an ISO 9001:2015 Registered Company

1970-72 Chevrolet Monte Carlowithout Factory Air

Evaporator Kit(561081)

904474 REV A 05/22/19, PG 1 OF 28

18865 Goll St. San Antonio, TX 78266 Phone: 800-862-6658

Sales: sales@vintageair.comTech Support: tech@vintageair.com

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904474 REV A 05/22/19, PG 2 OF 28

Table of ContentsCover..................................................................................................................................Table of Contents.................................................................................................................Packing List/Parts Disclaimer..................................................................................................Information Page.................................................................................................................Wiring Notice.......................................................................................................................Engine Compartment Disassembly, Condenser Assembly and Installation, Compressor and Brackets......................................................................................................Passenger Compartment Disassembly..................................................................................... Kick Panel Modification, Firewall Modification............................................................................Defrost Duct Installation, (Optional) Hose Adapter Installation (If Equipped)................................ Fresh Air Cap & Kick Panel Cover Preparation......................................................................... Fresh Air Cap & Kick Panel Cover Preparation (Cont.), Wiring Installation...................................Wiring Installation (Cont.)...................................................................................................Kick Panel Cover Installation, Fresh Air Cap Installation...........................................................Firewall Cover Installation....................................................................................................Evaporator Installation........................................................................................................Evaporator Installation (Cont.)............................................................................................. Vehicles without Astro Vents, Vehicles with Astro Vents............................................................Drain Hose Installation, Lubricating O-rings, A/C Hose Installation............................................Heater Hose & Heater Control Valve Installation, A/C & Heater Hose Routing..............................Final Steps........................................................................................................................ Control Panel & Duct Hose Routing....................................................................................... Wiring Diagram.................................................................................................................Gen IV Wiring Connection Instruction...................................................................................Operation of Controls.........................................................................................................Troubleshooting Guide........................................................................................................Troubleshooting Guide (Cont.).............................................................................................Kick Panel Modification Template..........................................................................................Packing List.......................................................................................................................

1 2 3 4 5

6 7 8 91011121314 1516171819202122232425262728

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904474 REV A 05/22/19, PG 3 OF 28

OFF

DASH

HOT

FLR

HI

DEF

COLD

A C

Packing List: Evaporator Kit (561081)

No. 1.2.

Qty.11

Part No.762169784171

DescriptionGen IV Evaporator Sub CaseAccessory Kit

** 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

Accessory Kit784171

Gen IV Evaporator Sub Case762169

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904474 REV A 05/22/19, PG 4 OF 28

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. (28.8 oz.) or 816 grams 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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904474 REV A 05/22/19, PG 5 OF 28

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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904474 REV A 05/22/19, PG 6 OF 28

Engine Compartment Disassembly

1.2.3.4.5.

6.

Disconnect battery.Remove battery and battery tray (retain).Drain radiator.Remove OEM heater hoses (discard).Remove OEM blower assembly (discard). NOTE: To remove the blower assembly (under hood) and the air distribution system (under dash), the factory manual recommends removing the passenger side inner fender. Remove OEM heater wiring/vacuum harness molded grommet (See 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 1

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.

Inner Fender Panel

Heater HoseClamp

OEMBlower Motor

Assembly

7

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904474 REV A 05/22/19, PG 7 OF 28

Passenger Compartment Disassembly

1.2.3.4.5.6.7.8.

Remove the dash pad by removing (6) OEM screws (retain) (See Figure 1, 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 lower dash by removing the (8) OEM bolts (retain).Remove all hoses and ducting from the OEM louvers and astro vent door (if equipped) (See Figure 1, below).Remove OEM defrost duct assembly by removing (4) screws (See Figure 2, below).Remove OEM heater assembly (discard) (See Figure 2, below).Remove passenger side kick panel/fresh air door assembly as shown in Figure 1, Page 8.

Perform the Following:

Figure 1

Figure 2

NOTE: Removal of dashboard is required to install the evaporator. Vintage Air recommends using the factory service manual when disassembling and reassembling the dashboard.

DoorFlap

(6) OEM Screws

ControlPanel

DashPad

Heater Assembly& Related Ducting

InstrumentPanel

Defrost DuctAssembly

OEM HeaterAssembly

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904474 REV A 05/22/19, PG 8 OF 28

Kick Panel Modification1.

2.3.4.5.

