length CHEVROLET CAMARO 1967 1.G Chassis Workshop Manual

SECTION O

INFORMATION AND LUBRICATION

CONTENTS OF THIS SECTION

Page

General Information o-l

Lubrication 0-13

GENERAL INFORMATION

Model Identification and Vehicle Dimensions

Chevrolet

Chevelle

Chevy n

Corvette

Camaro
Page

0-1

0-1

0-2

0-2

0-3

0-3
Page

Unit and Serial Numbers o-3

Engine Number o-3

Vehicle Serial Number 0r3

Keys and Locks 0-4

Pushing,Towing and Lifting 0-7

Series

Biscayne

Bel Air

Tmpala.

Impala

Super Sport

Caprice
MODEL IDENTIFICATION-CHEVROLET

Model Number

6-Cyl

15311

15369

15335

15511,

15569

15535

15545

16387

16367

16369

16339

16335

16345

16787

16767

—

—

—

—
V-8

15411

15469

15435

15611

15669

15635

15645

16487

16467

16469

16439

16435

16445

16887

16867

16647

16639

16635

16645
Description

2-Door Sedan, 6-Passenger

4-Door Sedan, 6-Passenger

4-Door Station Wagon, 2-Seat

2-Door Sedan, 6-Passenger

4-Door Sedan, 6-Passenger

4-Door Station Wagon, 2-Seat

4-Door Station Wagon, 3-Seat

2-Door Sport Coupe, 5-Passenger

2-Door Convertible, 5-Passenger

4-Door Sedan, 6-Passenger

4-Door Sport Sedan, 6-Passenger

4-Door Station Wagon, 2-Seat

4-Door Station Wagon, 3-Seat

2-Door Sport Coupe, 4-Passenger

2-Door Convertible, 4-Passenger

2-Door Custom Coupe, 5-Passenger*

4-Door Custpm Sedan, 6-Passenger

4-Door Custom Wagon, 2-Seat

4-Door Custom Wagon, 3-Seat

*4-Passenger when optional bucket front seats are specified.

VEHICLE DIMENSIONS-CHEVROLET

Pertinent dimensions for the different models are shown in the following chart.

Model

Length Overall . .

Width Overall (Body)

Height Overall

Wheelbase

Tread-Front

Tread-Rear

Curb Weight: Approximately 3543 lbs.
Sedan

213.2"

79.6"

55.4"

119.0"

62.5"

62.4"

4-Door Sedan with
2-Door

Sport Coupe

213.2"

79.6"

54.4"

119.0"

62.5"

62.4"

L-6 Engine; 3685 lbs
Convertible

Coupe

213.2"

79.6"

55.3"

119.0"

62.5"

62.4"

. with V-8 Engine.
Station

Wagon

212.4"

79.6"

56.7"

119.0"

63.5"

63.4"

CHEVROLET CHASSIS SERVICE MANUAL

GENERAL INFORMATION 0-2

MODEL IDENTIFICATION-CHEVELLE

Series

Chevelle 300

Chevelle 300

Deluxe

Malibu

Super Sport

396

Concours
Model Number

6-Cyl

13111

13169

13311

13369

13335

13569

13539

13517

13567

13535

—

13735
V-8

13211

13269

13411

13469

13435

13669

13639

13617

13667

13635

13817

13867

13835
Description

2-Door -Sedan, 6-Passenger

4-Door Sedan, 6-Passenger

2-Door Sedan, 6-Passenger

4-Door Sedan, 6-Passenger

4-Door Station Wagon, 2-Seat

4-Door Sedan, 6-Passenger

4-Door Sport Sedan, 6-Passenger

2-Door Sport Coupe, 5-Passenger*

2-Door Convertible, 5-Passenger*

4-Door Station Wagon, 2-Seat

2-tooor Sport Coupe, 5-Passenger*

2-Door Convertible, 5-Passenger*

4-Door Station Wagon, 2-Seat

*4-Passenger when optional bucket seats are specified.

EL CAMINO
13380

13580
13480

13680
2-Door
Sedan
Pickup,
3-Passenger Reg.

2-Door
Sedan
Pickup,
3-Pass. Deluxe

VEHICLE DIMENSIONS-CHEVELLE

Pertinent dimensions for the different models are shown in, the following chart.

