1967 CHEVROLET CAMARO light

HEATER AND AIR CONDITIONING 1A-50

Fig.
64—Receiver-Dehydrator Mounting (Corvette)

3.

4.

5.

6.
To gain access to the blower motor end of the as-

sembly, remove the fender and skirt.

Remove the assembly to firewall attaching screws.

Remove the entire assembly from the vehicle.

Reverse the above procedure when installing the

assembly into the vehicle.

Core Replacement

1.
Disconnect the connections at the suction throttling

valve inlet and the expansion valve outlet. Remove

the expansion valve bulb from the core outlet line.

Cap all open lines. .

Remove the screws attaching the evaporator cover

to the firewall and to the evaporator assembly and

remove the cover.

Remove the screws attaching the core to the assem-

bly and remove the core.

Reverse the above steps for core replacement.

Add three fluid oz. refrigerant after installing a

new core, evacuate and charge the system.
2.

3.

4.

5.

Comfortron

The evaporator assembly is nearly identical to that
of the Four-Season system, and, with the exception of

additional wiring and vacuum hoses, service procedures

are the same.

Chevelle Four-Season System

Removal

•
1.
Purge the system of refrigerant, then remove the

right fender skirt and the hood hinge. Do not remove

the fender.

2.
Disconnect the high pressure line (between the

receiver-dehydrator and the thermostatic expansion

valve) at the expansion valve, and the suction throt-

tling valve to compressor line at the suction throt-

tling valve. Cap and seal all open lines.

3.
Remove the three screws attaching the duct assembly

to the evaporator housing and the blower assembly.

4.
Remove the bolts attaching the evaporator assembly

to the cowl and carefully pull the assembly from the

vehicle. The duct assembly will be removed at this

time also.

Core Replacement

1.
With the evaporator assembly removed from the

vehicle, remove the expansion valve and its bulb.

2.
Remove the four nuts and bolts holding the two

halves of the evaporator housing together and sepa-

rate the halves.

3.
The evaporator core may now be removed.

4.
Leak test the new core and connections, before in-

stalling the core in the housing, by installing the

expansion valve and all refrigerant lines. Connect an

R-12 cylinder to the low pressure compressor gauge

fitting and charge the system to cylinder pressure,

then leak test.

5. After satisfactorily testing the core, install it into

the housing and reassemble the two sides of the.

housing.

Installation

1.
Remove the right trim pad and the screws attaching

the air conditioning duct to the kick panel. This

should allow the duct to be pulled slightly loose from

the kick panel. If not it may be necessary to loosen

the entire duct to obtain the necessary clearance.

2.
Install the evaporator in the cowl being sure that

the duct assembly is in place between an evaporator

housing and the blower assembly.

3.
Replace all bolts and screws.

4.
Move the interior air conditioning duct until sure

that the duct gasket is properly positioned over the

evaporator housing flange. Proper gasket fit at this

point is of great importance.

5. Replace all refrigerant lines.

6. Evacuate and charge the system. Add three fluid oz.

refrigerant oil after installing a new core.

7. Replace the fender skirt and hood hinge.

Universal System All Vehicles

Core and/or Expansion Valve Replacement

Since repairs should never be made on the evaporator

core, a defective unit must be replaced. Before replacing

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

ent are not located at the hose connections or expansion

valve connections.

CHEVROLET CHASSIS SERVICE MANUAL

HEATER AND AIR CONDITIONING 1A-64

Fig.
90—Evaporator Wiring (Corvette)

AIR INLET VALVE

Four-Season System

Chevrolet

Figure 88 illustrates the vacuum valve which controls

the air inlet operation of the Four-Season System.

A vacuum tank and check valve is used to assure that

the air door will not change its position due to variations

in engine vacuum.

Camqro

Figure 89 illustrates the outside air inlet door assem-

bly, and the door in the kick pad which admits reeir-

culated air to the system.
BLOWER AND EVAPORATOR ASSEMBLY

(Corvette)

Replacement

1.
Remove the evaporator core as outlined under

"Evaporator Core Replacement".

2.
Remove the blower motor as outlined under "Blower

Motor Replacement".

3.
Remove the heater and air conditioning distributor

as outlined under "Air Distributor Duct Removal".

4.
Remove the remaining nuts attaching the blower

and evaporator assembly and the cover assembly

to the studs on the -firewall.

5. Replace the components removed by reversing the

removal, procedure.

AIR DISTRIBUTOR ASSEMBLY

AND OUTLET DUCTS

Four Season System

Chevrolet and Chevelle

Figures 92 through .95 illustrate the air distributor and

outlet ducts as used in the Chevrolet, Chevelle, Camaro,

and Corvette.