Remove kick panel grille (discard). Remove the kick panel by removing (5) OEM screws from the fresh air door assembly. Disconnect and discard the pull cable assemblies from the kick panel (See Figure 1, below).Install 1/2” plastic plugs to fill the holes left from the removal of the pull cable assembly (See Figure 2, below).Locate the template provided on Page 28. Place template on kick panel as shown in Figure 2a, below.Cut the fresh air door assembly as shown in Figure 2a, below.Reinstall the kick panel.

Kick Panel Cut Out

Template

1968-72 Chevelle

without A

/C

CutOut

OEMScrews

Kick PanelGrille

Fresh Air Door Assembly

Template

1/2” PlasticPlug

Cut Out This Section

Figure 1

Figure 2

Figure 2a

Fresh AirDoor Assembly

Firewall Modification1. Flatten the edges of the firewall opening (See Photo 1, below).NOTE: Firewall modification is required for firewall cover and drain hose installation.

Photo 1

Flatten Firewall Opening Edges

Engine Compartment Side

Pull CableAssemblies

9

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904474 REV A 05/22/19, PG 9 OF 28

Defrost Duct Installation1.2.

Install the defrost ducts under the dash, and secure using OEM screws as shown in Figure 1, below.If the vehicle is equipped with astro vents, install the astro vent caps as shown in Figure 1, below.

Figure 1

Figure 1

OEM Defrost Duct

Mounting FlangeOEM

Astro Vent(If Equipped)

OEM Screws

Defrost Duct

626670

OEMAstro Vent

(If Equipped)

Astro VentCap

498825

Driver SideLouver Hose

Adapter 498823

Passenger SideLouver Hose

Adapter 498824

(3) S-clips (3) S-clips

Astro VentCap

498825

Hose Adapter Installation (If Equipped) 1.2.

Install (3) S-clips onto hose adapters as shown in Figure 1, below.Install the driver & passenger side hose adapters inside the OEM louvers (See Figure 1, below).

Driver Side Passenger Side

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904474 REV A 05/22/19, PG 10 OF 28

Photo 1 Photo 2

Photo 3

Photo 4Photo 5

Fresh Air Cap &Kick Panel Cover Preparation

1.2.

3.

Install (4) large grommets and a 7/8” grommet into the fresh air cap (See Photos 1 & 2, below).On the inside of the fresh air cap, the letter “T” indicates the top mounting hole for the firewall (See Photo 3, below).From the center of the bottom left hole in the kick panel cover, measure 1 ½” down. Mark and drill a 5/8” hole for the 7/8” grommet (See Photos 4 & 5, below).

7/8” Grommet 33144-VUI

(4) Large Grommets 33137-VUI

Fresh Air Cap 622230

“T” Indicates Top Mounting Hole

Kick Panel Cap 626667

Drill 5/8” Hole

1 ½”

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904474 REV A 05/22/19, PG 11 OF 28

Photo 6

Photo 7

Fresh Air Cap &Kick Panel Cover Preparation (Cont.)

4. Install (4) large grommets and a 7/8” grommet into the kick panel cover (See Photos 6 & 7, below).

(4) Large Grommets 33137-VUI

7/8” Grommet 33144-VUI

Wiring Installation1.

2.

From the passenger compartment, route the heater control valve connector and wiring (red, white and green) through the 7/8” grommet in the kick panel cover (See Figure 1, below). NOTE: Leave approximately 1” of wiring between the kick panel cover and the harness connector. This allows enough wiring to reach the harness.Disconnect the circuit breaker from the main wiring harness (See Photo 1, below).

Photo 1

Figure 1

Circuit Breaker

7/8” Grommet 33144-VUI

Kick Panel Cover 626667

Approximately 1”

Heater Control Valve Connector and

Wiring (Red, White and Green)

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904474 REV A 05/22/19, PG 12 OF 28

Wiring Installation (Cont.)3.

4.

5.

Route the red, white and blue wires from the main wiring harness through the 7/8” grommet in the kick panel cover (See Photo 2, below). NOTE: Leave approximately 5” of wiring between the relay and the kick panel cover. This allows enough wiring to secure the relay to the mounting position.Route the heater control valve wiring (red, white and green) through the 7/8” grommet in the fresh air cap (See Photo 3, below).Route the main harness wiring (red, white and blue) through the 7/8” grommet in the fresh air cap (See Photo 4, below).

