SECTION 11

ACCESSORIES

CONTENTS OF THIS SECTION

Page

Gasoline Heater-500, 700 and 900 Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11-1 -1200 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11-25 Direct Air Heater-500, 700 and 900 Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. -1200 Series .. .... . . , ... . .. . .. . .... ... . . . . .. . . . .. .. . . .. " . . . . . . . . . . . . . .

11-28 11-32

Instrument Panel Cover-500, 700 and 900 Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .

11-35

GASOLINE HEATER-SOO,700 AND 900 SERIES INDEX General Description . . . . . . . . . . . . . . . . . . . . . . . .. Heating System Components .. . . . ... ..... . . Cycle of Operation . . . . . . . . . . . . . . . .. . . . . . .. Service Diagnosis .. . ....... .. ...... . .. . .... . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Diagnosis Guide .. . . ... ..... . . .... .. ...... Wiring .. ....... . ...................... , Ventilator Blower .. .... . .. . ........... .. Combustion Blower .. ... ....... . .... .. ... Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . .. Breaker Points. . . . . . . . . . . . . . . . . . . . . . . .. Ignition Coil. . . . . . . . . . . . . . . . . . . . . . . . . . . Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Overheat Switch. . . . . . . . . . . . . . . . . . . . . . . . Purge Switch . ... .. . ....... ...... .. .. . " Heater Control Switch. . . . . . . . . . . . . . . . . .. Fuel Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection of Burner. . . . . . . . . . . . . . . . . . . . Checking the Nozzle and Fuel Solenoid . . .. Solenoid Coil Check . ..... . . . . . . ... ... . Valve Check . .. ...... . ............... Nozzle and Spray Pattern Check . .... " Exhaust Tube . . . . . . . . . . . . . . . . . . . . . . . . . . Heat Exchanger ............... . ........ Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Service Operations . . . . . . . . . . . . . . . . . . . . . . . . . . Ventilator Blower Motor Replacement .......

Page 11-2 11-2 11-4 11-6 11-6 11-6 11-8 11-9 11-9 11-9 11-9 11-10 11-10 11-11 11-12 11-12 11-12 11-12 11-13 11-13 11-13 11-13 11-14 11-15 11-15 11-15 11-15

Page Combustion Blower Motor Replacement .... . 11-15 Thermostat Replacement ..... . .......... . . 11-17 Heater Control Switch Replacement . . . . .. .. . 11-17 Ignition Unit Base Assembly (Breaker Points) Replacement ...... . .... .. . . 11-17 Ignition Coil Replacement .. .... .... . .. ... . 11-18 Overheat Switch Replacement ...... . . . .. . . . 11-18 Purge Switch Replacement .... . .. .. .... ... . 11-18 11-18 Relay Replacement . Burner Assembly .. .. . ....... .... . . .. .... . 11-18 Removal . .. . . .. ... . .. .. . .. . ... . . .. .... . 11-18 Disassembly ... . . .. . . . . ... .... .. . . . . . . . . 11-20 Assembly ... . .... . ..... . ...... .. .... . 11-20 Installation . ............. . ........ .. .. . . 11-20 Spark Plug Replacement ..... .. ...... .. .. . . 11-21 Nozzle Replacement ............ . . ...... . . . 11-21 Solenoid Coil Replacement .. . ....... . ..... . 11-21 Heat Exchanger Replacement .... .. .... ... . 11-22 Heater Unit (Complete) ... . ..... .... .. . .. . . 11-22 Removal and Installation .... ..... . .. . .. . 11-22 Air Distributor Case Replacement .... ... .. . 11-23 Controls ............. . ............... .. . . 11-23 Control Knob and Cable Replacement .... . 11-23 Control Assembly Replacement .......... . 11-23 Control Adjustments .. .... . . . ... ..... .. . 11-23 Specifications ... . . . ...... . . . . . . . . . . . . . . . . . . . 11-24 Special Tools .............................. . 11-24 CORVAIR SHOP

MANUAL

ACCESSORIES 11-2

Fig. 11-1-Heater Components Mounted in Front Compartment

GENERAL DESCRIPTION The Corvair gasoline heater is designed to provide an ample volume of outside heated air within two minutes after the switch is turned on, thus reducing the customary wait for engine warm-up and windshield defrosting. Basically the heating system consists of the following components:

HEATING SYSTEM COMPONENTS Refer to Figures 11-1, 11-2 and 11-3. Heat Exchanger and Burner Assembly-The heat exchanger and burner assembly consists of a cylindrical stainless steel heat exchanger and a burner assembly which are enclosed in a case and mounted on the right side of the dash panel in the front compartment. Outside air is drawn through the cowl vent and into the heater through an opening in the right of the fender wheelhouse area and forced into the car interior through the blower case and air distributor assembly. The case surrounding the heat exchanger provides a channel through which outside air flows into the air distributor. The burner is equipped with a nozzle to spray the fuel , a mixer cup to mix the fuel with combustion air and a spark plug to ignite the mixture. A solenoidoperated on-off valve controls the flow of fuel.

