295 16-1

PART 16-1 PAGE PART 16-4GENERAL VENTILATING, HEATING,AND ACCESSORIES SERVICE

PART 16-2VENTILATING AND HEATING.

PART 16-3AIR CONDITIONING 16-13

16-11

GROUP16

PAGERADIO 16-21

PART 16-5SPEED CONTROL

PART 16-6

16-25

AUTOMATIC HEADLIGHT DIMMER . . .16-27PART 16-7

SPECIFICATIONS 16-30

PART GENERAL VENTILATING, HEATING,

1 I AND ACCESSORIES SERVICE

Section Page Section Page1 Diagnosis and Testing 16-1 3 Cleaning and Inspection 16-92 Common AdjustmentsandRepairs . 16-9

fl DIAGNOSIS AND TESTING

VENTILATING AND HEATING TROUBLE DIAGNOSIS GUIDE

I. Burnedout fuse or loose wires 8. A kinked, clogged,or collapsedto the heaterblower, water hose.

2. Defective motor ground. 9.’ Improperly connecte,d heater3. Fan loose on motor shaft or hoses.

INSUFFICIENT OR NO HEAT motor stalled. 10. Pluggedheatercores.4. Defective heaterblower switch. 11. Improperly installed engine5. Defective blower motor. thermostat.6. Defective thermostat. 12. Air leaks in the ventilation7. Defective water control valve, system.

INSUFFICIENT OR NOI. Improperly adjusted defroster 4. Pluggedor loose defrosternoz

air duct doors. zle.DEFROSTING 2. Disconnecteddefrosterhose. 5. Obstructed defroster openings

3. Binding defrosterdoors. at windshield.

TOO MUCH HEAT 1. Defective water control valve. 2. Malfunctioningthermostat.

AIR CONDITIONING TROUBLE DIAGNOSIS GUIDE

1. Inoperativemagnetic clutch. 8. Suction pressurelow, discharge2. Inoperative blower, pressureOK.:J. Obstructed air passages. 9. Suction pressure high, dis4. Complete loss of charge no charge pressureOK.

INSUFFICIENT OR NOCOOLING

bubbles in sight glass at system 10. Discharge pressurelow, sucstart up. tion pressurehigh.

5. Partial loss of charge con- 11. Compressordefective,or loosetirtiious bubbles in sight glass after compressorbelt.start up. 12. Vacuum lines kinked, clogged,

6. Servicevalves improperly set. loose, or off.7. Inoperative servo. 13. Thermostat defective.

16-1

I

CONTINUED ON NEXT PAGE

16-2 GROUP 16-VENTILATING, HEATING, AND ACCESSORIES 296

AIR CONDITIONING TROUBLE DIAGNOSIS GUIDE Continued

INSUFFICIENT OR NOCOOLING Continued

14. Clutch lead disconnectedorbroken.

15. Expansion valve inoperative,

stays openor closed.16. Plugsleft in compressorunder

service valve.

1. Loose, torn, or misalignedbelt. parts in compressor.NOISY COMPRESSOR 2. Loose,or slipping clutch. 4. Compressorloose on bracket.

3. Foreign material or damaged

COMPRESSOR VIBRATION 1. Broken or loose mountingbracket.

2. Looseclutch.3. Loose belt.

RADIO TROUBLE DIAGNOSIS GUIDE

1. Burnedout fuse. tive speaker.

NO RECEPTION 2. Reversedbattery polarity.3. Defective antennaor lead.

Be surethatpropervoltageis available at the set, then substitutethe

4. Shortedspeakerlead or defec- known good antennaandspeaker.

NOISY RECEPTION-ENGINE NOTRUNNING

1. Looseconnections.

3. Receivernot properly groundedto instrumentpanel.

NOISY OR ERRATICRECEPTION

NOISY RECEPTION-ENGINE RUNNING1. Defective suppression equip-

NOISY RECEPTION-CAR IN MOTION1. Loose or broken lead-incable.2. Loose or defective radio an

ment. tenna.2. Suppression condensers not 3. Defective wheel static col

properly grounded. lectors.

1. Voice coil rubbing on center 3. Foreignmaterialon cone.DISTORTED OR GARBLED pole pieceof speakermagneteither 4. Bent or twisted speakermount-SOUND front or rear speaker. ing.

2. Torn speakercone.

1. Beyond normal reception dis- ception is poor be sure that antennaWEAK RECEPTION tancefrom station FM only. is at 30-32 inch height beforetrying

2. Defective antenna. If FM re- a new antenna.

NO SOUND FROM 1. One speaker defective. tive. Operate fader to determineONE SPEAKER 2. Wiring to dead speakerdefec- speakerat fault.

ELECTRIC ANTENNA TROUBLE DIAGNOSIS GUIDE .

MOTOR DOES NOT 1. Burned out fuse. 3. Poor ground.OPERATE 2. Defective switch or wiring. 4. Defective motor.

MOTOR OPERATES IN ONLY 1. Defective switch or wiring.ONE DIRECTION 2. Defective motor.

MOTOR RUNS BUT WANDS 1. Bent or corrodedwands.DO NOT MOVE 2. Defective drive assembly.

SPEED CONTROL TROUBLE DIAGNOSIS GUIDE

BLOWING FUSES 1. Short or ground in the wiring circuit Fig. 1.

1. Accelerator linkage is broken 3. Blown fuse. Fuse block is acNO SPEED CONTROL or disconnected. cessiblethrough left sideof glovebox.RESPONSE 2. Drive cable broken or dis- 4. Loose connections or broken

connected. wires internal or external.

CONTINUED ON NEXT PAGE

297 PART 16-1-GENERAL VENTILATING, HEATING, AND ACCESSORIES SERVICE

SPEED CONTROL TROUBLE DIAGNOSIS GUIDE Continued

16-3

CONSTANT PRESSURE ONACCELERATOR PEDALREGARDLESS OF SELECTORSETTING

l Blown fuse. 4. Inoperative motor or locked2. No current at No. 2 Terminal, drive screw.3. Control cable is improperly

ad’isted.

AUTOMATIC CONTROL DOESNOT ENGAGE WHENTHESLIDESWITCH IS MOVED TO LOCK

.

1. No current at No. 3 Terminal. 2. Brake releaseswitch improperlyadjusted.

AUTOMATIC CONTROLREMAINS ENGAGED WHENTHE BRAKE PEDAL ISDEPRESSED

1. Brake switch improperly ad- 2. Inoperativebrake switch.jusied.

PULSATING ACCELERATORPEDAL

1. Speedometercable or drive 3. Improper accelerator linkagecable xinked. adjustment.

2. Lack of lubrication on cables.

CARBURETOR DOES NOTRETURN TO NORMAL IDLE

1. improper carburetoror acederaicw linkage adjustment.

SPEEDOMETER DOES NOTREGISTER OR THE UNITDOES NOT OPERATE

]l Speedometerdrive gear in the transmissionto the powerunit.transmissiondamaged. 3. Broken speedometercable.

2. Broken drive cable from the 4. Defective speedometer.

SPEEDOMETER NOISE Cables bent or kinked. 3. Noisy speedometerhead.2 Lack of cable lubrication.

+} TERMINAL

K-i 533-A

FIG. i-Wiring Diagram

16-4 GROUP 16-VENTILATING, HEATING, AND ACCESSORIES

CONTROL

IINCREASE

SENSITIVITY

11534-A

FIG. 2-Driver Control Knob

AUTOMATIC HEADLIGHTDIMMER

DIAGNOSIS TIPS

If the headlightsdim at the wrongdistance occasionally, the car probably has been meeting cars withbadly aimedheadlights.

Repeateddimming at the wrongdistancemaybe causedby the adjustment of the sensitivity control knobFig. 2.

If oncoming cars are blinking be-

fore the lights aredimmed, turn theknob clockwiseto increasethe sensitivity and the lights will dim sooner.Turn the knob the other way, andthe lights will hold on the upperbeamlonger.

Someperfectlynormal roadconditions, suchas snowor fog, will causethe headlightsto dim even if anothercar is not approaching.This is aplus factor for the driver. It is farsafer to drive on low beam throughrain, snow and fog.

Side lighting may causethe lightsto dim. Light objects such as whitepicket fences, flashing traffic lights,billboards, and distant cars in hillycountry may trigger the unit. Thishigh degreeof sensitivity is necessaryin order for the unit to do its jobproperly.

Brightly-lighted areasgasstations,intersections,or lighted streets,etc.will dim the lights.

Snow or dirt on the windshieldmay block thephototube.Sometimeswiper blades in front of the unitmay block its vision. This reducessensitivity and can causecycling. Itmay be necessaryto lower the right-

wiper blade one or two notches toassureclear vision.

If the unit doesn’tswitch to upperbeam immediately after the approachingcar passes,it may simplybe out of adjustment. To correctthe situation, follow the procedurefor sensitivity and aim adjustment.

TESTING VENTILATINGAND HEATING

Use the following procedure tocheck for malfunction of the heatervacuum system. The procedurewilldetermineif thereare leaks, pinchedlines or lines not connected.

1. Insert a vacuum gauge in thevacuumsupply line black line nearthe dash connectorblock See Fig.3.

2. Set the regulator lever at theMAX position. Set the vents-heaterlever at the OFF position.

3. Start the engineandrun it untilat least 16 inchesof vacuumis obtained. Stop the engine.

4. Recordthe vacuum reading. Ifthis readingdecreasessteadily, thereis a leak in the check valve or thevacuum systemfrom the checkvalve

CHART 1 -Heater Vacuum Line Operation Regulator Lever at MAX

Vents-HeaterLever Position

VacuumTo Line

AmountOf Vacuum

In Line

Air Door PositionDoors with no vacuumapplied are closed0

R-LBlack-BlueStripeBlack-GreenStripeBlack-OrangeStripe

14 InchesMercuryMinimum

OutsideAir ClosedLeft Vent OpenRight Vent Open

RBlack-Blue StripeBlack-OrangeStripe

14 InchesMercuryMinimum

OutsideAir ClosedRight Vent Open

L Black-BlueStripeBlack-GreenStripe

14 InchesMercuryMinimum

OutsideAir ClosedLeft Vent Open

OFF Black.Blue Stripe14 InchesMercuryMinimum

OutsideAir Closed

HEAT

DE-ICE

Black-Red StripeBlack-Brown Stripe

Black-WhiteStripeBlack-RedStripeBlack-Brown Stripe

14 InchesMercuryMinimum

14 InchesMercuryMinimum

OutsideAir OpenHeaterWater Valve Open

Defroster OpenOutsideAir OpenHeaterWater Valve Open

DECREASESENSITIVITY

DETENTPOSITION

298

NORMALSENSITIVITY

Some air is bled by the defrost-heatdoor in both closedpositions.

PART 16-1-GENERAL VENTILATING, HEATING, AND ACCESSORIES SERVICE 16-5

to the vents-heatercontrol Refer

to Fig. 3.

5. Move the vents-heatercontrollever to the positionsshown in Chart2, observethe drop in vacuum onthe gauge.Repeatsteps 3 and 4 betweeneach lever movementto bringthe vacuumback to 16 inches.

6. If any vacuum drop is less than

indicated, check for pinched lines,plugged lines, plugged fittings, orpartial cycle due to a binding door.If any vacuum drop is greater thanthat indicated, check for leaks, linesnot connected,or defective components.

If a single vacuum actuatoris malfunctioning, check the vacuum atthe actuatorChart I. If the vacuum is within limits, the actuatoris defective or the door is binding.

AIR CONDITIONINGUse the following procedure to

check for malfunction of the heater-air conditionervacuum system.Theprocedurewill determineif thereare

CHART 2-Vacuum Drop vs. Vents-Heater Lever Position

Vents-HeaterLever Movement

Vacuum DropInches of Mercury

OFF to HEAT 0.75-3.0

HEAT to DE-ICE 0.25-2.5

DE-ICE to HEAT 0.1.5

HEAT to OFF 0.5-3.0

OFF to L 0.25-2.0

L to R 0.25-2.0

R to R-L 0.25-2.0

leaks,pinchedlines or lines not connected.

