Wiring CHEVROLET CAMARO 1967 1.G Chassis User Guide

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-55

r-TO COMPRESSOR

^GROMMET^-^^Q^S

L.H. REAR—>*<^ >

BRACKET
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A
r—FORWARD

\ BRACKET

*-^"^
\
EVAPORATOR

BLOWER
ASM

\
-BRACE

===:

7—-INSTRUMENT PANEL

f REINFORCEMENT

/

/

f
R.H. REAR
M

BRACKET
m

K BRACKET—^

#INLET
V

M
"6"
RING
\

/
\N

1
-
DASH PANEL—v

GROMMET—^
\

OUTLET—v
A^

J/

X
\—
OUTLET
"O"
RING

A \~-EVAPORATOR

,
&
BLOWER
ASM
INLET

TUBE

Fig.
72—Evaporator Mounting—Universal Unit

9. Replace
the
core
and
valve assembly, with
the
bow-

den cable
in
place,
in the
evaporator case
and
install

the
two
case-to-door bracket attaching screws.

10.
With
the
gasket
in
place, install
the
back cover
of

the evaporator case
and its
attaching screws and
the

seal around
the
evaporator inlet
and
outlet tubes.

11.
Reach through
the
face plate opening
and,
using
the

plastic plug, attach
the
thermostatic switch capillary

tube
to the
evaporator core.

Installation

Within
the Car

1.
Attach system wiring
as
necessary
to the
evaporator

case.

2.
Carefully pass
the
evaporator inlet
and
outlet pipes

through
the
special grommet
in the
dash panel.

3.
Insert
the
evaporator studs through their drilled

holes
in
the
instrument panel flange
and
reinforce-

ment
and,
reaching through
the
glove
box
door
and
ash tray opening, install
the nut
and washer
on
each

stud.

4.
Replace
the
screws attaching
the two
evaporator

case brackets
to
the
blower bracket and distributor

bracket.

5. Replace
the
shield
and
attaching screws protecting

the lower right mounting bracket.

6. Reaching through
the
face plate opening, attach
the

evaporator bowden cable.

7. Replace
the
face plate and attaching screws, feeding

the control knob stems through
the
proper openings

in
the
face plate.

8. Replace
the
control stem bezels
and
control knobs.

9. Replace
the
drain hoses.

10.
Replace
the
glove
box
and
ash
tray.

Under
the
Hood

11.
Replace
the
spacer bracket, screw
and nut on the

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-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-60

Fig.
81-P.O.A. Installation (Camaro)

NOTCH IN SUPPORT

TO ENGAGE SLOT !N VALVE

WHEN VALVE IS ROTATED

TO ANGLE AS SHOWN

Fig.
82-P.O.A. Installation (Chevelle)
Fig.
83—P.O.A. Installation (Corvette)

3.
Remove the electrical connector at the switch to be

replaced.

4.
Remove the switch knob. Remove the switch retain-

ing screws
and:
switch.

Installation

1.
Insert replacement switch into face plate and attach.

2.
Install the switch knob and connect the wiring

connector.

3.
If the thermostatic switch is being replaced, the

capillary tube should be formed to the same shape as

the unit removed.

4.
Attach the capillary to the core (fin sensing type)

and replace the face plate and attaching screws.

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-66

Fig.
93—Chevelle Four-Season Ducts

8. Remove the radio speaker and grille.

9. Remove the right outlet duct.

10.
Disconnect the bowden cables from their brackets

and operating levers on the distributor assembly.

11.
Disconnect the flexible tubing from the center and

left side outlet ducts at the air distributor assembly.

12.
Remove the heated air distributor ducts from the

air-distributor assembly.

13.
Remove the single remaining distributor to dash

panel attaching nut (the others were removed from

beneath the hood when the core cover was removed

in Step 2) located at the right end of the air dis-

tributor assembly.

14.
Carefully pull the assembly out from under the

dash, disconnecting the compressor switch wiring

connector and the water valve control switch vacuum

lines.
Installation

Reverse the removal procedure to reinstall the air

distributor assembly.

COMFORTRON AUTOMATIC

CONTROL COMPONENTS

The Comfortron system is the same as the Chevrolet

Four Season system insofar as the basic system compo-

nents are concerned. , Most removal and installation

procedures wUl remain as stated for the Four Season

system except where the automatic control components

are encountered. Each such component will be covered

in the pages which follow.

