1967 CHEVROLET CAMARO charging

[x] Cancel search: charging

battery battery capacity wheelbase power steering fluid driver seat adjustment clock

Load previous 8 pages

Page 67 of 659

CHEVROLET CAMARO 1967 1.G Chassis Workshop Manual
HEATER AND AIR CONDITIONING 1A-44

UNIVERSAL SYSTEM

EVACUATION CONNECTION

GAGE VALVE WITH

SCHRADER VALVE

& ADAPTER

(Attach
to
gage line

before attaching to

fitting).

HIGH PRESSURE

GAGE VAL

Page 68 of 659

CHEVROLET CAMARO 1967 1.G Chassis Workshop Manual
HEATER AND AIR CONDITIONING 1A-45

• A very badly leaking compressor seal.

• Collision damage to the system components.

As a quick check on compressor oil charge, with the

engine off, carefull

HEATER AND AIR CONDITIONING 1A-45

• A very badly leaking compressor seal.

• Collision damage to the system components.

As a quick check on compressor oil charge, with the

engine off, carefully crack open the oil drain plug on the

bottom of the compressor. If oil comes out, the com-

pressor has the required amount of oil To further check

the compressor oil charge, should the above test show

insufficient oil, it is necessary to remove the compressor

from the vehicle, drain and measure the oil.

Checking Compressor Oil Charge

1.
Run the system for 10 minutes at 500-600 engine

rpm with controls set for maximum cooling and

high blower speed.

2.
Turn off engine, discharge the system, remove

compressor from vehicle, place it in a horizontal

position with the drain plug downward. Remove the

drain plug and, tipping the compressor back and

forth and rotating the compressor shaft, drain the

oil into a clean container, measure and discard the

oiL

3.
a. If the quantity drained was 4 fluid oz. or more,

add the same amount of new refrigerant oil to

the replacement compressor.

b.
If the quantity drained was less than 4 fluid oz.,

add 6 fluid oz. of new refrigeration oil to the

replacement compressor.

c. If a new service compressor is being installed,

drain all oil from it and replace only the amount

specified in Steps 3a and 3b above.

d. If a field repaired compressor is being installed,

add an additional 1 fluid oz. to the compressor.

4.
In the event that it is not possible to idle the com-

pressor as outlined in Step 1 to effect oil return to

it, proceed as follows:

a. Remove the compressor, drain, measure and

discard the oil.

b.
If the amount drained is more than 1-1/2 fluid

oz.
and the system shows no signs of a major

leak, add the same amount to the replacement

compressor.

c. If the amount drained is less than 1-1/2 fluid oz.

and the system appears to have lost an excessive

amount of oil add 6 fluid oz. of clean refrigeration

oil to replacement compressor, 7 fluid oz. to a

repaired compressor.

If the oil contains chips or other foreign ma-

terial, replace the receiver-dehydrator and flush
or replace all component parts as necessary. Add

the full specified volume of new refrigeration oil

to the system.

5.
Add additional oil in the following amounts for any

system components being replaced.

Evaporator 3 fluid oz.

Condenser . . . . ... . . . . . . 1 fluid oz.

Receiver-Dehydrator ....... 1 fluid oz.

NOTE: When adding oil to the compressor, it

will be necessary to tilt the rear end of the

compressor up so that the oil will not run out

of the suction and discharge ports. Do not set

the compressor on the shaft end.

Adding Oil to the System

The system should be completely assembled and un-

charged before adding oil. Use only uncontaminated

refrigerant oil (525 viscosity) and add as follows:

1.
Connect the low pressure line from the gauge set

to the low pressure gauge fitting on the P.O.A.

valve (Four-Season) or low pressure fitting on the

compressor connector Mock (Universal System).

2.
Connect the high pressure line from the charging

station gauge set to the compressor muffler or high

pressure side of the connector block.

3.
Disconnect the high pressure line from the gauge set,

make certain that the line is clean, and place the

end in a graduated container.

4.
Pour enough refrigerant oil into the container so

that the required volume may be drawn into the

system by the high pressure hose.

5.
Close the high pressure valve at the gauge set,

and open the low pressure valve.

6. Operate the vacuum pump to drop the pressure within

the system and cause atmospheric pressure to force

oil through the high pressure line into the system.

When the oil level has dropped the required volume,

pull the line out of the oil container and continue

vacuum pump operation to force the oil contained

in the line into the system.

7.
Shut off the vacuum pump and connect ttye high

pressure line to the gauge set. Open the high

pressure valve and evacuate the system through

the high and low pressure sides of the system.