Model

Sedan

197.0"

75.0"

54.1"

115.0"

58.0"

58.0"
2-Door

Sport Coupe

197.0"

75.0"

53.2"

115.0"

58.0"

58J0"
Convertible

Coupe

197.0"

75.0"

53.9"

115.0"

58.0"

58.0"
Station

Wagon

199.9"

75.0"

56.7"

115.0"

58.0"

58.0"
Sedan

Pickup

199.9"

75.0"

56.7"

115.0"

58.0"

58.0"
Length Overall .

Width Overall (Body)

Height Overall . . .

Wheelbase. .

Tread-Front

Tread-Rear .

Curb Weight: Approximately 3104 lbs. 4-Door Sedan with L-6 Engine 3258 lbs. with V-8 Engine.

MODEL IDENTIFICATION-CHEVY II

Series

100

NOVA

NOVA SS
Model Number

L-4

11111

11169

mmm.

—
6 Cyl.

11311

11369

11335

11569

11537

11535

11737
V-8

11411

11469

11435

11669

11637

11635

11837
Description

2-Door Sedan, 6-Passenger

4-Door Sedan, 6-Passenger

4-Door Station Wagon, 2-Seat

4-Door Sedan, 6-Passenger

2-Door Sport Coupe, 5-Passenger

4-Door Station Wagon, 2-Seat

2-Door Sport Coupe, 4-Passenger

CHEVROLET CHASSIS SERVICE MANUAL

GENERAL INFORMATION 0-3

VEHICLE DIMENSIONS-CHEVY II

Model

Length Overall

Width Overall (Body) . . . .

Height Overall

Wheelbase

Tread-Front

Tread-Rear . . .
Sedan

183.0"

71.3"

56.7"

110.0"

56.8"

56.3"
2-Door

Sport Coupe

183.0"

71.3"

54.4"

110.0"

56.8"

56.3"
Station

Wagon

187.4"

71.3"

57.6"

110.0"

56.3"

55.8"

Curb Weight: Approximately 2668 lbs. 4-Door Sedan with L-4 Engine; 2767
lbs.
with L-6 Engine; 2959lbs.

with V-8 Engine.

MODEL IDENTIFICATION-CAMARO
VEHICLE DIMENSIONS-CORVEnE

Model Number

6-Cyl

12337

12367
V-8

12437

12467
Description

2-Door Sport Coupe, 4-Passenger

2-Door Convertible, 4-Passenger

VEHICLE DIMENSIONS-CAMARO

Model

Length Overall .....

Width Overall (Body) . .

Height Overall

Wheelbase

Tread-Front

Tread-Rear
Sport Coupe

Convertible

184.7"

72.6"

50:8"

108.0"

59.0"

58.88"

Weight: Sport Coupe with L6 Engine 2908 lbs.; with

V-8 Engine 3063 lbs.

MODEL IDENTIFICATION-CORVETTE

Model

Number

19437

19467
Description

2-Door Sport Coupe, 2-Passenger

2-Door Convertible, 2-Passenger

UNIT AND SERIAL NUMBER LOCATIONS

For the convenience of servicemen when writing up

certain business papers, such as L. & M.R.'s Product

Information Reports, or reporting product failures in

any way, we are showing below the location of various

unit numbers. These unit numbers and their prefixes

and suffixes are necessary on these papers for various

reasons—such as accounting, follow-up on production,

etc.
Model

Length Overall

Width Overall (Body). . .

Height Overall.

Wheelbase

Tread-Front

Tread-Rear .
Convertible
Sport

Coupe

175.1"

69.6"

49.8"
49.6"

98.0"

56.8"

57.6"

Curb Weight: 3145 lbs. Convertible

3135 lbs. Sport Coupe

with Base V-8

The prefixes on certain units identify the plant in which

the unit was manufactured, and thereby permits proper

follow-up of the plant involved to get corrections made

when necessary.

Engine Unit Number

The engine unit number (figs. 3 and 4) shows manu-

facturing plant, month and day of manufacture, and

transmission type. A typical engine number would be

F1210FA, which would breakdown thus:

F~Manufacturing Plant (F—Flint, T—Tonawanda)

12—Month of manufacture (December)

10—Day of manufacture (tenth)

FA—Transmission and engine type

Vehicle Serial Number

A typical vehicle serial number tag (fig. 1) yields

manufacturers identity, vehicle type, model year, as-

sembly plant and production unit number when broken

down as shown in the following chart.