Corvette

Right Outlet Duct

Removal

1.
Remove the clamp screw at the inner end of the

outlet duct and loosen the clamp.

2.
Remove the screw and lock washer attaching the

duct outer mounting tab to the body hinge pillar

brace.

3.
Pull the duct and clamp down and away from the

distributor assembly. Disconnect the courtesy light.

4.
The duct extension assembly may now be removed

if desired as well as the deflector assembly. See

Figure 95.

AIR COND.

PULL
AIR PULL- DEFROSTER

FAN PULL HOT PULL

Fig.
91—Corvette Four-Season Controls

CHEVROLET CHASSIS SERVICE MANUAL

HEATER AND AIR CONDITIONING 1A-65

Fig.
92—Chevrolet Four-Season Ducts

Installation

Reverse

assembly.
the removal procedure to reinstall the duct

Left Outlet Duct

Removal

1.
Remove the two parking brake lever bracket to

dash brace attaching screws and move the lever and

cable so they will not interfere with the duct

removal.

2.
Remove the screw and lock washer attaching the duct

outer bracket to the hinge pillar support.

3.
Remove the screws and lock washers attaching the

duct assembly to the dash brace bracket.

4.
Carefully pull the outer end of the duct downward,

detaching the courtesy light from its bracket.

5. Loosen the screws clamping the outlet duct to dis-

tributor assembly flexible tubing at the outlet duct.

The outlet duct may now be removed from beneath

the instrument panel.

6. The duct extension assembly and the deflector as-

sembly may be removed, if desired, as seen in

Figure 95.

Installation

The duct assembly is installed by reversing the re-

moval instructions.

Center Outlet Duct

Removal

1.
Remove the right and left console trim panels.

2.
Remove the radio receiver.

3.
Remove the electric clock.
4.
Remove the knobs, nuts and bezels from the two

air conditioning controls above the clock, AIR COND.

PULL and COLD IN-HOT PULL.

5. Carefully pull the outlet duct and control cables

loose from the rear of the center console and work

it down and out from under the dash. The left hand

control cable runs through the left hand flexible

tubing and may be left in the tubing after it is dis-

engaged from the duct. The right hand control cable

must also be pulled from the duct assembly as the

duct is removed.

6. The center deflector barrel assembly may now be

removed if necessary. Snap off the hairpin clips to

remove the barrel and spacer washers.

Installation

Reverse the removal procedure for installation.

AIR DISTRIBUTOR ASSEMBLY

Removal

1.
Drain the cooling system radiator.

2.
Remove the heater hoses from the core pipes and

remove the cover attaching nuts and cover surround-

ing the core pipes.

3.
Remove the glove compartment assembly and the

glove compartment door.

NOTE:.
See "Section 1 - Body" for removal

and installation of body items.

4.
Remove the right kick pad.

5. Remove the right and left center console trim panels.

6. Remove the radio receiver assembly.

7. Remove the defroster duct.

CHEVROLET CHASSIS SERVICE MANUAL

HEATER AND AIR CONDITIONING 1A-81

HORN RELAY

r

CONN.-

14 BROWN

(TO FUSE

PANEL)
BATTERY
1

—I ^ COMPR

ESSOR

DASH y

V-^ PANEL \

GROMMET—%
1 \

_ J~ ") "^

>14 BLACK/RED STRIPE-

FUSE .20 AMP.

•WIRE ASM. BLOWER-

MOTOR
14 BLACK 1

IGNITION SWITCH1

(ACCESSORY

TERMINAL)

CONTROL SWITCH
-RESISTOR

CONN.

•14 TAN

•16 BLACK

LIGHT BLUE STRIPE

•THERMOSTAT CONTROL

EVAPORATOR & BLOWER ASM.

Fig.
117—Universal System Wiring Diagram (Typical)

CHEVROLET CHASSI

CORVETTE BODY 1B-2

Fig.
1—Steel
Reinforcing Members

by loosening the hinge retaining bolts (lower) and moving

the hood to the limit of slotted holes in hinge strap.

The upper surface of hood may be brought flush with

adjacent surfaces by shimming under hinges and adjust-

ment of bumper screw and catch bolt engagement. Figure

3 illustrates desired spacing.

Hood Catch

The hood catch should be adjusted so that catch bolts

enter lock plates freely and catch bolt length should be

adjusted so that rubber bumpers are slightly compressed

in latched position.

Entrance of catch bolt into the plate may be adjusted

by loosening the three catch bolt mounting screws enough

to allow movement of bolt assembly.

Synchronization of catch release may be made by ad-

justing the cable retainer located at left hand catch plate

assembly.

HOOD ASSEMBLY

Removal

1.
If hood is to be reinstalled, scribe a line around hood

hinge upper strap as shown in Figure 4.