Complete the charging operation as outlined in Step

10 under "Evacuating and Charging System".

COMPONENT REPLACEMENT AND MINOR REPAIRS

REFRIGERANT LINE CONNECTIONS

"O"
Rings

Always replace the "O" ring when a connection has

been opened. When replacing the "O" ring, first dip it

in refrigeration oil. Always use a backing wrench on

"O"
ring fittings to prevent the pipe from twisting and

damaging the "O" ring. Do not overtighten. Correct

torque specifications are as follows:
Metal

Tube

O.D.

1/4

3/8

1/2

5/8

3/4
Thread and

Fitting

Size

7/16

5/8

3/4

7/8

1-1/16
Steel

Tubing

Torque*

13

33

33

33

33
Alum.

Tubing

Torque*

6

12

12

20

25

* Pound Feet

CHEVROLET CHASSIS SERVICE

Page 69 of 659

CHEVROLET CAMARO 1967 1.G Chassis Workshop Manual
HEATER AND AIR CONDITIONING 1A-46

MAKE ANGULAR CUT

FOR HOSE REMOVAL

LOCATING

BEAD

SEALING

BEADS
LOCATING

BEAD
not to nick or score the sealing beads when

cutting off the hose. Cutting the h

HEATER AND AIR CONDITIONING 1A-46

MAKE ANGULAR CUT

FOR HOSE REMOVAL

LOCATING

BEAD

SEALING

BEADS
LOCATING

BEAD
not to nick or score the sealing beads when

cutting off the hose. Cutting the hose lengthwise

may result in this problem.

Fig.
58—Hose Clamp Connections

NOTE:
Where steel to aluminum connections

are being made, use torque for aluminum tubing.

Hose Clamps (Fig. 58)

When hose clamp connections are encountered special

procedures are necessary for both installation and

removal.

Installation

1.
Coat tube and hose with refrigeration oil.

2.
Carefully insert hose over the three beads on the

fitting and down as far as the fourth, or locating,

bead. Hose must butt against this fourth bead.

CAUTION: Use no sealer of any kind.

3.
Install clamps on hose, hooking the locating arms

over the cut end of the hose.

4.
Tighten the hose clamp screw to 35-42 lb. in.

(except Corvette) 30-38 lb. in. (Corvette). DO NOT

RETORQUE.

Removal

1.
Carefully, with a sharp knife, make an angle cut in

the hose as shown in Figure 58. This should loosen

the hose so that it may be worked off the fitting.

2.
Cut off slit end of hose when reinstalling. Reinstall

as described above.

CAUTION: Use only approved refrigeration

hose. Never use heater hose. Use extreme care
REPAIR OF REFRIGERANT LEAKS

Any refrigerant leaks found in the system should be

repaired in the manner given below:

Leaks at "O" Ring Connection

1.
Check the torque on the fitting and, if too loose,

tighten to the proper torque. Always use a backing

wrench to prevent twisting and damage to the "O"

ring. Do not overtighten. Again leak test the joint.

2.
If the leak is still present, discharge the refrigerant

from the system as described under "Evacuating

and Charging Procedures."

3.
Inspect the ''O" ring and the fitting and replace if

damaged in any way. Coat the "O". ring before re-

installed with refrigerati6n oil and install carefully.

4.
Retorque the fitting, using a backing wrench, and

then add 1/2 to 1 lb. of R-12 to the system and

recheck for leaks.

CAUTION: Do not operate the system with this

small refrigerant charge.

5. Purge the system, thus removing the 1/2 to 1 lb.

installed in Step 4 above.

6. Evacuate and charge the system.

Leaks at Hose Clamp Connection

1.
Check the tightness of the clamp itself and tighten

if necessary. Recheck for leak.

2.
If leak has not been corrected discharge the system

and loosen clamp and remove hose from connection.

Inspect condition of hose and connector. Replace

scored or damaged parts.

3.
Dip end of new hose in refrigerant oil and carefully

reinstall over connector. Never push end of hose

beyond the locating bead. Properly torque the clamp.

4.
Recheck the system for leaks by installing 1/2 to 1

lb.
of R-12 into the system. Do not run compressor.

5. Purge. the system, thus removing the 1/2 to 1 lb.

installed in Step 4 above.

6. Evacuate and charge the system.

Compressor Leaks

If leaks are located around the compressor shaft seal

or shell, replacement of necessary seals should be made

as outlined under "Compressor" in the Chassis Overhaul

Shop Manual.

REFRIGERANT HOSE FAILURE

After a leak or rupture has occurred in a refrigerant

hose, or if a fitting has loosened and caused a consider-

able loss of refrigerant and oil, the entire system should

be flushed and recharged after repairs have been made.

