1968-69 chevrolet chevelle - vintage air › instructions_pdf › 564471.pdf · accessory kit,...
TRANSCRIPT
an ISO 9001:2008 Registered Company
1968-69 Chevrolet Chevelle with Factory AirEvaporator Kit
(564471)
18865 Goll St. San Antonio, TX 78266 Phone: 210-654-7171
Fax: 210-654-3113www.vintageair.com
904471 REV C 04/22/15, PG 1 OF 25
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904471 REV C 04/22/15, PG 2 OF 25
Thank you for purchasing this evaporator kit from Vintage Air. When installing these components as part of a complete SureFit™ system, Vintage Air recommends working from front to back on the vehicle, installing the condenser kit, hose kit, and compressor first, followed by the wiring, evaporator, and finally the control panel.
Cover..................................................................................................................................Table of Contents.................................................................................................................Packing List/Parts Disclaimer..................................................................................................Information Page..................................................................................................................Wiring Notice.......................................................................................................................Engine Compartment Disassembly..........................................................................................Condenser Assembly and Installation, Compressor and Brackets, Pulleys,Passenger Compartment Disassembly..................................................................................... Defrost Duct Installation, Hose Adapter Installation..................................................................Fresh Air Cap Installation, Kick Panel Fresh Air Cap Installation.................................................. Firewall Cover Installation, Evaporator Installation.................................................................. Evaporator Installation (Cont.).............................................................................................Evaporator Installation (Final).............................................................................................. Center Louver Installation................................................................................................... Drain Hose Installation, Lubricating O-rings, A/C Hose Installation............................................ Heater Hose & Heater Control Valve Installation, A/C & Heater Hose Routing 1968 Chevelle......... Heater Hose & Heater Control Valve Installation, A/C & Heater Hose Routing 1969 Chevelle......... Final Steps........................................................................................................................ Control Panel & Duct Hose Routing........................................................................................ Wiring Diagram..................................................................................................................Gen IV Wiring Connection Instruction...................................................................................Operation of Controls..........................................................................................................Troubleshooting Guide.........................................................................................................Troubleshooting Guide (Cont.)..............................................................................................Evaporator Rear Bracket Template........................................................................................Packing List.......................................................................................................................
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Table of Contents
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904471 REV C 04/22/15, PG 3 OF 25
OFF
DASH
HOT
FLR
HI
DEF
COLD
AC
Packing List: Evaporator Kit (564471)
No. 1.2.
Qty.11
Part No.762169784166
DescriptionGen IV Evaporator Sub Case, 4-Vent with 2” & 2 ½”Accessory Kit, 1968-69 Chevrolet Chevelle with Factory Air
** Before beginning installation, open all packages and check contents of shipment. Please report any shortages directly to Vintage Air within 15 days. After 15 days, Vintage Air will not be responsible for missing or damaged items.
NOTE: Images may not depict actual parts and quantities. Refer to packing list for actual parts and quantities.
1
2
Gen IV Evaporator Sub Case 4-Vent
w/ 2” & 2 ½”762169
Accessory Kit784166
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904471 REV C 04/22/15, PG 4 OF 25
Important Notice—Please ReadFor Maximum System Performance, Vintage Air Recommends the Following:
New Vintage Air-supplied Sanden Compressor: No additional oil needed (Compressor is shipped with proper oil charge).All Other Compressors: Consult manufacturer (Some compressors are shipped dry and will need oil added).
NOTE: Vintage Air systems are designed to operate with R134a refrigerant only. Use of any other refrigerant could damage your A/C system and/or vehicle, and possibly cause a fire, in addition to potentially voiding the warranties of the A/C system and its components.
Refrigerant Capacities:Vintage Air System: 1.8 lbs. (1 lb., 12 oz.) of R134a, charged by weight with a quality charging station or scale. NOTE: Use of the proper type and amount of refrigerant is critical to system operation and performance.Other Systems: Consult manufacturer’s guidelines.
Lubricant Capacities:
Safety Switches
Service Info:Protect Your Investment: Prior to assembly, it is critical that the compressor, evaporator, A/C hoses and fittings, hardlines, condenser and receiver/drier remained capped. Removing caps prior to assembly will allow moisture, insects and debris into the components, possibly leading to reduced performance and/or premature failure of your A/C system. This is especially important with the receiver/drier. Additionally, when caps are removed for assembly, BE CAREFUL! Some components are shipped under pressure with dry nitrogen.Evacuate the System for 35-45 Minutes: Ensure that system components (Drier, compressor, evaporator and condenser) are at a temperature of at least 85° F. On a cool day, the components can be heated with a heat gun or by running the engine with the heater on before evacuating. Leak check and charge to specifications.
Your Vintage Air system is equipped with a binary pressure safety switch. A binary switch disengages the compressor clutch in cases of extreme low pressure conditions (Refrigerant Loss) or excessively high head pressure (406 PSI) to prevent compressor damage or hose rupture. A trinary switch combines Hi/Lo pressure protection with an electric fan operation signal at 254 PSI, and should be substituted for use with electric fans. Compressor safety switches are extremely important since an A/C system relies on refrigerant to circulate lubricant.
Bolts Passing Through Cowl and/or Firewall:To ensure a watertight seal between the passenger compartment and the vehicle exterior, for all bolts passing through the cowl and/or firewall, Vintage Air recommends coating the threads with silicone prior to installation.