Photo 3

Photo 2

Photo 4

Kick Panel Cover 626667

Heater Control Valve Connector and Wiring (Red, White and Green)

Fresh Air Cap 622230

7/8” Grommet 33144-VUI

Main Wiring Harness

(Red, White and Blue)

Approximately 5”

Main Wiring Harness

(Red, White and Blue)

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904474 REV A 05/22/19, PG 13 OF 28

Kick Panel Cover Installation1.2.3.

Route the A/C and heater hoses through the kick panel cover as shown in Figure 1, below.Apply 1/4” bead of silicone around the back side of the kick panel cover as shown in Figure 1, below.Secure the kick panel cover using (5) #8 x 1 ¼” screws as shown in Figure 1, below.

Mating Surface of Kick Panel Cover

Figure 1

Figure 1

#10 A/C Hose

#6 A/C Hose

#6 A/C Hose

(2) Heater Hose

(2) Heater Hose

Silicone

(5) #8 x 1 ¼” Screws

Photo 1

Fresh Air Cap Installation

1.2.3.

4.

Route the A/C and heater hoses through the fresh air cap as shown in Figure 1, below.Gently pull the slack from the hoses in the passenger compartment, making sure the hoses are not kinked.Slide the fresh air cap into position, and secure it to the firewall using (2) #14 x 3/4” sheet metal screws (See Photo 1, below).Apply silicone around the outer edge of the fresh air cap (See Photo 1, below).

NOTE: The fresh air cap installs on the engine side of the firewall.

#10 A/C Hose

Secure Fresh Air Cap with (2) #14 x 3/4” Sheet Metal Screws

Apply SiliconeAround Fresh

Air Cap

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904474 REV A 05/22/19, PG 14 OF 28

Back Sideof Firewall

Cover

Engine Compartment View

Passenger Compartment

View

Firewall Cover Installation

1.2.

3.

4.5.6.

7.

Install (3) 1/4-20 x 3/4” bolts with pushnut bolt retainers onto the firewall cover (See Photo 1, below).From the engine side compartment, temporarily install the firewall cover onto the firewall (See Photo 2, below).From the passenger compartment, trace around the firewall opening onto the firewall cover (See Photo 3, below).Remove the firewall cover and apply insulation to the traced area (See Photos 4 & 5, below).Apply silicone to the mating surface of the firewall cover (See Figure 1, below).Install the firewall cover onto the firewall, and secure it using (3) 5/8” washers and (3) 1/4-20 nuts with star washers (See Photo 6, below).Clean the firewall and necessary areas, and then apply heat blocking insulation.

NOTE: For proper system operation, Vintage Air recommends using heat blocking insulation in the area around the evaporator unit (firewall, kick panel, inner cowl and firewall covers). Due to tight clearance for the evaporator unit, between the firewall and dash, Vintage Air recommends an insulation thickness of no more than 1/4”.

Photo 1 Photo 2Photo 3

Photo 4 Photo 5

Photo 6

Figure 1

Trace Around Firewall Opening

(3) 1/4-20 x 3/4” Bolts with Pushnut Bolt Retainer

Install (3) 5/8” Washers and (3) 1/4-20 Nuts with Star Washers

Firewall Cover

Insulation

Firewall Cover

Apply Insulation to Traced Area

Silicone

15

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904474 REV A 05/22/19, PG 15 OF 28

Evaporator Installation1.

2.

3.4.

On a workbench, install (2) heater fittings with properly lubricated O-rings (See Lubricating O-rings, Page 18 and Photo 1, below). Install the evaporator front & rear brackets onto the evaporator, and secure them using (5) 1/4-20 x 1/2” serrated hex cap screws as shown in Photos 2 and 3, below.Install (2) 1/4-20 x 1 ½” studs onto the evaporator rear bracket as shown in Photo 4, below.Lay the evaporator sub case on the passenger side floorboard. Install the A/C & heater hoses on the evaporator as shown in Figure 1, Page 16, and A/C hose installation instructions on Page 18. NOTE: Wrap the #10 fitting connections with press tape (See Figure 1, Page 16).

