1967 CHEVROLET CAMARO tow

HEATER AND AIR CONDITIONING 1A-32

5.
Check hose clamp connections. If clamp screw torque

is less than 10 lb. in., retighten to 20-25 lb. in. Do

not tighten to new hose specifications or hose leak-

age may occur.

6. If there is evidence of an oil leak, check the com-

pressor to see that the oil charge is satisfactory.

7.
Check the system controls for proper operation.

6000 MILE INSPECTION

1.
Check unit for any indication of a refrigerant leak.

2.
If there is an indication of an oil leak, check the

compressor proper oil charge.

3.
Check sight glass for proper charge of Refrigerant-

12.

4.
Tighten the compressor brace and support bolts and

check the belt tension.

5.
Check hose clamp connections as in step 5 above.

6. Check thermostatic switch setting (Universal and

All-Weather Systems.)

PERIODIC SERVICE

• Inspect condenser regularly to be sure that it is not

plugged with leaves or other foreign material.

Fig.
46—Compressor Connector Block—Typical
• Check evaporator drain tubes regularly for dirt or

restrictions.

• At least once a year, check the system for proper

refrigerant charge and the flexible hoses for brittle-

ness,
wear or leaks.

• Every 6000 miles check sight glass for low refriger-

ant level.

• Check belt tension regularly.

• Every week - during winter months or other periods

when the system is not being operated regularly- run

the system, set for maximum cooling, for 10 or 15

minutes to insure proper lubrication of seals and

moving parts.

INSTALLING GAUGE SET TO CHECK

SYSTEM OPERATION

Compressor Suction and Discharge Connector

Compressor connector assemblies used on all vehicles

are of the same basic design consisting of the inlet

(suction) and outlet (discharge) connections, gauge fittings

and muffler and, in general, the assemblies differ only in

the location of the gauge fittings.

On Universal and Four-Season Systems the outlet line

extends along side of and toward the front of the com-

pressor and the muffler in the line is bracket mounted to

the compressor body. In all Universal Systems the gauge

fittings for both low and high pressure sides of the sys-

tem are located in the connector body. On Four-Season

Systems the high pressure gauge fitting is located on the

muffler and the low pressure gauge fitting is on the POA

Valve.

The Chevy n All-Weather System compressor con-

nector assembly is similar to the Universal System

connector assembly described above except that the

muffler extends straight out from the connector and

is not bracket mounted to the compressor.

Universal and Chevy II All-Weather System

1.
Install Gauge Adapter (J-5420 or J-9459) onto the

high and low pressure hoses of the gauge set.

2.
With the engine stopped, remove the caps from the

cored valve gauge, connectors on the compressor

fittings block.

3.
Connect the gauge lines with adapters to the threaded

connectors on the compressor fittings block.

Four-Season and Comfortron Systems

Installation of the gauge set onto the Four-Season and

Comfortron systems is accomplished in the same manner

as outlined above except that system performance checks

must be performed with the low pressure hose line and

adapter attached to the fitting on the POA valve. Charging

procedures should be performed with the high pressure

gauge line connected to the high pressure gauge fitting

located on the outlet line muffler and the low pressure

gauge line attached to the POA fitting.

CAUTION: When removing gauge lines from

the compressor fittings block be sure to remove

the adapters from the fittings rather than the

gauge lines from the adapters.

PERFORMANCE TEST

This test may be conducted to determine if the system

is performing in a satisfactory manner and should be

used as a guide by the serviceman in diagnosing trouble

CHEVROLET CHASSIS SERVICE 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 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

HEATER AND AIR CONDITIONING 1A-56

BLACK & RED

IGNITION—-y^****

SWITCH -"A

/
BLOWER LEAD—^^^

RESISTOR—-" \^<

ASM.
f'

i
'fu^^^^A^^^^^r"G^OUH£>
WIRE

^^
k4

^EVAPORATOR HARNESS

' EVAPORATOR & BLOWER ASM.

Fig.
73—Underdash Wiring—Universal System (Typical)

evaporator outlet pipes. Locate the bracket about

1/2" from the dash panel.

12.
Replace the inlet and outlet hoses and hose clamp

connections.

13.
Evacuate and charge the system. Add three fluid oz.

refrigerent oil after installing a new core.

14.
Check system performance.

Corvette

Replacement (Fig. 78)

1.
Purge the system of refrigerant.

2.
Drain the engine radiator. Then remove the radiator

supply tank from its brackets, the heater water

valve and vacuum line from the firewall, and the

heater hoses from the core pipes. Carefully fold the

hoses,
valve and tank away from the evaporator

case.

3.
Remove the right hand hood lock support.
SCREW DRIVER

(NARROW BLADE) T£

GROOVE

A. Insert screw driver in

tang toward terminal

B. Pry tang back out to

when reinstalled into
RMINAL

\ CONNECTOR

TANG

groove & press

to release.

insure locking

connector.

Fig.
74—Terminal Removal—Universal System

4.
Disconnect the expansion valve equalizer line con-

nection and the evaporator oil bleed line from the

POA.