Heater Hose (Not Included With This Kit):Heater hose may be purchased from Vintage Air (Part# 31800-VUD) or your local parts retailer. Routing and required length will vary based on installer preference.
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904471 REV C 04/22/15, PG 5 OF 25
Important Wiring Notice—Please Read
Some Vehicles May Have Had Some or All of Their Radio Interference Capacitors Removed. There Should Be a Capacitor Found At Each of the Following Locations:
1. On the positive terminal of the ignition coil.2. If there is a generator, on the armature terminal of the generator.3. If there is a generator, on the battery terminal of the voltage regulator.
Most alternators have a capacitor installed internally to eliminate what is called “whining” as the engine is revved. If whining is heard in the radio, or just to be extra cautious, a radio interference capacitor can be added to the battery terminal of the alternator.
It is also important that the battery lead is in good shape and that the ground leads are not compromised. There should be a heavy ground from the battery to the engine block, and additional grounds to the body and chassis.
If these precautions are not observed, it is possible for voltage spikes to be present on the battery leads. These spikes come from ignition systems, charging systems, and from switching some of the vehicle’s other systems on and off. Modern computer-operated equipment can be sensitive to voltage spikes on the power leads, which can cause unexpected resets, strange behavior, and/or permanent damage.
Vintage Air strives to harden our products against these types of electrical noise, but there is a point where a vehicle’s electrical system can be degraded so much that nothing can help.
Radio interference capacitors should be available at most auto and truck parts suppliers. They typically are cylindrical in shape, a little over an inch long, a little over a half inch in diameter, and they have a single lead coming from one end of the cylinder with a terminal on the end of the wire, as well as a mounting clip which is screwed into a good ground on the vehicle. The specific value of the capacitance is not too significant in comparison to ignition capacitors that are matched with the coil to reduce pitting of the points.
Care must be taken, when installing the compressor lead, not to short it to ground. The compressor lead must not be connected to a condenser fan or to any other auxiliary device. Shorting to ground or connecting to a condenser fan or any other auxiliary device may damage wiring, the compressor relay, and/or cause a malfunction.
When installing ground leads on Gen IV systems, the blower control ground and ECU ground must be connected directly to the negative battery post.
For proper system operation, the heater control valve must be connected to the ECU.
•
•
•
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904471 REV C 04/22/15, PG 6 OF 25
Engine Compartment Disassembly
1.2.3.4.5.6.7.8.
9.10.11.
Disconnect battery.Remove battery and battery tray (retain).Drain radiator.Evacuate the A/C system if necessary.Remove the OEM condenser and drier (discard) (See Figure 1, below).Remove OEM A/C lines from compressor to evaporator (discard) (See Figure 1, below).Remove OEM compressor and bracket (discard) (See Figure 1, below).Remove evaporator blower assembly (discard). NOTE: To remove the evaporator and blower assembly (under hood) and the air distribution system (under dash), the factory manual recommends removing the passenger side inner fender.Remove OEM heater hoses, A/C hoses, hardlines and drier (discard) (See Figure 1, below).Remove A/C and heater wiring/vacuum harness molded grommet (See Figure 1, below).Install a 1 ¾” plug in the firewall as shown in Figure 1, below.
NOTE: Before starting the installation, check the function of the vehicle (horn, lights, etc.) for proper operation, and study the instructions, illustrations, & diagrams.Perform the Following:
Figure 11 ¾” Plug317102
OEM A/C & HeaterWiring/Vacuum Harness
Molded Grommet
BatteryTray
A/C Hoses
Grommet
(4) OEMMounting Screws
(4) OEMMounting Screws
NOTE: On 1968 models only, once the battery is removed, remove A/C hoses and grommet from beside the battery tray (Retain the (4) OEM grommet mounting screws).
1968 Chevelle
1969 Chevelle Shown
Cover Plate640678-FCR
(Included in StandardHose Kit)
Apply a BeadOf Silicone
Around Opening
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904471 REV C 04/22/15, PG 7 OF 25
Condenser Assembly and Installation1.2.
Refer to separate instructions included with the condenser kit to install the condenser.Binary switch installation (Refer to condenser instructions).
Compressor and Brackets1. Refer to separate instructions included with the bracket kit to install the compressor bracket.
Pulleys1. In most instances, the belt lengths will remain the same.
Passenger Compartment Disassembly
1.2.3.4.5.6.7.8.9.
Remove the dash pad by removing (6) OEM screws (retain) (See Figure 2, below).Lower the steering column. Protect the steering column with a cloth.Disconnect all wires and cables from the instrument panel, speedometer, control panel and radio.Remove the instrument panel retaining screws at the top, bottom and side of panel.Remove all hoses and ducting from the OEM louvers (See Figure 2, below).Remove the (2) OEM under dash louver assemblies (discard) (See Figure 2, below).Remove the OEM defrost duct assembly by removing the (4) screws (See Figure 3, below).Remove the OEM A/C and heater assembly (discard) (See Figure 3, below).Remove the passenger side kick panel/fresh air door assembly as shown in Figure 2a, below.
Perform the Following:
NOTE: Removal of dashboard is required to install the evaporator. Vintage Air recommends using the factory service manual when disassembling and reassembling the dashboard.