Photo 1 Photo 2

Photo 3 Photo 4

(2) Heater Fittings

Evaporator Front Bracket 647066

Evaporator Rear Bracket 655002

Evaporator Rear Bracket 655002

1/4-20 x 1/2” Serrated Hex Cap Screw

(2) 1/4-20 x 1 ½” Studs

Evaporator Unit

1/4-20 x 1/2” Serrated Hex Cap Screw

16

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904474 REV A 05/22/19, PG 16 OF 28

Figure 2

Figure 1

Figure 2a

Press Tape

#6 A/C Hose

#10 A/C Hose

(2) 1/4-20 Nuts and

Flat Washers

HoseClamps

OEMBolt

Heater Hoses

Evaporator Installation (Cont.)

1.

2.

3.

Lift evaporator unit up under the dashboard. Secure loosely to the firewall from the engine compartment side using (2) 1/4-20 nuts and flat washers (See Figure 2, 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 screw, secure the evaporator front bracket between the dash bracket and cowl bracket (See Figure 2a, below).Verify that evaporator unit is level and square to the dash; then tighten all mounting bolts. NOTE: Replace the (2) 1/4-20 x 1 ½” studs with (2) 1/4-20 x 3/4” bolts and tighten.

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.

EvaporatorFront

Bracket647066

Kick PanelCover

NOTE: Coat bolt threads with silicone before installing nuts and washers.

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904474 REV A 05/22/19, PG 17 OF 28

Figure 1

Figure 1

1.2.

Install the louver housings under the dash as shown in Figure 1, below.Install louvers into the housings as shown in Figure 1, below.

Vehicles with Astro Vents1.2.

Install the center louver under the dash as shown in Figure 1, below.For astro vent hose adapter installation, refer to Page 9.

(6) #8 x 1/2”Pan Head Screws

(2) #8 x 1/2”Pan Head Screws

18

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904474 REV A 05/22/19, PG 18 OF 28

1”2 ½”

Figure 1

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.

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 2 ½” to the left. Drill a 5/8” hole through the firewall (See Figure 1, below).Install the drain hose to the outlet on the bottom of the evaporator unit, and route it through the firewall (See Figure 1, below).

A/C Hose Installation

1.

2.

3.

4.

Locate the #8 compressor A/C hose. Lubricate (2) #8 O-rings (See Lubricating O-rings, above) and connect the 135° fitting with service port to the #8 discharge port on the compressor. Then route the straight fitting to the #8 condenser hardline coming through the core support (See Figure 1, Page 19, and Figure 1, Page 20). Tighten each fitting connection as shown in Lubricating O-rings, above.Locate the #10 compressor A/C hose. Lubricate (2) #10 O-rings (See Lubricating O-rings, above) and connect the #10 135° fitting with service port to the #10 suction port on the compressor. Then route the 90° fitting to the #10 fitting on the evaporator (See Figure 1, Page 16, Figure 1, Page 19, and Figure 1, Page 20). Tighten each fitting connection as shown in Lubricating O-rings, above.Locate the #6 evaporator A/C hose. Lubricate (2) #6 O-rings (See Lubricating O-rings, above) and connect the straight fitting to the #6 hardline coming through the core support from the drier. Then route the 90° fitting to the #6 fitting on the evaporator (See Figure 1, Page 16, Figure 1, Page 29, and Figure 1, Page 20). Tighten each fitting connection as shown in Lubricating O-rings, above.Using a #10 Adel clamp and a 10-32 x 1/2” pan head screw with a nut, secure the #10 A/C hose to the alternator bracket as shown in Figure 1, Page 19.

Standard Hose Kit:

1. Refer to separate instructions included with modified hose kit.Modified Hose Kit:

EvaporatorCase

Drain Hose

1”

2 ½”

19

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904474 REV A 05/22/19, PG 19 OF 28

FRO

M E

VAPO

RATO

R

TO W

ATE

R PU

MP

FRO

M IN

TAKE

MA

NIF

OLD

Heater Hose & Heater Control Valve Installation

A/

C &

Hea

ter

Hos

e R

outi

ng

1.

2.

Route a piece of heater hose from the water pump to the top heater fitting of the heater core as shown in Figure 1, Page 16, and Figure 1, 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 1, Page 16, and Figure 1, below. NOTE: Install heater control valve in line with intake manifold (pressure side) heater hose. Secure using hose clamps as shown in Figure 1, below. Also note proper flow direction.

