Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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Removal and Installation NOTE: If an A/C evaporator core leak is suspected, the A/C evaporator core must be leak tested before it is removed from the vehicle. For additional information, refer to Component Tests in Section 412-00. NOTE: Installation of a new suction accumulator is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator. 1. Recover the refrigerant. For additional information, refer to Section 412-00. 2. Remove the instrument panel. For additional information, refer to Section 501-12. 3. Remove the junction box splash shield, if equipped. 4. Disconnect the cable ends. 5. Remove the junction block bracket. 1. Disconnect the electrical connector. 2. Remove the screws. 3. Detach the pin-type retainers and remove the junction block bracket. 6. Using suitable tools, clamp off the heater core inlet and outlet hoses. 7. Gently push each heater hose towards the heater core, compress the clip, and disconnect the heater hoses from the heater core. For additional information, refer to Section 412-00. 8. Disconnect the refrigerant spring lock couplings from the evaporator inlet and outlet. For additional information, refer to Section 412-00. 9. Remove the screw and the RH demister adapter. 10. Remove the screws and remove the defroster duct and LH demister adapter as an assembly. 11. Remove the nut. 12. Remove the nut. 13. Disconnect the vacuum line from the parking brake release solenoid. 14. Disconnect the vacuum connector from the panel/floor vacuum control motor. 15. Disconnect the vacuum line. 16. Remove the screw. 17. Remove the screw. 18. Remove the nut.

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1. Release fuel pressure. See FUEL PRESSURE RELEASE . Disconnect battery cables and remove battery. Drain cooling system. Mark hinges and remove hood. 2. Disconnect intake air temperature (IAT) sensor and remove air intake duct and air cleaner assembly. Remove accelerator cable splash shield. Remove radiator hoses. Disconnect transmission cooler lines from radiator (A/T models). 3. Remove radiator shroud attaching screws and position over fan blades. Remove water pump pulley, fan, fan clutch and shroud. Remove radiator hoses. Remove heater hoses. Remove transmission cooling lines (A/T models). Remove radiator. Mark and disconnect all fuel lines, cables, electrical connectors and vacuum hoses from engine. Remove EGR sensor. Disconnect block heater (if equipped). Remove generator. Discharge A/C system (if equipped) using approved refrigerant recovery/recycling equipment. Remove A/C compressor. Remove A/C compressor mounting bracket with power steering pump attached, and position aside. 4. Raise and support vehicle. Disconnect engine ground cable. Remove starter motor. Remove nut retaining transmission cooler line bracket, 4 torque converter bolts, and disconnect 2 transmission harness connectors (A/T models). Disconnect exhaust pipe flange. Disconnect transmission harness connector and HO2 sensor (M/T models). Remove 6 transmission-to-engine bolts. 5. Lower vehicle. Support transmission with floor jack. Attach lifting device to engine and support engine. Remove 2 upper transmission-to-engine bolts. On automatic transmission models, disconnect and separate heated exhaust gas sensor connector from bracket on bell housing. 6. Remove 4 motor mount retaining nuts and remove engine.

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All vehicles 5. Remove the radiator. For additional information, refer to Section 303-03A. 6. If equipped, remove the A/C condenser core. For additional information, refer to Section 412-03. 7. If equipped, disconnect the climate control vacuum connector. All except supercharged vehicles 8. Remove the bolts and position the power steering reservoir aside. All vehicles 9. Disconnect the exhaust manifold to exhaust gas recirculation (EGR) valve tube lower fitting and remove the tube. 10. Disconnect the generator electrical connections and remove the generator. 11. NOTE: Battery removed for clarity. Disconnect the 38-pin, 42-pin and 16-pin electrical connectors. 12. Disconnect the electrical connector and remove the connector from the bracket. 13. Remove the bolts and the connector bracket cover. 14. Remove the 38-pin connector from the bracket. 15. Disconnect the starter relay electrical connections and position the cables aside. 16. Remove the bolts and connector bracket. 17. Compress the holding tabs and disconnect the heater hoses from the heater core. 18. Raise and support the vehicle. For additional information, refer to Section 100-02. 19. If equipped, remove the skid plate. 1. Remove the bolts. 2. Remove the skid plate. 20. Remove the A/C compressor, if equipped. For additional information, refer toSection 412-03. 21. Remove the drain plug and drain the engine oil. All except supercharged vehicles 22. Remove the starter motor. For additional information, refer to Section 303-06. 23. If equipped, install the A/C line (muffler) bracket. Manual transmission vehicles 24. Remove the clutch disc and pressure plate. For additional information, refer to Section 308-01. Automatic transmission vehicles 25. Remove the transmission fluid cooler tubes from the block mounted clip. 26. Remove the bolts and the flexplate inspection cover. 27. Remove the cylinder block opening cover. 28. Remove the torque converter-to-flexplate nuts. Discard the nuts. 29. NOTE: The upper two transmission-bolts will be removed later. Remove the lower five transmission-to-engine bolts. 30. Remove the nut and the transmission oil filler tube.

