clutch CHEVROLET CAMARO 1967 1.G Chassis User Guide

HEATER AND AIR CONDITIONING 1A-37

VACUUM SYSTEM COMPONENT FUNCTION

Component

Air Door Diaphragm

Power Servo

Vacuum Relay Valve

Mode Door Diaphragm

Defroster Diaphragm

Transducer

Thermo Vacuum Valve
Vacuum Applied

Air Door Open to Outside Air

(Closed to Car Body)

Maximum Heat

Vacuum Applied to One Port Opens a Passage

Through the Valve to Allow Transducer Vacuum

to be Supplied to the Power Servo

Vacuum to Linkage Side

Air Flow Out Heater

Ducts

Full Airflow Out Heater

Outlet
Vacuum to Covered Side

Airflow Out of Upper

Outlets

Full Airflow Out Defroster

Outlets (Full De-ice)
No Vacuum Applied

Air Door Open to

Re circulated Air

(Open to Car Body)

Maximum Cooling

No Vacuum Applied Closes

Vacuum Supply to Power

Servo

Airflow Out of Upper and

Lower Outlets Door Open

1"
from 100% Lower Out-

let Position

Airflow Divided 1/3 Out

Defroster Outlets 2/3

Out Heater Outlets

Supplies Modulated Vacuum to Power Servo

Zero Voltage Applied to Transducer

Results in Maximum Vacuum Supply
10 Volts Applied to Transducer

Results in No Vacuum Supply

(Coolant Hot) Passes Vacuum When System is Calling For Outside Air

MAINTENANCE AND ADJUSTMENTS

EVAPORATOR CONTROL VALVE (POA)

(Chevrolet, Chevelle, Comoro, and Corvette

Four Season) (Chevrolet Comfortron)

The only check for proper POA valve operation is to

check the suction pressure at the valve as during a

performance test. The POA valve is an absolute valve

and will provide different gauge readings based on the

altitude where the readings are being taken. Correct

gauge reading at sea level is 29.5 psig. Gauge readings

will be one-half psi higher for each additional 1000 feet

of elevation. The following table lists gauge readings at

different altitudes. If a valve gives improper gauge

readings, it must be replaced since it is not repairable

or adjustable.

29.5

30.0

30.5

31.0

31.5

32.0

32.5

33.0

33.5

34.0

34.5
psig.

psig.

psig.

psig.

psig.

psig.

psig.

psig.

psig.

psig.

psig.
— Sea 1

— 1000

— 2000

— 3000

— 4000

— 5000

— 6000

— 7000

— 8000

— 9000
Level

ft.

ft.

ft.

ft.

ft.

ft.

ft.

ft.

ft.

— 10000 ft.
THERMOSTATIC SWITCH

(Universal and Chevy II All-Weather System)

Thermostatic switches used in Universal and All-

Weather systems differ only in the capillary tube sensing

unit.

The Chevy n All-Weather System thermostatic switch

has an air sensing capillary which is coiled and attached

to the front of the evaporator core with plastic plugs.

This type of unit is controlled by the temperature of the

air leaving the evaporator.

Universal systems make use of a thermostatic switch

with a fin sensing capillary or a self-supporting air sens-

ing capillary. This capillary controls the switch by

sensing the temperature of the metal fins or the air

leaving the fins.

Checking for Proper Operation

1.
Install the gauge set and set up the vehicle as

described under Performance Test.

2.
Movement of the temperature control knob should

result in a definite change in suction pressure and

cycling of the compressor clutch.

• If compressor continues to operate regardless of

the knob adjustment, it indicates that the points

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-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-76

Fig.
112—-Heater Core Removal—Four-Season System (Corvette)

3.
Replace the core case into the car as described

under Heater and Air Distributor Assembly.

COMPRESSOR

The same basic six.cylinder reciprocating compressor

is used in all systems.

