battery CHEVROLET CAMARO 1967 1.G Chassis User Guide

HEATER AND AIR CONDITIONING 1A-6

CHEVROLET SHOWN AS TYPICAL

Fig.
8—Heater Hose Routing (Chevrolet Shown as Typical)

cables, defroster hoses and the

place and install all at-

4.

5.

6.
Attach all bowden

wiring connector.

Set heater assembly into

taching nuts and screws.

Attach inlet and outlet hoses.

Replace glove box and glove box door.

Refill cooling system.

Defroster Duct

Installation of the defroster duct as used in Chevy H

vehicles is illustrated in Figure 14.

Blower Motor

Replacement

1.
Remove the heater assembly from the firewall.

Remove the five screws attaching the motor and

blower to the heater assembly.

2.
Remove the retainer attaching blower to the motor

shaft.

3.
Replace blower on new motor assembly, balance and

reinstall into heater assembly.

Fan Control

Replacement

1.
Remove the screws at the dash lower edge which

retain the control assembly and lower the assembly.

2.
Disconnect the blower harness connector and remove

the switch retaining screws and switch.

3.
Install the replacement switch with the nylon bearing

inserted into the AIR - FAN lever slot.

4.
Connect the blower harness connector and remount

the control assembly in the dash.
CORVETTE

Blower Assembly

Removal

1.
Remove the radiator supply tank from its retaining

straps and move it out of the way, then disconnect

the battery positive cable.

NOTE:
It is not necessary to drain the radiator.

2.
Remove the connectors from the blower motor.

3.
Scribe or chalk a mark on the blower motor mount-

ing plate and blower assembly.

4.
Remove the five screws retaining the blower mount-

ing plate to the blower inlet assembly.

Withdraw the blower assembly from the inlet

5.

assembly.

Disassembly

Remove the blower wheel from the motor by removing

the nut and tapping the motor shaft with a soft hammer.

Installation

1.
Assemble the blower to motor and using the scribe

mark, properly position the blower assembly on the

inlet assembly and install the five screws.

2.
Replace the electrical connectors on the blower

motor.

3.
Replace the radiator supply tank and the battery

positive cable.

Blower and Air Inlet Assembly

Removal

1.
Drain the radiator.

2.
Remove the radiator supply tank from its retaining

straps and swing it out of the way.

3.
Remove the battery.

CHEVROLET CHASSIS SERVICE MANUAL

HEATER AND AIR CONDITIONING 1A-8

Fig.
12—Control Assembly (Camaro)

3.
Replace the battery and radiator supply tank.

4.
Replace each heater hose to its proper core

connection.

5. Refill the radiator.
Defroster Duct

Figure 19 illustrates the installation of the Corvette

defroster duct.

Fig.
13—Chevy II Heater Components Removal
Fig.
U-Defroster Duct (Chevy 11)

CHEVROLET CHASSIS SERVICE MANUAL

HEATER AND AIR CONDITIONING 1A-9

Fig.
15-Heater Control Assembly and Cables (Chevy II)

Resistor Removal

Two screws attach the resistor to the rear side of

the heater assembly.

Heater Assembly

Removal

1.
Drain the radiator.

2.
Remove the radiator supply tank from its support
Fig.
16—Heater Hose Routing (Chevy II)

straps and move it out of the way.

3.
Remove the battery.

4.
Remove the water supply hoses from the core

connections.

5. Remove the blower and air inlet assembly as de-

scribed above.

6. Remove the glove compartment and the panel on

either side of the instrument panel console as out-

lined in the Body Section of this manual.

Fig.
17—Corvette Heater and Blower Inlet Assembly

CHEVROLET CHASSIS SERVICE MANUAL

HEATER AND AIR CONDITIONING 1A-10

PLATE RETAINERS

CORE BRACKET SCREWS

Fig.
18—Corvette Heater Core Removal

7. Place a protective covering (waterproof if possible)

over the carpeting under the heater.

8. Remove the two bowden cables from the instrument

panel and disconnect the wiring connectors from the

blower switch and from the resistor.

9. Carefully work the heater assembly out from beneath

the dash.

Core Removal

1.
Remove the heater assembly as described above.
2.
Remove the sheet metal nuts which retain the core

mounting plate to the core housing.

3.
Remove the screws attaching the core brackets to

the core mounting plate and separate the core and

plate. .

Installation

1.
Assemble the core to plate with non-hardening

sealer. Attach the core mounting screws.

2.
Attach the core and plate assembly to the case with

the two sheet metal nuts. The assembly is ready for

installation as described below.