Manufacturer

Identity1

1
Body

Style2

5645
Model

Year8

7
Assembly

Plant*

F
Unit

Number5

100025

CHEVROLET CHASSIS SERVICE /MANUAL

LUBRICATION 0-14

SAE 5W-30 oils may be used during periods when

temperatures of 32° and below are to be expected.

Types of Oils

In service, crankcase oils may form sludge and varnish

and under some conditions, corrosive acids unless pro-

tected against oxidation.

To minimize the formation of these harmful products

and to assure the use of oil best suited for present day

operating conditions, automobile manufacturers have de-

veloped a series of sequence tests designed to evaluate

the ability of any oil to properly lubricate automobile

engines.

It is recommended that only those oils which are

certified by their suppliers as meeting or exceeding the

maximum severity requirements of these sequence tests

(or GM Standard 4745-M) be used in Chevrolet engines.

Certified sequence tested oils will be described as such

on their containers.

Maintaining Oil Level

The oil gauge rod is marked "Full" and "Add Oil."

These notations have broad arrows pointing to the level

lines.
The oil level should be maintained between the

two lines, neither going above the "Full" line nor under

the "Add Oil" line. DO NOT OVERFILL. After operating

vehicle allow a few minutes for oil to return to crankcase

before checking oil level.

Check the oil level frequently and add oil when

necessary.

Oil and Filter Change Intervals

NOTE:
Under prolonged dusty driving condi-

tions,
it is recommended that these operations

be performed more often.

OIL

To insure continuation of best performance, low main-

tenance cost and long engine life, it is necessary to

change the crankcase oil whenever it becomes contami-

nated with harmful foreign materials. Under normal

driving conditions draining the crankcase and refilling

with fresh oil every 60 days or every 6000 miles which-

ever occurs first, is recommended.

It is always advisable to drain the crankcase only after

the engine has become thoroughly warmed up or reached

normal operating temperature. The benefit of draining is,

to a large extent, lost if the crankcase is drained when

the engine is cold, as some of the suspended foreign

material will cling to the sides of the oil pan and will not

drain out readily with the cold, slower moving oil.

OIL FILTER

Change engine oil filter every 6000 miles or every 6

months, whichever occurs first.

NOTE:
For Vehicles in heavy duty operation

involving continuous start-stop or prolonged idl-

ing, engine oil should be changed after 2500-

3000 miles of operation. The filter should be

changed after 5000-6000 miles of operation.
Crankcase Dilution

Probably the most serious phase of engine oil deterio-

ration is that of crankcase dilution which is the thinning

of the oil by fuel vapor leaking by pistons and rings and

mixing with the oil and by condensation of water on the

cylinder walls and crankcase.

Leakage of fuel, or fuel vapors, into the oil pan occurs

mostly during the "warming up" period when the fuel is

not thoroughly vaporized and burned. Water vapor enters

the crankcase through normal engine ventilation and

through exhaust gas blow-by. When the engine is not

completely warmed up, these vapors condense, combine

with the condensed fuel and exhaust gases and form acid

compounds in the crankcase.

As long as the gases and internal walls of the crank-

case are hot enough to keep water vapor from con-

densing, no harm will result. However, when the engine

is run in low temperatures moisture will collect and

unite with the gases formed by combustion resulting in

an acid formation. The acid thus formed is likely to

cause serious etching or pitting which will manifest itself

in excessively rapid wear on piston pins, camshaft

bearings and other moving parts of the engine, oftentimes

causing the owner to blame the car manufacturer or the

lubricating oil when in reality the trouble may be traced

back to the character of fuel used, or a condition of the

engine such as excessive blowby or improper carburetor

adjustment.

Automatic Control Devices to Minimize

Crankcase Dilution

All engines are equipped with automatic devices which

aid greatly in minimizing the danger of crankcase

dUution.

The thermostat, mounted in the cylinder head water

outlet, restricts the flow of water to the radiator until a

predetermined temperature is reached, thus minimizing

the length of time required to reach efficient operating

temperature, reducing the time that engine temperatures

are conducive to vapor condensation.

