heater CHEVROLET CAMARO 1967 1.G Chassis Manual Online

HEATER
AND AIR CONDITIONING IA-79

BAT.
CABLE

ASM

A/C
wrg fwd of
dash

exc
bat.
cables,
ext
wire
&

compressor
grd
wire
is
part

of engine wiring harness.

"COMPRESSOR"
SW:

"OFF" POSN

"ON"
POSN
RELAY

ASM

/-DASH

/
PANEL

RESISTOR

ASM

LUTCH

COIL

:OMI

GRD
WIRE
ASM
MPRESSOR

BAT.
TERM

ON START

MTR SOL

EXTENSION WIRE ASM

._
J

J
^-CONTROL
SW

CONTACTS

B TO NONE

BTOL

BTOL&M

BTOL6H

•IGN SW ACCSY TERM.

A/C wrg
to
rear
of
dash

of
inst pnl harness.

Fig.
115—CheveIle—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-81

HORN RELAY

r

CONN.-

14 BROWN

(TO FUSE

PANEL)
BATTERY
1

—I ^ COMPR

ESSOR

DASH y

V-^ PANEL \

GROMMET—%
1 \

_ J~ ") "^

>14 BLACK/RED STRIPE-

FUSE .20 AMP.

•WIRE ASM. BLOWER-

MOTOR
14 BLACK 1

IGNITION SWITCH1

(ACCESSORY

TERMINAL)

CONTROL SWITCH
-RESISTOR

CONN.

•14 TAN

•16 BLACK

LIGHT BLUE STRIPE

•THERMOSTAT CONTROL

EVAPORATOR & BLOWER ASM.

Fig.
117—Universal System Wiring Diagram (Typical)

CHEVROLET CHASSI

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

ENGINE 6-26

6. Remove lifting device and lifting adapter then install

rocker arm covers as outlined.

7.
On synchromesh equipped vehicles, install clutch

cross-shaft engine bracket, then adjust and connect

clutch as outlined in Section 7.

8. Connect:

• Speedometer cable.

• Shift linkage at transmission.

• Transmission cooler lines (if so equipped).

9. Install propeller shaft.

10.
Remove jack stands and lower vehicle.

11.
Connect: \ '

Power steering pump lines (if so equipped).

Vacuum line to power brake unit (if so equipped).

Exhaust pipes at manifold flanges.

Accelerator linkage at pedal lever.

Fuel line at fuel pump.

Engine cooler lines (if so equipped).

Oil pressure gauge lines (if so equipped).

12.
Connect wires at:

Coil

Oil pressure switch

Temperature switch

Delcotron

Starter solenoid

13.
Install pulley, fan blade and fan belt as outlined in

Section 6K.

14.
Install radiator and shroud as outlined in Section 13.

15.
Install and adjust hood as outlined in Section 11.

16.
Connect battery cables.

17.
Fill with coolant, engine oil and transmission oil,

then start engine and check for leaks.

18.
Perform necessary adjustments and install air

cleaner.

INTAKE MANIFOLD

Removal

1.
Drain radiator and remove air cleaner.

2.
Disconnect:

Battery cables at battery.

Upper radiator and heater hose at manifold.

Accelerator linkage at pedal lever.

Fuel line at carburetor. ;

Wires at temperature sending switch and coil

(both sides).

Power brake hose at carburetor base.

Spark advance hose at distributor.

Crankcase ventilation hoses (as required).

3.
Remove distributor cap and mark rotor position with

chalk. Remove distributor clamp and distributor,

then position distributor cap rearward clear of

manifold.

4.
Remove coil.

5.
Remove manifold-to-head attaching bolts, then re^

move manifold, (with carburetor on) from engine and

discard gaskets and seals.

6. If manifold is to be replaced,,transfer:

Carburetor and carburetor mounting studs.

Temperature sending switch.

Water outlet and thermostat (use new gasket).

Heater hose adapter.

Choke coil.

Installation

1.
Clean gasket and seal surfaces of manifold, cylinder
heads and block.

2.
Install manifold end seals on block as shown (fig.

2V).

3.
Install side gaskets on cylinder heads using sealing

compound around water passages (fig. 2V).

4.
Install manifold bolts, and torque to specifications in

the sequence outlined on the Torque Sequence Chart.

5.
Install coil.

6. Install distributor with the rotor pointing at the chalk

mark, then install distributor cap.

NOTE:
If the crankshaft has been rotated while

the distributor was removed, time distributor to

number 1 cylinder as outlined in Section 6Y.

7.
Connect:

Battery cables at battery.

Upper radiator and heater hose at manifold.

Accelerator linkage at pedal lever.

Fuel line at carburetor.

Wires at temperature sending switch and coil

(both sides)!

Power brake hose at carburetor base.

Spark advance hose at distributor.

Crankcase ventilation hoses (as required).

Fill with coolant, start engine, check for leaks and

adjust timing and carburetor idle speed and mixture.

EXHAUST MANIFOLD

Removal

NOTE:
If equipped with "Air Injection Reactor

System", remove air manifold and tubes as out-

lined in Section 6T.