I. Insert a vacuum gauge in thevacuumsupply line black line nearhe dash connectorblock Refer toFig. 4.

2. Set the regulator lever at theMAX position. Set the vents-heaterever at the OFF position.

3. Start the engineandrun it untilit least 16 inchesof vacuum is obtained. Stop the engine.

4. Record the vacuum reading. Ifthis readingdecreasessteadily, thereis a leak in the check valve or thevacuum system from thecheckvalveto the vents-heatercontrol Refer toFig. 4.

5. Move the vents-heatercontrollever to the positionsshownin Chart4, observethe drop in vacuumon thegauge.Repeatsteps3 and 4 betweeneach lever movement to bring thevacuum back to 16 inches.

RIGHT VENTDUCT

299

TO CARBURETOR

TUBING COLOR CODE

B-BR BLACK.BROWNSTRIPE

B BI.ACKB-RI BLACK-BLUE STRIPE

B.R BLACK-RED STRIPEGR GRAY8.0 BLACK-ORANGE STRIPEB-G BLACK-GREEN STRIPE

B-W BLACK-WHITE-STRIPE

VACUUMRESERVOIR.TANK

LEFT VENT DUCT

AIR

T CONNECTOR.

HEATER PLENUM

CONNECTOR’

K 1377-B

F 1G. 3-Heater-Vacuum Line Connections

16-6

TUBING COLOR CODE

B-GR-BLACK-GRAY STRIPEB-R----BLACK-RED STRIPE

B-RI-BLACK-BLUE STRIPEB-BR-BLACK-BROWN STRIPE

8-BLACKB-G-BLACK-GREEN STRIPEB-O - BLACK-ORANGE STRIPEB-W-BIACK-WHITE STRIPEB-P-BLACK-PINK STRIPE8-T-BLACK-TAN STRIPEB-Y - BLACK-YELLOW

LEFT VENTDUCT

CONNECTOR

T

B-G

GROUP 16 - NTILATING, HEATING, AND ACCESSORIES

FIG. 4-Heater-Air Conditioner-Vacuum Line Connections

CHART 3-Heater-Air Conditioner Vacuum Line Installation Regulator Lever at MAX

300

A/C Vents-heaterLever

Position

VacuumTo

Line

Amountof

VacuumIn Line

Air Door PositionsAll Doors or Valves not

indicated are closed

RECBlack-Blue StripeBlack-Pink StripeBlack-Yellow Stripe

14 inchesMercuryMinimum

Outside Air Closed, EvaporatorShuttersOpenOutsideAir Bleed ClosedThermostaticSwitch Operating

FRESHBlack-Blue StripeBlack-White StripeBlack-Yellow Stripe

14 InchesMercuryMinimum

OutsideAir Closed, EvaporatorShutters OpenOutside-Air Bleed OpenThermostaticSwitch Operating

R-L

Black-Blue StripeBlack-Pink StripeBlack-GreenStripeBlack-OrangeStripe

14 inchesMercuryMinimum

Outside Air Closed, EvaporatorShutters OpenOutsideAir Bleed ClosedLeft Vent OpenRight Vent Open

RBlack-Blue StripeBlack-Pink StripeBlack-OrangeStripe

14 InchesMercuryMinimum

OutsideAir Closed, EvaporatorShutters OpenOutsideAir BleedClosedRight Vent Open

LBlack-Blue StripeBlack-Pink StripeBlack-GreenStripe

14 InchesMercuryMinimum

Outside Air Closed, EvaporatorShutters OpenOutsideAir BleedClosedLeft Vent Open

OFF Black-Blue StripeBlack-Pink Stripe

14 InchesMercuryMini mum

OutsideAir Closed, EvaporatorShutters OpenOutsideAir Bleed Closed

HEATBlack-Brown StripeBlack-Red StripeBlack-Tan Stripe

14 Inches -

MercuryMinimum

HeaterWater Valve OpenOutsideAir Open, EvaporatorShuttersClosedToe Board Heat Open

DE-ICE,

Black-Brown StripeBlack-Red Stripe

14 InchesMercuryMinimum

Heater Water Valve OpenOutsideAir Open, EvaporatorShutters Closed

DASH CONNECTORBLOCK

B-G

K-i 384-B

PART 16-1 -GENERAl. VENTILATING, HEATING, AND ACCESSORIES SERVICE 167

moving small tracesof refrigerant

Vents-HeaterLeverMovement

Vacuum DropInches of Mercury

DE-ICE to HEAT 0.25-2.5

HEAT to OFF 2.5-5.5

OFF to 1. 0.25-2.0

L to R 0.25-2.0

R to R-L 0.25-2.0

R-L to FRESH 0.5-3.0

FRESH to REC 0.25-2.5

6. if any vacuumdrop is less thanindicated, check for pinched lines,pluggedlines, pluggedfittings, or partial cycle due to a binding door.

If any vacuum is greater than that

indicated, check for leaks, lines notconnected,or defectivecomponents.

If a single vacuumactuator is malfunctioning, checkthe vacuum at theactuator Chart 3. if the vacuumis within limits, the actuator is defective or the door is binding.

CHECKING FOR LEAKS

Attach the manifold gauge setFig. 5. Leaveboth manifold gaugevalves at the maximum clockwiseposition. Set both service valves atthecenterposition.Both gaugesshouldnow show approximately60 to 80pounds prssure at 75 F. if verylittle or no pressureis indicated, leavethe vacuumpump valve closed, openthe Refrigerant-12 tank valve, andset the low pressuremanifold gaugevalve to the counterclockwise position. This opensthe system to tankpressure.

Check all connections, and thecompressorshaftseal for leaks, usinga flame type leak detectorFig. 6.Follow the directions with the leakdetector. The smaller the flame themore sensitive it is to leaks. Therefore to insure accurate leak indication keep the flame as small aspossible.The copperelementmust bered hot. If it is burned away, replacethe element.

Hold the open end of the hose ateach suspectedleakpoint for two orthree seconds. The flame will normally be almost colorless.The slight-.est leak will be indicated by a bright

color to the flame. Be sure to checkthe manifold gauge setand hosesforleaks as well as the rest of the systern.

vapor.

SPEED CONTROL

PERFORMANCE CHECKS’

After servicing the speed controlunit, the car should be road testedfor proper operation of the speedcontrol in both the manualand automatic control positions. The speedcontrol unit cannotbe testedwiththe car on a hoist or jack.

MANUAL OPERATION

1. Set the selector dial for anydesired speed.

2. With the car in motion, a resistanceshould be felt at the acceleratorpedal when the pre-selectedspeedis reached.

3. Drive while holding the accelerator pedal against the back pressure. The car should maintain a constantspeedat the selectedsettingevenwhen traveling up or down hills.

4. Push through the acceleratorresistance to increase car speedabovethe speedcontrol selectorsetting. The resistanceshould continueat all speedsabove the pre-setspeed.

301

CHART 4-Vacuum Drop vs. Vents-Heater Lever Position

If the surrounding air is per.meated with refrigerant gas, theleak detectorwill indicate this gasall the time. Good ventilation isnecessaryto prevent this situation. A fan, even in a well venti.lated area, is very helpful in re

TOSERVICE VALVE PORT SERVICE Ki 543-A

FIG. 5-Manifold Gauge Set

TURN ON NEADLAMPS, AND LET UNIT WARM-UP FOR ABOUT30 SECONDS. COVER THE PHOTOTUBE UNIT WITH A DARKCLOTN. OPERATE FOOTSWITCH.

30216-8 GROUP 16-VENTILATING, HEATING, AND ACCESSORIES

5. Checkto see if the selectedcarspeedcan be increasedor decreasedat any time by turning the selectordial. The acceleratorpedal must beheld againstthe back pressureduring this test.

AUTOMATIC OPERATION

Before road testing the car forautomatic operation, the speedcontrol system should be testedfor cancellation when the brake pedal isdepressed.

1. Turn the ignition switch to theACC position. -

2. Press the acceleratorpedal tothe floor. Push the slide switch toLOCK.

3. Releasethe slide switch, andacceleratorpedal. The speed controlshould hold the acceleratorpedal inthe full throttle position.

4. Depress the brake pedal 1/4 -

________________________________

inch. The acceleratorpedal shouldreturn to the normal position.

5. Road test the car and set the

__________________________________

selectorknob to any desired speed.

6. When the pre-set speed isreached,hold the acceleratorpedalagainst the resistanceand push theslide switch to LOCK. The carshouldnow be automaticallycontrolled andmaintain the selectedspeed.

7. Test to see if the speedcan beincreasedor decreasedby turningthe dial.

8. Again test to see if the automatic speedcontrol cancelsby lightlydepressing the brake pedal or byturning the ignition switch to theOFF position. It is not necessaryto change the speedsetting whenre-engaging the automatic speedcontrol. It can only be engagedwhen the selectedspeed is reachedand the accelerator pedal is heldagainst the resistance pressurewhen the slide switch is pushedto LOCK.

IF HEADLAMPS GO TO UPPER BEAM.SYSTEM IS OPERATING BUT NEEDSSENSITIVITY ADJUSTMENT.

IF HEADLAMPS STAY ON LOWER BEAM, POSITION AMPLIFIER‘HOtD CONTROL IN APPROXIMATE CB’ITEROF ITS TRAVELTHIS WILL RUMINATE THE POS5IBILTY OF LOCKING HEAD.LAMPS ON LOW BEAM DUE TOCOMPLEFB MISADJUSTMENT.IF NEADLAMPS REMAIN ON LOWER BEAM WHEN PHOTO.TUBE US AGAIN COVERED. CHECK THE FOLLOWING.

DISCONNECT THE PHOTOTUBE UNIT HARNESS FROM THE[FIER - OPERATE FOOTSWITCN.

IF HEADLAMPS GO TO UPPER BEAM. TROUBLEIS IN TUE PHOTOTUBE UNIT. REMOVE THEPHOTOTUBE UNLTANDAMPUPIEEFOR REPAIR.

UP HEADEAMPS REMAIN OH LOWER BEAM, TROUBLE IS INAMPUFIER UNIT OR FOOTSWITCH.

[LL4Ew FOO;SWITCN. OPERATE POOTEW;TCHT1

FIG. i-Trouble Shooting-Locked on Low Beam

IF HEAOLAMPS REMAIN OH LOW BEAM, REMOVE THEAMPLIFIER ONLY FOR REPAIR.

Ki 540-A

q

7 1

FIG. 6-Testing for Leaks

IF HEADLAMPS SWITCH FROM LOWER BEM TOUPPER BEAM, TROUBLE WAS IN FOOTSWITOL

9. Disengage he unit by movingthe switch to the OFF position.

PART 16-1 -GENERAL VENTILATING, HEATING, AND ACCESSORIES SERVICE 16-9

AUTOMATIC HEADLIGHTDIMMER

PRELIMINARY TEST

1. Turn the headlampsto the fullON position. Allow about 30 seconds for the headlight dimmer towarm up. With the car in a lightedarea, the lights should be on low-beam regardless of the position ofthe foot switch. if upper-beam isobtainedin one position of the footswitch, check the fuse.

2. Depress the foot switch about1/s-inch to the detent. The lightsshould change to the upper-beamand then change hack to the lower-beam when the foot switch is released, if the foot switch is in theAutomatic position. if not, cyclethe foot switch to obtain the automatic position.

3. Place a hand or a dark clothover the phototuhc unit. The lightsshould switch to the upper-beam.Removethe cloth or hand. The lightsshould change back to the lower-beam. The unit will not go to upper-beam if the phototube unit temperature is above90 F. Therefore,checkto see if the phototube is hot. If itis, allow it to cool and repeat theabove checks.

If the headlights operate as explained in steps 1, 2, and 3, the device should operate correctly withthe properaiming and sensitivity adjustments.If the lights do not operateas describedin the above steps, referto Figs. 7 and 8.