CHEVROLET CHASSIS SERVICE MANUAL

HEATER AND AIR CONDITIONING 1A-67

Fig.
94—Camaro Four-Season Ducts

Heater and Air Distributor Assembly

Removal

rfooo

1.
Disconnect battery ground cable.

2.
Drain radiator (do not purge refrigerant system).

3.
Disconnect all connectors attached to the Comfortron

wiring harness which are on the engine side of the

firewall. Push the wiring harness grommet through

the firewall to the rear.

4.
Disconnect the four vacuum hoses coming from the

underdash through the large firewall grommet. Push

the hose grommet through the firewall to the rear.

5.
Remove the nuts from the heater and air distributor

case studs which project through the firewall from

the dash side.

6. Disconnect the heater hoses from the core tubes.

Under Dash

1.
Remove glove box assembly.

2.
Remove the dash center face plate, ash tray assem-

bly, and any radio and/or tape equipment.

3.
Remove the Comfortron control assembly mounting

screws and lower the control unit.
4.
Remove the vacuum line from the kick pad valve

diaphragm.

5.
Disconnect all harness connectors between the Com-

fortron harness and the rest of the dash wiring.

6. Remove the air distributor duct which supplies the

dash outlets.

7.
Remove the screws attaching the heater and air

distributor to the firewall.

8. Pull the assembly rearward then down to remove

from the dash. Pull the Comfortron wiring harness

and vacuum hose assembly through the firewall.

Installation

1.
Place the entire case assembly with wiring, vacuum

hoses,
and control assembly into the car on the floor.

2.
Pass the underhood wiring harness and vacuum hose

harness as far as possible through the appropriate

firewall holes.

3.
Lift the assembly up into position and pass the case

studs through the firewall mounting holes. Attach

the case to the firewall with the mounting screws.

4.
Mount the dash outlet air distributor duct to the face

of the case.

CHEVROLET CHASSIS SERVICE MANUAL

HEATER AND AIR CONDITIONING 1A-68

Fig.
95—Corvette Four-Season Ducts

5. Connect the various Comfortron harness connectors

to the dash wiring and connect the vacuum hose to

the kick pad valve diaphragm. Push the vacuum hose

harness and wiring harness through the firewall to

the proper location and install their respective

grommets.

6. Raise the control unit into place and install the

mounting screws. Check that all connections are

complete.

7. Replace any radio and/or tape equipment, the ash

tray assembly, and face plate.

8. Replace the glove box assembly.

9. Connect the heater hoses to the core tubes, and

attach the nuts to the case studs through the firewall.

10.
Reconnect the four vacuum hoses as follows: Purple

to the cylinder on the thermo-vacuum valve, yellow

tracer to the body of the thermo-vacuum valve, red

tracer to the vacuum source "Tee" connection, and

white tracer to the vacuum tank inlet.

11.
Connect the wiring harness to the underhood air

conditioning components.

12.
Refill cooling system, connect battery ground cable

and check system performance.

Vacuum Tank

The vacuum tank is mounted on the firewall as shown

in Figure 97. Notice that the two vacuum lines are

clamped to the vacuum tank ports. *

Thermal Vacuum Valve

This heat operated vacuum valve is located in the

heater core input line. Figure 98 illustrates valve instal-

lation with clamps attaching the water hoses as well as

the vacuum hoses in place.
Resistor Assembly

Figure 99 illustrates the location and installation of

the blower speed resistor assembly.

Relays

Two relays are used in the system, both mounted on the

evaporator case as shown in Figure 100. The mounting

bracket forms a common ground for the relays and as a

plug for the hole in the evaporator housing used in the

Four Season system for resistor installation.

Sensors (Thermistors)

Ambient Switch and Sensor

This combination unit, which engages the compressor

clutch at about 40°F and also senses outside air tem-

perature and sun load, is mounted to the firewall within

the engine compartment with its long neck extending

deep into the cowl vent plenum chamber. Figure 98 il-

lustrates this installation,

In-Car Sensor

This sensor is located beneath the lip of the instru-

ment panel overhand just to the right of the driver as

shown in Figure 101.

Removal

1.
Remove glove box assembly.

2.
Disconnect sensor wires connector at harness.

3.
Remove sensor mounting screws, remove sensor

and pull wires and connector through hole in dash.

Installation

1.
Insert connector and

through the dash hole.
wires of replacement sensor

CHEVROLET CHASSIS SERVICE MANUAL