1.
Disconnect battery ground cable.
-

2.
Disconnect and remove Delcotron (as required).

3.
On 396 and 427 cu. in. engines, remove spark plugs

Fig. 2V - Intake Manifold Gasket and Seal Location

CHEVROLET CHASSIS SERVICE MANUAL

SECTION 6K

ENGINE COOLING

INDEX

Page

General Description . . . 6K-1

Maintenance and Adjustments 6K-1

Coolant Level 6K-1

Coolant System Checks 6K-1

Periodic Maintenance 6K-2

Cleaning 6K-2

Reverse Flushing 6K-2

Radiator 6K-2
Page

Cylinder Block and Cylinder Head 6K-2

Hot Water Heater 6K-2

Fan Belt . 6K-2

Adjustment ....". 6K-2

Thermostat . 6K-2

Replacement 6K-2

Water Pump. . . . 6K-3

Removal 6K-3

Installation 6K-3

GENERAL DESCRIPTION

A pressure cooling system is provided for on all

models by a pressure type radiator cap (fig. 1). The

pressure type radiator cap used is designed to hold a

pressure above atmospheric pressure in the cooling

system. Excessive pressure is relieved by a valve within

the cap that opens to radiator overflow.

The water pump is a ball bearing, centrifugal vane

impeller type. It requires no care other than to make

certain the air vent at the top of the housing and the drain

holes in the bottom do not become plugged with dirt or

grease. Removal and installation of the water pump is

covered in this section. For overhaul procedures of the

water pump refer to Section 6K of the Passenger Chassis

Overhaul Manual.
For radiator, refer to Section 13 of this manual For

radiator shroud, refer to Section 11 of this manual.

Fig.
I—Pressure Radiator Cap

MAINTENANCE AND ADJUSTMENTS

Coolant Level

The radiator coolant level should only be checked when

the engine is cool, particularly on cars equipped with air

conditioning. If the radiator cap is removed from a hot

cooling system, serious personal injury may result

The cooling system fluid level should be maintained

one inch below the bottom of the filler neck of the radia-

tor when cooling system is cold, or at the bottom of the

filler neck when the system is warm. It is very impor-

tant that the correct fluid level be maintained. The seal-

ing ability of the radiator cap is affected when the cooling

level is too high.

All passenger car cooling systems are pressurized

with a pressure cap which permits safe engine operation

at cooling temperatures of
up
to 247°F.

When the radiator cap is removed or loosened, the

system pressure drops to atmospheric, and the heat

which had caused water temperature to be higher than

212°F, will be dissipated by conversion of water to

steam. Inasmuch as the steam may form in the engine

water passages, it will blow coolant out of the radiator

upper hose and top tank, necessitating coolant replace-

ment Engine operating temperatures higher than the

normal boiling point of water are in no way objectionable

so long as the coolant level is satisfactory when the

engine is cooL

Upon repeated coolant loss, the pressure radiator cap

and seat should be checked for sealing ability. Also, the
cooling system should be checked for loose hose con-

nections, defective hoses, gasket leaks, etc.

Coolant System Checks

1.
Test for restriction in the radiator, by warming the

engine up and then turning the engine off and feeling

the radiator. The radiator should be hot at the top

and warm at the bottom, with an even temperature

rise from bottom to top. Cold spots in the radiator

indicate clogged sections.

2.
Water pump operation may be checked by running the

engine while squeezing the upper radiator hose. A

pressure surge should be felt Check for a plugged

vent-hole in pump.

NOTE:
A defective head gasket may allow ex-

haust gases to leak into the cooling system.

This is particularly damaging to the cooling

system as the gases combine with the water to

form acids which are particularly harmful to

the radiator and engine.

3.
To check for exhaust leaks into the cooling system,

drain the system until the water level stands just

above the top of the cylinder head, then disconnect

the upper radiator hose and remove the thermostat

and fan belt. Start the engine and quickly accelerate

several times. At the same time note any appreci-

able water rise or the appearance of bubbles which

CHEVROLET CHASSIS SERVICE MANUAL

ENGINE COOLING 6K-2

are indicative of exhaust gases leaking into the coolr

ing system.

Periodic Maintenance

Periodic service must be performed to the engine cool-

ing system to keep it in efficient operating condition.

These services should include a complete cleaning and

reverse flushing as well as a reconditioning service.

In the course of engine operation, rust and scale ac-

cumulate in the radiator and engine water jacket. The

accumulation of these deposits can be kept to a minimum

by the use of a good rust inhibitor but it should be

remembered that an inhibitor will not remove rust al-

ready present in the cooling system.

Two common causes of corrosion are: (1) air suction--

Air may be drawn into the system due to low liquid level

in the radiator, leaky water pump or loose hose con-

nections; (2) exhaust gas leakage—Exhaust gas may be

blown into the cooling system past the cylinder head

gasket or through cracks in the cylinder head and block.

Cleaning

A good cleaning solution should be used to loosen the

rust and scale before reverse flushing the cooling

system. There are a number of cleaning solutions avail-

able and the manufacturer's instructions with the particu-

lar cleaner being used should always be followed.