Ji the system has been open to atmosphere for any pro-

longed period of time the receiver-dehydrator should be

replaced.

PREPARING SYSTEM FOR REPLACEMENT

OF COMPONENT PARTS

Air conditioning, like many other things, is farily

simple to service once it is understood. However, there

CHEVROLET CHASSIS SERVICE MANUAL

Page 76 of 659

CHEVROLET CAMARO 1967 1.G Chassis Workshop Manual
HEATER AND AIR CONDITIONING 1A-53

Fig.
70—Wiring and Vacuum Lines—Four-Season (Camaro)

Installation

1.
Connect the expansion valve to the refrigerant pipes.

Attach the capillary bulb to the

HEATER AND AIR CONDITIONING 1A-53

Fig.
70—Wiring and Vacuum Lines—Four-Season (Camaro)

Installation

1.
Connect the expansion valve to the refrigerant pipes.

Attach the capillary bulb to the evaporator.

2.
Attach the evaporator to the- case. Attach the inlet

and outlet pipes clamps.

3.
Assemble the case halves. Insert the capillary tube

from the thermostatic switch between the fins as

shown in Figure . Attach the cover plate to the

case.

4.
Mount the unit to the dash and connect the refrigerant

lines.

5.
Evacuate and charge the system. If a new evaporator

was installed, add three fluid ounces of refrigerant

oil to the system before charging.

6. Test system operation.

Chevy II All-Weather System

Removal

Under
the Hood

1.
Purge the refrigerant from the system.

2.
Remove the refrigerant hoses from the evaporator

inlet and outlet connections extending through the

special grommet in the dash panel and into the

engine compartment.

3.
Remove the screw, nut, spacer bracket and grommet

from the outlet connection pipes.
Within the Car

4.
Remove the glove box, ash tray and ash tray

retainer.

5.
Reach through the glove box door to disconnect the

air conditioning "on" door bowden cable (fig. 75).

6. Remove the two shield attaching screws and shield

(A, fig. 76) which covers the lower right evaporator

bracket-to-blower bracket attaching screw (B, fig.

76),
then remove this screw.

7.
Behind the lower left side of ihe evaporator, remove

the evaporator bracket-to-heater distributor bracket

attaching screw (C, fig. 76).

8. Reaching through the glove box door and ash tray

openings, remove the two nuts and washers (D,

fig.
76) attaching the evaporator assembly studs to

the lower instrument panel flange and reinforcement.

9. Disconnect the drain hoses and carefully pull the

evaporator unit toward the rear of the vehicle.

10.
Disconnect wiring connectors (see fig. 77) as nec-

essary and remove the evaporator unit from the

vehicle.

Gore and/or Expansion Valve Replacement

A defective unit must be replaced since repairs should

never be made on the evaporator core. Before replacing

the core, however, check to be sure that any leaks pres-

sent are not located at the hose connections or expansion

valve connections. The following procedure assumes that

the evaporator unit has been removed from the vehicle

as outlined above.

CHEVROLET CHASSIS SERVICE MANUAL

Page 107 of 659

CHEVROLET CAMARO 1967 1.G Chassis Workshop Manual
HEATER
AND AIR
CONDITIONING
1A-84

SPECIAL TOOLS

18
19 20 21 23 24
28
30

32

Fig.
120—Air Conditioning—Special Tools

1.

1A.

IB.

2.

3.

4.

5.

6.

7.
00*

9.

10.

11.

12.

13.

14

Page 270 of 659

CHEVROLET CAMARO 1967 1.G Chassis Workshop Manual
ENGINE
6-5

Service Battery and Battery Cables

1.
Measure the specific gravity of the electrolyte in

each cell (fig. 6). If it is below 1.230 (corrected to

80°F.) recharge with a slow rate char

ENGINE
6-5

Service Battery and Battery Cables

1.
Measure the specific gravity of the electrolyte in

each cell (fig. 6). If it is below 1.230 (corrected to

80°F.) recharge with a slow rate charger, or if de-

sired, further check battery.

2.
Connect a voltmeter across the battery terminals and

measure the terminal voltage of the battery during

cranking (disconnect the coil primary lead at the

negative terminal during this check to prevent engine

from firing). If the terminal voltage is less than 9.0

volts at room temperature, approximately 80°

±
20°
F.,
the battery should be further checked. See

Section 6Y for further tests.

3.
Inspect for signs of corrosion on battery, cables and

surrounding area, loose or broken carriers, cracked

or bulged cases,- dirt and acid, electrolyte leakage

and low electrolyte level. !Fill cells to proper level

with distilled water or water passed through a

"demineralizer".

