bulb CHEVROLET CAMARO 1967 1.G Chassis Workshop Manual

HEATER
AND AIR
CONDITIONING
1A-41

OUTLET

1

TO EXPANSION
^

VALVE
TO
OIL

BLEED LINE

^ INLET

Fig.
51—Evaporator Pressure Control Valve—POA

turn increments until
the
suction pressure rises
to

the correct pressure.

5.
If the
pressure
is
more than
it
should
be,
turn the

adjusting screw counter-clockwise until
the
proper

pressure
is
reached.

6. After adjusting
the
switch, install the capillary to
its

normal position
and
observe
the
operation
of the

system
for
several minutes. Then
if
the operation
is

satisfactory remove the gauge
set,
replace the switch

and reinstall the face plate onto the evaporator case.

EXPANSION VALVE

A malfunction
of the
expansion valve will
be
caused

by
one of the
following conditions: valve stuck open,

valve stuck closed, broken power element,
a
restricted

screen
or an
improperly located
or
installed power

element bulb.
The
first three conditions require valve

replacement.
The
last two may be corrected by replacing

the valve inlet screen
and by
properly installing
the

power element bulb.

Attachment
of the
expansion valve bulb
to the
evap-

orator outlet line
is
very critical.
The
bulb must be

attached tightly
to the
line
and
must make good contact

with
the
line along
the
entire length
of
the bulb. A loose
bulb will result
in
high
low
side pressures and poor

cooling.
On
bulbs located outside
the
evaporator case

insulation must be properly installed.

The external equalizer line shown
in
Figure
55 is
not

used
in the
Custom
and
Chevy
II
All-Weather systems.

Indications
of
expansion valve trouble provided by the

Performance Test are
as
follows:

VALVE STUCK OPEN
OR
BROKEN POWER

ELEMENT

Noisy Compressor.
•

No Cooling
-
Freeze
Up.

VALVE STUCK CLOSED
OR
PLUGGED SCREEN

Very Low Suction Pressure.

No Cooling.

Fig.
52-P.O.A. Valve Installed
Fig.
53—Thermostatic Switch Removal

CHEVROLET CHASSIS SERVICE MANUAL

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-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-51

RETAINER

WASHER

GLASS

•O"
RING

Fig.
65-Sight Glass Replacement

Removal

1.
Purge the system.

2.
Disconnect the refrigerant lines at the right rear of

the unit.

3.
Remove the unit from the dash. Disconnect all elec-

trical connectors.

4.
Remove the front cover, withdraw the thermostatic

switch capillary, and separate to the case halves.
5. Remove the clamps from the evaporator inlet and

qutlet pipes.

6. Remove the screws which attach the evaporator to

the case and remove evaporator. '

7. Ljoosen the clamp which mounts the capillary bulb

to the evaporator. Disconnect the inlet and outlet

pipes from the expansion valve and remove the

expansion valve.

Fig.
66—Evaporator Mounting (Chevrolet and Camaro)
Fig.
67—Evaporator Mounting (Chevelle)

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-54

Fig.
71-Wiring-AH Weather (Chevy II)

1.
Loosen the lock screws and remove the two control

knobs from the front of the evaporator unit. Then

use a suitable spanner wrench to remove the two

nuts beneath the control knobs.

2.
Remove the screws (located in the outer ball outlets)

attaching the face plate.to the evaporator case. Then

remove the face plate and, reaching through this

opening, carefully remove the plug attaching the

thermostatic switch capillary tube to the evaporator

core.

3.
Turning the unit over, remove the screws attaching

the back cover and gasket to the case and remove

the cover and gasket.

4.
From the top of the case, remove the screws attach-

ing the evaporator core brackets to the case.

5.
Carefully draw the core and expansion valve assem-

bly out of the case.

NOTE: The air conditioning "on" door bowden

cable, which extends through the core, will also

be removed at this time.

6. Remove the expansion valve power element from

the low pressure line.
7.
Disconnecting the high pressure and low pressure

lines from the valve, remove the valve from the

core.