A water by-pass is included in the cooling system,

utilizing a hole in the front of, the cylinder block. This

allows a limited circulation of coolant, bypassing the

thermostat until thermostat opening temperatures are

reached. This system provides a uniform coolant tem-

perature throughout the engine, eliminating localized

hot-spots, improving exhaust valve life, provides fast

warmrup of lubricating oil and fast temperature rise in

the coolant which provides fast heater operation in cold

weather.

A thermostatic heat control on the exhaust manifold

during the warming up period, automatically directs the

hot exhaust gases against the center of the intake mani-

fold, greatly aids in proper vaporization of the fuel.

An automatic choke reduces the danger of raw or

unvaporized fuel entering the combustion chamber and

leaking into the oil reservoir.

An.
efficient crankcase ventilating system drives off

fuel vapors and aids in the evaporation of the raw fuel

and water which may find its way into the oil pan.

CRANKCASE BREATHER CAP

Clean and re-oil at every oil change..

CHEVROLET CHASSIS SERVICE MANUAL

HEATER AND AIR CONDITIONING 1A-33

within the system. The following fixed conditions must be

adhered to in order to make it possible to compare the

performance of the system being tested with the stan-

dards below:

1.
Doors and windows closed. (Car inside or in shade.)

2.
Hood up and engine exhaust suitably ventilated.

3.
Vehicle in NEUTRAL with engine running at 2000

rpm.

4.
Air Conditioning controls set for -

• Maximum cooling.

• High blower speed.

5.
TEMP knob and AIR knob set for full recirculating

air. On Comfortron systems* move the control lever

to REAR and pull the white vacuum hose from the

transducer. Plug the hose. An alternate method is to

install the J-22368 Tester (described later in this

section) and operate it on MANUAL control to main-

tain maximum cooling and blower speed.

6. Gauge set installed.

7.
System settled out (run-in approximately
10
minutes).

8. A thermometer placed in front of vehicle grille and

another in the right hand diffuser outlet.

PERFORMANCE DATA

The following Performance Data define normal opera-

tion of the system under the above conditions. Relative

humidity does not appear in the tables because after

running the prescribed length of time on recirculated air

and maximum cooling, the relative humidity of the air

passing over the evaporator core will remain at ap-

proximately 35% to 40% regardless of the ambient

temperature or humidity.

Should excessive head pressures be encountered at

higher ambient temperatures, an 18" fan placed in front

of the vehicle and blowing into the condenser will provide

the extra circulation of air needed to bring the pressures

to within the limits specified.

NOTE: Higher temperatures and pressures will

occur at higher ambient temperatures, fti areas

of high humidity it is possible to have ther-

mometer and gauge readings approach but not

reach the figures listed in the performance

tables and still have a satisfactory operating

unit. However, it is important to remember that

low pressure has a direct relationship to nozzle

outlet temperature. If pressure is too low, ice

will gradually form on the evaporator fins, re-

stricting airflow into the passenger area and

resulting in insufficient or no cooling.

Four-Season and Comfortron System

Chevrolet and Camaro
Chevelle

(Refrigerant
Charge
=

Temperature
of Air

Entering Condenser

Engine rpm

Compressor

Head Pressure

Evaporator Pressure

at POA

Discharge Air Temp,

at Right Hand Outlet
3
Lbs. -

70°

145-

155

38-

41
80°

170-

180
12 02

90°
.)

100°

2000

205-

215

29.5 -

39-

42
41-

43
255-

265

30.5

42-

45
110°

260-

270

psi

43-

46
120°

295-

305

45-

48
(Refrigerant Charge =

Temperature of

Air Entering

Condenser

Engine rpm

Compressor Head

Pressure

Evaporator
Pressure

at
POA

Discharge Air

Temp, at Right

Hand Outlet
3 Lbs. -

70°

150

160

37-

40
80°

175

185
12 Oz.)

90° 100°

2000

210 250

220 260

29.5 - 30.5

37-

40
38-
39-

41 42
110°

280

290

psi

40-

44
120°

290

300

41-

45

Corvette

(Refrigerant Charge =

Temp, of Air

Entering Condenser

Engine rpm

Compressor

Head Pressure

Evaporator
Pressure

at
POA

Outlet
Air

Temperature

(at Right
Outlet)
3
Lbs.

70°

150-

170

38-

40
- 4 Oz.)