The top of the battery should be clean and the bat-

tery hold-down bolts properly tightened. Particular

care should be taken to see that the top of the battery

is kept clean of acid film and dirt. When cleaning

batteries, wash first with a dilute ammonia or soda

solution to neutralize any acid present and then flush

off with clean water. Keep vent plugs tight so that

the neutralizing solution does not enter the cell. The

hold-down bolts should be kept tight enough to prevent

the battery from shaking around in its holder, but

they should not be tightened to the point where the

battery case will be placed under a severe strain.

To insure good contact, the battery cables should

be tight on the battery posts. Oil battery terminal

felt washer. If the battery posts or cable terminals
are corroded, the cables should be cleaned separately

with a soda solution and wire brush. After cleaning

and before installing clamps, apply a thin coating of

petrolatum to the posts and cable clamps to help

retard corrosion.

If the battery has remained undercharged, check

for loose or defective fan belt, defective Delcotron,

high resistance in the charging circuit, oxidized

regulator contact points, or a low voltage setting.

If the battery has been using too much water, the

voltage output
is-
too high.

Service Deicotron and Regulator

The Delcotron and regulator tests during tune up con-

sist of the above battery tests; the condition of the battery

indicating further tests and adjustments as outlined in

Section 6Y.

Service Belts (Fig. 7)

Inspect belt condition.

Check and adjust if necessary for correct tension of

belt, as follows:

• Using a strand tension gauge, check the belt tension.

• Adjust belt until the specified tension is reached.

(See Tune Up Chart.)

Service Manifold Heat Valve (Figs. 8 or 9)

Check manifold heat control valve for freedom of oper-

ation. If shaft is sticking, free it up with GM Manifold

Heat Control Solvent or its equivalent.

NOTE: Tap shaft end to end to help free it up.

Tighten Manifold

Tighten intake manifold bolts to specifications in the

FLAME

ARRESTOR
FLAME

ARRESTOR

NON-VENTED\

CAP
V\ VALVE

CLOSED
POSITIVE (283 & 327)

POSITIVE
(IN LINE)

POSITIVE
(327)

POSITIVE
(396 & 427)

Fig.
10 -
Crank case
Ventilation Systems

CHEVROLET CHASSIS SERVICE MANUAL

Page 326 of 659

CHEVROLET CAMARO 1967 1.G Chassis Workshop Manual
SECTION 6Y

ENGINE ELECTRICAL

CONTENTS
OF
THIS SECTION

Page

System

6Y-19
6Y-32

6Y-34

BATTERY

INDEX

Page

General Description 6Y_i

Types of Batteries 6Y-1

Dry Charged Batteries 6Y-2

Acti

SECTION 6Y

ENGINE ELECTRICAL

CONTENTS
OF
THIS SECTION

Page

System

6Y-19
6Y-32

6Y-34

BATTERY

INDEX

Page

General Description 6Y_i

Types of Batteries 6Y-1

Dry Charged Batteries 6Y-2

Activating Dry Charged Batteries 6Y-2

Wet Charged Batteries 6Y 2

Periodic Service 6Y-3

Common Causes of Failure 6Y-3

Delco Eye 6Y_3

Electrolyte Level
AY
3

Water Usage ] \ 6Y_3

Cleaning 6Y_4

Cables 6Y_4

Carrier and Holddown 6Y-4
Page

Safety Precautions 6Y-4

Charging Procedures . . gY_4

Slow Charging gY-4

Fast Charging . * 6Y-4

Emergency Boost Charging 6Y-4

Test Procedures QY-S

Visual Inspection 6Y-5

Instrument 6Y-5

Full Charge Hydrometer Test. 6Y-5

Specific Gravity Readings 6Y-5

Cell Comparison Test . 6Y-5

Installing Battery 6Y-5

GENERAL DESCRIPTION

The battery (fig. lb) is made up of a number of separ-

ate elements, each located in an individual cell in a hard

rubber case. Each element consists of an assembly of

positive plates and negative plates containing dissimilar

active materials and kept apart by separators. Hie ele-

ments are immersed in an electrolyte composed of dilute

sulfuric acid. Plate straps located on the top of each ele-

ment connect all the positive plates and all the negative

plates into groups. The elements are connected in series

electrically by connectors that pass directly through the

case partitions between cells. The battery top is a one-

piece cover of hard rubber construction. Tfte cell con-

nectors, by-passing through the cell partitions, connect

the elements along the shortest practical path (fig. 2b).