Fig

ure

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Hos

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A/C

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6178

#6

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20

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904474 REV A 05/22/19, PG 20 OF 28

2”

(4) S-clips

Glove BoxCap

626670

Cut Off 2” (Discard)

#6 A/C Hose

#10 A/C Hose

Top ofGloveBox

Figure 1Figure 2

Figure 3

Final Steps1.2.3.

4.5.6.7.

8.9.

10.

11.12.

Install duct hoses as shown in Figure 1, Page 21.Install the control panel assembly. Refer to the control panel instructions.Plug the wiring harnesses into the ECU module on the sub case as shown in Figure 1, Page 21. Wire according to the wiring diagrams on Pages 22 and 23.Modify the glove box as shown in Figure 2, below.Install (4) S-clips onto the glove box cap, and install it onto the glove box as shown in Figure 3, below.Reinstall all previously removed items (battery tray, battery, and inner fender).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 24.

(2) Heater Hoses

21

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904474 REV A 05/22/19, PG 21 OF 28

Control Panel & Duct Hose Routing

Figure 1

Back Sideof PC BoardAssembly

Control PanelHarness

From ECU232007-VUR

Driver Side Defrost Duct

2” x 18”

Driver Side Louver

2 ½” x 32”

Passenger Side Louver

2 ½” x 36”

Plug FromWiring Harness232600-VUA

Passenger Side Defrost Duct

2” x 12”Under Dash

Center Louver2” x 20”

22

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904474 REV A 05/22/19, PG 22 OF 28

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 E, 10/6/2017

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

23

www.vintageair.com

904474 REV A 05/22/19, PG 23 OF 28

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.

24

www.vintageair.com

904474 REV A 05/22/19, PG 24 OF 28

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

OFF

HOT COLD

DEFFLRA /C

HI

DASH

OFF

HOT COLD

DEFFLRA /C

HI

DASH

OFF

HOT COLD

DEFFLRA /C

HI

DASH

OFF

HOT COLD

DEFFLRA /C

HI

ww

w.v

inta

gea

ir.c

om

25 904474 REV A 05/22/19, PG 25 OF 28

Sym

pto

m

Con

dit

ion

Ch

ecks

A

ctio

ns

Not

es

Blo

wer

sta

ys o

n hi

gh s

peed

whe

n ig

nitio

n is

on.

1a.

No

othe

r fu

nctio

ns w

ork.

Che

ck f

or d

amag

ed p

ins

or

wires

in c

ontr

ol h

ead

plug

.Ve

rify

tha

t al

l pin

s ar

e in

sert

ed in

to p

lug.

Ens

ure

that

no

pins

are

ben

t or

dam

aged

in E

CU

.Che

ck f

or d

amag

ed g

roun

d w

ire

(whi

te)

in c

ontr

ol h

ead

harn

ess.

Verify

con

tinui

ty t

o ch

assi

s gr

ound

with

whi

te c

ontr

ol

head

wire

at v

ario

us p

oint

s.

Loss

of gr

ound

on

this

wire

rend

ers

cont

rol h

ead

inop

erab

le.

All

othe

r fu

nctio

ns w

ork.

Che

ck f

or d

amag

ed b

low

er

switc

h or

pot

entio

met

er a

nd

asso

ciat

ed w

irin

g.

Blo

wer

sta

ys o

n hi

gh s

peed

whe

n ig

nitio

n is

on

or o

ff.

Unp

lug

3-w

ire

BSC c

ontr

ol

conn

ecto

r fr

om E

CU

. If

blo

wer

sh

uts

off,

ECU

is e

ither

im

prop

erly

wired

or

dam

aged

.

Be

sure

the

sm

all,

20 G

A w

hite

gro

und

wire

is c

onne

cted

to

the

bat

tery

gro

und

post

. If

it is

, re

plac

e th

e EC

U.

Unp

lug

3-w

ire

BSC c

ontr

ol

conn

ecto

r fr

om E

CU

. If

blo

wer

st

ays

runn

ing,

BSC is

eith

er

impr

oper

ly w

ired

or

dam

aged

.

Che

ck t

o en

sure

tha

t no

BSC w

irin

g is

dam

aged

or

shor

ted

to v

ehic

le g

roun

d. T

he B

SC o

pera

tes

the

blow

er

by g

roun

d si

de p

ulse

wid

th m

odul

atio

n sw

itchi

ng.

The

posi

tive

wire

to t

he b

low

er w

ill a

lway

s be

hot

. If

the

“g

roun

d” s

ide

of t

he b

low

er is

sho

rted

to

chas

sis

grou

nd,

the

blow

er w

ill r

un o

n H

I.