LOCKED ON UPPER BEAM

L5 FUSE

DISCONNECT AMPLIFIER PROM PHOTOTUEE1HARNESS AND GROUND THE WHITE WIRE INAMPLIFIER PORTION OF CONNECTOR.

O COMMON ADJUSTMENTS AND REPAIRS NOT APPLICABLE

SEE IN-CAR ADJUSTMENTSAND REPAIRS PART 16-2

U CLEANING AND INSPECTION

VENTILATING AND HEATING

When installing a new vents-heatervalveor a regulatorvalve, inspect fordIrt and foreign objects Also, checkto be sure the vacuum hoses areclean and not pinched or cracked.Be sure the pointer is not bent orrubbing.

Wheneverthe battery ground cable

k removed, make certain the cableci.imp and the battery terminal postHc clean and dry before assembly.

AIR CONDITIONINGOn a compressor ctutch installa

tim, carefully remove any burrs ordirt that may he on the compressorsf.ft. The shaft must he dry andbrightly polished. Then install the

key in the shaft.When the compressoris disassem

bled, completelyclean all gasketsurfaces of shredsand foreign objects.

If the compressor shaft seal isbeing replaced, inspect the compressor internally and clean out dirt orchips as required.

See also ventilating and heating,this section.

303

IF HEADI.AMPS SWITCH TO LOWER REAM.I TROUBLE IS IN PHOTOTUBE UNIT. REMOVE

ROTH THE PHOTOTUBE AND AMPLIFIER

L1R REPAIR.

P HEADLAMPS DO NOT SWITCH TOLOWERBEAM, TROUBLE IS IN THE AMPLIFIER OR IPOOTS WITCH.

DISCONNECT RED WIRE FROM FOOTSWITCHTETITCJ

IF LOW BEAM IS OBTAINED IN BOTHPOSITIONS OF THE FOOTSWITCH, IREPLACE FOOTSWETCH. _,,,,J

NO OVERRIDE

__

IIF OPERATION OF BOTH UPPER AND LOWER IBEAM IS OBTAINED, TROUBLE IS IN AMPLIFIERUNIT. REMOVE ONLY THE AMPLIFIER FORREPAIR.

1FOOTITCHINAUTOMASITIO.I UNCOVER THE PHOTOTUBE UNIT. DISCONNECT I

CIITHE

1TDLAMPS REMAIN ON LOW BEAMIF OVERRIDING UPPER BEAM IS OR. IN OVERRIDE POSITION. REMOVE THETAINED, REPLACE POOTSWITCH. AMPLIFIER FOR REPAIR.

FIG. 8-Trouble Shooting-Locked on Upper Beam or No Over-Ride

K1 541-A.

GROUP 16-VENTILATING, HEATING, AND ACCESSORIES

FIG. 9-CheckingCompressor Oil Level

COMPRESSOR OIL LEVELCHECK

Under normalconditions,whentheair cooling system is operatingsatisfactorily, the compressoroil levelneed not be checked. There is noplace for the oil to go except inside the sealedsystem.When the caris first started, some of the oil willhe pumpedinto the rest of the systern. After 15 minutes of operation,most of the oil is returned to thecompressorcrankcase.

Check the compressoroil levelonly if a portion of the refrigerantsystem is being replaced, or ifthere was a leak in the systemand the refrigerant is being replaced.

Checkthe oil after the system hasbeenchargedand hasbeen operatingat an engine speedof 1500 rpm for15 minutes in 60 F. surroundingairtemperatureor above. Turn off theengine, and isolate the compressor.Seein-Car Adjustmentsand Repairs,Part 16-2. Remove the oil fillerplug from the compressorFig. 9,

FIG. lO-CompressorOil Level Dip Stick

give higher system pressures. Thelowest figures given are for an ambient surrounding air temperatureof 75 F., 50% relative humidity.

The low pressuredicate a pressurepounds. The highshould indicate aseven times the low300 pounds.

gaugeshould in-of from 12-50pressure gaugepressuresix orpressure,or 80-

At idle speedanda surroundingair temperature of 100-110 F.,thehigh pressuremay go as highas 300 pounds or more. If it becomes necessaryto operate the airconditioner under these conditions,keep the high pressuredown witha fan directed at the condenserandradiator.

16-10 304

insert a flattened ½-inch diameterrod Fig. 10 in the oil filler holeuntil it bottoms.The rodshould show½-inch of oil. This is equivalent to9 ouncesof oil. It may be necessaryto rotate the compressorcrankshaftslightly by hand so that thedip rodwill clear the crankshaft. If additional oil is neededin thecompressor,add Suniso5 or CapellaE refrigerator compressoroil, or equivalent.

NOTE:OIL TO BE CHECKED WITHKEYWAY IN SHAFT FACINGTHE HEAD OF THE COMPRESSOR

If more than ½-inch of oil is indicated, as might happenif a newcompressor is installed,and oil already in the system is pumpedbackto the compressor,draw out theexcessoil until the proper quantity is

11544-A indicated.Replace the oil filler plug, and

then evacuateandconnectthecompressorbackinto the system. Be sureto check the compressorfiller opening for leaks.

CHECKING SYSTEMPRESSURES

.2 NOTCHES,YB" APART

11542-A

The pressuresdevelopedon thehigh pressureand low pressuresideof the compressorindicate whetheror not the system is operatingproperly.

Attach the manifold gauge setFig. 5. It will not be necessarytoattach the Refrigerant-12tank unlessrefrigerant is to be added to the system. Set both manifold gaugevalvesat the maximum clockwise,or closed,position. Set both service valves atthe centerposition.

Checkthesystempressureswiththeenginerunningat 1500 rpm,allcontrolsset for maximum cooling,and the front of the car at leastfive feet from any wall.

The actual pressuresindicated onthe gaugeswill dependon the temperature of the surrounding air andthe humidity. Higher air temperatures along with low humidity, will

DEFROSTER OUTLET

AIR DOOR CONTROL

305 - 16-11

VENTILATING AND HEATING

Section Page Section Page1 Descriptionand Operation 16-11 3 Removal and Installation 16-112 In-Car Adjustmentsand Repairs 16-11

fl DESCRIPTION AND OPERATIONTheheatercontrol systemincorpo- COWt OUTSIDE AIR INLET

ratestwo levers.The upper, or regulator lever, controls the heat ternperature and ventilation quantityfrom minimum to maximum Theventsheater lever controls the airduct doors for outside air heatedair and defrosting. A 4-positionblower control switch is usedto givethreeblower speedsfor low, mediumandhigh volumes of air for heatingand defrosting Fig I shows theheaterinstallation Some air is bledby the defrost-heat door in bothclosedpositions.

A wiring diagram covering both -

heatingandair conditioning is shownin Fig. 13, Part 16-3. /

yHEATER CORE AND WATER BLOWER ASSEMBLY HEATER THERMOSTAT 11372-5

TEMPERATURE CONTROLFIG. i-Heater Installation

Thewatertemperaturecontrol system consistsof a thermostatand a In operation, when the regulator the water valve, thus regulating thewater control valve,

lever on the instrument panel is flow of water through the heaterThe thermostatis mountedon the moved to the right for heat, vacuum core.

heaterblower case and is subjected is applied to the thermostat,setting The vents-heaterlevercontrolsvacto dischargedheater air. The Dole- the sensing element for the desired uum to the vacuum actuatorsto optype water control valve is mounted temperature.This in turn controls crate the various vent and heateroutsidethe heaterblower case. the amount of vacuum directed to doors.

O IN-CAR ADJUSTMENTS AND REPAIRSVACUUM ACTUATORS preloadedfor about a ½-inch travel BRACKET ADJUSTMENT

The vacuum actuatorsare adjust- of the actuatorconnectinglink, with 1. Loosen the two vacuum motorno vacuum applied, attachingscrewsor nuts.able for proper air door operation.

2. Move the motor until the preWith no vacuum applied, adjust the Adjust the fresh air door actuator load indicator is flush with themotorright andleft freshair vent actuators so that the door is completelyclosed body. The dampermustbe in its nor-andthe defrosteractuatorso that the door arm in maximum clockwise mal position with no vacuumapplied.vent doors and defrosteroutlet door position when the vents-heaterlever 3. Tightenthe two bracketattachare closed. Make these adjustments is at the OFF position engine run- ing screws or nuts and check theso that the actuator return spring is ning. operationof the motor.

WATER CONTROL VALVE

0 REMOVAL AND INSTALLATIONHEATER CORE

REMOVAL1. Start the engine and set the

heatercontrols for maximum heat,to open the heaterwater valve.

2. Stop the engine and drain thecoolant. Disconnectthe heatercorehoses.

3. Remove the front cover of theheatercore housing Fig. 2.

4. Removetheheatercore mounting screwsand remove the core.

INSTALLATION1. Place the new core in position

with the spongerubbersealson each

‘16-12 GROUP 16-VENTILATING, HEATING, AND ACCESSORIES

heater core inlet tube. Install themounting screws.

2. Connectthe heatercore hoses.The hose from the water valve connects to the heatercore lower inletpipe.

3. Fill the cooling system. Bleedthe system at the upper heatercoreinlet pipe.

4. Check for leaks. Then installthe core housingfront cover. Checkthe heateroperation.

VENTS-HEATER VALVE

REMOVAL

1. Disconnect the battery groundcable.

2. Remove the mounting screwsand control knobs, and removethefront casting and the dial.

3. Removethe plate assembly.4. Remove the vents-heatervalve

andthe vacuumlines.

INSTALLATION

1. Install the vacuum lines on anew vents-heatervalve, and installthevalve.

2. Install the plate assembly andits mounting screws.

3. Install the front casting anddial, the mounting screws, and thecontrol knobs.

4. Connect the battery groundcable.

REGULATOR VALVE

Removethe front casting and thedial. Then remove the mountingscrewsandcontrol knobs, disconnectthe vacuum hoses and remove theregulator valve.

BLOWER MOTOR

The blower motor, mountedin theblower housing on the engine sideof the dash, can be removed by disconnecting the motor connectingwires andventilation tube andby removing the mounting nuts andscrews.The heaterblowerwiring circuit is shown in Fig. 3.

BLOWER SWITCH

306

FIG. 2-Heater Core Removal

Disconnect the battery groundcable. Removethe front casting anddial. Removetheplate assembly.Disconnecttheswitchwires, andremovethe switch.

LOCATED IN HORNRELAY MOUNTING PI.ATE

ri

Ki 553-A

FIG. 3-Heater Blower Wiring Circuit

16-13307-

AIR CONDITIONING

Section Page Section Page1 DescriptionandOperation2 In-Car AdjustmentsandR

16-13epairs 16-14

3 Removal andInstallation 16-16

fl DESCRIPTION AND OPERATION

The combined heater-air conditionerincorporatestwo control levers.The regulator lever controls bothheatingandcooling temperatureandventilation quantity, from minimumto maximum.The vents-heaterlevercontrolsthe air duct doors for freshair, heated air, defrosting, cooledrecirculatedair, andcooled freshair.The cooled fresh air is part recirculated and part fresh. A 4-positionblowercontrol switch is usedto givethreeblower speedsfor low, mediumandhigh volumesof air for heating,defrosting,andcooling. Fig. 1 showsthe heater-airconditionerinstallation.Some air is bled by the defrostdoors and the toe-board heat doorwhen they are in their closed positions.

A wiring diagram covering bothheatingandair conditioning is shownFig. 13 at the endof this part ofthe manual.

RECEIVER UNITThe air cooling system storesthe

liquid Refrigerant-12under pressurein a combination receiveranddehydrator. The pressurein the receivernormally varies from about 80 to300 psi, dependingon thesurrounding air temperatureand compressorspeed. The receiver and condensercomeschargedand markedwith thetotal weight, so that any leak, indicated by a loss in weight, can bedetectedbefore assembly.

Thedehydratorremovesanytracesof moisture that may haveaccumulated in the system. Even smallamounts of moisture will cause anair cooling unit to malfunction. Afusible plug is screwed into the receiver. This will releasethe refrigerant before the refrigerant temperature exceeds2l2 F.