An excellent preparation to use for this purpose is GM

Cooling System Cleaner. The following directions for

cleaning the system applies only when this type cleaner

is-used.

1.
Drain the cooling system including the cylinder block

and then close both drain plugs.

2.
Remove thermostat and replace thermostat housing.

3.
Add the liquid portion (No. 1) of the cooling system

cleaner.

4.
Fill the cooling system with water to a level of about

3 inches below the top of the overflow pipe.

5. Cover the radiator and run the engine at moderate

speed until engine coolant temperature reaches 180

degrees.

6. Remove cover from radiator and continue to run the

engine for 20 minutes. Avoid boiling.

7. While the engine is still running, add the powder

portion (No. 2) of the cooling system cleaner and

continue to run the engine for 10 minutes.

8. At the end of this time, stop the engine, wait a few

minutes and then open the drain cocks or remove

pipe plugs. Also remove lower hose connection.

CAUTION: Be careful not to scald your hands.

NOTE:
Dirt and bugs may be cleaned out of

the radiator air passages by blowing out with air

pressure from the back of the core.

Reverse Flushing

Reverse flushing should always be accomplished after

the system is thoroughly cleaned as outlined above.

Flushing is. accomplished through the system in a direc-

tion opposite to the normal flow. This action causes the

water to get behind the corrosion deposits and force

them out.

Radiator

1.
Remove the upper and lower radiator hoses and re-

place the radiator cap,

2.
Attach a lead-away hose at the top of the radiator.
3.
Attach a new piece of hose to the radiator outlet

connection and insert the flushing gun in this hose.

4.
Connect the water hose of the flushing gun to a water

outlet and the air hose to an air line.

5. Turn on the water and when the radiator is full, turn

on the air in short blasts, allowing the radiator to

fill between blasts of air.

CAUTION: Apply air gradually as a clogged

radiator will stand only a limited pressure.

6. Continue this flushing until the water from the lead-

away hose runs clear.

Cylinder Block and Cylinder Head

1.
With the thermostat removed, attach a lead-away

hose to the water pump inlet and a length of new hose

to the water outlet connection at the top of the engine.

NOTE:
Disconnect the heater hose when re-

verse flushing engine.

2.
Insert the flushing gun in the new hose.

3.
Turn on the water and when the engine water jacket

is full, turn on the air in short blasts.

4.
Continue this flushing until the water from the lead-

away hose runs clear.

Hot Water Heater

1.
Remove water outlet hose from heater core pipe.

2.
Remove inlet hose from engine connection.

3.
Insert flushing gun and flush heater core. Care must

be taken when applying air pressure to prevent

damage to the core.

Fan Belt

Adjustment

1.
Loosen bolts at Delcotron slotted bracket.

2.
Pull Delcotron away from engine until desired ten-

sion reading is obtained with a strand tension gauge.

Refer to Section 6, "Engine Tune-Up".

3.
Tighten all Delcotron bolts securely.

Thermostat

The thermostat consists of a restriction valve actuated

by a thermostatic element. This is mounted in the hous-

ing at the cylinder head water outlet above the water

pump,
thermostats are designed to open and close at

predetermined temperatures and if not operating properly

should be removed and tested as follows.

Replacement

1.
Remove radiator to water outlet hose.

2.
Remove thermostat housing bolts and remove water

outlet and gasket from thermostat housing (fig. 2).

3.
Inspect thermostat valve to make sure it is in good

condition.

4.
Place thermostat in hot water 25° above the temper-

ature stamped on the thermostat valve.

5. Submerge the valve completely and agitate the water

thoroughly. Under this condition the valve should

open fully.

6. Remove the thermostat and place in water 10° below

temperature indicated on the valve.

7. With valve completely submerged and water agitated

thoroughly, the valve should close completely.

8. If thermostat checks satisfactorily, re-install, using

a new housing gasket.

9. Refill cooling system.

CHEVROLET CHASSIS SERVICE MANUAL

ENGINE COOLING 6K-3

Fig.
2— Replacing Thermostat
Water Pump

Removal

1.
Drain radiator and break loose the fan pulley bolts.

2.
Disconnect heater hose, lower radiator hose and

by pass hose (as required) at water pump.

3.
Loosen Delcotron and remove fan belt then remove

fan bolts, fan and pulley.

4.
Remove pump to cylinder block bolts and remove

pump from engine.

NOTE:
On in line engines, pull the pump

straight out of the block first, to avoid damage

to impeller.

Installation

1.
Install pump assembly on cylinder block and tighten

bolts securely. Use on new pump to block gasket(s).

2.
Install pump pulley and fan on pump hub and tighten

bolts securely.

NOTE:
A guide stud (5/16"-24 x 1-1/2" bolt

with the head removed) installed in one hole of

the fan hub will aid in aligning hub, pulley and

fan.
Remove stud after starting the remaining

three bolts.

3.
Connect hoses and fill cooling system.

4.
Install fan belt and adjust as previously outlined.

5. Start engine and check for leaks.

CHEVROLET CHASSIS SERVICE MANUAL