 1-11 Bull's-Eye 1-11 Line-Checking 1-12 Chemical Discoloration 1-12 Crazing 1-12 Dirt in Paint 1-13 Dry Spray 1-13 Etching 1-13 Fish-Eyes 1-13 Mottling 1-14 Off-Color 1-14 Excessive Orange Peel 1-14 Overspray 1-14 Pin-Holing 1-15 Rust Spots 1-15 Sand or File Marks 1-15 Sand Scratch Swelling 1-16 Sweat Out or Bloom 1-16 Thin Paint 1-16 Water Spotting 1-16 Wheel Burn 1-16 Special Body Service Tools 1-16 MANUAL DESCRIPTION INTRODUCTION This publication contains the essential removal, installation, adjustment and maintenance procedures for servicing all 1969 Fisher Body Styles. This information is current as of time of publication approval. INDEX The preceding page contains a "Table of Contents" which lists the section number and subject title of each main body area section. The first page in each main body area section has an index to the subjects included in that section. An alphabetic index covering the entire manual is located in section 18. PAGE AND FIGURE NUMBERS All page numbers and figure numbers consist of two sets of digits separated by a dash. The digits preceding the dash identify the main body area section. The digits following the dash represent the consecutive page number or figure number within the particular body area section. REFERENCE TABS The first page of each section is marked with a ready-reference black tab corresponding with the table of contents page. TEXT Unless otherwise specified, each service procedure covers all body styles. Procedures covering speci- fic styles are identified by the style number, body series number, body type letter or similar designa- tion. A description of these designations is covered in this section under ''Model Identification". ILLUSTRATIONS Where possible, illustrations are placed in close proximity to the accompanying text and should be used as part of the text.

1-2 GENERAL INFORMATION MODEL IDENTIFICATION CHART Division Chevrolet Pontiac Oldsmobile Buick Sales Name Chevelle Nomad Chevelle "300" Deluxe Chevelle Malibu Chevelle - Concours Estate Biscayne Bel Air Impala Caprice Camaro Chevy Nova Corvair "500" Corvair Monza Tempest Tempest Custom Tempest LeMans Tempest Safari Tempest GTO Catalina Executive Bonneville Firebird Grand Prix F-85 Cutlass Cutlass Supreme 442 Custom Vista-Cruiser Delta 88 Delta Custom 88 Delta Royale 88 Ninety Eight Ninety Eight Luxury Toronado Toronado Deluxe Special Deluxe Special Deluxe Skylark Skylark Custom Sport Wagon GS 400 LeSabre LeSabre Custom Wildcat Wildcat Custom Electra "225" Electra "225" Custom Riviera Body Type A A A A B B B B F X Z z A A A A A B B B F G A A A A A B B B C C E E • A A A A A A B B B B C C E Series 13200 13400 13600 13800 15400 15600 16400 16600 12400 11400 10100 10500 23300 23500 23700 23900 24200 25200 25600 26200 22300 27600 33200 33600 34200 34400 34800 35400 36400 36600 38400 38600 39400 39600 43300 43400 43500 44400 44400 44600 45200 45400 46400 46600 48200 48400 49400 Styles 35-36 27-35-36-37-45-46-69-80 35-36-37-39-45-46-67-69-80 35-36-45-46 11-36-69 11-36-46-69 36-37-39-46-47-67-69 36-39-46-47- 37-67 27-69 37 37-67 27-69 27-35-36-37-39-67-69 27-37-39-67 36 37-67 36-37-39-46-67-69 37-39-36-46-69 37-39-46-67-69 37-67 . 57 77 . 35-36-39-67-69-77-87 39-69-87 67-77-87 55-56-65-66 37-39-67-69 37-39-69 47 39-57-67-69 39-69 87 87 27-69 35-36-37 37-69 37-39-67-69 56-66 37-67 37-39-69 37-39-67-69 37-39-69 37-39-67 39-57-69 39-57-67-69 87