EVAPORATOR UNITWhen the cooling systemis in op

eration, the liquid Refrigerant-l2flows from the combination receiverand dehydratorunit through a flex-

FIG. i-Heater-Air Conditioner Installed

ible hoseto the evaporatorcoolingunit where it is allowed to evaporate at a reducedpressure.The evaporator assembly is mounted on thepassengercompartmentside of thedash.

EXPANSION VALVEThe rate of refrigerant evapora

tion is controlled by an expansionvalve Fig. 2 which allows onlyenoughrefrigerant to flow into theevaporator to keep the evaporatoroperatingefficiently, dependingon itsheat load.

The expansion valve consists ofthe valve and a temperaturesensingcapillary tube and bulb. The bulbis clampedto the outlet pipe of theevaporator.Thus, the valve is controlled by evaporatoroutlettemperature. An internal equalizer appliesevaporatoroutletpressureto onesideof the valve diaphragm.Thus, thevalve is controlled by both evap

11368-5

orator outlet temperatureand outletpressure.

The restrictingeffect of theexpansion valve at the evaporatorcausesalow pressureon the low pressuresideof thesystemof 12-50psi, dependingon the surrounding air temperatureand compressorspeed.

FIG. 2-Expansion Valveand Liquid Sight Glass

HEATER CORE

/ OUTSIDE AIR DOOR

EVAPORATOR SHUTTERS

AIR OUTLET REGISTER

I,’

/ , HEATER WATER CONTROL VALVE

BLOWER AS’LY "N HEATER THERMOSTAT

TOE BOARD HEAT DOOR

TUNNEL AIR DUCT

GROUP 16-VENTILATING, HEATING, AND ACCESSORIES

LIQUID SIGHT GLASS

A liquid sight glass is mountedinthe expansionvalve Fig. 2. Thesight glass is used to check whetheror not there is enoughliquid refrigerant in the system. Foam seeninthe sight glass while the compressoris operating,is an indication of lossof refrigerant. See "Diagnosis andTesting," Part 16-1.

COMPRESSOR UNIT

The evaporatedrefrigerant leavingthe evaporatornow in the form of a

TEFLON SEALS

SERVICEVALVES

FIG. 4-CompressorService Valves Removed

11549-A

gas at a pressureof 12-50 psi, ispumped by the compressorlocatedon the engineFig. 3, into the topof the condenserlocatedin front ofthe radiator.

The compressormaintainsa pressureon its high pressureside of from80-300 psi, depending on the surrounding air temperatureand compressorspeed.

As the now heatedandcompressedrefrigerant gas flows down throughthecondenser,it is cooledby air passing betweenthe sectionsof thecondenser,and the cooled, compressedrefrigerant gas condensesto liquidrefrigerantwhich then flows into thereceiver. Before the liquid refrigerant flows on to the expansionvalve,it makes one more pass across thebottom of the condenserwhere it isfurther cooled.

MAGNETIC CLUTCHTo control the amount of cooling

that the system produces,the compressor is electrically cut in andout of operationby theuseof a magnetic clutch pulley mounted on thecompressorcrankshaft.Themagneticclutch is controlledby athermostaticswitch which has its temperaturesensingtube inserted in the fins ofthe evaporatorcore.

SERVICE VALVESThe servicevalveson the compres

sor are used to test and service thecooling system Fig. 4. The highpressureservice valve, mounted atthe outlet to the compressor,allowsaccessto thehigh pressureside of thesystem for attaching a pressuregauge,or a servicing hose.

The low pressurevalve, mountedat the inlet to the compressor,allowsaccessto the low pressureside of thesystemfor attachingapressuregauge,or a servicinghose.

Both service valves may be usedto shut off the rest of the systemfrom the compressorduring compressor service.

THERMOSTATIC SWITCHThe thermostatic switch controls

the operationof the compressorbycontrolling the compressormagneticclutch. The temperaturesensingtubeof theswitch is placedin contactwiththe evaporatorfins.

When thetemperatureof the evaporator becomestoo cold, the thermostatic switch opens the magneticclutchelectricalcircuit, disconnectingthe compressor from the engine.When the temperatureof the evaporator rises to the upper limit atwhich the thermostaticswitch is set,the thermostatic switch closes andenergizesthe magnetic clutch. Thisconnectsthe compressorto the engine andcooling actionbeginsagain.

When the ignition switch is off,or the cooling control thermostaticswitch is in theoff position, the magnetic clutch is not energized, andthe cooling system can not operate.

When the ignition switch is onengine running, and the coolingcontrol is in the cooling range, themagnetic clutch is energized, thecompressoris connectedto the engine, and the cooling system is inoperation.

The thermostaticswitch may beadjusted to maintain an averageevaporatortemperatureof from 30’-60’ F. Fig. 5. The thermostaticswitch operatingdifferentialtemperature at any one setting is 6’ F. Theswitch is controlled by the regulatorcontrol.

0 IN-CAR ADJUSTMENTS AND REPAIRS

VACUUM ACTUATORS

The vacuum actuators Fig. 2,are adjustable for proper air dooroperation.The singleactingactuatorsare adjustedso that the actuatorre

turn springsare preloadedfor about1/8 inch travel of the actuator connecting links, with no vacuum applied.

so that the door is completelycloseddoor arm maximum clockwiseposition when the vents-heaterlever isat the OFF position engine run-

16-14 308

FIG. 3-Compressor Installed

K15 18-A

FIG. 5-Thermostatic Switch

Adjust the fresh air door actuator ning.

PART 16-3-AIR CONDITIONING 16-15

Adjust the fresh air bleed crankso that the fresh air door is completely closed when the vents-heaterlever is at the OFF position enginerunning.

Adjust the evaporatorshutter sothat the shutter is completely openwhen the vents-heatercontrol is atthe REC position. Also see bracketadjustmentinstructionsunder‘Ventilating and Heating."

ISOLATING THE COMPRESSOR

To isolatethe compressorfrom thesystem, turn both the high and thelow pressureservice valvesto the extremeclockwiseposition Figs, 6 and7. Loosen the cap on the highpressure service valve gauge port,and al1ov the gasto escapeuntil thecompressoris relieved of refrigerantpressure.

Loosen the cap a small amountonly, and do not remove it untilthe pressureis completelyrelieved.

To connect the compressorbackinto the system, evacuatethe compressorat the high pressureservicevalve gaugeport, close the vacuumpump valve, turn both servicevalvesto the maximum counterclockwiseposition, and cap the high pressureservice valve gauge port and servicevalve stems.

DISCHARGING THE SYSTEM

Dischargethe refrigerantfrom thesystem. except the compressor,hetore replacing any part of the sys

To dischargethe system, connectthe manifold gaugeset to the systemFig. 5, Part 16-1. Do not connectthe manifold centerconnectionhosesto the Refrigerant-12 tank, or vacuum pump. Place the open end ofthesehosesin a garageexhaustoutlet. Set the high pressuremanifoldgaugevalveat the maximumcounterclockwiseor openposition. Openthehigh pressureservice valve a slightamount Fig. 7, and allow therefrigerant to discharge slowly fromthe system.

Do not allow the refrigerant torush out, as the oil in the compressor will be forced out along with it.

CHARGING THE SYSTEM

The procedure for charging dependson whethera partial chargeora complete charge is being made.When a complete charge is to bemade, check for leaks first See"Diagnosis and Testing," Part 16-i,then releasethe pressureand evacuate the system.

EVACUATING THE SYSTEM

Attach the manifold gauge set, atank of Refrigerant-12and a vacuumpump to the system Fig. 8. Makecertain that the Refrigerant-12 tankvalve is tightly closed. Set both service valvesto the mid-position. Openboth manifold valves Fig. 8. Release any pressurein the system.

Open the vacuumpump valve andrun the pump until the low pressure

309

FIG. 6-Low PressureService Valve Gauge Port

FIG. 1-High PressureService Valve Gauge Port

gaugereadsat least25 inches,andasclose to 30 inchesof vacuumas possible. Continuevacuumpump operation for 20 to 30 minutesto boil anymoistureout of the system. Close thepump valve. Turn off the pump.

MAKING A PARTIAL CHARGE

Attach the manifold gauge set.Open both manifold valves. Closethe vacuum pump valve. Open theRegfrigerant-12 tank valve. Purgethe air from the high pressurehoseby looseningthe high pressurehoseat the service valve for a few sec

EXHAUST PORT

LLOW PRESSURE SERVICE VALVE CENTERED

HIGH PRESSURE SERVICE VALVE BACK SEATED

PRESSURE AND VACUUM

Vacuum Pump1

LOW PRESSURE VALVE OPEN I HIGH PRESSUREHIGH PRESSURE VALVE CLOSED XI 545-A

tern. FIG. 8-Evacuating the System

GROUP 16-VENTILATING, HEATING, AND ACCESSORIES

onds. Tighten the connectionsandset the high pressuremanifold gaugevalve at the maximum clockwiseposition. Loosen the low pressuregaugehose slightly at the low pressureservicevalve, for afew seconds,to purgethe air from thehose.Tighten the connection.Set both servicevalvesat thecenterposition Fig. 9.

Run the engineat 1500 rpm withall controls at the maximum coldposition. Charge the systemuntil allfoam disappearsfrom the sight glass,then add ½-poundof Refrigerant-12.Shut the Refrigerant-12tank valve.

It may be necessaryto place theRefrigerant-12tank in a containerof hot waterat about150° F. to forcethe gas from the tank during charging.

Never heat the Refrigerant-12tank with a torch. A dangerousexplosion may result.

Setboth servicevalvesat themaximum counterclockwiseposition. Removethe gaugeset, andcap the service valve gaugeports andvalve stem.

MAKING A COMPLETE CHARGECheck for leaks first See "Diag

nosis and Testing," Part 16-1, releasethe pressure,then evacuatethesystem. Leave both service valves atthe mid-position and the vacuumpump valve closed. Leave the lowpressuremanifold gaugevalve at themaximum counterclockwiseor openposition. Set the high pressuremanifold gauge valve at the maximumclockwise or closed position. Set allcontrols to the maximum cold position.

Open the Refrigerant-12 tankvalve. Run the engineat 1500 rpm.Chargethe system until 2½-poundsof refrigerant have been weighedinto it. During the charging,the highpressuremay build up to an excessive value. This can be caused byan overchargeof refrigerant, or anoverheatedengine, in combinationwith high surroundingtemperatures.Never allow the high pressure toexceed 240-pounds while charging.Stop the engine,determinethe cause,and correct it.

After the proper chargehasbeenmade,close the Refrigerant-12tankvalve, and check the system pressuresfor properoperation.Set bothservicevalves at the maximumcounterclockwise position. Remove thegaugeset, and cap the servicevalvegaugeports and valve stems.

CHARGING FROM SMALLCONTAINERS

Refrigerant-12 is available in onepoundcans.A scale is not necessaryif these small containers are usedinsteadof a tank.

Attach the hose, that would normally go to the large tank, to thespecialvalve that is providedfor thesmall cans. Close the valve maximum clockwise position andfollowthe procedurefor leak testing,evacu

ating and charging the system aspreviously given.

For charging,attacha onepoundcan of Refrigerant-12to the specialvalve, and openthe valve. Keep thecan in an upright position. Whenthecan is empty no frost showing,close the valve, remove the emptycan, attach a new one, and openthe valve again.

Allow only ½ of the third can ofrefrigerant to be pumped into thesystem by closing the valve at thecan when the frost line hasreached½ way down the can. The systemwill then have been charged with2½-poundsof refrigerant.

Check the system pressures,setboth servicevalves at the maximumcounterclockwiseposition. Removethe gauge set, and cap the servicevalve gaugeports andvalve stems.

0 REMOVAL AND INSTALLATION

AIR CONDITIONING

SAFETY PRECAUTIONS

Refrigerant-l2, which is used inthe air conditioner system, is nonex

plosive, noninfiammable, noncorrosive, has practically no odor, and isheavierthan air. Although it is classified as a safe refrigerant, certainprecautionsmust beobservedto pro-

tect thepartsinvolved andthe personwho is working on the unit.