Repl

ace

BSC (

This

will

req

uire

rem

oval

of ev

apor

ator

fr

om v

ehic

le).

No

othe

r pa

rt r

epla

cem

ents

sh

ould

be

nece

ssar

y.

Com

pres

sor

will

no

t tu

rn o

n (A

ll ot

her

func

tions

w

ork)

.

2.

Syst

em is

not

cha

rged

.Sy

stem

mus

t be

cha

rged

for

co

mpr

esso

r to

eng

age.

Cha

rge

syst

em o

r by

pass

pre

ssur

e sw

itch.

Dan

ger

: N

ever

byp

ass

safe

ty s

wit

ch w

ith

en

gin

e ru

nn

ing

. S

erio

us

inju

ry c

an r

esu

lt.

Syst

em is

cha

rged

.

1b

.

Trou

ble

shoo

tin

g G

uid

e

Che

ck f

or f

aulty

A/C

po

tent

iom

eter

or

asso

ciat

ed

wirin

g (N

ot a

pplic

able

to

3-po

t co

ntro

ls).

Che

ck f

or d

isco

nnec

ted

or

faul

ty t

herm

isto

r.

Che

ck c

ontin

uity

to

grou

nd o

n w

hite

con

trol

hea

d w

ire.

Che

ck f

or 5

V o

n re

d co

ntro

l hea

d w

ire.

Che

ck 2

-pin

con

nect

or a

t EC

U h

ousi

ng.

To c

heck

for

pro

per

pot

func

tion,

che

ck v

olta

ge a

t w

hite

/blu

e w

ire.

Vol

tage

sh

ould

be

betw

een

0V a

nd

5V,

and

will

var

y w

ith p

ot

leve

r po

sitio

n.

Dis

conn

ecte

d or

fau

lty

ther

mis

tor

will

cau

se

com

pres

sor

to b

e di

sabl

ed.

Red

wire

at A

/C p

ot s

houl

d ha

ve a

ppro

xim

atel

y 5V

w

ith ig

nitio

n on

. W

hite

w

ire

will

hav

e co

ntin

uity

to

chas

sis

grou

nd.

Whi

te/

Blu

e w

ire

shou

ld v

ary

betw

een

0V a

nd 5

V w

hen

leve

r is

mov

ed u

p or

dow

n.

3. Com

pres

sor

will

no

t tu

rn o

ff

(All

othe

r fu

nctio

ns

wor

k).

Che

ck f

or f

aulty

A/C

po

tent

iom

eter

or

asso

ciat

ed

wirin

g.

Che

ck f

or f

aulty

A/C

rel

ay.

Repa

ir o

r re

plac

e po

t/co

ntro

l wirin

g.

Repl

ace

rela

y.

See

blo

wer

sw

itch

chec

k pr

oced

ure.

ww

w.v

inta

gea

ir.c

om

26 904474 REV A 05/22/19, PG 26 OF 28

Sym

pto

m

Con

dit

ion

Ch

ecks

A

ctio

ns

Not

es

Syst

em w

ill n

ot

turn

on,

or

runs

in

term

itten

tly.

4.

Wor

ks w

hen

engi

ne is

not

runn

ing;

shu

ts o

ff w

hen

engi

ne is

sta

rted

(T

ypic

ally

ear

ly G

en I

V,

but

poss

ible

on

all

vers

ions

).

Noi

se in

terf

eren

ce f

rom

eith

er

igni

tion

or a

ltern

ator

.

Inst

all c

apac

itors

on

igni

tion

coil

and

alte

rnat

or.

Ensu

re

good

gro

und

at a

ll po

ints

. Re

loca

te c

oil a

nd a

ssoc

iate

d w

irin

g aw

ay f

rom

ECU

and

ECU

wirin

g. C

heck

for

bur

ned

or lo

ose

plug

wires

.

Verify

con

nect

ions

on

pow

er

lead

, ig

nitio

n le

ad,

and

both

whi

te g

roun

d w

ires

.

Verify

pro

per

met

er f

unct

ion

by c

heck

ing

the

cond

ition

of

a kn

own

good

bat

tery

.