GENERAL INFORMATION 1-3 MODEL IDENTIFICATION CHART (Cont'd.) Division Cadillac - GM of Canada Acadian and Beaumont GM of Canada Pontiac Sales Name Fleetwood Sixty Special Fleetwood Brougham Sedan Calais DeVille Fleetwood Seventy-Five Eldorado Acadian Beaumont Deluxe Custom Strato Chief Laurentian Parisienne 2+2 Grande Parisienne Body Type C C C C D E X A A A B B B B B Series 68000 68100 68200 68300 69700 69300 71400 73200 73400 73600 75400 75600 76400 76800 76600 Styles 69 69 47-49 47-49-67-69 23-33 47 27-69 35-36 27-37-69 35-36-37-39-67-69 36-37-69 36-37-46-69 36-37-39-46-67-69 37-67 36-37-39-46 INTRODUCTION MODEL IDENTIFICATION 33 4-Door Due to the variety of body styles available, certain body styles have been grouped in this publication as an aid to identification. These group designations may be used individually or in various combinations. In addition to the model identification chart, an explanation of the principal categories follows: BODY SERIES NUMBER The body series number may be used to indicate three possibilities: Division - first digit and four zeros (ex. 10000 Chevrolet; 20000 Pontiac). Division and Car Line - first two digits and three zeros (ex. 33000 Oldsmobile F-85; 45000 Buick LeSabre). Division, Car Line and Style Group - First three digits and two zeros (ex. 25200 Catalina; 25600 Executive). BODY STYLE IDENTIFICATION The last two digits of the body series number indicate body style type as follows: STYLE DESCRIPTION 11 2-Door - Notch Back - Pillar Sedan 23 4-Door - Limousine with 1 Auxiliary Seat 27 2-Door - Notch Back - Pillar Coupe - Limousine with Auxiliary Seat and Center Partition Window - Station - 2 Seat - Single Acting Tailgate - Station Wagon - 2 Seat - Dual Acting Tailgate - Notch Back - Hardtop Coupe - Notch Back - Hardtop (4 Win- dow) Sedan - Station Wagon - 3 Seat - Single Acting Tailgate - Station Wagon - 3 Seat - Dual Acting Tailgate - Notch Back - Hardtop Coupe - Notch Back - Hardtop (4 Win- dow) Sedan - Station Wagon - 2 Seat - Single Acting Tailgate - Station Wagon - 2 Seat - Dual Acting Tailgate - Notch Back - Hardtop Coupe - Station Wagon - 3 Seat - Single Acting Tailgate - Station Wagon - 3 Seat - Dual Acting Tailgate - Convertible Coupe - Notch Back - Pillar (4 Win- dow) Sedan - Plain Back Pillar Coupe - Plain Back - Hardtop Coupe - Pick-Up Delivery BODY STYLE NAME Body style names are used for group classification 35 36 37 39 45 46 47 49 55 56 57 65 66 67 69 77 87 80 4-Door 4-Door 2-Door 4-Door 4-Door 4-Door 2-Door 4-Door 4-Door 4-Door 2-Door 4-Door 4-Door 2-Door 4-Door 2-Door 2-Door 2-Door

1-4 GENERAL INFORMATION as follows (style numbers suffix shown in brackets): Closed Style Two-door sedan (11) Two-door coupe (27,77) Four-door sedan (69) Limousine (23,33) Hardtop Sport coupe hardtop (37, 47, 57, 87) Sedan hardtop (39, 49) Station Wagon Station wagon two seat (35-36, less skylight; 55-56 with skylight) Station wagon three seat (45-46 less skylight; 65-66 with skylight) Convertible Coupe (67) Sedan Delivery (80) BODY NUMBER PLATE The body number plate identifies the model year, car division, series, style, body assembly plant, body number, trim combination, paint code and date build code (Figs. 1-1 and 1-2). On Corvair styles the body number plate is attached to the left side of the motor compartment cross rail. On Cadillac "C & D" styles, the plate is located on the left upper portion of the horizontal surface of the shroud. On all other cars, the plate is located on the left upper portion of the vertical surface of the shroud. DIVISION SERIES-i MODEL YEAR ST TR i -BODY STYLE UNIT NUMBEI ASSEMBLY PLANT BOC|Y BY | FISHER I 32"2T T l T ,0000, •000, TIME BUILT CODE-J TRIM COMBINATION NUMBER 123456' BDY J2, £$ PNJ THAT GENEPAL MOTORS CORPORATION CERTIFIES TO THE DEALER VEHC LE OONFORMSTOALL US MOTOR VEHICLE SAFETY STWDAttDS APPLI<|;ABI|£ AT TIME OF M M UFACTURE LOWER BODY COLOR HIS FEDERAL UPPER BODY -COLOR OR FABRIC COLOR 3305 MODEL MIIMB . D YEAR NUMBER TRIM COMBINATION NUMBER THIS VEHICLE CONFORMS TO ALL U.S. FEDERAL MOTOR VEHICLE SAFETY STANDARDS APPLICABLE AT TIME OF MANUFACTURE 3271 Fig. 1-1-Body Number Plate - U.S. Models Fig. 1-2—Body Number Plate - Canadian Models VEHICLE IDENTIFICATION NUMBER The Vehicle Identification Number (serial number) is located on the left horizontal surface of the instrument panel which is visible from outside the car. Figure 1-3 shows a typical installation. Fig. 1-3—Typical Vehicle Identification Number