Use only Refrigerant-12.At normal atmosphericpressures

andtemperatures,liquid Refrigerant-

16-16 310

LOW PRESSURE

FIG. 9-Charging the Air Conditioning System

311 PART 16-3-AIR CONDITIONING

12 evaporatesso quickly that it tendsto freeze anything that it contacts.For this reason, extreme care mustbe taken to prevent any liquid refrigerant from coming in contactwith the skin and especiallythe eyes.

Refrigerant-12is readily absorbedby most types of oil. It is thereforerecommendedthat a bottle of sterilemineral oil and a quantity of weakboric acid solution be kept nearbywhen servicing the air conditioningsystem. Shouldany liquid refrigerantget into the eyes,use a few dropsofmineral oil to wash them out, andthen wash the eyes clean with theweak boric acid solution. Seek adoctor’s aid immediatelyeventhoughirritation may haveceased.

Always wear safetygoggleswhenservicing any part of the refrigerating system.

The Refrigerant-12in the systemisalways under pressure. Becausethesystem is tightly sealed,heat appliedto any part would causethis pressureto build up excessively.

To avoid a dangerous explosion,never weld, use a blow torch,solder, steam clean, bake bodyfinishes, or use any excessiveamount of heat on, or in the immediate area of, any part of the aircooling system or refrigerant supply tank, while they are closedto the atmosphere whether filledwith refrigerant or not.

The liquid refrigerant evaporatesso rapidly that the resulting refrigerant gas will displace the air surrounding the areawhere the refrigerantis released.To preventpossiblesuffocation in enclosedareas,alwaysdischargethe refrigerantfrom an aircooling system into the garageexhaust collector. Always maintaingood ventilation surrounding thework area.If the car is to be under-coated, make certain that the undercoating does not plug theevaporator drain tubes.

Although Refrigerant-12gas, under normal conditions,is non-poisonous, the discharge of refrigerantgas nearan open flame can producea very poisonousgas. This gas willalso attack all bright metal surfaces.This poisonousgas is generatedinsmall quantitieswhen the flame-typeleak detectoris used.Avoid inhalingth fumes from the leak detector.Make certain that Refrigerant-12is both stored and installed inaccordancewith all state and localordinances.

gas into the cooling unit, alwayskeepthe tank in an upright position.If the tank is on its side or upsidedown, liquid Refrigerant-12 willenter the system and damagethecompressor. In surrounding airtemperatures above 90°F., prolonged engine idle will result inexcessivelyhigh compressorpressures.

EVAPORATOR

REMOVAL

1. Disconnect the batterygroundcable.

2. Remove the carburetor aircleaner.

3. Discharge the refrigerant intothe garageexhaustsystem.

4. Disconnectthe refrigerantlinesfrom the evaporator,andremovetheexpansionvalve Fig. 10.

5. Disconect the vacuum linesat the junction block.

6. Disconnectthe wires from thethermostatic switch.

7. Remove the instrument panelinsulation board SeeGroup 15.

8. Remove the sun visor mounting brackets.

9. Removethecornerpostgarnishmoulding.

10. Remove the five screws retaining the upper section of theinstrument panel. Carefully lift therear end of the panel and slide itaway from the windshield.

11. Disconnect the phototube unitplug from the amplifier of the automatic headlight dimmer.

12. Removethe upper panel.

13. Disconnectthe right and leftdefrosterhosesat the evaporator.

14. Disconnect the right and leftregisterhoses at the evaporator.

15. Disconnectboth centerregisterhosesat the instrumentpanel.

16. Removefive screwsjust backof windshield.

17. Remove four vertical bolts,two at steering column, the othertwo at outer ends of instrumentpanel.

18. Pull instrumentpanel back toallow clearancefor removalof evaporator.

19. Remove evaporator mountingscrews and remove the evaporator.

INSTALLATION1. Position the evaporatorto the

dash and drive the mountingscrews.2. Reposition instrument panel

and install the four vertical bolts.3. Drive the five screws which

attachthe instrumentpaneljust backof the windshield.

4. Connect both center registerhosesto the instrumentpanel.

5. Connectthe right and left register hosesto the evaporator.

6. Connect the right and left defroster hosesto the evaporator.

7. Position the upper section ofthe instrumentpanel such that thephototubesunit plug can be connectedto the amplifier, andmake theconnection.

8. Carefully slide the panel to thecorrect position and drive the fiveretaining screws.

9. Install the instrumentpanel insulationboard SeeGroup 15.

16-17

RECIRCULATING DOORVACUUM ACTUATOR EXPANSION VALVE WINDSHIELD WIPER MOTOR

When admitting Refrigerant- 12 FIG. lO-Evaporator Refrigerant Line Connections

GROUP 16-VENTILATING, HEATING, AND ACCESSORIES

______312

FIG. li-EvaporatorShutter Actuator

10. Connectthe wires to the thermostatic switch.

11. Connect the vacuum lines atthe junction block.

12. Install the expansion valveandconnectthe refrigerant lines.

13. Charge the system. See In-Car Adjustments and Repairs. Asthere will be no pressurein the system to begin with, be sure to checkfor leaks after charging the system.

14. Install the carburetor aircleaner.

15. Connect the battery ground

16. Operate and test the air condicable.

tioner.

EVAPORATOR CORE

Removethe evaporator assemblyfrom the car, and remove the airdeflectorplate. Disconnecttheevaporator shutter vacuum actuatorandremovethe evaporatorshutter. Remove the evaporatorcore mountingscrews and remove the evaporatorcore.

Install the new core in the housing. Install the evaporator shuttersand connect the actuator arm. Install the air deflector, and installthe evaporatorassemblyin the car.

EVAPORATORSHUTTER ACTUATOR

The evaporator shutter vacuumactuatoris mountedinsidethe evaporator housing Fig. 11. To removeand install, removethe blower housing and the access plate on theengine sideof the dashpanel.

INSTALLATION

Before installing the compressor,see Cleaning and Inspection- AirConditioning Part 16-1.

1. Mount the clutch on the shaftand install the mounting screw andwasher,finger-tight.

2. Place the compressor on themountingbracketandinstall the fourmounting bolts, finger-tight.

3. Connectthe clutch wire, energize the clutch andtorquethe clutchmounting bolt to specifications. Ifthe new compressor was shippedwith a bolt and washer in the endof the crankshaft, remove and discard the bolt and use a bolt with anylon insert in it.

4. Install andadjust thedrive belt,and tighten the mounting bolts tospecifications.Do not exceedtorquespecifications as misalignment canresult.

5. Install the service valves onthe compressorusing new gaskets.Tighten the servicevalve flared nutsto specifications.Do not over-tighten the flared nuts. The new ROTOLOK service valves can be rotatedslightly on their seat without

SERVICE VALVE GASKET

HEAD

SCREW

16-18

COMPRESSOR

REMOVAL

1. Isolate the compressor SeeIn-Car Adjustments and Repairs anddisconnectthetwo servicevalvesandhoses from the compressor Fig.4.

2. Energizethe clutch and loosenand remove the clutch mountingbolt.

3. Install a 5/ 11 inch bolt in theclutch drive shaft hole. With theclutch still energized,tighten the boltto loosen the clutch from the shaft.Disconnect the clutch wire at the

K1385-B bullet connector.

4. Loosen the muffler bracket attaching bolt, located below themuffler.

5. Loosen the compressormounting bolts. Slide the compressortoward the center of the engine,removethe drive belt and the clutch,and then removethe mounting boltsand the compressor.

6. With the compressor on thework bench, remOve the key fromthe shaft.

SERVICE VALVE

PLATE-TO.BODY GASKET

SEAL KIT

GUIDE PIN

CRANKCASE BODY

CAP SCREW

SEAL COVER PLATE GASKET

WASHER

BASE PLATE Xl 139.D

FIG. l2-York Compressor Assembly

PART 16-3-AIR CONDITIONING ‘16-19

breaking the high pressure seal.This is not an indication of a loosevalve.

6. Tighten the muffler bracketattaching bolt.

7. Leak test the compressor,thenevacuateit and connect it back intothe system.

8. Check the oil level in the compressor and add or remove oil ifnecessary.See Cleaning and Inspection, Part 16-1.

COMPRESSOR COMPONENTS

All compressorremoval and installation operations, except belt replacement. can be performed onlyafter the unit has been isolated fromthe rest of the system. See In-CarAdjustments and Repairs.

VALVE PLATE

Removal

1. Isolate the compressorand disconnect the service valves. Removethe twelve head bolts.

2. Remove the cylinder head and

valve plate from the top of the cornpressorbody Fig. 12. Do not tapor hit the aluminum headwith anyhard tool, as damagecould result.

3. Removeanddiscardall gaskets,and be sure to clean gasket shredsfrom all gasketsurfaces.

4. Examine the cylinders and topof the pistons, particularly in caseof valve breakage.If thereare scoremarks, replace the compressor assembly.

5. If the cylindersand pistons arein good condition, check the valveplate and valve leaves for damage.If the valve assembly is in goodcondition, it can be used again. Ifthe valve plate is damaged, installthe entire replacement kit whichincludes the valve plate, valveleaves, and the two gaskets Fig.12.

6. When the valve plate assemblyis re-used, wash it in clean solventand dry in dry air.

7. Check the oil for dirt. If thesystem is not clean, replace the oil.

Installation

1. Starting with the valve plategasket, assemble the parts in theorder shown in Fig. 12. Insert thecylinder head bolts carefully toavoid damaging the gaskets..Beforeassembly, apply a film of new refrigeration oil to both sides of bothgaskets.

2. Tighten all bolts finger tight,and then torque the bolts a quarterturn at a time to specifications.Dothis by tightening the service valvebolts first. Then tighten the remaining bolts in a sequenceso thosediagonally opposite are evenly drawn tothe required torque.

3. Connect the compressor intothe system.

4. Check the oil level in the compressor, and add or remove oil ifnecessary.SeeCleaning and Inspection, Part 16-I.

BELTREMOVAL ANDINSTALLATION

1. Loosen the four compressormounting bolts, and slide the corn-

K.1517-A

313

TO BATTERY TERMINAL

-STAR1ER RELAY

HEATER SWITCH INLO POSITION

A/C SWITCH INOFF POSITION

Joo

LJo

HEATER A/C/1 SWITCH

‘-HEATER SWITCH INMEDIUM POSITIONA/C SWITCH INOFF POSITION

FIG. l3-Wiring Diagram Heater and Air Conditioner

16-20 GROUP 16-VENTILATING, HEATING, AND ACCESSORIES

pressortoward the centerof the carto removethe belt.

2. Place the new belt in position,and slide the compressortoward theoutside of the car and tighten thefour mounting bolts.

3. Adjust the belt tension tospecifications.

CLUTCH

REMOVAL ANDINSTALLATION

1. Energizethe clutch and loosenand remove the clutch mountingbolts.

2. Install a /8-11 inch bolt in theclutch drive shaft hole. With theclutch still energized,tighten the boltto loosen the clutch from the shaft,then removethe magneticclutch.

3. install the clutch, the clutchmounting bolt, and the washer.

4. Energizethe clutch, andtorquethe bolt to specifications.

CRANKSHAFT SEAL

REMOVAL1. Isolate the compressor, and

remove from the car. See In-CarAdjustments and Repairs.

2. Remove the clutch and removethe Woodruff key.

3. Remove the seal plate bolts,andremovethe plate andgasket.Donot mar the sealing surfaces,or thepolished shaft surface.

4. Remove the carbon seal ringandseal housing assemblyfrom thecrankshaft.A disassembledview ofthe crankshaft seal assembly is included in Fig. 12.

5. Remove the base plate and inspect internal compressor for foreign particles.Clean out as required.

6. Clean all old gasket materialfrom the sealplate andthecompressor. Make certain that the shaft,the seal plate and the compressorgasketsurfacesare completelycleanbefore installing the new seal.