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Except Air-Conditioned Cars 1967 MODELS 1. Disconnect the negative battery cable and drain the radiator. 2. Remove the heater hoses from the core. The top hose connects to the water pump and the lower hose goes to the thermostat housing or intake manifold. 3. Remove the cables and all electrical connections from the heater and defroster assembly. 4. Remove the nuts from the core case studs located on the firewall. 5. From inside the car, remove the case-to-firewall mounting screws and the heater and defroster assembly. 6. Remove the retaining springs and core. 7. Install the core and retaining springs, making sure the core-to-case sealer is in good condition. 8. Complete the installation by reversing the removal procedure. 1968-77 MODELS 1. Disconnect the negative battery cable. 2. Drain the radiator. 3. Disconnect the heater hoses. Plug the core inlet and outlet. 4. Remove the nuts from the air distributor duct studs on the firewall. 5. On 1970-77 Camaros: remove the glove box and radio, then the defroster duct-to-distributor duct screw. Pull the defroster duct out of the way, then pull the distributor duct from the firewall mounting. Remove the resistor wires. Lay the duct on the floor. 7. Remove the core assembly from the distributor duct. 8. Reverse the procedure to install. Use new sealer on the duct flange, if necessary.

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The heater-A/C housing assembly must be removed from the vehicle and disassembled for service access of the blower motor, blower motor wheel, heater core, evaporator coil, blend-air door, and each of the various mode control doors. WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY . REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel from the vehicle. Refer to: “Body and Frame : Interior Moulding/Trim : Dashboard/Instrument Panel : Service and Repair” See: Body and Frame\Interior Moulding / Trim\Dashboard / Instrument Panel\Service and Repair 3. If the vehicle is not equipped with air conditioning, go to Step 6. If the vehicle is equipped with air conditioning, recover the refrigerant from the refrigerant system. Refer to: “Heating and Air Conditioning : Service and Repair” See: Service and Repair 4. Disconnect the liquid line refrigerant line fitting from the evaporator inlet tube. 5. Disconnect the accumulator inlet tube refrigerant line fitting from the evaporator outlet tube. Install plugs in, or tape over all of the opened refrigerant line fittings. 6. Drain the engine cooling system. Refer to: “Engine, Cooling and Exhaust : Cooling System : Service and Repair” See: Engine, Cooling and Exhaust\Cooling System\Service and Repair 7. Disconnect the heater hoses from the heater core tubes. Install plugs in, or tape over the opened heater core tubes. 8. Remove the four nuts from the heater-A/C housing mounting studs on the engine compartment side of the dash panel. 9. Remove the nut that secures the heater-A/C housing mounting brace to the stud on the passenger compartment side of the dash panel. 10. Pull the heater-A/C housing rearward far enough for the mounting studs and the evaporator condensate drain tube to clear the dash panel holes. 11. Remove the heater-A/C housing from the vehicle. DISASSEMBLY 1. Place the heater-A/C housing on a work bench, with the heater-A/C housing cover facing down. 2. Remove the two screws that secure the heater-A/C housing cover to the top of the blower motor housing cover. 3. If the vehicle is so equipped, unplug the two vacuum harness connectors from the recirculation air door actuator. 4. Unplug the vacuum harness connector from the panel-defrost door actuator. 5. Remove the four screws that secure the floor duct to the bottom of the heater-A/C housing and remove the duct from the housing.