8. At this point either the expansion valve, evaporator

core or both may be replaced.

a. If replacing the expansion valve, use new etO"

rings and make the connections carefully to

eliminate possible refrigerant leaks. Position

the power element bulb so that it lies flush with

the low pressure line and has the insulating

material properly in place.

b.
If the evaporator core is to be replaced, it will

be necessary to remove the air conditioning

door bowden cable from the core and install it

in the same location in the replacement core.

If no passage has been provided for this purpose

in the replacement core, a pointed instrument

such as a pencil may be forced through core

vanes at the proper location to provide the re-

quired opening. Also remove the spacer bracket,

nut and screw from the inlet and outlet pipes of

the evaporator core and place them in a like

position on the replacement core.

CHEVROLET CHASSIS SERVICE MANUAL

HEATER AND AIR CONDITIONING 1A-57

EVAPORATOR PIPES

DISTRIBUTOR RELAY GRD.

ASSEMBLY & WASHER

EVAPORATOR ASM.
BLOWER

SHROUD

(RACKET

(PART OF

BLOWER)

Fig.
76—Evaporator Removal—All Weather

7. Disconnect the thermostatic expansion valve to evap-

orator inlet connector, remove the power element

bulb from the evaporator outlet line and carefully

move .the valve and its inlet hose away from the

evaporator case.

8. Remove the electrical connectors from the relay

and resistor terminals.

9. Remove the screws attaching the evaporator case

cover to the case. See Fig. 79. The core is bracket

mounted to the cover and the entire core and cover

assembly may now be removed from the vehicle.

10.
Remove the two cover to core bracket screws and

separate the core from the cover.

11.
Install the new core to the cover being sure that the

grommets are properly installed around the inlet

and outlet lines.

12.
Reinstall the core and cover assembly into the evap-

orator case and replace the attaching screws.
13.
Reinstall the STV and expansion valves, the equal-

izer line connection and the evaporator oil bleed line

from the STV.

NOTE:
Use all new «O" rings.

14.
Reinstall the radiator supply tank, water valve and

vacuum line, and replace the heater hoses onto the

core pipes being sure not to switch the hoses. Then

refill the radiator.

15.
Add three fluid oz. refrigerant oil after installing a

new core, evacuate and charge the system.

EXPANSION VALVE

The thermostatic expansion valve is factory adjusted

and pre-set and cannot be adjusted after installation. A

malfunctioning valve must be replaced. However, before

proceeding, check all other possible causes of the trouble.

Make certain that the power element bulb is properly

CHEVROLET CHASSIS SERVICE MANUAL

HEATER AND AIR CONDITIONING 1A-58

Fig.
77-Underdash Wiring-All Weather

positioned on the low pressure line, tightly clamped and

has the insulation in place. Make certain the liquid inlet

screen between valve and receiver- dehydrator line is not

clogged. After checking the screen and the location and

mounting of the thermo-bulb, proceed with replacement of

the valve assembly. A malfunctioning valve may result

from a stuck open or shut needle caused by corrosion^ or

a discharged power element caused by a broken capillary

line or tip.

Four-Season System Chevrolet, Chevelle,

Corvette, and Camaro

Replacement

1.
Purge the system and, on Chevelle models, drop

the right fender skirt.

2.
Remove the expansion valve power element bulb

from the low pressure line and the equalizing line

from the POA valve.
3.
Remove the low and high pressure connectors from

the valve, in that order. Remove the screw and

bracket attaching the expansion valve to the blower

case and remove the valve.

4.
Before replacing the valve, check to be certain the

inlet screen, is not clogged. If the screen is plugged,

replace it and check valve operation. If screen is

clear or if valve still malfunctions after screen re-

placement proceed with the valve replacement.

5. Install the new valve by connecting the lines. Clamp

the power element bulb of the new valve to the top of

the low pressure line and the equalizing line to the

suction throttling valve.

NOTE:
Be sure to replace the insulation around

the power element bulb and that the power ele-

ment makes good physical contact with the suc-

tion line.

6. Evacuate and charge the system.

CHEVROLET CHASSIS SERVICE MANUAL

HEATER AND AIR CONDITIONING 1A-59

Fig.
78—Evaporator Mounting (Corvette)

7. Check the system for proper operation.

Universal System

Follow the procedure outlined under " Evaporator" for

the Universal System.

