check engine CHEVROLET CAMARO 1967 1.G Chassis Owner's 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-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-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

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-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-77

Compressor Belt Tension Adjustment

Adjust the compressor belt to the specifications shown

in the Tune-Up chart in the Engine section of this manual.

COMPRESSOR FAILURE

If the compressor has failed mechanically to the ex-
tent that metal chips and shavings are found in it, the

system should be checked for foreign material and

cleaned as described under Foreign Material in the

System.

CHEVROLET CHASSIS SERVICE MANUAL

CORVETTE BODY 1B-29

CUSHION

CUSHION ASNi.^ty** ACCESS

#2 BODY BRACKET

( 67 ONLY)
SHIM

( 37 POSITION).

CUSHION ASM.

( 37)

SHIM

( 67 POSITION)

CUSHION

( 37 ONLY)

#1 BODY BRACKET

Fig.
65—Body Mounts

PRECAUTIONS

Creams are available to protect the skin from a con-

dition known as occupational, or contact dermatitis. This

common type of dermatitis is not contagious. Improved

resin formulas in the approved kits have almost elimi-

nated skin irritation. Cream is supplied with the kit for

men who may have a tendency toward skin irritation

from the resins or dust.

The application of these creams is recommended

whenever the Resin Kit materials are used. Generally,

the cream is not required when the plastic solder kit is

being used. Directions for using the cream is as follows:

a. Wash hands clean. Dry thoroughly.

b.
Squeeze about 1/2 inch (or 1/2 teaspoonful) of

#71 cream into palm of hand.

c. Spread evenly and lightly until cream disappears.

Work cream into cuticle, between fingers and

around wrists.

d. Apply second coat, repeating Steps b and c.

e. Hold hands briefly under cold running water to

set cream.

2.
Remove resin mixture from hands as soon as possi-

ble and imperatively before mixture starts to gel.

This can be observed by the action of the material

being used. Resin may be removed with lacquer

thinner by washing in soap and water.

3.
Respirators are recommended when grinding. Also

some minor skin irritation from glass and powdered

cured resin may be evident. Washing in cold water

will help to minimize.

4.
Use a belt sander with a vacuum attachment for dust

control if possible.
5. Resin mixtures may produce toxic fumes and should

be used in well ventilated areas.

6. Be careful not to get any resin material on clothing.

7. Use the right materials for the job. It is important

to use the approved kits because Chevrolet's rigid

quality standards assure you the right material to

do the job. Other materials available may not meet

the required engineering and safety standards.

8. Keep the materials, utensils and work area clean

and dry. These repairs involve chemical reactions,

and dirt or moisture may upset the chemical bal-

ances and produce unsatisfactory results.

9. Before starting repair operations, look for hidden

damage by applying pressure around the damaged

area, looking for hairline cracks and other breakage.

Check for minor damage at other points in the vehi-

cle such as around exhaust pipes, grille, headlamps

and points of wear or rub. Early repair of this

minor damage may prevent major repair later.

PLASTIC SOLDER
KIT

The Plastic Solder Repair Kit is used for minor re-

pairs on the Corvette body. These materials will produce

an easy, quick and lasting repair in the case of small

cracks, surface imperfections and small holes.

1.
Use paint remover or power sander, and remove

finish from damaged area. Carefully inspect for

other areas requiring repair.

2.
Mix the materials (fig. 72).

3.
Apply the material, using a putty knife or rubber

squeegee, Figure 73. Work the material into the

repair and build the material up to the desired

CHEVROLET CHASSIS SERVICE

SECTION 2

FRAME

INDEX

Page

General Description 2-1

Chevrolet 2-1

Cheveile '. 2-1

Repair Procedures 2-1
Page

Checking Frame Alignment 2-1

Car Preparation 2-1

Tramming Sequence 2-1

Reference Point Dimensions 2-1

GENERAL DESCRIPTION

CHEVROLET AND CHEVELLE

Frames used on Chevrolet and Cheveile lines are basi-

cally the same, consisting of full length right and left

side members joined laterally by crossmembers. Sev-

eral different frames are used in each line to meet the

various vehicle size and function requirements but the

basic shape for each line remains the same. Differences

between frames in a given line exist only in metal gauge,

part size and numbers of parts necessary to meet the

particular structural requirements of the models

involved.