INSTALLATION

1. Lubricate the new shaft sealparts in clean compressoroil. Position the seal assemblyon the crankshaft, with the carbon ring towardthe seal plate.

3. Torque the bolts to specifications.

4. Make certain that there areno burrs or dirt on the compressorshaft. Then install the key, the belt,and the clutch.

5. Install the new base plate gasket and install the base plate. Addnew compressoroil to specifications.See Cleaning and Inspection, Part16-1.

6. Install the compressor.7. Adjust the belt tension to speci

fications.

HEATER CORE, REGULATORVALVE, AND VENTS-HEATER VALVE

For removal and installation, follow the procedures given in theheater section of this manual.

BLOWER MOTORThe blower motor is mounted in

the blower housing on the enginecompartmentsideof thedashFig. 1.The motor is removedby disconnecting the motor connectingwires andventilation tube, then removing themounting nuts and screws.

314

2. Position the new gasketon thecompressorandinstall the sealplate.

315 ‘16-21

PART Section Page1 DescriptionandOperation 16-21

1 6 RADIO 2 In-Car AdjustmentsandRepairs 16-21- 3 Removaland Installation 16-21

o DESCRIPTION AND OPERATION

An AM and an AM/FM radio are antenna is mounted on the right front speakerare used. Figs. 1 andavailablefor 1964. Both radioshave fender.The antennaswitch is located 3 showthe radio schematicdiagrams.push button tuning as well as man- under the rear edge center of theual tuning. An electrically operated crashpad. A rearseatspeakeranda

O IN-CAR ADJUSTMENTS AND REPAIRS

PUSH BUTTON ing knob. The station is correctly buttons that shift from the correctADJUSTMENT tuned in when the clearest tone is tuning point.

heard. Carefully push the button in On the AM/FM radio push oneTurn the radio on. Pull out the all the way, then releaseit. AM button all the way in before ad-

desiredpush button and reduce the Adjust the remaining buttons and justing the AM buttons. Push onevolume to a low value. Tune in the checkall the positions for repeatac- FM button all the way in beforedesired station with the manual tun- curacy.Repeatthe procedurefor any adjusting the FM buttons.

B REMOVAL AND INSTALLATION

RADIO

REMOVAL

1. Disconnect the battery groundcable.

2. Remove the radio controlknobs, andthe heatercontrol knobs.

3. Removethe 7 upperscrewsfromthe instrument panel reinforcementbracket.Removethe 5 upperinstrument panel bezel mounting screwsandremovethe reinforcementbrackçt. Remove the 5 lower instrumentpanel bezel mounting screws, andremovethe bezel.

4. Remove the right and left sunvisors, and the right and left windshield pillar garnish mouldings.

5. Remove the retaining screwsfrom the upper front instrumentpanel. Lift the panel anddisconnectthe photo tube lead at the quick disconnectand removethe upperpanel.

6. Remove the radio supportmounting bolt from the upper panelarea. Remove the radio mountingplate at the face of the radio.

7. Pull the radio out of the instrument panel and disconnect theantenna lead, speaker lead andpower lead and remove the radioFig. 4.

INSTALLATION

power lead and antennalead to theradio and insert the radio into theinstrumentpanel.

2. Install the upper mounting boltto the radio through the upper instrumentpanel.

3. Install the mounting plate onthe face of the radio and the instrument panel.

4. Connectthe batteryand checkthe operationof the radio.

GREENDOWN

5. Place the upper front instrument panel in position, connect thephoto tube leadandinstall the panelmounting screws.

6. Install the center instrumentpanel bezel.

7. Install the heaterandradio control knobs.

8. Install the right and left windshield pillar garnish mouldings, andthe right and left sun visors.

j --:::IT2

/ GAS.E4.NUT

.ANTENNA MOUNTREINFORCEMENT

K1387-B

1. Connect the speaker lead, FIG. i-Antenna Installation

* THE EXACT VALUE TO BE DETERMINED BYPRODUCTION PROCESS. REPLACE WITH THESAME VALUE OF THE ORIGINAL PART.

TUNING RANGE.540 TO 1610 KC INPUTVOLTAGE.14.4V DC IF FREQ-262.5 KC.

CAUTION

A" LEAD MUST BE CONNECTED TOPOSITIVE 1± SIDE OF POWER SUPPLY.RADIO WILL NOT OPERATE AND DAMAGETO COMPONENTS WILL RESULT IFCONNECTED OTHERWISE.

ANT 1 ANT-2 OSCJSEC. R.F.

_______

F F SF S S F

TRIMMER

OSC. PRI.LI, 12-13 AND L4 CONNECTION DETAIL

Xl 421- B

0

0C.u

rn

-I

-I

C,

=ni

-I

C,

6UV 1000KC FOR1 WATT OUTPUT OF400 CYCLE OUTPUT.

AN1 RECEPT

1

,3.

0

m20

1.5UV t 1000KC FOR 25UV @ 2624KC FOR 1200UV © 262.5KC FOR .003V Z12, TOP OF VOLUME1 WATT OUTPUT OF 1 WATT OUTPUT OF 1 WATT OUTPUT OF CONTROL @400 CYCLES400 CYCLE OUTPUT. 400 CYCLE OUTPUT. 400 CYCLE OUTPUT. FOR 1 WATT OUTPUT.

r..

NOTES:CAPACITORS-UNLESS OTHERWISE SPECIFIEDDECIMAL VALUES IN MF ALL OTHERS IN MMFVOLTAGES-MEASURED FROM POINT INDICATEDTO CHASSIS WITH A VTVM.±10% NO SIGNAL INPUT.

ON-OFFSWITCH

ONVOLUMECONTROL

A" LEADDC

+ C25B *: C23[500MF L.c4 s.P...LC24

LIGHT LEAD14.8V DC

FM 02 04 Q5 06 D3ANT4 98 MC TO 10.7 MC ._.©.e._____IOJMC.._____..©.m___10.7MC-_...©.t 10.7 MC 10.7 MC ..J.4_10.7 MC TO.-..®8X 400 .1X200X 05 lOX 06 D2AMANTQ-.- 1000 Ik___________..__..®.. 1000 KC TO

________

262.5KC l25’ 262.5KC______.©..._.262.5 KC TO 400 K O25V 400 ACROSSlx R4OA FOR 1 WATT

2092417.21-SAM RF 2092418-5*C32 AM CONV *C36 I.F. *R31 FMER OUTPUT*C2 *C5 *C12 60X FM I.E. FM AND AM

*12-18 39 FM RF 6.8 FM MJ?_Q2*Cl 1.0 v-’-i *I.2.2.7#i1 *1.2-2.7j..2092418.5 27K 2092418.7 FM DET2092417-21 30 T5 Q7 R35 _JZ...2092055-7

I 11 .8V2," 1 16 L’’t1Tt 1 t1 I[j’ 20TV14 C13 Q25T 5 FM 2201 lr1 06 FM20 ----i 220! r 14 I

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*62.120-.-1-...J4 ff 4 12.2 --mv1I 1T2 44 - 2 J4.4V I ‘--s-- 3/f.01 ‘O1UF 07 320L3 I [II J 3vR

*C35 2 ii 47K c 4.7K

*3 7UF R27 I rYo,.-,1r 2.7K l.01UF C46150’ j lI444 *R341__*R36 Ilso

I*Rl1l*R1 2 L._.2o92o55_5IlNOM1-L2 UH p ,eJ_2. UH- Orangejj C25 RI 3 r

I *RiC6.O051’ii*C11I *C16. L4A 0UF

___

c2 CL9..Qi4zjJr 2L_..tpEjJ A4R; tR37FM c ó80 A 41 3 H C29C

______________

re _*!NOM 12K UF_*R49UH2.2L__19ThlUFL4 180K

2$C28I *1802092417-6 - 1 *I Q3Y

____

4I15 4

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6i9R22[3201 24I

56 0i’t 1.2K 3 D2 - AM FML2 470K III *C26

R63 I il! R15 .01UF.oo68TA"C47 N470 L6jI4.7K13r C391 FfT1ir,SIE

_____

220’ C40 III1.8K /Ti2.15I II 1800 C27{C3lk’

39.2K NOM1I

I t -1K *R17’ UF ,01UF1 R21B!acki R2 294.7K I 0022 II

*R39*R3A .J R5 *C1

1 r 22 I* *JP9B I .........*R2 C56 I’R57 r-2o92o55- L

17 .005 47K

-

__ ______ __________

C43 .00222.2KL-- PECI sK / PECJ

______________________________ ____________ _____________

C384

______ ________________ __________________________

iUI57

________ ____________________

.1IIJFC7 *R6----

______________ ________

.005 820 1.8V Dl 2092055-1470K

_______________________

*R58 39K

FMR9 AM0

*33K-22OK,,/t 222092055.3 5UF C23r CONNECUONS FOR REAR SPEAKER 1 60 NOM

AM FM

SWI

LNOTE:

INPUT SIGNAL MODULATED 400 CPS. 22.5KC DEVIATION.

_________ ____________

.01 UF SERIES TO TRANSISTOR COLLECTOR -

_____________

ELEMENTS FOR GAIN MEASUREMENTS. 033 UF

_______________________

OUTPUTMEAsuREDWm1A V.T.V.M. ‘*R49AM 30 UUF SERIES AND 30 UUF SHUNT AT ANTENNA SOCKET 0.1. UFSERIES 10 10K 18K PEC 6 3.3K I *820.3.3KTRANSISTOR BASE ELEMENTS FOR GAIN MEASURMENTS. I.. . - - - . - j#SET R42 FOR 1 AMP COLLECTOR CURRENT -NO SIGNAL MEASURE WITH CURRENT -

METER FROM COLLECTOR TO GROUND.*EXACT VALUES DETERMINED BY PRODUCTION PROCESS. REPLACE WITH SAMEVALUE AS ORIGINAL.ALL RESISTANCE IN OHMS. 1/2 WATT AND ± 20% TOLERANCE UNLESS OTHERWISE STATED. K=1000. M MEGI-IM.ALL CAPACITANCE IN MICROMICROFARADS. 100 VOLTS MIN. AND ± 20% TOLERANCE UNLESS OTHERWISE STATED. GMVGUARANTEED MIN. VALVE.FM TUNING RANGE FROM 88MC TO 1O8MC. AM TUNING RANGE FROM 540KC TO 1600KC.

____________________________

FM IF. FREQUENCY 10.7MC. AM IF. FREQUENCY 262.5KC.VOLTAGE MEASUREMENTS:

1. ALL DC VOLTAGES MEASURED WITH A 20.000 OHM/VOLT METER. NO SIGNAL INPUT.2. ALL AC VOLTAGES MEASURED WITH AN AC V.T.V.M. AT FULL VOLUME. 1 WATT OUTPUT.3. ALL VOLTAGES MEASURED WITH RESPECT TO CHASSIS.4. ALL VOLTAGES MEASURED WITH + 14.1 VOLTS INPUT WITH NEGATIVE TERMINAL GROUNDED, * 10% A 5%

P3R4OA *R47 *680.1.5KFRONTVOL *R46 liST AUDIO DRIVER POWER OUTPUT ‘ ICONT 3.9K I20924.8 P/O 2092609-1 2091859-11 TjJ J2 P2A I

TAPPED C50 *R4 1.8VPEC 6 R60 010 I-1i2A

SPEAKER

I’

80

ARrr2-f2v12.

R558n.J

AT .2UF 68i1i.8V ...-..*R61 22K 100 128V .trfv i.’AC I

8.2KNTC FADERI ISPEAKERI

75K

R4OBJ,8 JPEC ilK

p T.C.p I 7 : 2A 500 UP 16V CONTROL:7 P7AII ‘<

250K C49R44 500 I 450 140 I*R53.915 6.8 UF !j I T6V 1.JF I 6VT I PTC.033 UF 8 - -- 2W

NO UNGROUNDED AC POWERED TESTEQUIPMENT SHOULD EVER BE USED.