Figure 2
Figure 3
Figure 2aDefrost Duct
Assembly
Fresh AirDoor Assembly
A/C & Heater Assembly
InstrumentPanel
ControlPanel
A/C & Heater Assembly& Related Ducting
PassengerSide
Kick Panel
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904471 REV C 04/22/15, PG 8 OF 25
Defrost Duct Installation1. Install the defrost ducts under the dash, aligning them with the OEM opening. Secure the defrost ducts to the
cowl using #10 x 1/2” sheet metal screws as shown in Figure 4, below.
Figure 4
Figure 5
OEMLouver
Hose Adapter49870-VCI
Hose Adapter49870-VCI
Install(3) S-clips
#10 x 1/2”Sheet Metal
Screw
Driver SideDefrost Duct
Assembly626673
Cowl
OEMDefrost Duct
Opening
DefrostDuct
Driver Side Defrost Duct
Assembly626673
Passenger SideDefrost Duct
Assembly626674
Passenger SideDefrost Duct
Assembly626674
Hose Adapter Installation1.2.
Install (3) S-clips onto the hose adapters as shown in Figure 5, below.Install the driver and passenger side hose adapters outside the OEM louvers (See Figure 5, below).
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904471 REV C 04/22/15, PG 9 OF 25
Fresh Air Cap Installation1.2.3.
4.5.
Install (4) grommets into fresh air cap (See Figure 6, below).Apply a 1/4” bead of silicone around the back side of the fresh air cap as shown in Figure 6, below.Attach the fresh air cap to the firewall using a 1/4-20 x 1 ½” bolt and washer (See Figure 6, below). NOTE: Fresh air cap installs on the engine side of the firewall.Install a 5/8” plug and grommet in the firewall. See Figure 6, below.Using the template on Page 24, drill a 5/16” hole in the firewall as shown in Figure 6, below.
Figure 6
Figure 7
Figure 7a
Figure 7b#6 A/CHose #6 A/C
Hose
#10 A/CHose
#10 A/CHose
(5) OEMScrews
(2) Heater Hoses
1/4-20 x 1 ½”Bolt with Washer
(4) Grommets33137-VUI
Fresh AirCap
Silicone
Silicone
Enlarge Existing Holein Firewall to 5/16”
OEM Heater Holein Firewall
Back Sideof Fresh Air
Cap
Back Side ofKick Panel
Fresh Air Cap
EngineCompartment
Side ofFirewall
NOTE: Firewall covermounting holes mustbe enlarged.
FIREWALL TEMPLATE
68-69 CHEVELLEw/ AC TEMPLATEFIREWALL/EVAP. BRKT
Drill5/16”Hole
Grommet33145-VUI
5/8” Plug33142-VUI
(4) Grommets33137-VUI
(2) Heater Hoses
Kick Panel Fresh Air Cap Installation1.2.
3.
4.
Install (4) grommets into the kick panel fresh air cap (See Figure 7a, below).Route A/C and heater hoses through the fresh air cap and kick panel fresh air cap as shown in Figures 7 and 7b, below.Apply a 1/4” bead of silicone around the back side of the kick panel fresh air cap as shown in Figure 7a, below.Secure kick panel fresh air cap using OEM screws as shown in Figure 7b, below.
Enlarge Existing Holein Firewall to 5/16”
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904471 REV C 04/22/15, PG 10 OF 25
Figure 8
Figure 9
Front EvaporatorBracket647065
1/4-20 x 1/2”Hex Bolt
(3) 1/4-20Nuts with
Star Washers
Firewall Cover Installation1.2.
Apply a 1/4” bead of silicone around the back side of the firewall cover as shown in Figure 8, below.From inside the car, install the firewall cover onto the firewall using (3) 1/4-20 X 1” hex bolts, (3) flat washers and (3) 1/4-20 nuts with star washers (See Figure 8, below).
Silicone
Back Side ofFirewall Cover
(3) 1/4” x 3/4”Flat Washers
(3) 1/4-20 x 1”Hex Bolts
Firewall Cover648170
Evaporator Installation1.
2.
3.
4.
On a workbench install (2) heater fittings with properly lubricated O-rings (See Figure 15, Page 14, and Figure 10, Page 11).Install a 1/4-20 x 1” hex bolt and a 1/4-20 x 1 ½” hex bolt with 1/2” spacer and (2) 1/4” push nut bolt retainers on evaporator rear bracket as shown in Figure 10, Page 11.Install the evaporator front and rear mounting brackets onto the evaporator using (5) 1/4-20 x 1/2” hex bolts and tighten as shown in Figure 9, below, and Figure 10, Page 11.Lay the evaporator sub case on the passenger side floorboard. Install the A/C and heater hoses onto the evaporator as shown in Figure 11, Page 12, and hose installation instructions on Page 14. NOTE: Wrap the #10 fitting connections with press tape (See Figure 11, Page 12).
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904471 REV C 04/22/15, PG 11 OF 25
Figure 10
Evaporator Installation (Cont.)
(2) 1/4-20 x 1/2”Hex Bolts
(2) 1/4-20 x 1/2”Hex Bolts
1/4” Push NutBolt Retainer
1/4” Push NutBolt Retainer
1/2” Spacer1/4-20 x 1 ½”
Hex Bolt
1/4-20 x 1”Hex Bolt
1968-69 ChevelleMounting Holes
Rear EvaporatorBracket
655000-VUB
(2) HeaterFittings
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904471 REV C 04/22/15, PG 12 OF 25
Evaporator Installation (Final)
1.
2.
3.
4.