An overheat switch is provided to open the electric circuit to the solenoid fuel valve and shut off the fuel in the event the temperature should rise above a predetermined maximum. This switch will automatically reset itself when the heater cools down. Ignition System-The ignition coil is mounted on the outside of the heater case. The combustion blower operates the breaker points. When the current is interrupted by the opening of the points, a high-voltage current is generated by the coil's secondary circuit which fires the spark plug. Thermostat-The output of the heater is regulated by the thermostat in the air distributor. The thermostat contains a bimetal helix which is affected by temperature and which controls a microswitch through an adjustable linkage. The microswitch, in turn, cycles the fuel and ignition, on and off, to maintain the desired temperature in the passenger compartment. Purge Switch-The purge switch is located on the upper half of the heater case and supplies current to the combustion blower when the heater is turned on. It is designed to allow the blower to run up to two minutes after the car ignition is turned off. During this period, a properly operating purge switch will purge the combustion chamber of all products of combustion. Solenoid Relay-The purpose of the fuel solenoid relay is to break the fuel circuit and thus prevent the CORVAJR

SHOP

MA.NUAL

I I I I I I I I I I I I I I I I I I I

ACCESSORIES 11-3

IGNITION COIL HEAT EXCHANGER VENTILATOR BLOWER

SPARK PLUfi COLD OUTSIDE AIR

AIR DISTRIBUTOR

FILTER NOZZLE../'

DRAIN ~

EXHAUSTJ '---- TO CAR INTERIOR THERMOSTAT

COMBUSTION BLOWER IGNITION UNIT BA.SE (BREAKER POiNlIS) COMBUSTION AIR

PRESSURE REGULATOR FROM GAS TANK

-

OVERFLOW TO GAS TANK TO BURNER

\---l r-- · TO CARBURETOR ~ ENGINE FUEL PUMP

Fig. 11-2-HeatlnSl System Schematic

flow of fuel to the combustion chamber in the event of any interruption of the electrical supply to the combustion blower. The relay is mounted on the top half of the heater case, just above the ignition coil. Heater Control Switch-The heater control (Fan) switch is installed on the right side of the air distributor and is actuated by a::l air shutoff door to the ventilator blower. The door is provided to shut off outside ram air when the heater is not in use. The heater control switch is connected to the door through a lever arm. This arrangement insures that the air door will be open whenever the heater is used. The switch controls the speed of the ventilating air blower and also provides power to the heater thermostat, yvhich, in turn, controls heater operation. Ventilator Blower-The ventilating air blower is mounted on the heater case and pulls air in through the cowl vent and across the heat exchanger, blowing it into the air distributor. The blower system permits selection of high or low volume air. Combustion BJower-·The combustion air blower is designed to provide the- proper amount of air for combustion of the gasoline which is admitted to the burner

through the nozzle. The blower, itself, is mounted on the right fender skirt inside the baggage compartment. The breaker points are attached to the end of the motor and are actuated by the cycling of a two-lobed cam which is fitted over an extended shaft of this motor. Distributor and Defroster Components-An air distributor is mounted to the interior of the car at the dash panel below the plenum chamber and serves to direct air received from the ventilating air blower either directly to the car interior through an opening at the floor area or through defroster openings, hoses and outlets to the windshield area. A control cable operated door in the distributor proportions the amount of air directed to windshield or floor areas. The distributor contains the thermostat which regulates the output of the heater and the heater control (Fan) switch which controls the ventilation blower speed and provides power to the heater system. Control Assembly The heater control assembly is mounted to the lower flange of instrument panel at center of panel (without CORVAIR SHOP MANUAL

ACCESSORIES 11-4

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ISOLENO~

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MOTOR

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WHITE

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COMBUSTIO N BLOWER

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~Q

I:I:~I ~ ~

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~I BLACK

(BROWN BLACK

CONNECTOR

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COIL

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DISTRIE'~JTOR

GREEN

I

[!;;

L,

"---= --

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CONTROL LAMP

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VENTILATOR BLOWER MOTOR

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RED

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REEsTOR

SWITCH