GENERAL INFORMATION 1-5 LOCK CYLINDER CODING FIVE BITTING LEVEL LOCK CYLINDER AND KEY All 1969 style cars are equipped with new lock cylinders and keys. The keyway has been revised so that prior model keys will not enter current model lock cylinders. Two non-interchangeable keyways are used on 1969 model cars. One keyway, known as type "E", is used in all ignition, front door and station wagon tail gate lock cylinders. Type " E " keys will have a square head and be marked similar to keys used for 1968 styles, except that a capital letter "E" will be located on the shank just below the coining on the head, in place of capital letter "C". In addition, a code number within the series 0J00 to 9J99, or 0K00 to 9K99 will be stamped on the knock-out portion on the keyhead. This number identifies the lock combination and is used when ordering or making new keys. The second keyway, known as type "H", is used in the instrument panel compartment, console compartment, rear compartment, front compartment and station wagon rear floor compartment lock cylinders. Type "H" keys will have oval heads and will be similar to keys used for 1968 styles, except that a capital letter "H" will be stamped on the shank just below the coining on the head, in place of capital letter "D'\ In addition, a code number within the series 0L00 to 9L99, or 0M00 to 9M99 will be stamped on the knock-out portion of the key head. This number identifies the lock combination and is used when ordering or making new keys. Key code numbers are stamped on the "knockout" plug in the key head and on the lock cylinder hous- ing (to facilitate replacement or duplication of key). After the code number has been recorded by the owner, the plugs should be knocked out of the key head. From these numbers, the lock combination can be determined by use of a code list (available to owners of key cutting equipment from equipment suppliers). If key code numbers are not available from records or from the "knock-out" plug, lock combination (tumbler numbers and position arrangement) can be determined by laying the key on the diagram in Figure 1-4. >4ARK OF EXCELLENCE 1 2 3 4 5 POSITION LEVELS Fig. 1-4—Key Code Diagram

1-6 GENERAL INFORMATION CUTTING KEYS After the special code has been determined, either from the code list or the Key Code Diagram (Fig- ure 1-4) cut a blank key to the proper level for each of the six tumbler positions, and check the key in the lock cylinder. The new key should agree with the combination opposite the code number in the code list. REPLACEMENT LOCK CYLINDERS New lock cylinders are available from the servicing Parts Warehouse with the new lock cylinder locking bar staked in place. Tumblers are also available and must be assembled into the cylinder according to the procedure outlined below. ASSEMBLY AND CODING LOCK CYLINDERS- ALL LOCK CYLINDERS EXCEPT GLOVE AND CONSOLE COMPARTMENTS Tumblers for all locks except the glove and console compartments are shaped exactly alike, with the exception of the position of a notch on one side. As the key is inserted in the lock cylinder, the tumblers are raised to the correct height so that the notches on each tumbler are on the same level. When the notches on all six tumblers line up, the locking bar is pushed into the notches by two small springs, allowing the cylinder to turn in its bore. Five types of tumblers are used to make all the various lock tumbler combinations and each is coded according to a number, 1 through 5,- stamped on its side. 1. Determine lock cylinder tumbler numbers and tumbler arrangement by use of a numerical key code lock cylinder code list. Code lists are made available to owners of key cutting equipment by equipment suppliers. NOTE: To determine which tumblers should be installed in what position for a given key, when a code list is not available, proceed as follows: a. Lay the key on the Key Code Diagram (Fig- ure 1-4) with the key outlined by the diagram as accurately as possible. b. Starting at the head of the key blade, determine and record the lowest level (tumbler number) that is visible in position #1 and subsequent position numbers 2 through 6. After tumbler numbers and arrangement have been determined, assemble as follows: 2. Starting at the open end (head) of the cylinder, insert the tumblers in their proper slots in the order called for by the code, as shown in Figure 1-5. LOCK CYLINDER HEAD LOCK YLINDER 2754 Fig. 1 -5-—Installing Tumblers 3. Pull out side bar with fingers so that tumblers will drop completely into place (Fig. 1-5). Insert one tumbler spring in the space pro- vided above each tumbler. NOTE: If the springs become tangled, do not pull them apart - unscrew them. 4. Insert the spring retainer so that the two end prongs slide into the slots at either end of the cylinder. Press the retainer down. (See Figure 1-6). TUMBLER SPRING RETAINER STAKE ETAINER HERE LOCK CYLINDER HEAD 2755 Fig. 1-6—Installing Spring Retainer 5. To determine if tumblers have been properly installed, insert key into lock cylinder. If tumblers are installed properly the side bar will drop down. If bar does not drop down,