Two variations of the basic compressor are used. One,

with a displacement of 12.6 cu. in. is used with the Four-

Season System. The second model, having displacement

of 10.8 cu. in. is used with the Universal and All-Weather

Systems.
AH Systems

Removal

1.
Purge the refrigerant from the system.

2.
Remove connector attaching bolt and connector. Seal

connector outlets.

3.
Disconnect electrical lead to clutch actuating coil.

4.
Loosen brace and pivot bolts and detach belt.

5. Remove the nuts and bolts attaching the compressor

brackets to the mounting bracket.

6. Before beginning any compressor disassembly, drain

and measure oil in the compressor. Check for

evidence of contamination to ..determine if remainder

of system requires servicing. Compressor Servicing

information is located in the Chassis Overhaul

Manual.

Installation

1.
li oil previously drained from the compressor upon

removal shows no evidence of contamination, replace

a like amount of fresh refrigeration oil into the com-

pressor before reinstallatLon. If it was necessary to

service the entire system because of excessive con-

tamination in the oil removed, install a full charge of

"fresh refrigeration oil in the compressor. (See

Checking Compressor Oil Charge under Checking

Oil)

2.
Position compressor on the mounting bracket and

install all nuts, bolts and lock washers.

3.
Install the connector assembly to the compressor

rear head, using new "O" rings.

4.
Connect the electrical lead to the coil and install

and adjust compressor belt.

5. Evacuate and charge the system.

6. Leak test the system and check for proper operation.

Fig.
113—Heater Hoses^-Four-Season System (Corvette)

CHEVROLET CHASSIS SERVICE MANUAL

HEATER AND AIR CONDITIONING 1A-78

WIRING DIAGRAMS

Blower

Motor

Resistor
•

Asm

EVAPORATOR—v

ASM.
\

-Diode
(Arc I

suppressor)
^\

16B
—>

-COMPRESSOR

Clutch Coil

•To battery positive

(+) terminal
No vacuum

in hose
#3

Blower

intake

air

Outside

air entry

Valve

by vacuum
in

hose
#3
Valve

normally

closed (spring

held)

Inside

car
air

(Recirc.)
AIR INLET

VALVE

POSITION:

Outside
air
intake

Recirc. air'intake

CONTROL ASM

TEMP CONTROL LEVER

(Operates temp valve

cable
&
equipment
in

chart shown below)
Compressor
Sw.

(Normally closed

Temp valve

begins
to
open

valveV

cable
arm

•Fan Speed Selector Switch

Switch

lever

position

Off

Low

Med

High
Contacts

made

B
to
None

BtoL

B to L
&
M

B to
L
& H
Fan

speed

Low

Low

Med

High
Resistance

in series with

Bio Motor

Hi

Rl

(RiR2)/(Rl+R2)

None

•Blower switch contacts must
be
dosed

before
fan
switch will
be
operable.
COLD
(O.
A.)

COLD a.A.)

Blower

H
y—low
switch

M/
-med
(Norm,

closed

contacts)

Fan speed switch

(See chart
at
left)

To vacuum,

tank

EXTENSION—vy

Horn relay "Bat" WIRE
ASM
X
harness

terminal

V
.**-__.. ;_
1 I panel

Legend:

___. —
Production wiring

Wire
is
part
of
equip.

•—————* Air
conditioning
wrg.
| i

T Agn. sw.

accsy

I term.

I
Temp

Control

Lever

Position

OFF

VENT.

COLD(I.A.)

COLEKO.AJ

HOT
Blower

(Master)

switch

contacts

Open

Closed

Closed

Closed

Closed
Vac switch

connects

vac source

to hose
#

#2

#2
&
#3

None

#3

#2
&
#3
Compressor

switch

contacts:

Open

Open

Closed

Closed

Open
Blower

intake
air

Outside
car air

intake used

Inside
car air

recirculated

Outside
car air

intake used

.Outside
car air

intake used

Fig. 114—Chevrolet—Four-Season Wiring Diagram

CHEVROLET CHASSIS SERVICE MANUAL

HEATER
AND AIR
CONDITIONING
1A-80

EVAPORATOR ASM.