With the length of the electrical circuit inside the

Battery reduced to a minimum, the internal voltage drop

is decreased resulting in improved performance, par-

ticularly during engine cranking at low temperatures.

The hard, smooth one-piece cover greatly reduces the

tendency for corrosion to form on the top of the Battery.

The cover is bonded to the case with sealing compound

that forms an air tight seal between the cover and case.

Protection for the Battery charging circuit (10 gage

wire) is provided by a pigtail lead which is a fusible Hnk

off the battery positive cable (14 gage wire). This lead is

an integral part of the Battery cable assembly and serv-

icing requires replacing the complete cable assembly.

TYPES
OF
BATTERIES

There are two types of Batteries—the "dry charge"

type and the "wet charge" type. The difference in types

depends on the method of manufacture.
ONE PIECE

CELL COVER

VENT PLUG
ELECTROLYTE LEVEL

INDICATOR

HOLD-DOWN SLOT

Fig.
lb—Battery

CHEVROLET CHASSIS SERVICE MANUAL

Page 328 of 659

CHEVROLET CAMARO 1967 1.G Chassis Workshop Manual
ENGINE-EIECTRICAI 6Y-3

PERIODIC SERVICING

Since the Battery is a perishable item which requires

periodic servicing, a good maintenance program will

insure the longest possible Battery life.

COMM

ENGINE-EIECTRICAI 6Y-3

PERIODIC SERVICING

Since the Battery is a perishable item which requires

periodic servicing, a good maintenance program will

insure the longest possible Battery life.

COMMON CAUSES OF FAILURE

If the Battery tests good but fails to perform satis-

factorily in service for no apparent reason, the following

are some of the more important factors that may point to

the cause of the trouble.

1.
Vehicle accessories inadvertently left on overnight to

cause a discharged condition.

2.
Slow speed driving of short duration, to cause an

3.
undercharged condition.

A vehicle

capacity.
electrical load exceeding the generator

4.
Defect in the charging system such as high resist-

ance, slipping fan belt, faulty generator or voltage

regulator.

5. Battery abuse, including failure to keep the Battery

top clean, cable clamps and posts clean and tight,

and improper addition of water to the cells.

LEVEL INDICATOR

The Battery features an electrolyte level indicator,

which is a specially designed vent plug with a transparent

rod extending through the center (fig. 5b). When the elec-

trolyte is at the proper level, the lower tip of the rod is

immersed, and the exposed top of the rod will appear

very dark; when the level falls below the tip of the rod,

the top will glow. ,

The Indicator reveals at a glance if water is needed,

without the necessity of removing the vent plugs (fig. 6b).

The Level Indicator is used in only one cell (second

cell cap from positive Battery post) because when the

electrolyte level is low in one cell, it is normally low in

all cells. Thus when the Indicator shows water is needed,

check the level in all six cells.

An alternate method of checking the electrolyte level is

to remove the vent plug and visually observe the electro-

lyte level in the vent well. The bottom of the vent well

features a split vent which will cause the surface of the

electrolyte to appear distorted when it makes contact.

The electrolyte level is. correct when the distortion first

appears at the bottom of the split vent (fig. 4b).

ELECTROLYTE LEVEL

The electrolyte level in the Battery should be checked

regularly. In hot weather, particularly during trip driv-

ing, checking should be more frequent because of more

rapid loss of water. If the electrolyte level is found to be

low, then colorless, odorless, drinking water should be

added to each cell until the liquid level rises to the split

vent located in the bottom of the vent well. DO NOT

OVERFILL because this will cause loss of electrolyte

resulting in poor performance, short life, and excessive

corrosion.

CAUTION: During service only water should be

added to the Battery, not electrolyte.

The liquid level in the cells should never be allowed to

drop below the top of the plates, as the portion of the
INDICATOR

ELECTROLYTE LEVEL

CORRECT

Fig.
5b—Cut-Away View Showing Electrolyte at Proper Level

with Indicator Having Dark Appearance

plates exposed to air may be permanently damaged with a

resulting loss in performance.

WATER USAGE

Excessive usage of water indicates the Battery is being

overcharged. The most common causes of overcharge

are high Battery operating temperatures, too high a volt-

age regulator setting, poor regulator ground wire con-

nection. Normal Battery water usage is approximately

one to two ounces per month per battery.

INDICATOR

Fig.
6b—Cut-Away View Showing Electrolyte at Low Level

with Indicator Having Light Appearance

CHASSIS SBtVKZ MANUAL

Load next 8 pages

Page: < prev 1-8 9-16 17-24 25-32 next >

wiring fog light spare tire dimensions warning lights center console