5.
Disconnect the evaporator outlet to POA inlet

connector.

6. Remove the POA bracket to evaporator case attach-

ing bolts. Then carefully move the valve and its

outlet hose away from the evaporator case.

Fig.
75-Cable Removal-All Weather

CHEVROLET CHASSIS SERVICE MANUAL

HEATER AND AIR CONDITIONING 1A-61

INSERT CAPILLARY

BETWEEN FINS AT

ARROW

Fig.
84—Thermostatic Switch Capillary Installation

All-Weather System (Thermostatic Switch Only)

Chevy II

Replacement (See Fig. 85)

1.
Remove both control knobs and control stem bezels

from the evaporator assembly.

2.
Remove the face plate attaching screws located in

the outer ball outlets and lift off the face plate.

3.
Remove the two thermostatic switch attaching

screws.

4.
Disengage the plastic plug attaching the thermostatic

switch capillary tubing to the face of the evaporator

core (fig. 84).

5. Draw the switch out of the case through the face plate

opening, disconnecting the electrical connectors.

6. Reinstall the new switch by reversing the removal

procedure.
Fig.
85—Thermostatic Switch Removal

unit as outlined under
ALL-WEATHER-PULL CABLE

All-Weather System

Chevy II

Removal

1.
Remove the evaporator

EVAPORATOR.

2.
Remove the screws which attach the front and rear

case halves.

3.
Remove clamp from the evaporator pipes and sep-

arate case halves.

4.
Remove face plate retaining screws located in outer

ball outlets.

5. Remove control knobs and retaining nuts.

6. Remove face plate.

7. Remove cable to case retaining screw and thermo-

static switch mounting screw.

8. Remove evaporator to case mounting screws.

9. Withdraw evaporator with cable and thermostatic

switch assembly. Be careful to prevent kinks in the

thermostatic capillary.
10.
Pull the cable out toward the air outlet side of the

evaporator.

Installation

1.
Pass the replacement cable through the same channel

in the evaporator fins. If a new evaporator is being

installed, a channel will need to be opened between

the evaporator fins. This may be done by pushing a

pointed pencil between the fins beginning at the air

outlet side of the core, two inches to the right of the

left side of the fins and between the third and fourth

tubes down from the top. The cable channel should

exit at the air inlet side of the core between the first

and second tubes down from the top.

CHEVROLET CHASSIS SERVICE MANUAL

HEATER AND AIR CONDITIONING 1A-63

Under Dash

7. Remove ash tray and retainer, and glove box.

8. Remove blower case to air inlet adapter bracket

retaining screw.

9. Remove screw attaching air distributor to firewall.

10.
Remove nuts retaining evaporator case to lower lip

of dash. Withdraw evaporator drain tubes.

11.
Lower complete heater - air conditioning assembly.

12.
Remove screw retaining blower case to air distrib-

utor and separate them.

13.
Remove blower to case attaching screws. Disconnect

motor wire and remove blower assembly.

14.
Remove blower from motor shaft.

Installation

1.
Assemble blower to motor shaft.

2.
Mount motor in blower case and connect wire.

3.
Assemble blower case to air distributor and install

retaining screw.

4.
Lift the complete assembly into place and install

attaching screws and nuts.

5. Replace ash tray retainer and tray and glove box.

6. Replace nuts (engine side of dash) on heater case

studs and connect heater hoses.

7. Replace evaporator pipe clamp and grommet.

8. Replace the refrigerant hoses.

9. Evacuate and charge the refrigeration system and

refill the cooling system.

10.
Check system performance.

Universal Blower Assembly

Removal

1.
Remove the universal unit from its dash mounts.

2.
Remove the cover plate and separate the upper and

lower case halves. Remove blower motor mounting

strap screw and swing strap outward.

3.
Remove blower assembly. Loosen the blower wheel

setscrews and remove the wheels from the motor

shaft. . ' .
Fig.
88-Air Inlet Assembly (Chevrolet)

Installation

1.
Install the blower wheels on the motor so that the

lower blades curve toward the firewall side of the

unit when the motor is placed in the case. Tighten

the setscrews.

2.
Place the motor in the bracket with the electrical

connector side of the motor to the right side of the

bracket. Attach the mounting strap.

3.
Assemble the case halves and attach the cover plate.

4.
Remount the unit to the dash.

Fig.
87—Blower Assembly—Universal System
Fig.
89—Air Doors (Camaro)

CHEVROLET CHASSIS SERVICE

CORVETTE BODY 1B-5

Fig.
4—Scribing
Line
Around
Hood
Hingje

2.
Remove cowl "kick" pad grille. |

3.
Disengage control cable fastened to cowl vent by nut

retainer. !

4.
Remove vent control knob retained by
|
set screw.

5. Remove center console trim and pass control cable

under instrument panel with care, avoiding damage

to electrical connections. j

Installation

Install vent assembly following removal procedure in

reverse order. Check operation of vent. Connect positive

battery cable.
Fig.
6—Instrument
Panel Tray

2.
Remove four screws retaining side reveal moldings.

3.
Remove upper reveal molding after marking molding

and header rail to ease reinstallation as shown in

Figure 14.

