1967 CHEVROLET CAMARO oil pressure

HEATER AND AIR CONDITIONING 1A-42

EXTERNAL

EQUALIZER LINE

Fig. 54—Thermosratic Switch Adjustment

POORLY LOCATED POWER ELEMENT BULB

Normal Pressure.

Poor Cooling.

ENGINE IDLE COMPENSATOR

This additional aid to prevent stalling during prolonged

hot weather periods is included with all air conditioned

vehicles. The idle compensator is a thermostatically

controlled air bleed which supplies additional air to the

idle mixture. On V-8 engines, with factory installed air
Fig. 55—Expansion Valve

conditioning systems, the compensator is located within

the carburetor and is accessible when the engine air

cleaner is removed. On all other vehicles the compen-

sator is threaded into a manifold, fitting below the

carburetor. All compensators are factory set and are

non-adjustable. A malfunctioning unit should be replaced.

NOTE:
If engine idle is erratic, hold the idle

compensator valve closed with a pencil or

wooden dowel while adjusting the idle mixture

screw(s). Never attempt to bend the bimetal

strip or attempt any valve adjustment.

EVACUATING AND CHARGING PROCEDURES

1967 AIR CONDITIONING SYSTEM CAPACITIES

Four-Season Systems (Chevrolet and Chevelle)

Universal System (Chevrolet, Chevelle and Camaro)

Universal and All-Weather System (Chevy II)
Refrigerant Charge

3 lbs., 12 oz.

3 lbs.

2 lbs., 8 oz.
Oil Charge

11 ozs. 525 viscosity

11 ozs. 525 viscosity

11 ozs. 525 viscosity

PURGING THE SYSTEM

In replacing any of the air conditioning components the

system must be completely purged or drained of re-

frigerant. The purpose is to lower the pressure inside

the system so that a component part can be safely

removed.

1.
With engine stopped install high and low pressure

lines of gauge set to the proper high and low pres-

sure gauge fittings (see "Installing Gauge Set to

Check Operation").
2.
With plug removed from the centerline on the gauge

manifold, open high pressure gauge valve and dis-

charge the vapor slowly through the center

connection.

CAUTION: Do

compressor

refrigerant.
not open valves too much or

oil may be discharged with the

A rag wrapped around the end of

the center gauge line will prevent the splashing

of oil in the event of accidental rapid discharge.

CHEVROLET CHASSIS SERVICE MANUAL

HEATER AND AIR CONDITIONING 1A-43

LOW PRESSURE

CONTROL
HIGH PRESSURE

CONTROL

3

VACUUM

CONTROL
4

FREON

CONTROL

Fig,
56—Charging Station Controls

3.
When the pressure is reduced to below 100 pounds

on the high pressure gauge, open the low pressure

gauge valve and continue discharging until all re-

frigerant has been released. Close both gauge valves.

EVACUATING AND CHARGING THE SYSTEM

GENERAL NOTE: La all evacuating procedures

shown below, the specification of 26-28 inches

of Mercury vacuum is used. These figures are

only attainable at or near Sea Level Elevation.

For each 1000 feet above sea level where this

operation is being performed, the specifications

should be lowered by 1 inch. Example: at 5000

ft. elevation, only 21 to 23 inches of vacuum can

normally be obtained.

Whenever the air conditioning system is open for any

reason, it should not be put into operation again until it

has been evacuated to remove air and moisture which

may have entered the system.

The following procedures are based on the use of the

J-8393 Charging Station.

Filling Charging Cylinder

1.
Open control valve on refrigerant drum.

2.
Open valve on bottom of charging cylinder allowing

refrigerant to enter cylinder.

3.
Bleed cylinder valve on top (behind control panel) as

required to allow refrigerant to enter. When re-

frigerant reaches desired level (see "Air Condition-

ing System Capacities"), close valve at bottom of

cylinder and be certain bleed valve is closed

securely.

NOTE: It will be necessary to close bleed valve

periodically to allow boiling to subside to check

level in sight glass.

Installing Charging Station to System

1.
Be certain all valves on charging station are closed.

2.
Connect high pressure gauge line to high pressure

gauge fitting. (See "Installing Gauge Set to Check

System Operations.")
3.
See Figure 56. Turn high pressure control (2) one

turn counter-clockwise (open). Crack open low pres-

sure control (1) and allow refrigerant gas to hiss

from low pressure gauge line for three seconds,

then connect low pressure gauge line to low pressure

gauge fitting.