Heater Assembly Installation

1.
Carefully position the heater assembly in place on

inner surface of dash panel, then install the blower

and air inlet assembly on heater studs extending

through to the engine side of the panel. Attach the

seven stud nuts.

2.
Install electrical connectors to the blower switch and

resistor and reinstall the bowden cables to the

instrument panel.

3.
Replace the blower electrical connectors.

4.
Replace the heater hoses. (See Figure 20)

5. Replace the battery and the radiator supply tank.

6. Refill the radiator and check for leakage.

7. Check heater operation and make control adjustments

as necessary.

8. Replace the console panels and the glove

compartment.

CHEVROLET CHASSIS SERVICE MANUAL

HEATER AND AIR CONDITIONING 1A-34

a. Blower comes on High speed.

b.
Cold air comes from A/C outlets.

3.
Rotate Temperature Dial to 85°F.

a. Blower speed will decrease to Low speed then

increase to Medium or High.

b.
Air temperature changes from Cold to Hot and

comes out heater outlet.

4.
Move control lever to LOW Front, with Temperature

Dial at 85°F. Blower operates at Low and Medium

speeds.

5.
Move control lever to Rear, set Temperature Dial

at 65°F.

a. Blower goes to High speed and maintains high

air flow.

b.
All air comes from A/C outlets.

6. Move control lever to DE-FOG.

a. Blower is on Medium or High Speeds.

b.
Air comes from Defroster and Heater Outlets.

7.
Move control lever to DE-ICE.

a. Blower is on High Speed.

b.
Air temperature goes to warm and most of air

comes from defroster nozzle, with small amount

of air coming from heater outlet.

c. Outside air door is open - (door valve is closed

to car body).

8. Move control lever to REAR (dial at 65°). Outside

air door moves outboard. (Door valve is open to

car body).

CHEVROLET COMFORTRON TESTER

The J-22368 Automatic Temperature Control Tester

when in AUTOMATIC position, may be used to perform
Comfortron system checks without disturbing normal car

operation.

Under MANUAL control tester allows the operator to

set and hold a predetermined blower speed
and.
temper-

ature. The tester can also be used to measure external

system voltages by using the probe.

To Install the Tester

1.
Remove the three-terminal male connector from the

Amplifier on the Comfortron control head.

2.
Plug this connector into the three terminal female

connector (with yellow wire)
on
the Tester.

3.
Plug the remaining three-terminal male connector

on the Tester into the Amplifier on the control head.

4.
Attach the black ground lead to any good ground

point available in the car.

5.
Remove the large vacuum hose from Transducer and

connect it to the Tester vacuum hose nipple.

6. Connect the Tester vacuum hose (short hose) to the

Transducer.

Quick Test Procedure

With the J-22368 Tester installed as outlined above,

the following quick checks may be made to pinpoint

the cause of system malfunctions. This quick check

procedure is reproduced on the "swing out" plastic

instruction card attached to the back of the Tester.

Before performing the checking procedure, start the

engine and allow to run on fast idle until operating

temperature is reached. Then set the dash control lever

to HI-FRONT position and the dash control Temperature

Dial to 75° and proceed with the following steps:

Step

1

2

3

4

5A

5B
Tester Settings

Rocker

Switch

Manual

Manual.

Manual

Manual

Manual

Auto-

matic
Voltage

Source

Sensor

Amplifier

or

Control

Cal.

Trans-

ducer

Amplifier

or

Control

Cal.

Amplifier

or

Control

Cal.
Manual

Control

150

150

a. Max.

Heat*

b.
Max.

Cold*

a. Max.

Cold*

b.
Max.

Heat*

Set to

150 for

Comfortron

System

Same as 5A.

Allow 5 min.

for system

to stabilize

with doors

and windows

closed.
Tester Should

Indicate:

Battery Voltage

Battery Voltage

0-4 Volts

8 Volts Min.

8 Volts Min.

0-3 in. Vac.

0-4 Volts

9 in. Min. Vac.

6.5 Volts

5.5 to 7.5 Volts
To Correct Abnormal Indication:

Check fuse and wiring.

Check for open in sensor circuit.

See Service Manual:

Malfunctioning Amplifier or Temperature

Dial.

Check for open or bad ground in trans-

ducer circuit or replace transducer.

Rotate car temperature dial until meter

reads 6.5 volts. Car temperature should

'•- indicate 75°. If not, see temperature

calibration which follows.

After 5 minutes of operation check for

defective sensor.

•This setting should result in HIGH blower speed. Refer to shop manual for further operational checks.