CORVETTE

The Corvette frame is a rigid perimeter unit, with five
crossmembers. From the rear kick-up forward, trap-

azoidal shaped, closed side members outline and protect

the passenger compartment. At the cowl area, the side

members curve inward in a sweeping "S" shape, to pro-

vide a sturdy foundation for the engine mounts and clear-

ance for front wheel movement. From the kick-up

rearward, box-sectioned side rails provide fore and aft

support for the rear axle and suspension. Lateral sup-

port is provided by five variously shaped welded-in

crossmembers, including the front unit, which formerly

was bolted-in.

CHEVY II AND CAMARO

Underbody alignment checking procedures will be found

in the Body Service Manual.

REPAIR PROCEDURES

CHECKING FRAME ALIGNMENT

Vehicles involved in an accident of any nature which

might result in a "swayed" or "sprung" frame should

always be checked for proper frame alingment in addi-

tion to steering geometry and wheel alignment.

CAR PREPARATION

Preparing the car for the frame alignment check in-

volves the following:

1.
Place the car on level surface.

2.
The weight of the car should be supported at the

wheel locations.

3.
A visual damage inspection should be made to elim-

inate needless measuring. Obviously damaged or

misaligned areas can often be located by sight.

TRAMMING SEQUENCE

When checking a frame for alignment in case of dam-

age,
the first step is horizontal "X" checking with a

tram from similar given points on opposite side of the

frame.

Frame alignment checks on all models should be made

with the tram points set at the center of each locating

point indicated and the cross bar level to insure

accuracy.

When "X" checking any section of the frame, the

measurements should agree within 3/16". If they do not,
it means that corrections will have to be made.

If a tram gauge is not available, the "plumb bob"

method of checking may be used. To assure any degree

of accuracy when using this method, the vehicle should

be on a level floor.

By using this method, it is only necessary to have a
#

piece of cord attached to an ordinary surveyor's plumb

bob.
When measuring the distance between two points,

the free end of the cord should be placed on the reference

point allowing the plumb bob to hang on the floor. A check

mark should be made on the floor just under the tip of

the plumb bob. This operation should be repeated at all

reference points. With these points located on the floor,

they may easily be measured with a rule.

The second step is checking the vertical dimensions

from the datum plane to the points to be trammed. With

the proper settings the tram bar will be on a plane

parallel to that of the frame. The exception to this would '

be when one of the reference locations is included in the

misaligned area; then the parallel plane between the

frame and the tram bar may not prevail. After com-

pletion of the repairs, the tram gauge should be set at

the specified dimension to check the accuracy of the re-

pair operation.

ALIGNMENT REFERENCE POINT DIMENSIONS

Dimensions to holes are measured to dead center of

the holes and flush to the adjacent surface metal.

CHEVROLET CHASSIS SERVICE MANUAL

FRONT SUSPENSION 3-3

by means of a lower control arm inner pivot cam; on the

Chevelle, Camaro and Corvette by means of upper control

arm inner support shaft shims.

Caster angle is adjusted, on the Chevrolet and Chevy n

by means of a strut rod which runs from the lower con-

trol arm forward to a frame brace; on the Chevelle,
Camaro and Corvette by means of upper control arm

inner support shaft shims.

A stabilizer bar is used on all Chevelle and Corvette

models. Chevrolet Impalas, station wagons and V-8

engine equipped models are fitted with the stabilizer bar.

UPPER CONTROL ARM

STABILIZER

SPRING
LOWER CONTROL ARM

STEERING KNUCKLE

Fig.
3 - Front Suspension - Corvette

MAINTENANCE AND ADJUSTMENTS

Maintenance intervals recommended for lubrication of

front suspension components have been fully covered in

Section 0 of this manual. Only actual adjustment proce-

dures will be covered here.

NOTE:
Unless otherwise indicated all proce-

dures will apply to all five vehicles covered in

this manual.

FRONT WHEEL BEARING ADJUSTMENT

Proper front wheel bearing adjustment has a definite

bearing on the safe operation of a vehicle. Improperly

adjusted front wheel bearings will result in a lack of

steering stability causing wheel wander, shimmy and ex-

cessive tire wear. Very accurate adjustment is possible

because the spindles are drilled both vertically and hori-

zontally and the adjusting nuts are slotted in all six sides.

NOTE:
Wheel bearings should not
be.
repacked

or adjusted as a part of "New Car Conditioning".
1.
With wheel raised, remove hub cap and dust cap and

then remove the cotter pin from the end of the

spindle.

2.
While rotating wheel, tighten spindle nut to 12 lbs. ft

torque.

3.
Back off adjusting nut one flat and insert cotter pin.

If slot and pin hole do not line up, back off the adjust-

ing nut an additional 1/2 flat or less as required to

insert cotter pin.

4.
Spin the wheel to check that it rolls freely and then

lock the cotter pin by spreading the end and bending

it around.