4.
System is now ready for performance testing.

Evacuating and Charging System

1.
Install charging station as previously described.

Refer to Figure 56 and 57 while performing the

following operation.

2.
Remove Low Pressure gauge line from compressor.

3.
Crack open high (2) and low (1) pressure control

valves, and allow refrigerant gas to purge from

system. Purge slow enough so that oil does not

escape from system along with Refrigerant.

4.
When refrigerant flow stops, connect Low Pressure

gauge line to compressor.

5.
Turn on vacuum pump and open Vacuum Control

Valve (3).

6. With system purged as above, run pump until 28-29

inched of vacuum is obtained. Continue to run pump

for 15 minutes after the system reaches 28-29 inches

vacuum.

7.
If 28-29 inches cannot be obtained, close Vacuum

Control Valve (3) and shut off vacuum pump. Open

Refrigerant Control Valve (4) and allow 1/2 pound of

R-12 to enter system. Locate and repair all leaks.

8. After evacuating for 15 minutes, add 1/2 pound of

R-12 to system as described in Step 7 above. Purge

this 1/2 pound and reevacuate for 5 minutes. This

second evacuation is to be certain that as much con-

tamination is removed from the system as possible.

9. Only after evacuating as above, system is ready for

charging. Note reading on sight glass of charging

cylinder. If it does not contain a sufficient amount

for a full charge, fill to the proper leveL

10.
With High and Low pressure Valves (1 and 2) open,

close Vacuum Control Valve (3) and open Freon

Control Valve (4). Operating the heater and air

conditioner blower with the controls set for cooling

will help complete the charging operation.

NOTE: If the charge will not transfer com-

pletely from the station to the system, close

the high pressure valve at the gauge set, set

the air conditioning controls for cooling, check

that the engine compartment is clear of ob-

structions, and start the engine. Compressor

operation will decrease the low side pressure

in the system.

System is now charged and should be performance

tested before removing gauges.

CHECKING OIL

In the six cylinder compressor it is not recommended

that the oil be checked as a matter of course. Gener-

ally, compressor oil level should be checked only where

there is evidence of a major loss of system oil such as

might be caused by:

• A broken refrigerant hose.

• A severe hose fitting leak.

CHEVROLET CHASSIS SERVICE 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, 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

HEATER AND AIR CONDITIONING 1A-49

CHEVROLET

CHEVELLE

CHEVY II

CAMARO
the last possible moment. Be certain that the

direction of flow is correct before connecting

the pipes.

Chevrolet, Chevelle, Chevy II, and Camaro

Replacement

1.
Remove the receiver inlet and outlet connections and

the two receiver to fender skirt attaching screws.

2.
Carefully remove the receiver-dehydrator from the

vehicle.

3.
Replace the new receiver~dehydrator assembly in

the vehicle and install all attaching screws and re-

frigerant lines.

4.
Add one fluid oz. refrigerant oil, evacuate and charge

the system.

Corvette

Replacement

1.
Purge the system of refrigerant.

2.
Disconnect the "O" ring inlet

hose clamp outlet connection

openings.

3.
Remove the receiver-dehydrator to radiator support

bracket screws (production engine) or receiver-

dehydrator to condenser bracket screws (optional

engine) and remove the unit from the car.

4.
Install the new receiver-dehydrator applying 30 in.

lbs.
torque to the attaching screws.
connection and the

and tape the hose

NOTE:
Do not uncap the new receiver-

dehydrator until the last instant before

installation.

5.

2.

3.

Fig.
63—
Receiver-Dehydrator Mounting (Chevrolet,

Chevelle/ Chevy II, Camaro)
Connect the high pressure lines at the inlet (use a

new "O" ring and torque connection to 13 ft. lbs.)

and outlet (torque screw to 25 in. lbs.).

6. Add one fluid oz. refrigerant oil, evacuate, charge

and check the system.

Sight Glass Replacement-All Vehicles

If damage to the sight glass should occur, a new sight

glass kit should be installed. The kit contains the sight

glass,
seal and retainer. (See Figure 65.)

1.
Purge system.

Remove the sight glass retainer nut using a screw

driver and remove old glass and seal.