Chevy II All-Weather System

Replacement of Valve Assembly

1.
Purge the system of refrigerant and remove the

evaporator unit from the vehicle and the core from

the unit as described under "Evaporator."

2.
Remove the expansion valve power element bulb and

the equalizing line connection from the low pressure

line.

3.
Remove the low pressure and high pressure lines

from the valve. Remove the valve.

4.
Install the new valve by connecting the low pressure,

high pressure and* equalizing line connections and

clamp the power element of the new valve to the low

pressure line.

5. Replace the core and evaporator as covered under

"Evaporator."

EVAPORATOR CONTROL VALVE (POA)

(Chevrolet, Chevelle, Comoro, Corvette)

No repairs or adjustments are available on the POA

valve. A malfunctioning valve must be replaced. Figures

80,
81, 82 and 83 illustrate valve installation on the above

vehicles.

THERMOSTATIC SWITCH OR BLOWER SWITCH

Universal System

Removal

1.
Remove the screws attaching the cover plate to the

unit and pull the cover rearward.

2.
(Fin sensing type) Remove the thermostatic capillary

tube from the evaporator core to permit access to

the back of the cover plate.
Fig.
79—Evaporator Core Removal (Corvette)

Fig.
80-P.O.A. Installation (Chevrolet)

CHEVROLET CHASSIS SERVICE MANUAL

ENGINE-ELECTRICAL 6Y-7

CHARGING SYSTEM

INDEX

Page

General Description . 6Y-7

Maintenance and Adjustments 6Y-9

Static Checks . 6Y-10

System Condition Check and Voltage

•Regular Adjustment. 6Y-10

General Output 6Y-11

Generator Diode and Field Test 6Y-12

Indicator Lamp-Initial Field Excitation

Circuit Tests . 6Y-12
Page

Field Circuit Resistance Wire Tests 6Y-13

Field Relay Test and Adjustment 6Y-14

Other Harness Checks 6Y-14

Service Operations 6Y-14

Generator 6Y-14

Removal and Installation 6Y-14

Pulley Replacement. 6Y-14

Brush Replacement (6" Delcotron). 6Y-15

Double Contact Regulator . . . . . . 6Y-16

GENERAL DESCRIPTION

The charging system includes the battery, generator,

regulator, telltale light, and necessary wiring to connect

these components. The Delcotron is offered as standard

equipment, although there are various capacities avail-

able on all models.

The Delcotron continuous output A.C. generator (fig.

lc) consists of two major parts, a stator and a rotor. The

stator is composed of a large number of windings as-

sembled on the inside of a laminated core that is attached

to the generator frame. The rotor revolves within the

stator on bearings located in each end frame. Two

brushes are required to carry current through the two

slip rings to the field coils wound concentric with the

shaft of the rotor. Six rectifier diodes are mounted in the

slip ring end frame and are joined to the stator windings

at three internally located terminals.

Diodes are mounted in heat sinks to provide adequate

heat dissipation. The six diodes replace the separately
mounted rectifier as used in other types of application.

The diodes change the Delcotron A.C. current to D.C.

current.

Two regulators (fig. 2c) are available on the 1967 vehi-

cles,
a double contact two unit type and a transistor

regulator. The function of these regulators in the charg-

ing system is to limit the generator voltage to a pre-set

value by controlling the generator field current. Both

regulators have an internal field relay unit. The relay

unit allows the telltale lamp to light (as a bulb check)

with the ignition key on and engine not running. When the

engine is started and the generator begins to charge, the

indicator light goes out indicating that the system is op-

erating normally.

The double contact regulator, when used with the

special 63 amp air conditioning model generator (4 ohm

field coil) uses a field discharge diode internally in the

field circuit (figs. 3c and 4c). The added diode adapts the

BRUSH AND

TERMINAL

ASSEMBLY

SLIP RINGS
SLIP RING

END FRAME

_\

THRU

BOLT
DRIVE END

FRAME

BEARING

BEARING

DIODES

ROTOR

5.5" SERIES ID DELCOTRON
STATOR

ASSEMBLY
GREASE

RESERVOIR

BRUSH

FAN ASSEMBLY

6.2" SERIES 2D TYPE 150 DELCOTRON

Fig.
lc—Delcotron Cross-section View

CHEVROLET CHASSIS SERVICE MANUAL