2.
With aid of a helper to support hood, remove screws

retaining hinge straps and support assembly to hood.

If hinges are removed from vehicle, note amount of

shims under each hinge.

Installation

In replacing original hood, align hinge with scribe

marks made on removal and install retaining screws re-

moved from hinges and support.
If adjustment is required, proceed as outlined in this

section under Adjustments - Hood - Hood Catch.

HOOD PROP

Safety Retention Feature

When extended under hood service operations are

anticipated, the hood prop track and slide should be se-

cured by placing a 1/4" bolt and nut through the existing

holes.
This will prevent accidental closing of the hood

that could result in a serious injury.

FRONT EMBLEM

The front emblem is retained by special nuts which

may be reached by raising hood (fig. 5).

wiper arm on side of car
VENT GRILLES

Removal

1.
Remove windshield

affected.

2.
Remove four screws attaching grille to body (fig. 5).

3.
Lift grille far enough to gain access to windshield

washer hose and remove hose from nozzle.

4.
Remove grille from vehicle.

Installation

Grille may be installed by following removal procedure

in reverse order.

INSTRUMENT PANEL TRAY

The instrument panel tray may be removed from the

CHEVROLET CHASSIS SERVICE MANUAL

CORVETTE BODY 1B-15

Fig.
32—Removing Regulator

GLASS RUN CHANNEL-REAR

Removal

For parts identification refer to Figure 41.

1.
Remove door trim assembly as outlined in this

section.

2.
Remove window glass assembly as outlined in this

section.

3.
Remove 2 channel retaining screws and pass chan-

nels out through large opening in door inner panel

(fig. 42).

Fig.
33—Removing Ventilator Assembly 19437
Installation

1.
Position run channel in door and install bolts loosely.

2.
Install window glass as outlined in this section.

3.
Make necessary adjustments to channel as outlined

under Doors - Adjustments - Door Windows.

4.
Replace door window and door trim panel.

WINDOW REGULATOR-MANUAL

For parts identification see Figure 41.

Removal

1.
Remove trim panel as outlined in this section.

2.
Remove door window glass as outlined in this

section.

3.
Remove screws retaining regulator assembly to

door panel.

4.
Remove screws holding lower guide rail to door

panel.

5. Remove regulator assembly from large access open-

ing as shown in Figure 43.

Installation

Regulator may be installed by following removal pro-

cedure in reverse order. Always lubricate all guide rails

and rollers when regulator is disassembled. Test regula-

tor thoroughly before installing door trim panel. Adjust

window as outlined in this section.

WINDOW REGULATOR-POWER

In cases where window will not operate, check electri-

cal connections first. Figure 44 illustrates lpcation of

junctions, switches and circuit breaker.

Removal

Perform operations 1 thru 5 under Window Regulator-

Manual Removal. Note, however, that electrical connec-

tors must be removed from motor before performing

any operation on regulator. Figure 44 illustrates in-

stallation of regulator on door and regulator wiring.

Disassembly

NOTE:
Do not attempt to remove motor from

regulator until the following operations are per-

formed. THIS IS A SAFETY ITEM; arm is

spring-loaded and may cause injury if not locked

in position when motor is removed.

Refer to Figure 45.

1.
Place regulator assembly in vise.

2.
Using jumper leads to 12 volt power supply, operate

motor until semi-circular hole in sector gear cen-

ters over one of two weld nuts on mounting plate.

3.
Screw a l/4"-20 x 1" bolt into weld nut so that end

passes through hole in sector gear. It may be neces-

sary to enlarge hole in gear slightly with file or

drill. Install nut on bolt to lock arm in position.

Installation

1.
Be sure lock bolt has been removed if regulator

has been disassembled.

2.
Install lubricated regulator assembly and guide rails

in door in reverse order of removal.

3.
Install window as outlined in this section.

4.
Making sure connectors are securely installed on

motor, test operation of window thoroughly.

5. Install door trim panel and handles as outlined in

this section.

CHEVROLET CHASSIS SERVICE MANUAL

CORVETTE BODY 1B-22

16.

17.

Fig.
47-Door Handle and Lock Cylinder
18.

19.

20.

21.

1.
Screw - Handle Retaining

2.
Reinforcement

3. Gasket - Rear

4.
Handle Assembly

5. Cylinder Assembly - Lock
6. Escutcheon

7.
Retainer

8. Rod - Lock Cylinder

9. Gasket - Front

14.
Cut off painted portion of cartridge nozzle along

edge of paint line.

15.
Mix adhesive caulking material and accelerator

] thoroughly according to directions on container.
NOTE:
Once caulking material is mixed, there

will be approximately 35 minutes of working

time with the material. Subsequent steps should

be performed immediately after caulking ma-

terial is mixed.