Igni

tion

nois

e (r

adia

ted

orco

nduc

ted)

will

cau

se t

he

syst

em t

o sh

ut d

own

due

tohi

gh v

olta

ge s

pike

s. I

f th

isis

sus

pect

ed,

chec

k w

ith a

qu

ality

osc

illos

cope

. Spi

kes

grea

ter

than

16V

will

shu

t do

wn

the

ECU

. In

stal

l a

radi

o ca

paci

tor

at t

he

posi

tive

post

of th

e ig

nitio

nco

il (S

ee r

adio

cap

acito

r in

stal

latio

n bu

lletin

). A

fa

ulty

alte

rnat

or o

r w

orn

out

batt

ery

can

also

res

ult

in t

his

cond

ition

.

Will

not

tur

n on

und

er

any

cond

ition

s.Ve

rify

bat

tery

vol

tage

is

grea

ter

than

10

volts

and

less

than

16.

Loss

of m

ode

door

fu

nctio

n.

No

mod

e ch

ange

at

all.

Che

ck f

or d

amag

ed m

ode

switc

h or

pot

entio

met

er a

nd

asso

ciat

ed w

irin

g.

Part

ial f

unct

ion

of m

ode

door

s.

Typi

cally

cau

sed

by

evap

orat

or h

ousi

ng

inst

alle

d in

a b

ind

in t

he

vehi

cle.

Be

sure

all

mou

ntin

g lo

catio

ns li

ne u

p an

d do

n’t

have

to

be for

ced

into

pos

ition

.

Blo

wer

tur

ns o

n an

d of

f ra

pidl

y.

6.

Bat

tery

vol

tage

is a

t le

ast

12V.

Che

ck f

or a

t le

ast

12V a

t ci

rcui

t br

eake

r.En

sure

all

syst

em g

roun

ds a

nd p

ower

con

nect

ions

are

cl

ean

and

tight

.

Bat

tery

vol

tage

is le

ss

than

12V

.

5.

Trou

ble

shoo

tin

g G

uid

e (C

ont.

)

Che

ck f

or f

aulty

bat

tery

or

alte

rnat

or.

Cha

rge

batt

ery.

Syst

em s

huts

off b

low

er a

t 10

V. P

oor

conn

ectio

ns o

r w

eak

batt

ery

can

caus

e sh

utdo

wn

at u

p to

11V

.

7. Whe

n ig

nitio

n is

tu

rned

on,

blo

wer

m

omen

tarily

co

mes

on,

the

n sh

uts

off.

This

oc

curs

with

the

bl

ower

sw

itch

in

the

OFF

pos

ition

.

This

is a

n in

dica

tor

that

the

sy

stem

has

bee

n re

set.

Be

sure

the

red

pow

er w

ire

is o

nth

e ba

tter

y po

st,

and

not

on a

sw

itche

d so

urce

. Als

o, if

the

sy

stem

is p

ulle

d be

low

7V f

orev

en a

spl

it se

cond

, th

e sy

stem

will

res

et.

Run

red

pow

er w

ire

dire

ctly

to

batt

ery.

Che

ck f

or p

ositi

ve p

ower

at

heat

er v

alve

gre

en w

ire

and

blow

er r

ed w

ire.

Che

ck f

or g

roun

d on

con

trol

hea

d w

hite

w

ire.

Che

ck f

or o

bstr

ucte

d or

bi

ndin

g m

ode

door

s.Che

ck f

or d

amag

ed s

tepp

er

mot

or o

r w

irin

g.

Erra

tic fun

ctio

ns o

fbl

ower

, m

ode,

te

mp,

etc

.

Che

ck f

or d

amag

ed s

witc

h or

po

t an

d as

soci

ated

wirin

g.Re

pair o

r re

plac

e.

8.

Kick Panel Cut Out

Template

1968-72 Chevelle

without Facto

ry Air

Cut This Area

Cut AlongDotted Line

Cut AlongDotted Line

28

www.vintageair.com

904474 REV A 05/22/19, PG 28 OF 28

OFF

DASH

HOT

FLR

HI

DEF

COLD

A C

Packing List: Evaporator Kit (561081)

No. 1.2.

Qty.11

Part No.762169784171

DescriptionGen IV Evaporator Sub CaseAccessory Kit

NOTE: Images may not depict actual parts and quantities. Refer to packing list for actual parts and quantities.

1

2

Accessory Kit784171

Checked By:Packed By:

Date:

Gen IV Evaporator Sub Case762169