Lift evaporator unit up under the dashboard. Secure loosely to firewall from the engine compartment side using (2) 1/4-20 nuts and flat washers as shown in Figure 12, below. NOTE: To ensure proper drainage, it is very important that the evaporator is level, both left-right and fore-aft. Check for level on the flat portions of the case around the drain.Using the OEM bolt, secure the front evaporator mounting bracket between the dash bracket and cowl bracket as shown in Figure 12a, below.Verify that evaporator unit is level and square to the dash; then tighten all mounting bolts. NOTE: Tighten the bolt on the firewall first. Then tighten the front mounting bracket.Once evaporator is in place, route the A/C & heater hoses out the kick panel fresh air cap and through the fresh air cap.
NOTE: To ensure a watertight seal between the passenger compartment and the vehicle exterior, for all bolts passing through the firewall, Vintage Air recommends coating the threads with silicone prior to installation.
Figure 11
Figure 12
Figure 12a
Kick PanelFresh Air
Cap
OEMBolt
HeaterHose
#10 A/CHose
#6 A/CHose
(2) 1/4-20 Nutswith Flat Washers
PressTape
FrontEvaporator
Bracket647065
NOTE: Coat bolt threads withsilicone before installing nutsand washers.
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904471 REV C 04/22/15, PG 13 OF 25
Figure 13
Figure 13a
1968 Center Louver Installation1.2.
Install (4) S-clips on the hose adapter as shown in Figure 13, below.Install center louver hose adapter outside the OEM center louver assembly as shown in Figure 13, below.
Install(4) S-clips
DoorFlap
1969 Center Louver Installation1.2.3.
Remove the center louver door flap (See Figure 13a, below).Install (4) S-clips on the hose adapter as shown in Figure 13a, below.Install the center louver hose adapter outside the OEM center louver assembly as shown in Figure 13a, below.
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904471 REV C 04/22/15, PG 14 OF 25
Figure 14
Drain Hose Installation1.2.
3.
Locate the evaporator drain on the bottom of the evaporator case.In line with the drain, lightly make a mark on the firewall. Measure 1” down and drill a 5/8” hole through the firewall (See Figure 14, below).Install the drain hose to the outlet on the bottom of the evaporator unit and route it through the firewall (See Figure 14, below).
A/C Hose Installation
1.
2.
3.
Locate the #8 compressor A/C hose. Lubricate (2) #8 O-rings (See Figure 15, above) and connect the 135° female fitting with 134a service port to the #8 discharge port on the compressor. Then route the straight female fitting to the #8 condenser hardline coming through the core support (See Figure 16, Page 15, and Figure 16a, Page 16). Tighten each fitting connection as shown in Figure 15, above.Locate the #10 compressor A/C hose. Lubricate (2) #10 O-rings (See Figure 15, above) and connect the #10 135° female fitting with 134a service port to the #10 suction port on the compressor. Then route the 90° female fitting to the #10 fitting on the evaporator (See Figure 11, Page 12, Figure 16, Page 15, and Figure 16a, Page 16). Tighten each fitting connection as shown in Figure 15, above.Locate the #6 evaporator A/C hose. Lubricate (2) #6 O-rings (See Figure 15, above) and connect the straight female fitting to the #6 hardline coming through the core support from the drier. Then route the 90° female fitting to the #6 fitting on the evaporator (See Figure 11, Page 12, Figure 16, Page 15, and Figure 16a, Page 16). Tighten each fitting connection as shown in Figure 15, above.
Standard Hose Kit:
1. Refer to separate instructions included with modified hose kit.Modified Hose Kit:
Figure ##
O-ring Installs Over Male Insert to Swaged Lip
O-ring#6 O-ring
#8 O-ring #10 O-ring
O-ring
Supplied Oil for O-rings
Male Insert
Female Nut
Hold With This Wrench
Twist With This Wrench
Lubricating O-rings For a proper seal of fittings: Install supplied O-rings as shown, and lubricate with supplied oil.
NOTE: Standard torque specifications:#6: 11 to 13 ft-lb.#8: 15 to 20 ft-lb.
#10: 21 to 27 ft-lb.
Figure 15
DrainHose
EvaporatorCase 1”1”
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904471 REV C 04/22/15, PG 15 OF 25
Heater Hose & Heater Control Valve Installation
A/
C &
Hea
ter
Hos
e R
outi
ng
19
68
Ch
evel
le S
how
n
1.
2.
Route a piece of heater hose from the water pump to the top heater fitting of heater core as shown in Figure 11, Page 12, and Figure 16, below. Secure using hose clamps.Route a piece of heater hose from the intake to the bottom heater fitting of the heater core as shown in Figure 11, Page 12, and Figure 16, below. NOTE: Install heater control valve in line with intake manifold (pressure side) heater hose. Secure using hose clamps as shown in Figure 16, below. Also note proper flow direction.
Fig
ure
16
Com
pres
sor
Saf
ety
Switc
h(B
inar
y Ty
pe)
Scr
ew-o
n D
rier
(Ref
er t
o Con
dens
erIn
stru
ctio
ns)
#6
Drier
/Con
dens
erH
ardl
ine
3536
8-VCG
Hea
ter
Hos
e
From
Hea
ter
Con
trol
Val
veTo
Eva
pora
tor
From
Eva
pora
tor
To W
ater
Pum
pFr
om I
ntak
eM
anifo
ld
NO
TE:
Vin
tag
e A
ir s
yste
ms
req
uir
e(2
) 5
/8
” h
ose
nip
ple
s (n
ot s
up
plie
d).