__.._JNOTE: FADER CIRCUIT NOT INCLUDED ON

F4TBF AND F4TBM.

J4 I4.4V

I 110200 J5 TO DASH

II F4TBF, F4TBM,r- j-

- - LAMPS

El 200 F4TBS, F4TBC.- E2F4TBF AND C ONLY

I

X1423-A

DUMMYANTENNA

rFMkZ5050LLi ..>

‘I1 IFRONT’SPEAKER

‘<.jREAR SPEAKER

.

-I

.

CA3

-I,

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r-N

000

5-m20

UF

GROUP 16-VENTILATING, HEATING, AND ACCESSORIES 318

ANTENNA

1. Remove the right front fenderrear splash shield.

2. Disconnect the antenna lead-in from the antenna.Disconnecttheantenna motor wiring connectorFig. 1.

3. Removethe antennato fendertop retaining nut, stanchionandgasket.

4. Remove the motor supportbracket retaining screws. Remove

the antennaassembly through thesplashshield opening.

5. TO INSTALL: Place the antenna in position and install the antenna to fender mounting gasket,stanchion and retaining nut. Installthe retaining nut just tight enoughto permit alignment of the motorsupport bracket retaining screws.

6. Tighten the motor supportmounting screws; then, tighten the

antennato fender retaining nut.7. Connectthe motor wiring con

nector, andthe antennalead-in.8. Test the antennaoperation.9. Install the fender splashshield.

FRONT SPEAKER

1. Remove the ten center instrument panel bezel mounting screwsandthe bezel.

2. Remove the right and left sunvisors and the right and left windshield pillar garnish mouldings.

3. Remove the retaining screwsfrom the upper front instrumentpanel. Lift the panel and disconnectthe photo tube lead at the quick disconnectandremovethe upperpanel.

4. Remove the speakermountingscrews, disconnectthe speakerleadand removethe speaker.

5. Connectthe speakerlead, place

the new speakerin position and install the mounting screws.

6. Check for correct speakeroperation.

7. Placethe upperfront instrumentpanel in position, connect the phototube lead and install the panelmounting screws.

8. Install the center instrumentpanel bezel, the right and left windshield pillar garnish mouldings, andthe right and left sun visors.

REAR SEAT SPEAKER

To remove the rear seat speakeron convertiblecars, first removetherearseats,the quartertrim panelandthe packagetray. Thespeakeris thenaccessiblefor replacement.On thesedan,it is only necessaryto removethe sparetire for accessto the rearseatspeaker.

16-24

LEAD

SPEAKER LEADCONNECTION

RADIO

K 1556-A

FIG. 4-Radio Receiver Installation

319 16-25

!‘ SPEED CONTROL

Section Page Section Page1 DescriptionandOperation 16-25 3 Removal and Installation 16-262 In-Car Adjustments andRepairs 16-25

0 DESCRIPTION AND OPERATION

Thespeedcontrol unit is governeddirectly by car speed.A conventionalspeedometerdrive cable, connectedto the input shaft at the bottom ofthe control unit, drives a springloaded governor in the control unitandat the sametime drives a secondcable which extends to the speedometerheadby meansof a I : 1 gearset. The spring loading of the governor is varied and controlled byturning the selector knob locatedon the instrument panel. For example, with the selectorknob set at50 mph the tension in the governorspring is such that when the carspeed reaches50 mph the force ofrotation of the governor weights isbalancedby the governorspring tension.

When the speed control unit isusedas a mechanicalspeedreminderdevice,a resistanceor backpressureis felt at the acceleratorpedal atand above the speedselectedon theselectordial.

The position of the back pressurepoint will vary with the road grade.

The car speed can be increaseda any time by pushing the accelerator through the back pressure. Releasethe pressureon the acceleratorpedal and the car will slow downnormally.

Turn the selector dial higher orlower to increase or decreasethespeed setting. Back pressure willalways be felt when selectedspeedis reached.

The automaticspeed control fea

ture can be put into operation bymoving the slide switch to the lockposition it will return to the ONposition when released, when apre-selected speed is reached andthe acceleratorpedal is held againstthe reaction pressure.

The speedcontrol will now operate automatically without the needof foot pressureon the acceleratorpedal. The control unit motor willadvance or retract the accelerationpedal to maintain the pre-selectedspeed.The speedof the vehicle maybe increasedor decreasedby turningthe selector dial while the speedcontrol is operating automatically.

The automatic feature is releasedby depressingthe brake pedalwithinthe first ¼-inch of travel, movingthe slide switch to the OFF position,or by turning the ignition switchto the OFF position. Any of theseoperationsbreaks the electrical circuit and the unit returns to manualcontrol.

Insidethe control unit, an activator assemblyriding up and down ona shaft, moves the contact arm between motor points Nos. I and 2,located on the magnet assembly.Electrical contactbetweenthe pointon the contactarm andeither motorpoint activates a 12-volt reversiblemotor that rotates a drive screw.When the drive screw rotates,a nuton the screw moves the entire magnet assemblyto the position whereequilibrium is reached between thegovernor weights and the governor

spring. When the pre-selectedroadspeed is reacheda reaction pressureis felt on the acceleratorpedal.

When the car tendsto go slowerthan the pre-selectedspeed,as wouldbe the case in going up a hill, theactionof the governorweightscausesthe contact arm to contact motorpoint No. I. The motor now rotatesin the opposite direction; thus, themagnetassemblymovesto allow thethrottle to be opened, to maintainthe pre-selectedspeed.

When the car travels downhill, ittends to travel faster than the preselectedspeed.The resulting actionof the governor weights moves thecontact arm to motor point No. 2,causingthe motor to rotatethe drivescrew and move the magnetto closethe throttle.

FIG. 1-Speed ControlUnit-Cover Removed

IN-CAR ADJUSTMENTS AND REPAIRS

LINKAGE1. Remove the cotter key from

the acceleratorlinkage and pull thelinkage from the exterior arm.

2. Start and run the engine untilit operates at a slow idle.

3. Insert the gauge sleeveover the

gaugebolt andhold the exteriorarmsecurelyagainst the gauge pin Fig.2.

The gaugetool is supplied in SpeedControl Kits. However, if the gaugetool is not available, use a pieceof-inch ID. tubing of ½;-inch wall

thickness,two inches long.4. Adjust the swivel on the throt

tle linkage until the linkage will assemble to the exteriorarm.

5. Replacethe linkage and cotterpin.

6. Removethe gaugesleeve.

MOTOR -.POINTNO.1

., MOTORPOINTNO.2

GROUP 16-VENTILATING, HEATING, AND ACCESSORIES

EXTERIOR ARM

/

CONTROL CABLE

1. Rotate the selectordial towardits low setting, as far as it will turnwithout forcing.

2. Loosen the screw on the dustshield.This screw retainsthe controlcable in the bottom of the dustshield.

3. After looseningthe screw, pullthe control cable out of the dust

shield, making certain that the ferruleat the end of the cableis freeinthe bottom of the dust shield.

4. Reinsert the ferrule in the dustshield.Pushin lightly on the controlcable until it stops. Do not forcethe cablebeyond this position.

5. Again checkthe selectordial inorder to make certain it is at its lowsetting.

6. Again pushon thecontrol cableuntil it stops.While holding the cablein this position, tighten the screwon the dust shield securely.

BRAKE PEDAL RELEASE SWITCH1. Turn the ignition switch to the

ACC position, and speed controlslide switch to the OFF position.

2. Place a 12-volt test lamp between terminal No. 1 and groundFig. 3. Thetestlamp should beon.

3. If the lamp is out, check for ablown fuse.

4. If the lamp fails to go on whenthe fuse is good, test the switch forproper operation.

5. If the switch is good, inspectthe wiring for broken wires or looseconnectionsFig. 3.

FIG. 3-Checking BrakeRelease Switch Adlustment

6. With the switch installed andthe lamp on, depressthe brakepedalto determineif the lamp goes outwithin the first ¼-inch of pedaltravel.

7. If the lamp fails to go out during the first ¼-inch of travel, loosenthe switch adjustingnuts andreposition the switch so the lamp goes outduring the first ¼-inch of brakepedal travel. Tighten the adjustingnuts to specifications.

U REMOVAL AND INSTALLATION

CONTROL UNIT

Whenever a faulty power unit isremoved,the car can be driven withthe speedometeroperating, by removing the power unit cablesfromthe speedometerand transmission,and by installing a standardspeedometer cable and housing assemblybetweenthe transmissionandspeedometer.

REMOVAL1. Disconnectthe multiple electric

connectorat the power unit.2. Disconnectthe drive cable and

the speedometer cable from thepower unit.

3. Loosen the set screw at thelower end of the dust shield.

4. Remove the dust shield fromthe housing. Then slide the dustshield down the cable and slip theball end of the Bowden cableout ofits socket.

5. Disconnectthe acceleratorlinkage from the exterior arm plate onthe power unit.

6. Remove the two bolts securingthe power unit to its mountingbracket and removethe power unit,leaving the mounting bracket attachedto the fender dust shield.

INSTALLATION1. Position the power unit on its

mounting bracket and secureto thebracket with two bolts.

2. Connectthe acceleratorlinkageto the locking arm on the powerunitand adjust the linkage as describedin this sectionof the manual In-CarAdjustmentsandRepairs.

3. Install the ball end of the Bow-den cablein the socketon the powerunit.

4. Install the dust shield in thehousing.The dust shield hasbayonettype retention. Push in and turnclockwise. Do not tighten the setscrew on the end of the dustshield until the control cable isproperly adjusted.

5. Adjust the control cable as described under In-Car Adjustmentsand Repairs.

6. Connect the drive cable andspeedometercableto the power unit.

7. Connect the multiple electricconnector at the power unit.

SELECTOR ASSEMBLYAND CABLE REMOVAL

1. Open the hood and loosen thecableretaininglock screw at thebottom of the dust shield.

2. Rotate the dust shield ¼ turn

counterclockwiseandremoveit fromthe control unit.

3. Remove the dust shield fromthe cable.

4. From inside the car, removethe slide switch button, which willpull straight out.

5. Removethe two nuts which attach the assemblyto the instrumentpanel.

6. Remove the selectorassemblyfrom the instrumentpanel.

7. Disconnect the selector wiresandremovethe complete.assembly.INSTALLATION

1. Position the cable through thedash,and connectthe selectorwires.

2. Assemble the selectorassemblyto the instrumentpanel, andassemble the two nuts which attachit.

3. Install the slide switch leverbutton.

4. Position the dust shield on thecable.

5. Insert the dust shield in thehousing and turn the shield ¼ turnclockwiseto properly retain the dustshield. Do not tighten the set screwon the end of the dust shield untilthe control cable has been properlyadjusted. Adjust the control cable.See In-Car Adjustments and Repairs.

16-26

.1"

320

FiG. 2-Gauge Tool Installed

321 16-27

AUTOMATIC HEADLIGHT DIMMER

Section Page Section ‘ Page1 Description and Operation 16-27 3 Removal and Installation 16-292 In-Car AdjustmentsandRepairs 16-28

U DESCRIPTION AND OPERATION

/

/

The automatic headlight dimmer,which automatically switches theheadlight beam in responseto lightfrom an approachingcar, consistsofthree individual units: a phototubeunit, an amplifier unit, anda combination dimmer over-ride-type footswtich Fig. 1.

Headlights are automatically controlled only in one position of thefoot switch. Headlightschangefromautomatic operation to full timelower-beamwhen the foot switch isfully depressed.To obtain mornentary highway upper-beamfor signaling oncoming drivers, when usingautomatic control, or for checkingautomaticpositionof the foot switch.depressthe foot switch about½ inchto a detent.

When a car approacheswithin a

proper distance,light from its headlights, striking the phototube unit,causestheheadlightsto dim or switchto lower beam. At this time, if theapproachingcar’s headlightswere onupper beam, the driver would normally switch to lower-beam, whichwould greatly reduce the amount oflight striking thephototubeunit. Theautomatic headlight dimmer is designedto maintainor hold its vehicleheadlights on a lower beam, evenwith this reduction in light. Whenlight is removedfrom the phototubeunit, the headlights switch back toupper-beam.