Blower

Motor
INSIDE VALVE

(Normally closed

-spring held)

PLENUM VALVE

(Normally open

-spring held)
Actuator

(Vacuum

operated)

Inside car air (Recirc*

CONTROL ASM

TEMP CONTROL LEVER

•(Operates temp valve

cable
&
equipment in

hart shown below)

Temp valve

begins to

16DG

Fuse (In-line^

COMPRESSOR

Clutch Coil DASH-

PANEL

•Fan Speed Selector Switch

Switch

lever

position

Off

Low

"HeST

High
Contacts

B to
None

BtoL

B to L b U

BtoL&H
Fan

speed

Low

Low

Med

High
Resistance

in series with

Bio Motor

Rl

Rl

RlR2)/(Rl+R2)

None

•Blower switch contacts must be closed

before fan switch will be operable.

-To battery positive

(-0 terminal

•
Horn relay

terminal"
"Batf
To vacuum

tank

EXTENSION

WIRE
ASM
(Normally closed

contacts-*vac

operated)

7
*- Fan speed switch

(See chart at left)

•/-Wire is

\ part of

I inst panel

harness

Legend:

— Production wiring

————
Wire Is part of equip.

•mmmmmmmmmmmmmm*
AIT
Conditioning
WTg*
Temp

Control

Lever

Position

OFF

VENT

COLD

a.A.)

COLD

(O.A.)

HOT
Blower

(Master)

switch

contacts

Open

Closed

Closed

Closed

Closed
Vac switch

connects

vac source

to hose #

#2
&
#3

#2

#3

None

#2
Compressor

switch

contacts^

Open

Open

Closed

Closed

Open
Blower

intake air

Outside car air

intake used

Inside car air

recir culated

Outside car air

intake used

Outside car air

intake used

Fig.
116—Camaro—Four-Season Wiring Diagram

CHEVROLET CHASSIS SERVICE

HEATER AND AIR CONDITIONING 1A-82

•BATTERY

(POS)
CABLE
NOTE
When
control
switch*

is !TOFF"
&
Air
Cond
is
"ON"

(Control
knob
pulled
but) the

blower
fan'will
run at low
speed.
CONTROL
SWITCH

CONNECTIONS

OFF

LOW

MED

HIGH
B
TO
NONE

B
TO L

BTOL&M

B
TO L
&
H

COMPRESSOR
GROUND

WIRE
ASM
BATTERY

(NEGATIVE)

CABLE

COMPRESSOR
ASM

DASHPAJSTEL

GROMMET

16DG
CONTROL

SWITCH

RESISTOR

ASM

14LBL

14BRN
CLUTCH

COIL

EXTENSION

WIRE
ASM
-14BRN--N

JUNC

BLOCKi

OSTATIC

SWITCH

CONTACTS

NORMALLY

CLOSED
STARTING

MOTOR

SOLENOID

BLOWER

MOTOR
AIR
COND

CONTROL

(PUSH-PULL)

KNOB

DOOR
SWITCH

(PUSH
BUTTON

NORMALLY

CLOSED)
RELAY

ASM

HORN

RELAY

DIVERTER

DOOR CABLE

FUSE

PANEL

EVAPORATOR

ASM

IGNITION SWITCH-

ACCESSORY TERMINAL)

Fig. 118—All Weather Wiring Diagram (Chevy II)

CHEVROLET CHASSIS SERVICE MANUAL

HEATER AND AIR CONDITIONING 1A-83

DIVERTER DOOR

CRANK POSITIONS:

AIR COND "ON"

AIR COND "OFF*
AIR COND SWITCH

(PUSH BUTTON,

NORMALLY CLOSED

CONTACTS)

BLOWER MOTOR

CONTACTS

NORMALLY

4D

16

16B/Y

COMPRESSOR

GROUND WIRE

ASM

BAT.
TERMINAL

ON STARTING

MOTOR SOLENOID

' BATTERY

CABLE ASM:

NEGATIVE

POSITIVE—*
- CONTROL SWITCH

SET AT:

•OFF

LOW

MED

HIGH
CONTACTS:

BTOBL

BTOL

BTOM

BT0M6B,

CLUTCH

HOUSING
liOli: WHEN CONTROL

SWITCH IS AT "OFF" &

AIR COND. IS "ON", FAN

WILL RUN AT LOW SPEED.