NO
TE:
Flow
dir
ecti
on f
ollo
ws
mol
ded
arr
ow o
n v
alve
.
(3)
Tie
Wra
ps#
6 H
ose
0960
72#
6 D
rier
/Cor
eH
ardl
ine
0911
75
#8
Con
dens
er/
Com
pres
sor
Har
dlin
e09
1177
Hea
ter
Hos
e(H
eate
r Con
trol
Valv
e/In
take
)
#10
Suc
tion
Hos
e09
6076
#8
Dis
char
geH
ose
0960
75
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904471 REV C 04/22/15, PG 16 OF 25
Heater Hose & Heater Control Valve Installation
1.
2.
Route a piece of heater hose from the water pump to the top heater fitting of heater core as shown in Figure 11, Page 12, and Figure 16a, below. Secure using hose clamps.Route a piece of heater hose from the intake to the bottom heater fitting of the heater core as shown in Figure 11, Page 12, and Figure 16a, below. NOTE: Install heater control valve in line with intake manifold (pressure side) heater hose. Secure using hose clamps as shown in Figure 16a, below. Also note proper flow direction.
Fig
ure
16
a
Com
pres
sor
Saf
ety
Switc
h(B
inar
y Ty
pe)
Scr
ew-o
n D
rier
(Ref
er t
o Con
dens
erIn
stru
ctio
ns)
A/
C &
Hea
ter
Hos
e R
outi
ng
19
69
Ch
evel
le S
how
n
Hea
ter
Hos
e
Hos
eCla
mps
From
Hea
ter
Con
trol
Val
veTo
Eva
pora
tor
From
Eva
pora
tor
To W
ater
Pum
pFr
om I
ntak
eM
anifo
ld
NO
TE:
Vin
tag
e A
ir s
yste
ms
req
uir
e(2
) 5
/8
” h
ose
nip
ple
s (n
ot s
up
plie
d).
NO
TE:
Flow
dir
ecti
on f
ollo
ws
mol
ded
arr
ow o
n v
alve
.
Hea
ter
Hos
e(H
eate
r Con
trol
Valv
e/In
take
)
#10
Suc
tion
Hos
e09
6073
#8
Dis
char
geH
ose
0960
62
#6
Hos
e09
6072
#6
Drier
/Cor
eH
ardl
ine
0911
75
#8
Con
dens
er/
Com
pres
sor
Har
dlin
e09
1178
Tie
Wra
p
#8
Con
dens
erH
ardl
ine
0916
9-FF
D#
6 D
rier
/Con
dens
erH
ardl
ine
3536
8-VCG
#10
Ade
lCla
mp
with
10-3
2 x
1/2”
Pan
Hea
dScr
ew w
ithN
ut
17
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904471 REV C 04/22/15, PG 17 OF 25
Cut & Remove1 ½”
Glove Box62567-VCE
OEMScrews
3/8”Grommet
PassengerSide
Kick Panel
Figure 17
Figure 18
Figure 19
Final Steps1.2.
3.4.
5.6.7.8.
9.10.11.
12.13.
Install duct hoses as shown in Figure 20, Page 18.Route A/C wires (12 volt/grounds/binary switch/heater valve) through 3/8” grommet as shown in Figure 17, below.Install control panel assembly. Refer to control panel instructions.Plug the wiring harnesses into the ECU module on the sub case as shown in Figure 20, Page 18. Wire according to the wiring diagrams on Pages 19 and 20.Install new glove box.Modify passenger side kick panel as shown in Figure 19, below.Reinstall all previously removed items.Fill radiator with at least a 50/50 mixture of approved antifreeze and distilled water. It is the owner’s responsibility to keep the freeze protection at the proper level for the climate in which the vehicle is operated. Failure to follow antifreeze recommendations will cause heater core to corrode prematurely and possibly burst in A/C mode and/or freezing weather, voiding your warranty.Double check all fittings, brackets and belts for tightness.Vintage Air recommends that all A/C systems be serviced by a licensed automotive A/C technician.Evacuate the system for a minimum of 45 minutes prior to charging, and perform a leak check prior to servicing.Charge the system to the capacities stated on Page 4 of this instruction manual.See Operation of Controls procedures on Page 21.
Glove BoxDoor
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904471 REV C 04/22/15, PG 18 OF 25
Figure 20
Control Panel & Duct Hose Routing
PlugFromWiring
Harness231001-VUR
Center Louver2” x 20”
Defrost DuctPassenger Side
2” x 12”
Passenger SideLouver
2 ½” x 36”
Driver SideLouver
2 ½” x 32”
Defrost DuctDriver Side
2” x 18”
Control PanelHarness From ECU
232007-VUR
Back Sideof PC BoardAssembly
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904471 REV C 04/22/15, PG 19 OF 25
WHT/GRN
WHT/YELWHT/RED
RED
WHTBACKLIGHT NEG
FAN WIPER
MODE WIPER
TEMP WIPER
5V-SW
GND
BACKLIGHT POS
AC ANNUNCIATOR
PRE-WIRED
GEN IV WIRING DIAGRAMREV D, 5/6/2014
GEN IV ECU
PROGRAM
Wiring Diagram
TEMP
MODE
FAN
A/C(IF USED)
232007-VUR
232002-VUA
** CIRCUITBREAKER30 AMP
*** WIDE OPENTHROTTLESWITCH
(OPTIONAL)
* DASH LAMP(IF USED)
Dash Lamp Is Used Only With Type 232007-VUR Harness.Warning: Always Mount Circuit Breaker As Close to the Battery As Possible. (NOTE: Wire BetweenBattery and Circuit Breaker Is Unprotected and Should Be Carefully Routed to Avoid a ShortCircuit).Wide Open Throttle Switch Contacts Close Only at Full Throttle, Which Disables A/C Compressor.