Install the new glass and seal and retainer nut, being

careful not to turn the nut past the face of the hous-

ing. To do so may damage the "O" ring seal.

4.
Evacuate and recharge the system.

EVAPORATOR

Chevrolet and Camaro Four-Season System

The evaporator and blower case assembly is designed

so that the core may be removed without the need for

removing the entire unit from the vehicle. Instead,

only the side cover must be removed.

Removal and Installation of Entire Assembly

1.
Remove the inlet line at the expansion valve and the

suction throttling valve outlet connection.

2.
Remove the electrical connector from the blower

motor.

CHEVROLET CHASSIS SERVICE MANUAL

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-71

SUN-AMBIENT

SENSOR AND COMPRESSOR

CLUTCH SWITCH

HIGH BLOWER

DELAY RELAY

THERMAL

VACUUM

VALVE

Fig.
102-Comfortron Underhood Wiring

use when inspecting a damaged vehicle equipped with air

conditioning.

1.
Remove the drive belt. Cut belt off if necessary.

2.
Visually inspect the condenser, receiver-dehydrator,

compressor, mounting brackets, conditioning unit, all

connecting lines, and all controls to determine the

extent and nature of the damage.

a. No repairs, such as soldering, welding or braz-

ing, should be attempted on the condenser be-

cause of its construction. If the vapor passages

in the horizontal tubes or return bends or mani-

folds have been damaged in any way, the con-

denser should be replaced with a new one.

b.
The receiver-dehydrator should be replaced if

there is any evidence of its having sustained

either internal damage or a fracture at any of

the lines or welded joints or if the system has

been exposed to the atmosphere for an undeter-

mined period of time.

c. Examine the compressor for any visible external

damage.

d. The evaporator should be examined for damage

and, if necessary, removed or replaced or the

entire unit processed where damaged or exposed

to the atmosphere.

e. All connecting lines and flexible hoses should be

examined throughout their entire length for dam-

age.
If damaged in any manner, replace with new

lines.
f. Check all controls and connecting wires for

damage and replace with new parts where needed.

g. Check the clutch pulley for proper operation and

freedom from damage.

3.
Install gauge set.

4.
Purge the system. Pressure should not exceed 3 to

5 pounds.

5. Remove the compressor from mounting and remove

the oil test fitting.

6. Pour out the oil into a clean glass container and ex-

amine it for any foreign substance such as dirt,

water, metal particles, etc. If any of these are

present, the compressor and receiver-dehydrator

should be replaced and the other system components

should be flushed with liquid refrigerant.

7. If the oil is clean and free of any harmful substance,

replace oil with Frigidaire Oil available through

Parts Stock.

NOTE:
If the system components have been

replaced or flushed, replace the full charge of

oil. If not, add no more fresh oil than was

drained in Step 6.

8. Charge up the compressor to drum or can pressure

and leak test the compressor seals prior to in-

stallation of compressor.

9. Reinstall the compressor and evacuate the system

by following the Evacuating Procedure.

CHEVROLET CHASSIS SERVICE 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.

15.
J-8393

J-22368

J-21530

J-5453

J-9459

J-5420

J-6084

J-8433

J-9395

J-6272

J-6271

J-7151

J-5421

J-5403

J-6435

J-9396

J-9397
Charging Station

Comfortron System fester

Comfortron Temperature Dial Adjuster

Goggles

90° Gauge Line Adapter

Gauge Line Adapter

Leak Detector

Puller

Puller Pilot

No.
3
Multi-Opener (3-Can)

Fitzall Valve (Single
Can)

Non-Magnetic Clutch Shims

Pocket Thermometers
(2)