A sensitivity control knob, locatedat the back of the phototube unit,Fig. 2 Part 16-1, gives the drivera limited range of control over thesensitivity of the headlight dimmer.

A detentposition is provided in thecenterof thecontrol rangefor normalsensitivity as adjustedat the factory.When the control is in detentposition, the knob pointer should bepointing up. Rotating theknob clockwise the word FAR moves down,increasessensitivity. In this position,the headlightdimmerwill switch theheadlightsto lower beam when anapproachingcaris farther away thannormal.Rotating thecontrol counterclockwise the word NEAR movesdown, decreasesthe sensitivity,thusallowing an approachingcar to approach nearer before switchingoccurs.

PHOTOTUBE UNITThe phcitotubeunit uses a single

stagephototubefor sensinglight, andis mountedon the top-centerof theinstrument panel upper-cover. Thelens picks up light from approachingheadlightsand focusesit through afilter and mask onto the phototube.The phototubeconvertsthelight intoan electrical signal that can be usedby the amplifier unit.

AMPLIFIER UNITThe amplifierunit suppliesvoltage

to the phototubeunit and operatesthe integral power relay in responseto a signal from the phototubeunit.The unit is located at the left handside cowl Fig. 1.

A heavy duty power relay, withspecial alloy contacts for switchingthe headlights between upper andlower beam, is located above theamplifier unit.

FOOT CONTROL SWITCHThe foot switch is a specialdim

mer over-ride type that provideseither Automatic or Low-Beamcontrol of the headlights. It also actsas an over-ride for obtaining anover-riding high-beam when inAutomatic position. The over-ridesection of the foot switch functionsonly when the switch is in Auto-

DIM AND HOLD AREACCESSIBLE WITHOUT

"REMOVING TRIM PANEL

FOOT DIM#.ER SWITCH

FIG. i-Automatic Head Light Dimmer installation

K-1386 -a

16-28 GROUP 16-VENTILATING, HEATING, AND ACCESSORIES 322

matic position. A slight downwardpressureon top of the switch toa detent provides upper-beam, re-

matic position of the foot switch.Streetlights, encounteredin the city,areusually sufficient to maintain the

foot switch, the automaticheadlightdimmer is not an active part of theheadlight circuit. However, it is not

gardlessof light on the phototube vehicle headlights on lower-beam; turned off. It continues to functionunit. This arrangementpermits sig- however, the upper-beammay beob- as long as the headlightsare turnednaling the approachingdriver if he tamedwhen neededby holding foot on andis readyto provide automaticfails to switch to lower-beam and pressurein the over-ride position. control wheneverthe foot switch isalso providesa simple test for Auto- In the lower-beamposition of the returned to the Automatic position.

fl IN-CAR ADJUSTMENTS AND REPAIRS

Be certain that headlights andwindshield arefree of snow and dirtfor proper operation of the automatic headlightdimmer.

PHOTOTUBE UNIT VERTICALAIMING PROCEDURE

The phototube unit must be accurately aimedvertically. If the unit isaimedtoo low, backreflectionsfromthe headlightswhich are beingcontrolled, will lock the amplifier onlower-beam. However,the unit mustbe aimedas low as possibleto provide maximum tolerance for carloading.

1. Phototubeunit vertical aimingshould be done with the car unloaded,trunk empty exceptfor sparetire, gas tank at least half full, andwith tires at the correctpressure.

2. Locate the car on a level floorlevel within ¼ inch fore and aft ofthe car.

3. Rock thecar sidewaysto equalize thesprings.

4. Install the aiming device, partof the tester on the phototube unitFig. 2. The three-pointson theaiming device must be resting ontop of the phototube unit, and theaiming device must be touchingthe front of the phototube unit.

5. Observe the number stampedon the driver control knob rearface.

3. Turn the dim-hold switch momentarily to the Dim position toswitchthe lights to lower-beam,thenswitch back to the Hold position.If the lights do not switch to lower-beam, the amplifier dim -controlmust be turned completely clockwise and then readjusted afterHold adjustment is correct.

4. Adjust the intensity controlslowly counterclockwise until themeterpointer is on the Hold sensitivity adjustmentline.

5. Turn the amplifier Hold controlslowly counterclockwise,just to thepoint wherethe headlightsswitch toupper-beam. Do not go beyond thissetting.

6. Turn the intensity control allthe way clockwise.

7. Turn the Dim-Hold switch toDim position andbackto Hold position to obtain a lower beam.

8. Slowly turn the intensitycontrolcounterclockwisejust to the pointwhere headlampsswitch to upper-beam.The meterpointer should nowread in the green. Hold sensitivityrange on the meter scale Fig. 3.If not, return to step 1 and repeatall steps.

TesterLamp

Black

K1 536-A

Adjust the aiming dial until the corresponding number is under thepointer.

6. Adjust the vertical aim screwon the phototubeunit until thebubble is centeredin the level.

HOLD AND DIM SENSITIVITYADJUSTMENTS ON CAR

Hold sensitivity must be properly adjusted before adjusting Dimsensitivity. The phototube unitmust be covered with a black clothduring adjustments. Adjustmentsshould be madewith the phototubeunit temperature below 90’. If thecar has been in the sun immediately prior to checking, allow it tocool in a coveredplace for approximately one hour before the adjustment is actually made.

PREPARATION FORADJUSTMENT

PHOTOTUBE UNIT

1. Set the driver control to theDetent position.

2. Install the tester lamp Fig. 3.Coverthe testerlamp andphototubewith the black cloth furnished.

3. Start the engineand operateitat fast idle while making adjustments.

4. Turn the headlightson andwaitat least five minutes for the amplifier unit to stabilize. Place the footswitch in the Automatic position.

,D,IAL 5. Turn the zero corrector,on theface of the meter, until the meterpointer is on the zero set line.

6. Turn the testerintensity controlcounterclockwise.

7. Connectthe batteryleadsof thetesterto the battery terminals. Redlead to the positive terminal andblack leadto the negativeterminal.

HOLD SENSITIVITYADJUSTMENT

J-8674 1. Rotatethe amplifier Hold com11535-A pletely clockwise.

2. Rotate the tester intensity control all the way clockwise.

VERTICAL AIM SCREW

Aiming Device, ModelNo. 6-i- i-8674

FIG. 3-Dim and HoldSensitivity TesterFIG. 2-Vertical Aiming Device

PART 16-6-AUTOMATIC HEADLIGHT DIMMER

DIM SENSITIVITYADJUSTMENT

Dim sensitivity should not beadjusted until after Hold sensitivity is properly adjusted.

1. Rotate the amplifier Dim control completely counterclockwise.

2. Rotate the tester intensity control completelycounterclockwise.

3. Momentarily turn the Dim-Holdswitch on the tester to Hold, thenback to the Dim position to obtainupper-beam.

4. Adjust the tester intensity control until the meterpointer is at theDim sensitivity adjustmentline.

5. Slowly rotatethe amplifier Dimcontrol clockwise, just to the pointwherethe headlightsswitch to lower-beam. Do not go beyond thissetting.

6. Rotate the tester intensity control completelycounterclockwise.

7. Turn the Dim-Hold switch toHold, then back to Dim to obtainthe upperbeam.

8. Slowly rotatethe testerintensitycontrol clockwise just to the pointwherethe headlampsswitch to upperbeam.The meterpointershould nowread in the green Dim sensitivityrangeon the meterscale. If not, return to step 1 andrepeatall steps.

9. If the adjustment is correct,turn off the headlightsand disconnect the tester.

10. Remove the tester lamp fromthe PhototubeUnit.

U REMOVAL AND INSTALLATION

If the automaticheadlightdimmermalfunctionsandcannotbe removedfor repair immediately,manualoperation of the headlightsmay be obtained at the foot switch, in mostcases, by removing the fuse fromthe fuse holder. The fuse holder islocated in the amplifier wiring harness, just a few inches from theamplifier unit.

Shouldthe car have to be drivenwith the amplifier removed,manualoperationof the foot switch may beobtained by replacing the dimmerover-ride type foot switch with astandard foot switch, and pluggingthe standardcarwiring to it.

PHOTOTUBE

REMOVAL1. Disconnect the negative

ground cable from the battery.2. Remove the screws retaining

the upper section of the instrumentpanel.

3. Remove garnish molding fromwindshield pillars.

4. Carefully lift up the rear endof the panel and pull away from thewindshield.

5. Disconnect the phototube unitplug from the amplifier harness,Remove the top panel and phototubeunit.

6. Remove the phototube unitfrom the top panel.

INSTALLATION1. Install the phototube unit on

the top panel.

2. Position the top panel andphototube to permit connectingthe phototube plug to the amplifierharness.Then make the connection,pushing plug down through hole inspeakermounting plate.

3. Carefully position the top paneland drive in the retaining screws.

4. Replace garnish moldings onwindshield pillars.

5. Connectthe negative groundcable to the battery.

6. Check the aim and sensitivityadjustments See In-Car Adjustments and Repairs.

AMPLIFIER UNIT AND HARNESS

REMOVAL1. Disconnect the negative

ground cable from the battery.2. Remove the left hand cowl

trim panel.3. Disconnectthe amplifier wiring

harnessfrom the relay aboveamplifier, from the foot switch, andfromthe headlightwiring harness.

4. Removethe two amplifier unitmounting screws. Lower the amplifier and disconnectthe phototubetoamplifier cable.

INSTALLATION1. Connectthe phototubeto ampli

fier cable, position the amplifier, anddrive in the mounting screws.

2. Connect the amplifier unit tothe relay, to the foot switch, andtothe headlight wiring harness.

3. Install the left hand cowl trim

4. Connect the negative groundcable to the battery.

5. Check the Dim and Hold sensitivity adjustments See In-Car Adjustments and Repairs. If the caris to be driven without the automatic headlight dimmer, install astandard foot switch and connectthe car headlight harness to it.

FOOT DIMMER SWITCH

REMOVAL

1. Disconnect the negativeground cable from the battery.Very important.

2. Positionthe left side of the floormat backaway from tje areaof theswitch.

3. Remove two screws attachingthe switch to the floor pan. Lift theswitch from the floor pan.

4. Disconnect the wiring connectors from the switch.

INSTALLATION

1. Connect the wiring connectorsto the switch.

2. Positionthe switch on the floorpan, and drive in the two mountingscrews.

3. Position the floor mat in thearea of the switch.

4. Connect the negative groundcableto the battery. Should installation of a standard foot switch benecessary, remove the left sidecowl trim panel, and connect thecar headlight wiring harness tothe foot switch.

323 16-29

panel.

GROUP 16-VENTILATING, HEATING AND ACCESSORIES

PART16-1 SPECIFICATIONS

Belt operatedfor a minimum of 10 minutes is considereda usedbelt.

16-30 324

BLOWER MOTOR CURRENT DRAW

At Low Speed 2-3 Amperesatl2 volts

At Medium Speed 3-4 Amperesat 12 volts

At High Speed 4-6 Amperesat 12 volts

DRiVEN BELT TENSION

BetweenFan Pulley and Air Conditioner CompressorAll Engines New 120-150

Used 90-120

SPEED CONTROL

BRAKE PEDAL RELEASE SWITCH 1Adjustment Nut Torque 48-60Pound-inches]

RADIO

AIR CONDITIONING COMPRESSOR

Location Torque ft-lbs

Base Plate 7-li

Rear Cover Plate 7-10

* Cylinder Head 14.18

Front Seal Plate 13-17

ServiceValve Rotalock 35 Max.

Mounting Bolt 14-17

Oil Filler Plug 18-22

Clutch Mounting 15-22

Radio Current Draw 1 amperemax.@ 12 volts

AntennaCurrent Draw 8 amperes@ 12 volts

Oil Level: Vertical Mount Inch Minimum. Use Suniso 5 or Capella E.