Place caulking material in cartridge as shown in

Figure 59.

Carefully apply a smooth continuous bead of caulking

material on inside surface of glass next to edge

completely around glass (fig. 60). Caulking material

should be approximately 1/4 inch wide at the base

and form a pyramid 3/8 inch high. If during appli-

cation the pyramid collapses, wait about 2-3 minutes

for material to set up. If an air bubble is encoun-

tered in material back up the applicator and apply

sufficient material to fill void and to dispense the

bubble before continuing.

The reveal molding clips are self sealing and do

not require sealing before installing the rear glass.

With aid of helper, lift glass and carefully position

glass on spacers, matching up marks on glass and

body as shown in Figure 61.

Press glass lightly to set caulking material to rear

window opening flanges. Paddle material where nec-

essary to insure proper seal.

Watertest rear window immediately using a cold

water spray. If any water leaks are encountered, use

flat bladed screw driver or stick and paddle caulking

material into leak point to correct leak. Correction

of leak is usually more effectively performed by

paddling material from inside the body.

CAUTION: Do not run a heavy stream of water

directly on caulking material while the material

is still soft.

22.

Install the reveal moldings in the following sequence:

Top,
sides, lower and the caps in each upper corner.

23.
Carefully remove masking tape from inside of glass

and install garnish moldings.

Fig.
49—Door Sill Plate and Molding

Fig.
48—Door Hinge
1.
Plate - Door Sill

2.
Retainer - Sill Molding

3. Sill Molding
4.
"U" Nut - Sill Molding Retainer

5. Special Nut

6. Spring Nut - Sill Molding

CHEVROLET CHASSIS SERVICE MANUAL

CORVETTE BODY 1B-29

CUSHION

CUSHION ASNi.^ty** ACCESS

#2 BODY BRACKET

( 67 ONLY)
SHIM

( 37 POSITION).

CUSHION ASM.

( 37)

SHIM

( 67 POSITION)

CUSHION

( 37 ONLY)

#1 BODY BRACKET

Fig.
65—Body Mounts

PRECAUTIONS

Creams are available to protect the skin from a con-

dition known as occupational, or contact dermatitis. This

common type of dermatitis is not contagious. Improved

resin formulas in the approved kits have almost elimi-

nated skin irritation. Cream is supplied with the kit for

men who may have a tendency toward skin irritation

from the resins or dust.

The application of these creams is recommended

whenever the Resin Kit materials are used. Generally,

the cream is not required when the plastic solder kit is

being used. Directions for using the cream is as follows:

a. Wash hands clean. Dry thoroughly.

b.
Squeeze about 1/2 inch (or 1/2 teaspoonful) of

#71 cream into palm of hand.

c. Spread evenly and lightly until cream disappears.

Work cream into cuticle, between fingers and

around wrists.

d. Apply second coat, repeating Steps b and c.

e. Hold hands briefly under cold running water to

set cream.

2.
Remove resin mixture from hands as soon as possi-

ble and imperatively before mixture starts to gel.

This can be observed by the action of the material

being used. Resin may be removed with lacquer

thinner by washing in soap and water.

3.
Respirators are recommended when grinding. Also

some minor skin irritation from glass and powdered

cured resin may be evident. Washing in cold water

will help to minimize.

4.
Use a belt sander with a vacuum attachment for dust

control if possible.
5. Resin mixtures may produce toxic fumes and should

be used in well ventilated areas.

6. Be careful not to get any resin material on clothing.

7. Use the right materials for the job. It is important

to use the approved kits because Chevrolet's rigid

quality standards assure you the right material to

do the job. Other materials available may not meet

the required engineering and safety standards.

8. Keep the materials, utensils and work area clean

and dry. These repairs involve chemical reactions,

and dirt or moisture may upset the chemical bal-

ances and produce unsatisfactory results.

9. Before starting repair operations, look for hidden

damage by applying pressure around the damaged

area, looking for hairline cracks and other breakage.

Check for minor damage at other points in the vehi-

cle such as around exhaust pipes, grille, headlamps

and points of wear or rub. Early repair of this

minor damage may prevent major repair later.

PLASTIC SOLDER
KIT

The Plastic Solder Repair Kit is used for minor re-

pairs on the Corvette body. These materials will produce

an easy, quick and lasting repair in the case of small

cracks, surface imperfections and small holes.

1.
Use paint remover or power sander, and remove

finish from damaged area. Carefully inspect for

other areas requiring repair.

2.
Mix the materials (fig. 72).

3.
Apply the material, using a putty knife or rubber

squeegee, Figure 73. Work the material into the

repair and build the material up to the desired

CHEVROLET CHASSIS SERVICE