CHEVROLET CHASSIS SERVICE MANUAL

HEATER AND AIR CONDITIONING 1A-36

(These tests should be performed with the engine at operating temperature.)

SYSTEM CHECKS

Control

Head

Setting

High

Front

Lo

Front

Lo

Front

Hi

Front

Hi

Front
Tester Settings

Function

Manual

Manual

Manual

Manual

De-ice

65° on

Temp.

Dial

Hi

Front

Hi

Front

Hi

Front
Auto-

Matic

1 1

Auto-

matic

Manual

Manual
Manual

Control

Max.

Heat

Rotate

from

Max.

Heat to

Max.

Cold

150

Max.

Cold

Max.

Cold

Max.

Cold

Max.

Heat

Max.

Heat

Max.

Cold
Voltage

Trans-

ducer

Trans-

ducer

Ampli-

fier

Trans-

ducer

Probe

Probe

Trans-

ducer

Trans.
Tester Should

Indicate:

High Blower

Maximum Heat

Reduced Blower

Speed

Complete series of

blower changes from

Hi to Lo to Hi

again.

AMPLIFIE:

Remove conn, from c

Voltage reading she

Short this lead to grc

Voltage reading she

No voltage change in<

COMPRESSOR C

Cooling System

Operation

DE-ICE i

Assuming rest of

system is operating

normally: Max. Heat

1
to windshield.

SENSOR STR

•—

TRAtfSDtfC

0-3"
Vac. Reading

8 Volts Min.

9"
Min.
Vac.
Reading

0-4 Voltage Reading
If not, check

the following:

Fuse in Slock

In Line Fuse

High Blower

Delay Relay

Duct Delay

Thermistor

High Blower

Delay Sensor

Power Servo

Blower Switch

Resistor

Blower Motor

Wiring Harness

Blower Switch

Master Delay

Thermistor

Master Delay

Relay

Resistor

Power Servo

Blower Motor

CHECK

Resistor

I CHECK
Electrical Diagram

Probe Points:

1-2

8-9

10-21

20

18

19

*
9-46

-r

^2-3
15

16

Checked during

above procedure.

(This is a com-

plete step-by-step

high blower circuit

check which also

checks wiring

harness.)

4

5

6

L2-13

L4

""§2-15

39-46

1
16 1

14

22-40-42-44-15

.ontrol head temperature dial.

>uld be 9 volts minimum,

jund.

>uld be 0 volts,

iicates malfunctioning of amplifier.

JUTCJH CHUCK

Compressor Clutch

(Grille Temp, must

be above 40°.)

IRCUIT

Blower Switch

Master Delay

Relay

Transd

NGCl
ucer

Sensor String

2R CHECK

Transducer voltage

&t Max. Cold

position)

Transducer Ground

Hi Blower Outside

air (air door closed

to car body). Hot air

from heater outlets.

Hi Blower Recirc.

Air (air door open

to car body) cold air

from A/C outlets.
24-25-26-27-28
Voltmete

should re
ad

Battery Voltage

Battery Voltage

Battery Voltage

. Vtinimum
6
volts

Battery Voltage

Minimum
6
volts

Battery Vo]

Batterv Vo]
Ltage

Ltage

Battery Voltage

Batterv Voltage

3a

Bai
:terv Vo

tterv Vo
tage

tage

Minimum
6
volts

Batterv Voltage

Minimum
6
volts

Battery Voltage

Minimum
8
volts

Minimum 8 volts

Minimum 8 volts

Batterv Voltage

Minimum 8 volts

1 III • II »ll. —..• —•— . !!•• 1

Battery Voltage

3-23

20-10-21

38

29-30-31-32-33-

34-35-36

37-38

Defective Power Servo; Leak in Vacuum

System; Temp.; Door Link Disconnected

or Jammed; Defective Vacuum Relay

Valve

Defective Mode Door Diaphragm
Batterv Voltage

Battery Voltage

Zero Voltage

Battery Voltage

Battery Voltage

CHEVROLET CHASSIS SERVICE MANUAL

HEATER AND AIR CONDITIONING 1A-62

2.
Insert the evaporator assembly into the outlet case

half and mount the evaporator, thermostatic switch,

and cable to the case.

3.
Install the face plate to the case and install control

retaining nuts and knobs.

4.
Assemble the case halves and mount the evaporator

pipe clamp.

5. Install the evaporator assembly as previously

described under EVAPORATOR.

BLOWER ASSEMBLY

Four-Season System

Chevrolet and Camaro

Removal

1.
Disconnect battery ground cable.

2.
Remove the right front fender and skirt assembly.

3.
Disconnect the motor wire at the flange connector.

4.
Disconnect the rubber air cooling tube from the

motor.