JF8
BLK
ORA
TAN
VIEWED FROM WIRE SIDE
••
•
HEATERCONTROL VALVE
20
www.vintageair.com
904471 REV C 04/22/15, PG 20 OF 25
RED
CIRCUIT BREAKER30 AMP
+
+
-
BLACK
REDWHITE
RED
CHASSIS GROUND
A/CCOMPRESSOR
RELAY
Ignition Switch:
Dash Light:
NOTE: MOUNT RELAYIN DESIRED LOCATION
UNDER DASH
GREEN
FIREWALL
BLUE
BLUE
RED &
WHITE
VIOLET
(IGNITION HOTTERMINAL)
IGNITION SWITCH
DASH BACK LIGHT+0-12vTAN
GRAY
BLUE
WHITE
WHITE
REDRED
WHITE
COMPRESSOR
BATTERY
NOTE: CONNECT WHITEWIRES DIRECTLY TO
(-) BATTERY TERMINAL
BATRUN
12V
RED GREEN
RED
RED
BLUE
LATCH
BLACK
BINARYSAFETYSWITCH
YELLOW
ORANGE
WIRING HARNESS
Violet 12V Ign Switch Source (Key On Accessory) Position Must Be Switched.
Tan Wire Used Only With Vintage Air Supplied Control Panel With LED Back Light.
Binary: Connect As Shown (Typical Compressor Wiring). Be Sure Compressor Body Is Grounded.
Trinary Switch: Connect According To Trinary Switch Wiring Diagram.
Install With Servo Motor Facing Down, As Shown. Note Flow Direction Arrow Molded Into Valve Body, And Install Accordingly.
White Must Run To (-) Battery. Red May Run To (+) Battery Or Starter. Mount Circuit Breaker As Close to Battery As Possible.
Heater Control Valve:
Binary/Trinary & Compressor:
Circuit Breaker/Battery:
CONTROL WIRING HARNESS
NOTE: YELLOW & ORANGE
COMING FROM HARNESS ARE NOT
USED.
WIRING HARNESS
GRAY WIRE IS USED FOR PROGRAMING CONTROLS
IF APPLICABLE
WIRING HARNESS
Gen IV Wiring Connection Instruction
HEATERCONTROL VALVE
WARNING: ALWAYS MOUNT CIRCUIT BREAKER
AS CLOSE TO THE BATTERY AS POSSIBLE. (NOTE: WIRE BETWEEN BATTERY AND CIRCUIT BREAKER IS UNPROTECTED
AND SHOULD BE CAREFULLY ROUTED TO AVOID A SHORT CIRCUIT).
NOTE: HEATER CONTROL VALVE CONNECTION AND CHASSIS GROUND MAY BE LOCATED ON EITHER SIDE OF THE FIREWALL. ENSURECONNECTOR IS LATCHED
FIRMLY.
21
www.vintageair.com
904471 REV C 04/22/15, PG 21 OF 25
Operation of Controls
Adjust to desiredspeed.
Blower SpeedAdjust to desired
speed.
Adjust to desiredmode position (DASH position recommended).
Adjust to desiredspeed.
Adjust to DEFROST position for maximum defrost, or between FLOOR and DEFROST positions for a bi-level
blend (Compressor is automatically engaged).
Adjust to desired temperature.
For A/C operation, adjust tocoldest position to engage
compressor (Adjust between HOT and COLD to reachdesired temperature).
A/C Operation
Heat Operation
Defrost/De-fog Operation
On Gen IV systems with three lever/knob controls, the temperature control toggles between heat and A/C operations. To activate A/C, move the temperature lever/knob all the way to cold and then back it off to the desired vent temperature. For heat operation, move the temperature lever/knob all the way to hot and then adjust to the desired vent temperature. The blower will momentarily change speed, each time you toggle between operations, to indicate the change.
Blower Speed
Blower Speed
This lever/knob controlsblower speed, from
OFF to HI.
This lever/knob controls the mode positions,from DASH to FLOORto DEFROST, with a blend in between.
This lever/knob controlsthe temperature,
from HOT to COLD.
Blower Speed
Mode Control
Temperature Control
Blower Speed
TemperatureControl
A/C Light(When Lit, Compressor
is Engaged)
ModeControl
Temperature Control
Temperature Control
Temperature Control
Mode Control
Mode Control
Mode Control
For maximum heating, adjust to hottest position (Adjust between HOT and COLD to reach desired temperature).Adjust to desired
mode position(FLOOR position recommended).
DASH
HOT
DASH
HOT
DASH
HOT
DASH
HOT
ww
w.v
inta
gea
ir.c
om
22 904471 REV C 04/22/15, PG 22 OF 25
Sym
pto
m
C
on
dit
ion
C
heck
s
Act
ion
s
N
ote
s
Blo
wer
sta
ys o
n
hig
h s
pee
d w
hen
ig
nitio
n is
on.
1a.
No o
ther
funct
ions
work
.