80°

175-

195

29

38-

40
90°

2000

200-

200
100°

i*pm

240-

260
110°

285-

300

5-
30.5 psi

40-

42
41-

43
43-

45
120°

325-

335

45-

47

Alt Weather System

Chevy II

(Refrigerant
Charge
=

Grille Air

Temperature

Engine rpm

Compressor Head

Pressure

Compressor Suction

Pressure**

Discharge Air Temp,

at R/H Outlet**
2-1/2 Lbs.)

70°

120-

140

13

32-

37
80°

150-

160

14
CO
OO
CO
CO
90°
100°

1500

175-

185

15

35-

40
220-

230

15

36-

41
110°

240-

250

19

37-

42
120°

265-

275

19

38-

43

**When Compressor Clutch Releases

COMFORTRON SYSTEM OPERATIONAL TEST

This test, designed as a quick check of total system

operation, must be made with the engine operating at

minimum of 2000 rpm and coolant warm. Wait several

seconds between operations to allow the system to move

through its sequence of operation and arrive at the pre-

scribed mode of operation.

1.
With control lever in the OFF position, and Tem-

perature Dial at 65°F.

a. System is turned OFF, there is no air flow from

any of outlets.

2.
Control lever in HI Front and Temperature Dial set

at65°F.

CHEVROLET CHASSIS SERVICE MANUAL

HEATER
AND AIR
CONDITIONING
1A-41

OUTLET

1

TO EXPANSION
^

VALVE
TO
OIL

BLEED LINE

^ INLET

Fig.
51—Evaporator Pressure Control Valve—POA

turn increments until
the
suction pressure rises
to

the correct pressure.

5.
If the
pressure
is
more than
it
should
be,
turn the

adjusting screw counter-clockwise until
the
proper

pressure
is
reached.

6. After adjusting
the
switch, install the capillary to
its

normal position
and
observe
the
operation
of the

system
for
several minutes. Then
if
the operation
is

satisfactory remove the gauge
set,
replace the switch

and reinstall the face plate onto the evaporator case.

EXPANSION VALVE

A malfunction
of the
expansion valve will
be
caused

by
one of the
following conditions: valve stuck open,

valve stuck closed, broken power element,
a
restricted

screen
or an
improperly located
or
installed power

element bulb.
The
first three conditions require valve

replacement.
The
last two may be corrected by replacing

the valve inlet screen
and by
properly installing
the

power element bulb.

Attachment
of the
expansion valve bulb
to the
evap-

orator outlet line
is
very critical.
The
bulb must be

attached tightly
to the
line
and
must make good contact

with
the
line along
the
entire length
of
the bulb. A loose
bulb will result
in
high
low
side pressures and poor

cooling.
On
bulbs located outside
the
evaporator case

insulation must be properly installed.

The external equalizer line shown
in
Figure
55 is
not

used
in the
Custom
and
Chevy
II
All-Weather systems.

Indications
of
expansion valve trouble provided by the

Performance Test are
as
follows:

VALVE STUCK OPEN
OR
BROKEN POWER

ELEMENT

Noisy Compressor.
•

No Cooling
-
Freeze
Up.

VALVE STUCK CLOSED
OR
PLUGGED SCREEN

Very Low Suction Pressure.

No Cooling.

Fig.
52-P.O.A. Valve Installed
Fig.
53—Thermostatic Switch Removal

CHEVROLET CHASSIS SERVICE MANUAL

HEATER AND AIR CONDITIONING 1A-46

MAKE ANGULAR CUT

FOR HOSE REMOVAL

LOCATING

BEAD

SEALING

BEADS
LOCATING

BEAD
not to nick or score the sealing beads when

cutting off the hose. Cutting the hose lengthwise

may result in this problem.

Fig.
58—Hose Clamp Connections

NOTE:
Where steel to aluminum connections

are being made, use torque for aluminum tubing.

Hose Clamps (Fig. 58)

When hose clamp connections are encountered special

procedures are necessary for both installation and

removal.

Installation

1.
Coat tube and hose with refrigeration oil.

2.
Carefully insert hose over the three beads on the

fitting and down as far as the fourth, or locating,

bead. Hose must butt against this fourth bead.

CAUTION: Use no sealer of any kind.

3.
Install clamps on hose, hooking the locating arms

over the cut end of the hose.

4.
Tighten the hose clamp screw to 35-42 lb. in.

(except Corvette) 30-38 lb. in. (Corvette). DO NOT

RETORQUE.