"AIR COND-PULL"

KNOB (SHOWN IN "ON"

POSITION)

TO REGULATOR

HORN

RELAY
16 BRN-BODY WIRING

HARNESS-837

14BRN

I

^
IA^RN
* IGNITION SWITCH

« 12R ACCESSORY TERMINAL

12R f

AMMETER

LEGEND:

AIR COND WIRING (PART OF

ENGINE WIRING HARNESS)

WIRING IS PART OF EQUIP

REG PRODUCTION WIRING

Fig.
119—Corvette—Four-Season Wiring Diagram

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

BRAKES 5-15

Brake Shoes

Refer to parking brake shoe service procedures under

Disc Brakes in this section.

BRAKE PEDAL (Fig. 26)

Removal

NOTE: Refer to Section 1A for removal

air conditioning components if necessary.
of

1.

5.

b.

c.
Disconnect clutch pedal return spring (manual trans-

mission models only).

Disconnect clutch push rod at pedal.

Disconnect brake pedal return spring (Chevelle and

Camaro only).

Disconnect brake pedal from main cylinder push

rod by removing retainer and clevis pin.

Corvette only:

a. Remove steering column from vehicle as outlined

in Section 9.

Support main cylinder frdm inside engine com-

partment and remove four support brace nuts.

Remove four nuts and bolts securing support

plate to bracket and remove support plate.

d. Remove two screws securing bracket to under-

side of instrument panel and lower bracket and

pedals to floor.

Remove retainer from right side of pedal pivot

shaft.

7.
Slide clutch pedal assembly to the left and remove

from support brace.

8. Withdraw brake pedal and all nylon bushings.

Inspection

1.
Clean all metal parts with a good nontoxic cleaning

solvent.

2.
Wipe nylon bushings clean with a clean cloth.
6
CAUTION: Nylon bushings should not be treated

with cleaning agent of any nature.

3.
Inspect all nylon bushings for wear and damage.

4.
Inspect mating surface of bushings for wear and

damage—replace parts as required.

Installation

1.
Lubricate and install nylon bushings on pedal pivot

shaft, right side of support brace cutout, and through

both ends of brake pedal bore.

2.
Chevrolet, Chevy n, and Corvette: Position brake

pedal return spring on pedal arm and place pedal

assembly in support brace. Index return spring in

support brace cutout.

3.
Chevelle and Camaro: Place pedal assembly in

support brace.

4.
Slide pedal pivot shaft through support brace and

brake pedal bore.

5.
Install retainer to right side of pedal pivot shaft.

6. Corvette only:

a. Install bracket with pedal assemblies to underside

of instrument panel with two screws.

b.
Install support plate on bracket with four bolts

and nuts. • • ' •

c. Place main cylinder in position and install four

bracket and cylinder mounting bolts; secure en-

tire assembly with four nuts.

d. Install steering column in vehicle as outlined

in Section 9.

7.
Chevelle and Camaro: Install brake pedal return

spring.

8. On manual transmission models, connect clutch pedal

push rod to pedal bracket and install retainer. In-

stall clutch pedal return spring.

9. Adjust brake pedal free travel as outlined in this

section. Adjust stoplight switch as outlined in Section

CHEVROLET

CHEVELLE

Fig.
26—Brake Pedal Installation

CHEVROLET CHASSIS SERVICE MANUAL