#21 Snap Ring Pliers

#26 Snap Ring Pliers

Compressor Holding Fixture

Compressing Fixture
16.
J-9403

17.
J-9399

18.
J-9401

19.
J-9480

20.
J-9392

21.
J-9393

22.
J-9298

23.
J-9481

24.
J-8092

25.
J-9521

26.
J-5139

27.
J-9432

28.
J-9553

29.
J-21508

30.
J-21303

31.
J-9527

,
32.
J-9402
Clutch
Hub
Holding Tool

9/16" Thin Wall Socket

Hub
and
Drive Plate Assembly Remover

Hub
and
Drive Plate Assembly Installer

Seal Remover

Seal Seat Remover

Pulley Bearing Remover

Pulley and Bearing installer

Handle

Internal Assembly Support Block

Oil Pickup Tube Remover

Needle Bearing Installer

Seal Seat "O" Ring Remover

Seal Seat "O" Ring Installer

Shaft Seal Protector

Pressure Test Connector

Parts Tray

CHEVROLET CHASSIS SERVICE MANUAL

CORVETTE BODY 1B-T9

Fig.
43—Removing Regulator Assembly

REAR QUARTER

DOOR SILL PLATE AND MOLDING

Figure 49 shows assembly details of both the door sill

plate and molding. The sill plate which retains the car-*

pet, the cowl trim windlace and lock pillar front edge

trim are retained to the body by six screws.

The molding assembly, which replaces a rocker panel,

is quickly and easily replaced by removing 10 retaining

screws. The sill molding retainer is also fastened to the

body with screws.

REAR END

FOLDING TOP COMPARTMENT LID

Adjustments

Hinges

The folding top compartment lid should be adjusted so

that in the closed position the surface of the lid is flush

with surrounding body surfaces and space between lid

edge and body is 1/16" to 3/16" at sides and 3/16" to

1/4" at rear. Whenever lid position is changed on hinges,

lock engagement must be inspected and adjusted if neces-

sary. Adjust hinge position as follows:

1.
Scribe a line on lid surface following contour of hinge

strap.
This will ease observation of lid movement

during adjustment (fig. 51).

2.
To raise or lower top surface of lid, add or remove

hinge shims.

3.
To adjust spacing between lid edges and body, loosen

hinge-to-lid screws and shift lid as required.

Lock

Lock engagement may be adjusted as follows:

1.
Striker plates may be shimmed to adjust the depth

of lock engagement in striker plate. When this ad-

justment is made, release of lock should be tested

and adjusted as required.

2.
Release of lock may be adjusted by loosening lock

assembly retaining bolts and moving lock in ap-

propriate direction to the limit of slotted holes in

, lock base. Further adjustment may be gained by

moving cable retainer in appropriate direction.
Hinges

(Refer to Figure 52)

Removal

1.
Scribe around hinge as shown in Figure 51.

2.
Hinge may be removed as an assembly by opening

top compartment lid fully and removing 3 retaining

screws. Note number of shims found between hinge

frame and compartment floor.

3.
To remove spring from hinge assembly, close top

compartment lid as far as possible and insert Tool

J-9559 between expanded coils in spring. Opening

top compartment lid fully will allow removal of

spring as shown in Figure 53.

4.
As soon as spring is removed, insert long bolt sup-

plied with J-9559 through holes in end of tool, pass-

ing it through spring, and install nut on bolt.

Spring may be removed from J-9559 or J-9559 may be

installed in a new spring, by the following method:

1.
Place a closed 6 or 8 inch "C" clamp in a vise or

fasten it to a heavy bench top (bench should be fas-

tened to floor).

2.
Hook one end of spring in clamp and the other end

in hook of chain hoist, "cherrypicker" or equivalent,

as shown in Figure 54.

3.
Stretch the spring enough to allow insertion of

J-9559. Install through bolt if spring is not to be in-

stalled on hinge at once.

installation

1.
Install same number of shims as removed or, if

repairing collision damage, etc., position hinge in

compartment, install upper mounting screws, fill

gap between floor and hinge frame with shims and

install lower mounting screw.

2.
If spring has been removed from hinge, install

spring in J-9559 and place spring on hinge with com-

partment lid raised; closing lid releases J-9559 for

removal. Upper end of spring should rest in one of

three notches yielding best lid operation. About 3

pounds pressure should be necessary to close lid.

Lock

Removal

1.
Remove cable mounting clamps. Remove retainer

from control cable assembly and disengage cable

from control.

2.
Scribe a mark on lid following outer contour of lock

assembly.

3.
Remove 3 lock assembly retaining screws and re-

move lock from compartment lid.

Installation

1.
Place lock assembly on compartment lid within

scribed line and install retaining screws.

2.
Install end of cable in control assembly and fasten

retainer securely.

3.
Test operation of lock thoroughly, adjusting if neces-

sary as outlined in this section.

Control

Removal

1.
Remove inner mounting clamps from both cables

and disengage cables from control by removing

retainers.

CHEVROLET CHASSIS SERVICE MANUAL