5. Remove the motor to case attaching screws and re-

move the blower assembly. If the sealer acts as an

adhesive, pry the assembly carefully away from the

6. Remove the blower from the motor shaft.

Fig.
86—Blower Assembly—Four-Season (Chevrolet,

Chevelle, Camaro)
Installation

1.
Mount the blower to the motor shaft with the open end

of the blower away from the motor.

2.
Mount the assembly to the case with the attaching

screws.

3.
Connect the rubber tube and blower wire to the

motor.

4.
Replace the right front fender and skirt assembly.

5. Connect battery ground cable.

Chevelle

The blower assembly (fig. 86) is mounted to the dash

panel and contains the outside air-recirculated air

diverter door, the heating-cooling diverter door, the air

conditioning relay and resistor, the compressor actuating

switch, and the blower motor.

Replacement

1.
Disconnect the blower motor "hot" wire at the con-

nector and the ground lead on the Chevrolet.

2.
Detach the rubber cooling tube from the blower as-

sembly and remove the five bolts attaching the

blower motor to the blower assembly.

3.
Remove the motor and fan, disassemble fan from

motor and install on a new motor. If, because of

engine accessories, hoses restrict lifting the blower

assembly from the engine compartment, remove

blower from motor and lift units out separately.

Assemble replacement units under the restricting

hoses.

4.
Reinstall motor and fan into blower assembly. Re-

place cooling tube, ground wire and connect hot wire

to connector.

5. Check blower operations.

Corvette

Replacement

1.
Remove the radiator overflow tank and brackets and

pull the tank out of the way as far as the length of the

heater hose will permit.

2.
Disconnect the electrical connector and the rubber

air inlet tube from the blower motor.

3.
Remove the five blower flange to case attaching

screws and carefully remove the blower motor and

drum assembly.

4.
Remove the blower drum assembly and reinstall on

a new blower motor.

5. Replace the blower motor and drum assembly in the

case and reinstall all screws, hoses and electrical

connections.

All-Weather System

Chevy II

Removal

Under the Hood

1.
Purge the refrigerant from the system.

2.
Drain the radiator.

3.
Remove the refrigerant hoses at the evaporator

pipes.

4.
Remove the evaporator pipe clamp and grommet.

5. Remove three nuts from the blower case studs which

pass through the firewall.

6. Remove heater hoses from core tubes.

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

HEATER AND AIR CONDITIONING 1A-73

Fig.
105—Comfortron Control Head

10.
Introduce R-12 vapor at cylinder (room) temperature

and pressure.

11.
Leak test all fittings and connections and give partic-

ular attention to a leak test at the compressor shaft

seal if compressor has not been leak tested on the

bench.

12.
Complete system processing and charge system.

FUSES

A fuse, located in the junction block protects the entire

air conditioning system except for the blower when op-

erating at high speed.

A second fuse, to protect the high speed blower circuit,

is located in the electrical wiring between the horn relay

and the Air Conditioner relay (except Universal). The
Universal unit has a fuse in the line between the ignition

switch and the Air Conditioner blower switch. See the

specification page for the proper replacement fuse.

FOUR SEASON HEATER COMPONENTS

Corvette

The heater components of the system are, in general,

much the same as those of the standard Corvette heater.

Heater hoses carry the engine coolant to the heater core,

located in the air distributor duct beneath the instrument

panel.

A significant difference is that in the Corvette Air

Conditioning System there is no flow through the heater

core until the COOL IN-HOT PULL knob is pulled out.

This movement opens the vacuum switch on the air

distributor assembly and allows vacuum to be applied

to the water valve mounted in the engine compartment,

opening the valve. Thus the heater core is unheated

until needed, at which time it receives full flow of the

engine coolant. Air passing through the core receives

maximum heat which is tempered by mixing with un-

heated air before entering the passenger compartment.

Heater Core

Replacement

The heater core in the Corvette Air Conditioning

System is removed in the same manner as the core in

the Corvette heater. The distributor assembly must first

be removed from under the dash as covered previously

in this section before the core can be removed and

replaced.

Water Valve

Installation of the water valve is illustrated in Figure

113.
An inoperative valve must be replaced.

Chevrolet

Heater Core

Removal

1.
Disconnect battery ground cable.

2.
Drain radiator

3.
Remove right front fender and skirt assembly.

Fig.
106—Comfortron Temperature Dial Adjustment
Fig.
107—Amplifier Removal

CHEVROLET CHASSIS SERVICE MANUAL