NOTE:
Bearings should have zero preload and

.001"
to .008" end movement when properly ad-

justed on Chevrolet, Chevelle, Camaro and Cor-

vette; .000" to .004" on Chevy H.

5.
Install dust cap, hub cap or wheel disc and lower

wheel.

6. Perform the same operation on each front wheel.

CHEVROLET CHASSIS SERVICE MANUAL

BRAKES 5-9

COMPONENT REPLACEMENT AND REPAIRS

PARKING BRAKE-CHEVROLET, CHEVELLE AND

CAMARO (Figs. 19 and 20)

Pedal Assembly

Removal

NOTE:
Remove positive cable from battery to

eliminate the possibility of creating short cir-

cuits under dash.

1.
Place parking brake pedal in released position.

2.
Remove equalizer check nut, and separate cable

stud from equalizer.

3.
Remove two attaching nuts from mounting studs

located in engine compartment.

4.
Remove front cable .ball end from pedal assembly

swivel.

5. Remove pedal assembly to dash brace attaching

screw.

6. Remove pedal assembly by lowering rear slightly

to avoid scratching dash, and pulling, it out of the

firewall.

Installation

1.
Place pedal assembly in position with the two mount-

ing studs protruding through the holes provided in

the firewall.

2.
Install and tighten pedal assembly to dash brace

attaching screw.

3.
Position front cable ball end into pedal assembly

swivel.

4.
Install and tighten two attaching nuts on mounting

studs located in engine compartment.

5. Place
,
equalizer in position on center cable and

insert front cable stud through equalizer and secure

with check nut.

6. Adjust parking brake as outlined under Maintenance

and Adjustments in this section.

7. Connect positive battery cable.

Front Cable

Removal

NOTE:
Remove positive cable from battery to

eliminate the possibility of creating short cir-

cuits under dash.

1.
Place parking brake pedal in released position.

2.
Remove equalizer check nut, and separate cable

, stud from equalizer.

3.
Remove retainer from cable assembly at inner side

of frame rail.

4.
Remove ball end of cable from pedal assembly

swivel.

5. Compress expanded conduit locking fingers at toe

pan arid withdraw cable from car.

6. On Chevelle, if necessary, remove rubber tube

from front cable.

Installation

1.
On Chevelle, if necessary, replace rubber tube

over front cable.

2.
Position cable ball and conduit tip through cutout

in firewall. Make sure conduit locking fingers are

fully expanded and secured in cutout, then position

cable ball into pedal assembly swivel.
3.
Feed stud end of cable through frame rail and se-

cure with retainer on inner side of frame.

4.
Place one check nut on cable stud and insert stud

through equalizer, (make sure center cable is in

position), then place second check nut on stud.

5. Adjust parking brake as outlined in this section.

6. Connect positive battery cable.

Center Cable

Removal

1.
Place parking brake pedal in released position.

2.
Remove equalizer check nut and remove equalizer

from cable.

3.
Remove cable from cable guides.

4.
Disconnect center cable from rear cables at

connectors.

Installation

1.
Install cable ends into rear cable connectors.

2.
Place cable through equalizer and install equalizer

on to front cable stud, secure with check nut. (Do

not tighten.)

3.
Install cable in cable guides (figs. 19 and 20),

4.
Adjust parking brake as outlined in this section.

Rear Cables

Removal

1.
Place parking brake pedal in released position.

2.
Remove equalizer check nut and remove equalizer

from cable.

3.
Remove rear cable from connector.

4.
Remove retainer from rear cable at frame bracket.

Pull cable out of bracket.

5. Remove rear brake drum as outlined in this section.

6. Remove rear brake shoes as outlined in this section.

7. Remove cable end from parking brake actuating

lever.

8. Compress expanded conduit locking fingers at flange

plate entry hole and withdraw cable.

Installation

1.
Pass end of cable and conduit tip through flange

plate entry hole, making sure that conduit locking

fingers all expand fully.

2.
Connect cable end to actuating lever.

3.
Install rear brake shoes, drum and wheel as out-

lined in this section.

4.
Pass cable through frame bracket and install

retainer.

5. Install cable end into cable connector.

6. Position equalizer on center cable and place on

front cable stud, secure with check nut.

7. Make sure all center cable guides are in place

and adjust parking brake as outlined in this section.

PARKING BRAKE-CHEVY II (Fig. 21)

Lever Assembly

Removal

NOTE:
Remove positive cable from battery

to eliminate possibility of creating short cir-

cuits under dash.

CHEVROLET CHASSIS SERVICE MANUAL