GENERAL INFORMATION 1-7 remove the key, spring retainer, springs and tumblers and reassemble correctly. NOTE: If the tumblers have not been assembled correctly, they can be removed from the cylinder by holding cylinder with the tumbler slots down, pulling the side bar out with the fingers and jarring the cylinder to shake the tumblers out. This procedure is necessary because once the tumblers have been pressed down into the cylinder they are held in their slots by the side bar. 6. If, after checking, it is found that the lock cylinder is assembled properly, remove key and secure cylinder in a vise with spring retainer exposed. NOTE: Use leather or wood at each vise jaw to prevent damage to the cylinder. 7. Using a suitable staking tool, stake the spring retainer securely in place by staking the cylinder metal over the retainer at each end. Refer to Figure 1-6. ASSEMBLING AND CODING GLOVE AND CONSOLE COMPARTMENT LOCK CYLINDERS Only one type of tumbler is used to make the various lock tumbler combinations for glove and console compartment locks. Tumblers for these two lock cylinders are pre-assembled in the service replacement lock cylinder and require that a correctly coded key be inserted in the cylinder before and during cylinder coding. As the key is inserted in the coded lock cylinder, each tumbler is depressed so that no part of any tumbler is exposed above the level of the lock cylinder thereby allowing the cylinder to turn in its bore. NOTE: These two lock assemblies are equipped with four or five tumblers rather than six as used in other locks. Tumblers are used in positions 3-4-5-6 or 2-3-4-5-6 only. Tumblers which correspond to positions 1 and/or 2 on the key are not used. The non-brass, black "tumbler" that is closest to the head of the four tumbler lock cylinder is a locking device and must NOT be removed or filed. See Figure 1-7. TUMBLER TUMBLER 4 TUMBLER CYLINDER 5 TUMBLER CYLINDER LOCK CYLINDER RETAINER ( LOCKING DEVICE ) 2756 Fig. 1-7—Glove Compartment Lock Cylinder 1. Insert properly coded key in cylinder. 2. Place cylinder in a vise, bottom side up, using leather or wood at each vise jaw to prevent damage to the cylinder. 3. File tumblers down so that no part of any tumbler extends above the lock cylinder. NOTE: Do not file any part of the non-brass, black "tumbler" (retainer) on four tumbler lock cylinders. This is a locking bar and should not be altered. 4. Reverse lock cylinder position in vise and re- peat step #3 for top of tumblers. See Figure 1-8. LOCK CYLINDER RETAINER 4 TUMBLER CYLINDER NOTE: TUMBLERS FILED FLUSH WITH LOCK CYLINDER 2757 Fig. 1-8—Coded Glove Compartment Cylinder

1-8 GENERAL INFORMATION GLASS POLISHING REMOVAL OF MINOR SCRATCHES AND ABRASIONS- Description Minor glass scratches and abrasions can be effec- tively removed or substantially reduced by utiliz- ing the procedure and precautions presented in this section. The phases of glass polishing discussed in this section include the equipment required, the recommended procedure and the precautions necessary. There are two. basic types of automotive glass: (1) laminated safety plate (all windshield and skylight glass) and (2) solid tempered safety plate (all side windows and back glass, except skylight). A major concern in glass polishing is preventing double vision from developing in areas that will distort driver's vision. Eor this reason, less polishing can be done on the windshield in the driver's line of vision than in other areas. Dis- • tortion is most likely to result when attempting to remove deep scratches. Glass polishing is an operation that must be per- formed with reasonable care. The equipment and procedures recommended here were developed using cerium oxide compound (Glass-Nu or equivalent). Follow the manufactur- er's directions if other materials are used. The following equipment is recommended for glass polishing: 1. A low speed (600-1300 RPM) rotary polisher (Skil Model #570 or equivalent). 2. A wool felt rotary-type polishing pad, approxi- mately three inches in diameter and two inches thick. 3. Powdered cerium oxide (Glass-Nu or equivalent) mixed with water as the abrasive compound. 4. A wide mouth container to hold, the polish. Glass Polishing Procedure 1. Mix at least three heaping tablespoons of cerium oxide (Glass-Nu or equivalent) with sufficient water to obtain a creamy consistency. NOTE: If a larger proportion of cerium oxide (Glass-Nu or equivalent) is used, the compound cakes on the felt pad faster. If a small proportion is used the polishing time required will increase. 2. Agitate the mixture occasionally to maintain a creamy consistency. The powdered cerium oxide is insoluable in water and tends to separate. 3. Draw a circle around the scratches on the inside of the windshield with- a marking crayon or equivalent. Draw other lines directly behind scratches to serve as guides in locating the scratch during polishing (Fig. 1-9). HOLD PAD FLAT AGAINST GLASS Fig. 1-9—Minor Glass Scratch Removal 4. Use masking paper where needed to catch drippings or spattered polish. 5. Dip the felt pad attached to the polisher into the mixture several times to insure that the pad is well saturated. NOTE: Never submerge or allow the pad to stay in the mixture as it may loosen the bond between the pad and the metal plate. 6. Using moderate, but steady, pressure, hold the pad flat against the scratched area of the glass, and with a feathering-out motion, polish the affected area as shown in Figure 1-9. NOTE: Avoid excessive pressure which does not speed-up the operation and may cause overheating of the glass.

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1969 Fisher Body Service Manual

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