Chec
k fo
r dam
aged
pin
s or
wires
in c
ontr
ol hea
d p
lug.
Ver
ify
that
all
pin
s ar
e in
sert
ed into
plu
g.
Ensu
re t
hat
no
pin
s ar
e ben
t or
dam
aged
in E
CU
.
Chec
k fo
r dam
aged
gro
und
wire
(white)
in c
ontr
ol hea
d
har
nes
s.
Ver
ify
continuity
to c
has
sis
gro
und w
ith w
hite
contr
ol
hea
d w
ire
at v
ario
us
poin
ts.
Loss
of gro
und o
n t
his
wire
render
s co
ntr
ol hea
d
inoper
able
.
All
oth
er f
unct
ions
work
.Chec
k fo
r dam
aged
blo
wer
sw
itch
or
pote
ntiom
eter
and
asso
ciat
ed w
irin
g.
Blo
wer
sta
ys o
n
hig
h s
pee
d w
hen
ig
nitio
n is
on o
r off.
Unplu
g 3
-wire
BSC c
ontr
ol
connec
tor
from
ECU
. If
blo
wer
sh
uts
off,
ECU
is
eith
er
impro
per
ly w
ired
or
dam
aged
.
Be
sure
the
smal
l, 2
0 G
A w
hite
gro
und w
ire
is c
onnec
ted
to t
he
bat
tery
gro
und p
ost
. If
it
is,
repla
ce t
he
ECU
.
Unplu
g 3
-wire
BSC c
ontr
ol
connec
tor
from
ECU
. If
blo
wer
st
ays
runnin
g,
BSC is
eith
er
impro
per
ly w
ired
or
dam
aged
.
Chec
k to
ensu
re t
hat
no B
SC w
irin
g is
dam
aged
or
short
ed t
o v
ehic
le g
round.
The
BSC o
per
ates
the
blo
wer
by
gro
und s
ide
puls
e w
idth
modula
tion s
witch
ing.
The
posi
tive
wire
to t
he
blo
wer
will
alw
ays
be
hot.
If th
e “g
round”
side
of
the
blo
wer
is
short
ed t
o c
has
sis
gro
und,
the
blo
wer
will
run o
n H
I.
Rep
lace
BSC (
This
will
req
uire
rem
oval
of
evap
ora
tor
from
veh
icle
).N
o o
ther
par
t re
pla
cem
ents
sh
ould
be
nec
essa
ry.
Com
pre
ssor
will
not
turn
on
(All
oth
er funct
ions
work
).
2.
Sys
tem
is
not
char
ged
.Sys
tem
must
be
char
ged
for
com
pre
ssor
to e
ngag
e.Char
ge
syst
em o
r byp
ass
pre
ssure
sw
itch
.
Dan
ger:
Never
byp
ass
sa
fety
sw
itch
wit
h
en
gin
e r
un
nin
g.
Seri
ou
s in
jury
can
resu
lt.
Sys
tem
is
char
ged
.
1b
.
Tro
ub
lesh
oo
tin
g G
uid
e
Chec
k fo
r fa
ulty
A/C
pote
ntiom
eter
or
asso
ciat
ed
wirin
g (
Not
applic
able
to 3
-pot
contr
ols
).
Chec
k fo
r dis
connec
ted o
r fa
ulty
ther
mis
tor.
Chec
k co
ntinuity
to g
round o
n w
hite
contr
ol hea
d w
ire.
Chec
k fo
r 5V o
n r
ed c
ontr
ol hea
d w
ire.
Chec
k 2-p
in c
onnec
tor
at E
CU
housi
ng.
To c
hec
k fo
r pro
per
pot
funct
ion,
chec
k vo
ltag
e at
w
hite/
blu
e w
ire.
Voltag
e sh
ould
be
bet
wee
n 0
V a
nd
5V,
and w
ill v
ary
with p
ot
leve
r posi
tion.
Dis
connec
ted o
r fa
ulty
ther
mis
tor
will
cau
se
com
pre
ssor
to b
e dis
able
d.
Red
wire
at A
/C p
ot
should
hav
e ap
pro
xim
atel
y 5V
with ignitio
n o
n.
White
wire
will
hav
e co
ntinuity
to
chas
sis
gro
und.
White/
Blu
e w
ire
should
var
y bet
wee
n 0
V a
nd 5
V w
hen
le
ver
is m
oved
up o
r dow
n.
3. Com
pre
ssor
will
not
turn
off
(A
ll oth
er funct
ions
work
).
Chec
k fo
r fa
ulty
A/C
pote
ntiom
eter
or
asso
ciat
ed
wirin
g.
Chec
k fo
r fa
ulty
A/C
rel
ay.
Rep
air
or
repla
ce p
ot/
contr
ol w
irin
g.
Rep
lace
rel
ay.
See
blo
wer
sw
itch
chec
k pro
cedure
.
ww
w.v
inta
gea
ir.c
om
23 904471 REV C 04/22/15, PG 23 OF 25
Sym
pto
m
C
on
dit
ion
Ch
eck
s
Act
ion
s
N
ote
s
Sys
tem
will
not
turn
on,
or
runs
inte
rmitte
ntly.
4.
Work
s w
hen
engin
e is
not
runnin
g;
shuts
off w
hen
en
gin
e is
sta
rted
(T
ypic
ally
ear
ly G
en I
V,
but
poss
ible
on a
ll ve
rsio
ns)
.