Removal

1.
Carefully, with a sharp knife, make an angle cut in

the hose as shown in Figure 58. This should loosen

the hose so that it may be worked off the fitting.

2.
Cut off slit end of hose when reinstalling. Reinstall

as described above.

CAUTION: Use only approved refrigeration

hose. Never use heater hose. Use extreme care
REPAIR OF REFRIGERANT LEAKS

Any refrigerant leaks found in the system should be

repaired in the manner given below:

Leaks at "O" Ring Connection

1.
Check the torque on the fitting and, if too loose,

tighten to the proper torque. Always use a backing

wrench to prevent twisting and damage to the "O"

ring. Do not overtighten. Again leak test the joint.

2.
If the leak is still present, discharge the refrigerant

from the system as described under "Evacuating

and Charging Procedures."

3.
Inspect the ''O" ring and the fitting and replace if

damaged in any way. Coat the "O". ring before re-

installed with refrigerati6n oil and install carefully.

4.
Retorque the fitting, using a backing wrench, and

then add 1/2 to 1 lb. of R-12 to the system and

recheck for leaks.

CAUTION: Do not operate the system with this

small refrigerant charge.

5. Purge the system, thus removing the 1/2 to 1 lb.

installed in Step 4 above.

6. Evacuate and charge the system.

Leaks at Hose Clamp Connection

1.
Check the tightness of the clamp itself and tighten

if necessary. Recheck for leak.

2.
If leak has not been corrected discharge the system

and loosen clamp and remove hose from connection.

Inspect condition of hose and connector. Replace

scored or damaged parts.

3.
Dip end of new hose in refrigerant oil and carefully

reinstall over connector. Never push end of hose

beyond the locating bead. Properly torque the clamp.

4.
Recheck the system for leaks by installing 1/2 to 1

lb.
of R-12 into the system. Do not run compressor.

5. Purge. the system, thus removing the 1/2 to 1 lb.

installed in Step 4 above.

6. Evacuate and charge the system.

Compressor Leaks

If leaks are located around the compressor shaft seal

or shell, replacement of necessary seals should be made

as outlined under "Compressor" in the Chassis Overhaul

Shop Manual.

REFRIGERANT HOSE FAILURE

After a leak or rupture has occurred in a refrigerant

hose, or if a fitting has loosened and caused a consider-

able loss of refrigerant and oil, the entire system should

be flushed and recharged after repairs have been made.

Ji the system has been open to atmosphere for any pro-

longed period of time the receiver-dehydrator should be

replaced.

PREPARING SYSTEM FOR REPLACEMENT

OF COMPONENT PARTS

Air conditioning, like many other things, is farily

simple to service once it is understood. However, there

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-70

Fig.
98—Comfortron Thermal Vacuum Valve

Power Servo .

The Power Servo is attached, to the distributor duct.

The entire installation consists of the Servo Assembly

and its link assembly to the TEMP door. The Servo is

attached to the Air Selector Duct as shown in Figure 108.

Mode Shift Vacuum Diaphragm

Replacement

1.
Remove the heater distributor from the vehicle.

2.
Reach into the distributor through the AIR door

opening to reach and remove the vacuum diaphragm

mounting screws and diaphragm to door link screw

(remove piug from case to reach this screw).

3.
Reverse this procedure to replace.

4.
Adjust mode door without vacuum applied to dia-

phragm. The door should be open one inch from

sealing against the air distributor opening (inside of

case).
(Figure 109).
HIGH BLOWER

DELAY RELAY

.MASTER

DELAY

RELAY

Fig.
100—Comfortron Relays

COLLISION PROCEDURE-AII Systems

Whenever a car equipped with air conditioning unit is

involed in a collision or wreck, it should be inspected as

soon as possible. The extent of damage to any or all of

the component parts and the length of time the system

has been exposed to the atmosphere will determine the

replacement of parts and processing that will be re-

quired. The greater the length of time of exposure to the

atmosphere, the greater will have been the chances for

air, moisture and dirt to have entered and damaged the

system. Every case may be entirely different so it is not

possible to establish a hard and fast procedure to follow

each time. Good judgment must be used to determine

what steps should be taken in each specific case.

The following procedure is presented as a guide for

Fig.
99—Comfortron Resistor Assembly
Fig.
101—Comfortron Sensor Installation

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