4.
Mark position of lower reveal molding as shown in

Figure 15 and pry molding out of weatherstrip.

5. From inside vehicle carefully pry weatherstrip from

pinchweld flange of windshield frame (fig. 16) and

work windshield-weatherstrip assembly out of body

opening toward front of vehicle.

Checking Windshield Body Opening

When the vehicle has been involved in a collision or in

cases where windshield has been subject to "strain

WINDSHIELD

Consult Figure 12 for parts identification.

Removal

1.
Remove side, upper and lower garnish moldings

(fig. 13).

Fig.
5—Emblem dnd
Vent Grille
1.
Screen
Assembly

2.
Pad
Assembly
L H.
Fig.
7-Cowl
Area Trim

3.
Pad
Assembly
R. H. 5.
Cover

4.
Trim Panel
Assembly

CHEVROLET CHASSIS SERVICE MANUAL

CORVETTE BODY
1B-6

ASH TRAY

SET SCREW

(PART
OF
KNOB)
TENSION

ADJUSTING

SCREWS

Fig.
8—Console Trim

cracks",
the
windshield opening must
be
carefully

checked
for
irregularities
and
deformation.
To
check

windshield opening proceed
as
follows:

1.
With weatherstrip
and all
foreign material removed

from perimeter
of
opening and with molding clips
in

place, install windshield checking blocks (Special

Tool J-8942)
as
shown in Figure 17. Note that check-

ing blocks must
be
placed over molding clips
to

obtain proper alignment.

2.
Place
a new
windshield glass
in
opening, resting on

J-8942 blocks
as
shown in Figure
18.

3.
Check
fit of
glass carefully. Space between glass

and frame should not vary more than 1/8".

4.
Mark
and
repair
any
imperfections. Recheck
fit as

required.

Fig.
9—Special Clip
Fig.
10—Sun Visor and Inside Rear View Mirror

Installation

1.
Carefully clean
all
loose material
out of
windshield

frame
(fig. 19).

2.
Install
new
molding clips (Item
9, fig. 12).
Both

models
use 13
type
B
clips equally spaced on lower

frame section.
37
Models use 11 type A clips equally

spaced on the top frame section.

3.
Apply
a
bead
of gun
grade body sealer such
as

3M-1170
in
apex
of
windshield frame
as
shown
in

Figure
20.

4.
Install weatherstrip on windshield glass.

5. Starting
at
bottom center
of
glass, insert
a
piece
of

heavy cord such
as
chalk line,
etc. in
groove
of

weatherstrip.
Cut
cord long enough so that about 10"

of free length exists after going around windshield.

Knot ends
of
cord together where they meet at bot-

tom center
of
glass
and
draw knot into groove
(fig.

21).
Tape loose ends
to
inside surface
of
glass
as

shown.

6. Place weatherstrip windshield assembly
in
wind-

shield frame. From inside
of
vehicle grasp ends
of

cord and pull toward you.
It is
wise to have an assis-

tant exert gentle
but
firm pressure
on
outside sur-

face
of
glass
in the
area where string
is
emerging

from weatherstrip. Figure
22
illustrates action
of

string
on
weatherstrip.
Lip of
seal
is
pulled out of

frame apex and over pinchweld flange.

7. When string
has
been removed, carefully inspect

seating
of lip
over entire perimeter
of
windshield,

paying particular attention to corners.

8. Apply
2
beads
of
sealer on outer surface
of
weather-

strip
as
shown
in
Figure
23.
Inject
a
moderate

quantity
of
windshield cement such
as
3M-6699B

between windshield glass
and
weatherstrip using

pressure gun
as
shown
in
Figure
23.

9. Install lower reveal molding, aligning
it
with mark

made upon disassembly. Refer
to
Figure
12,
View

A, before attempting installation; note that flange
of

molding
and
clips (item
9) at
ends
of
molding must

pass between molding retaining clips and windshield

frame.
li
difficulty
is met in
engaging molding

flange with retaining clips,
a
piece
of
shim stock

may
be
used
as a
"shoe horn"
to
place flange be-

hind clips.

10.
Install
in
order named: Upper reveal molding (align-

ing marks made
at
disassembly); side weatherstrip

CHEVROLET CHASSIS SERVICE MANUAL

CORVETTE BODY IB-10

Fig.
19—Cleaning Windshield Frame

straps.
The position of the door is adjusted by sliding

the door fore and aft to the limit of the slotted holes in

hinge strap or by moving door toward or away from the

center of the vehicle, as desired, by installation or re-

moval of shims located between hinge rear strap and

door (fig. 27). To adjust door proceed as follows:

1.
Remove door trim panel as outlined in this section.

2.
Remove lock striker plate after first scribing a line

around it on lock pillar to ease alignment when

reinstalled. '
Fig. 21-Installing Cord

Fig. 22—Seating Weatherstrip

Fig. 20—Applying Sealer

Fig. 23—Applying Sealer and Cement

CHEVROLET CHASSIS SERVICE MANUAL