Nois
e in
terf
eren
ce f
rom
either
ig
nitio
n o
r al
tern
ator.
Inst
all ca
pac
itors
on ignitio
n c
oil
and a
lter
nat
or. E
nsu
re
good g
round a
t al
l poin
ts.
Rel
oca
te c
oil
and a
ssoci
ated
w
irin
g a
way
fro
m E
CU
and E
CU
wirin
g.
Chec
k fo
r burn
edor
loose
plu
g w
ires
.
Ver
ify
connec
tions
on p
ow
er
lead
, ig
nitio
n lea
d,
and b
oth
white
gro
und w
ires
.
Ver
ify
pro
per
met
er f
unct
ion b
y ch
ecki
ng t
he
conditio
n o
f a
know
n g
ood b
atte
ry.
Ignitio
n n
ois
e (r
adia
ted o
rco
nduct
ed)
will
cau
se t
he
syst
em t
o s
hut
dow
n d
ue
tohig
h v
oltag
e sp
ikes
. If
this
is s
usp
ecte
d,
chec
k w
ith a
qual
ity
osc
illosc
ope.
Spik
esgre
ater
than
16V w
ill s
hut
dow
n t
he
ECU
. In
stal
l a
radio
cap
acitor
at t
he
posi
tive
post
of th
e ig
nitio
nco
il (S
ee r
adio
cap
acitor
inst
alla
tion b
ulle
tin).
A
faulty
alte
rnat
or
or
worn
out
bat
tery
can
als
o r
esult
in t
his
conditio
n.
Will
not
turn
on u
nder
an
y co
nditio
ns.
Ver
ify
bat
tery
voltag
e is
gre
ater
than
10 v
olts
and les
sth
an 1
6.
Loss
of m
ode
door
funct
ion.
No m
ode
chan
ge
at a
ll.Chec
k fo
r dam
aged
mode
switch
or
pote
ntiom
eter
and
asso
ciat
ed w
irin
g.
Part
ial fu
nct
ion o
f m
ode
doors
.
Typic
ally
cau
sed b
y ev
apora
tor
housi
ng
inst
alle
d in a
bin
d in t
he
vehic
le.
Be
sure
all
mounting loca
tions
line
up
and d
on’t h
ave
to b
e fo
rced
in
to p
osi
tion.
Blo
wer
turn
s on
and o
ff r
apid
ly.
6.
Bat
tery
voltag
e is
at
leas
t 12V.
Chec
k fo
r at
lea
st 1
2V a
t ci
rcuit b
reak
er.
Ensu
re a
ll sy
stem
gro
unds
and p
ow
er c
onnec
tions
are
clea
n a
nd t
ight.
Bat
tery
voltag
e is
les
s th
an 1
2V.
5.
Tro
ub
lesh
oo
tin
g G
uid
e (
Co
nt.
)
Chec
k fo
r fa
ulty
bat
tery
or
alte
rnat
or.
Char
ge
bat
tery
.
Sys
tem
shuts
off b
low
er a
t 10V.
Poor
connec
tions
or
wea
k bat
tery
can
cau
se
shutd
ow
n a
t up t
o 1
1V.
7. When
ignitio
n is
turn
ed o
n,
blo
wer
m
om
enta
rily
co
mes
on,
then
sh
uts
off.
This
occ
urs
with t
he
blo
wer
sw
itch
in
the
OFF
posi
tion.
This
is
an indic
ator
that
the
syst
em h
as b
een r
eset
. Be
sure
the
red p
ow
er w
ire
is o
nth
e bat
tery
post
, an
d n
ot
on a
sw
itch
ed s
ourc
e. A
lso,
if
the
syst
em is
pulle
d b
elow
7V f
or
even
a s
plit
sec
ond,
the
syst
em w
ill r
eset
.
Run r
ed p
ow
er w
ire
direc
tly
to b
atte
ry.
Chec
k fo
r posi
tive
pow
er a
t hea
ter
valv
e gre
en w
ire
and
blo
wer
red
wire.
Chec
k fo
r gro
und o
n c
ontr
ol hea
d w
hite
wire.
Chec
k fo
r obst
ruct
ed o
r bin
din
g m
ode
doors
.
Chec
k fo
r dam
aged
ste
pper
m
oto
r or
wirin
g.
Err
atic
funct
ions
of
blo
wer
, m
ode,
te
mp,
etc.
Chec
k fo
r dam
aged
sw
itch
or
pot
and a
ssoci
ated
wirin
g.
Rep
air
or
repla
ce.
8.
24
www.vintageair.com
904471 REV C 04/22/15, PG 24 OF 25
EvaporatorRear Bracket
Template
Enlarge OEM Hole
5/16”
Drill5/16”
FirewallOpening
Firewall
25
www.vintageair.com
904471 REV C 04/22/15, PG 25 OF 25
OFF
DASH
HOT
FLR
HI
DEF
COLD
AC
Packing List: Evaporator Kit (564471)
No. 1.2.
Qty.11
Part No.762169784166
DescriptionGen IV Evaporator Sub Case, 4-Vent with 2” & 2 ½”Accessory Kit, 1968-69 Chevrolet Chevelle with Factory Air
NOTE: Images may not depict actual parts and quantities. Refer to packing list for actual parts and quantities.
1
2
Gen IV Evaporator Sub Case 4-Vent
w/ 2” & 2 ½”762169
Accessory Kit784166
Checked By:Packed By:
Date: