1966-67 chevelle - vintage air home - vintage air · 2017-10-16 · 2 901162 rev d 4/21/15, 1966-67...

1966-67 CHEVELLEwithout FACTORY AIR

561066

901162 REV D 4/21/15, 1966-67 CHEVELLE wo AC EVAP INSTR PG 1 OF 29

an ISO 9001: 2008 Registered Company

SS


PAGESTable of Contents

1. COVER 2. TABLE OF CONTENTS 3. PACKING LIST/PARTS DISCLAIMER 4. INFORMATION PAGE 5. WIRING NOTICE 6. ENGINE COMPARTMENT, CONDENSER ASSEMBLY, COMPRESSOR & BRACKET FIGURE 1 7. PASSENGER COMPARTMENT FIGURE 2 8. 66 CHEVELLE KICK PANEL MODIFICATION FIGURES 3 & 4 9. 66 CHEVELLE KICK PANEL MODIFICATION FIGURES 5, 6 & 6a10. DEFROST DUCT INSTALLATION & CENTER VENT ASSEMBLY INSTALLATION FIGURES 7 & 8 11. STANDARD DRIVER SIDE VENT TEMPLATE FOR VENT #49867-VCL FIGURE 912. STANDARD PASSENGER SIDE VENT TEMPLATE FOR VENT #49867-VCL FIGURE 1013. 66-67 CHEVELLE wo A/C CENTER VENT TEMPLATE FIGURE 1114. FRESH AIR COVER INSTALLATION & KICK PANEL FRESH AIR CAP INSTALLATION FIGURES 12, 13, 13a & 13b15. FIREWALL COVER INSTALLATION & EVAPORATOR INSTALLATION FIGURES 14 & 1516. BRACKET INSTALLATION CONT. FIGURE 1617. EVAPORATOR INSTALLATION CONT. FIGURES 17 & 1818. DRAIN HOSE INSTALLATION, LUBRICATING O-RINGS, A/C HOSE INSTALLATION, & MODIFIED A/C HOSE KIT FIGURES 19 & 2019. A/C & HEATER HOSE ROUTING 66-67 CHEVELLE FIGURE 2120. FINAL STEPS FIGURES 22 & 2321. CONTROL PANEL & DUCT HOSE ROUTING FIGURE 2422. WIRING DIAGRAM23. GEN IV WIRING CONNECTION INSTRUCTIONS24. OPERATION OF CONTROLS25. TROUBLESHOOTING INFORMATION26. TROUBLESHOOTING INFORMATION CONT.27. 66 CHEVELLE KICK PANEL MODIFICATION TEMPLATE28. 67 CHEVELLE KICK PANEL MODIFICATION TEMPLATE29. EVAPORATOR KIT PACKING LIST


** 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.

EVAPORATOR KITEVAPORATOR KIT PACKING LIST

No. QTY. PART No. DESCRIPTION

561066

1.2.

11

762169784161

1

ACCESSORY KIT784161

2

GEN IV 4-VENTwith 2” & 2 ½”

EVAPORATOR SUB CASE762169

GEN IV 4-VENT with 2” & 2 ½” EVAPORATOR SUB CASE 1966-67 CHEVELLE without A/C ACCESSORY KIT

NOTE: IMAGES MAY NOT DEPICT ACTUAL PARTS AND QUANTITIES.REFER TO PACKING LIST FOR ACTUAL PARTS AND QUANTITIES.


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.


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.

•

•

•


BATTERY, BATTERY TRAY (RETAIN). DRAIN RADIATOR, REMOVE RADIATOR (RETAIN).TO REMOVE THE BLOWER ASSEMBLY (UNDER HOOD) AND THE AIR DISTRIBUTION SYSTEM (UNDER DASH), THE FACTORY MANUAL INDICATES DOING THE FOLLOWING: REMOVE RIGHT INNER FENDER. OEM HEATER HOSES (DISCARD). SEE FIGURE 1.OEM HEATER WIRING (DISCARD). SEE FIGURE 1.

BEFORE STARTING THE INSTALLATION, CHECK THE FUNCTION OF THE VEHICLE (HORN, LIGHTS,ETC.) FOR PROPER OPERATION.

STUDY THE INSTRUCTIONS, ILLUSTRATIONS, & DIAGRAMS.

ENGINE COMPARTMENTREMOVE THE FOLLOWING:

FIGURE 1

CONDENSER ASSEMBLY & INSTALLATIONREFER TO SEPARATE INSTRUCTIONS INCLUDED WITH THE CONDENSER KIT TO INSTALL THE

HEATERHOSES

CONDENSER.BINARY SWITCH INSTALLATION (REFER TO CONDENSER INSTRUCTIONS).

REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH THE BRACKET KIT TO INSTALL THE COMPRESSOR BRACKET.

COMPRESSOR & BRACKETS

BATTERYTRAY

OEMBLOWER MOTOR

ASSEMBLY

INNERFENDER PANEL


PASSENGER COMPARTMENTREMOVE GLOVE BOX DOOR (RETAIN) AND GLOVE BOX (DISCARD).

REMOVE THE CABLES/WIRING FROM THE OEM HEATER ASSEMBLY (DISCARD).

REMOVE OEM DEFROST DUCT ASSEMBLY (DISCARD).

REMOVE CONTROL PANEL (RETAIN).

REMOVE RADIO (RETAIN).

PASSENGER SIDE KICK PANEL FRESH AIR CAP DOOR ASSEMBLY AS SHOWN IN FIGURE 3, PAGE 8, AND FIGURE 5, PAGE 9.

FIGURE 2

GLOVE BOX

GLOVE BOXDOOR

RADIO

CONTROLPANEL

OEMHEATER

ASSEMBLY

OEMDEFROST

DUCT ASSEMBLY


66 CHEVELLE KICK PANEL MODIFICATION

FIGURE 3

FIGURE 4

REMOVE KICK PANEL. REMOVE KICK PANEL FRESH AIR DOOR ASSEMBLY BY REMOVING (5) OEM SCREWS. DISCONNECT PULL CABLE ASSEMBLY FROM UNDER THE DASH (DISCARD). SEE FIGURE 3, BELOW.

CUT OUT KICK PANEL MODIFICATION TEMPLATE PROVIDED ON PAGE 27.ALIGN TEMPLATE ON BACK OF KICK PANEL AS SHOWN IN FIGURE 4, BELOW.CUT OUT GRILLE AS SHOWN IN FIGURE 4, BELOW.DRILL 3/16” HOLES IN KICK PANEL.

KICK PANEL CUT-OUT

TEMPLATE66-67 CHEVELLE

W/O AC

CUTOUT

TEMPLATE66

TOP

66

66

66

66

DRILL 3/16”HOLE

CUT THIS SECTION OUT

ALIGN WITHKICK PANEL

STUDS

ALIGN WITHWITH KICK PANEL

STUDS

BACK SIDE OF KICK PANEL

FRESH AIRDOOR ASSEMBLY

OEMSCREWS


67 CHEVELLE KICK PANEL MODIFICATION

FIGURE 5

FIGURE 6 FIGURE 6a

FRESH AIRDOOR ASSEMBLY.

TEMPLATE

31102-GUR1/2” PLASTIC

PLUG

REMOVE KICK PANEL GRILLE (DISCARD). REMOVE KICK PANEL BY REMOVING (5) OEM SCREWS FROM THEFRESH AIR DOOR ASSEMBLY. DISCONNECT PULL CABLE ASSEMBLY FROM THE KICK PANEL (DISCARD). SEEFIGURE 5, BELOW.

INSTALL 1/2” PLASTIC PLUG TO FILL THE HOLES LEFT FROM THE REMOVAL OF THE PULL CABLE ASSEMBLY.SEE FIGURE 6, BELOW. CUT OUT TEMPLATE PROVIDED ON PAGE 28.PLACE TEMPLATE ON KICK PANEL AND CUT OUT FRESH AIR DOOR ASSEMBLY AS SHOWN IN FIGURES 6 &6a.

PULL CABLEASSEMBLY

KICK PANELGRILLE

OEMSCREWS

KICK PANEL CUT-OUT

TEMPLATE

67 CHEVELLE

WO AC

CUTOUT

TEMPLATE

TOP

CUT THISSECTION

OUT


FIGURE 7

FIGURE 7a

DEFROST DUCT INSTALLATIONINSTALL DEFROST DUCTS UNDER DASH AND ALIGN WITH OEM OPENING. INSTALL THE DRIVER/PASSENGER SIDE DEFROST DUCT TO COWL USING A #10 x 1/2” SHEET METAL SCREW. SEE FIGURE7, BELOW. NOTE: 1966 CHEVELLE DRIVER SIDE DEFROST DUCT INSTALLS BEHIND THE STEERINGCOLUMN BRACKET, AND SECURES USING THE STEERING COLUMN OEM BOLT AS SHOWN INFIGURE 7a.

OEMDEFROST DUCT

OPENINGCOWL

1966 CHEVELLEDRIVER SIDE

SHOWN

STEERINGCOLUMN BRACKET

DEFROSTDUCT DEFROST

DUCT

#10 x 1/2” SHEET METAL

SCREW

FIGURE 8

FIGURE 8a

CENTER LOUVER

DRIVER SIDETEMPLATE

PASSENGER SIDETEMPLATE

2 ½” HOSEADAPTER

DRIVER AND PASSENGER SIDE LOUVER INSTALLATION

CENTER LOUVER INSTALLATION: REFER TO PAGE 13

CUT OUT TEMPLATE PROVIDED ON PAGE 11. PLACE THE DRIVER SIDE TEMPLATE ON THE DASH BYALIGNING THE LEFT SIDE OF THE TEMPLATE AGAINST THE EDGE OF THE DASH, THEN ALIGN THEBOTTOM OF THE TEMPLATE TO BOTTOM OF DASH AS SHOWN IN FIGURE 8.CUT OUT TEMPLATE PROVIDED ON PAGE 12. PLACE THE PASSENGER SIDE TEMPLATE ON THE DASH BYALIGNING THE RIGHT SIDE OF THE TEMPLATE AGAINST THE EDGE OF THE DASH, THEN ALIGN THEBOTTOM OF THE TEMPLATE TO BOTTOM OF DASH AS SHOWN IN FIGURE 8.ONCE TEMPLATE IS ALIGNED CORRECTLY, USE A CENTER PUNCH TO MARK THE HOLE ON THE DASH.REMOVE TEMPLATE. USE A 3” HOLE SAW TO CUT HOLE IN DASH. SEE FIGURE 8, BELOW.INSTALL LOUVERS IN DASH AS SHOWN IN FIGURE 8a, BELOW.

LOUVER BEZEL626665

LOUVER BRACKET642076

DASH

LOUVER490535

2 ⅞

”

2 ⅞

”


DRIVER SIDE LOUVER TEMPLATE

BOTTOM OF DASH

3”

HO

LE

FOLD HERE FOLD HERE

FIGURE 9

DRIVERSIDE

1966-67 CHEVELLEDRIVER SIDE

LOUVER TEMPLATE

PLUMBTHIS LINEWITH ALEVEL

(2) OEM BOLTS

CUT OUT


PASSENGER SIDE LOUVER TEMPLATE

FOLD HERE

GLOVE BOXDOOR OPENING

1966-67 CHEVELLEPASSENGER SIDE

LOUVER TEMPLATE

FOLD HERE

PLUMBTHIS LINEWITH ALEVEL

PASSENGERSIDE

3”

HO

LE

BOTTOM OF DASH

FIGURE 10

(2) OEM BOLTS

CUT OUT

2 1/16”

13 901162 REV C 8/27/14, 1966-67 CHEVELLE wo AC EVAP INSTR PG 13 OF 29

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FRESH AIR COVER INSTALLATION

FIGURE 13bFIGURE 13

KICK PANEL FRESH AIR CAP INSTALLATION

INSTALL (4) GROMMETS IN KICK PANEL FRESH AIR CAP. SEE FIGURE 13a, BELOW.ROUTE A/C AND HEATER HOSE THROUGH FRESH AIR CAP AND KICKPANEL FRESH AIR CAP AS SHOWN IN FIGURES 13 AND 13b, BELOW.APPLY A 1/4” BEAD OF SILICONE AROUND THE BACK SIDE OF KICK PANEL FRESH AIR CAP AS SHOWN IN FIGURE 13a, BELOW.SECURE KICK PANEL FRESH AIR CAP USING OEM SCREWS, AS SHOWN IN FIGURE 13b, BELOW. (5) OEM

SCREWS

SILICONE

BACK SIDE OF KICK PANEL

FRESH AIR CAP

66 CHEVELLE SHOWN

#10 A/CHOSE

#6 A/CHOSE(2) HEATER

HOSES

#10 A/C HOSE

#6 A/C HOSE(2) HEATER

HOSE

(4)GROMMETS33137-VUI

1/4-20 x 1 ½”BOLT w/ WASHER

SILICONE

BACK SIDEOF FRESH AIR

CAP

ENGINECOMPARTMENT

SIDE OFFIREWALL

FRESH AIRCAP

(4) GROMMETS33137-VUI

FIGURE 12

INSTALL (4) GROMMETS IN FRESH AIR CAP. SEE FIGURE 12, BELOW.APPLY A 1/4” BEAD OF SILICONE AROUND THE BACK SIDE OF THE FRESH AIR CAP AS SHOWN INFIGURE 12, BELOW.ATTACH FRESH AIR CAP TO FIREWALL USING A 1/4-20 x 1 ½" BOLT AND WASHER. SEE FIGURE 12,BELOW. NOTE: FRESH AIR CAP INSTALLS ON ENGINE SIDEOF FIREWALL.

FIGURE 13a


FIREWALL COVER INSTALLATIONAPPLY A 1/4” BEAD OF SILICONE AROUND THE BACK SIDE OF THE FIREWALL COVER AS SHOWN IN FIGURE 14, BELOW.

FROM INSIDE THE CAR, INSTALL FIREWALL COVER ONTO FIREWALL USING (4) 1/4-20 x 1” HEX BOLTS, FLAT WASHERS AND 1/4-20 NUTS WITH STAR WASHERS. SEE FIGURE 14, BELOW.

EVAPORATOR INSTALLATIONON A WORKBENCH, INSTALL (2) HEATER FITTINGS WITH PROPERLY LUBRICATED O-RINGS. SEE FIGURE 20 PAGE 18, AND FIGURE 16, PAGE 16.INSTALL (2) 1/4-20 x 1” HEX BOLTS AND (2) 1/4“ PUSH NUT BOLT RETAINERS ON EVAPORATOR REAR BRACKETAS SHOWN IN FIGURE 16, PAGE 16.INSTALL EVAPORATOR FRONT & REAR MOUNTING BRACKETS ON EVAPORATOR USING (6) 1/4-20 x 1/2” HEX BOLTS, AND TIGHTEN AS SHOWN IN FIGURE 15, BELOW & FIGURE 16,PAGE 16.LAY EVAPORATOR SUB CASE ON PASSENGER SIDEFLOORBOARD. INSTALL A/C & HEATER HOSEONTO EVAPORATOR AS SHOWN IN FIGURE 17, PAGE 17, AND HOSE INSTALLATION INSTRUCTIONS ON PAGE 19.NOTE: WRAP THE #10 FITTING CONNECTIONS WITH PRESS TAPE. SEE FIGURE 17, PAGE 17.

(2) 1/4-20 x 1/2”HEX BOLTS

FRONTEVAPORATOR

BRACKET643060

FIGURE 14

(4) 1/4-20 x 1”HEX BOLTS

FIREWALLCOVER648169

(4) 1/4” x 3/4”FLAT WASHERS

(4) 1/4-20 NUTS WITH

STAR WASHERS SILICONE

BACK SIDEOF FIREWALL

COVER

FIGURE 15


REAREVAPORATOR

BRACKET643059

(2) HEATERFITTINGS

(2) 1/4-20 x 1/2”HEX BOLTS

BRACKET INSTALLATION CONT.

FIGURE 16

(2) 1/4-20 x 1/2”HEX BOLTS

18290-VUB 1/4-20 x 1”HEX BOLT

189125-MUR1/4” PUSH NUTBOLT RETAINER

18290-VUB1/4-20 x 1”HEX BOLT

189125-MUR1/4” PUSH NUTBOLT RETAINER


(2) 1/4-20 NUTSw/ FLAT WASHERS

FIGURE 18

EVAPORATOR INSTALLATION CONT.

KICK PANELFRESH AIR

CAP

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 18.SECURE THE FRONT EVAPORATOR MOUNTING BRACKET TO COWL USING (2) #14 x 3/4” HEX SHEET METAL SCREWS. SEE FIGURE 18, BELOW.VERIFY THAT THE EVAPORATOR UNIT IS LEVEL AND SQUARE TO THE DASH. THEN TIGHTEN ALL MOUNTING BOLTS. NOTE: TIGHTEN THE BOLT ON FIREWALL FIRST. THEN TIGHTEN THE FRONT MOUNTING BRACKET.

FIGURE 17

HEATER HOSE

#6 A/C HOSE

PRESSTAPE

#10 A/C HOSE

(2) #14 x 3/4”SHEET METAL

SCREWS


LOCATE THE #8 COMPRESSOR A/C HOSE. LUBRICATE (2) #8 O-RINGS (SEE FIGURE 20, ABOVE) AND CONNECTTHE 90° FEMALE FITTING TO THE #8 DISCHARGE PORT ON THE COMPRESSOR. ROUTE THE 45° FEMALE FITTING w/ 134a SERVICE PORT TO THE #8 CONDENSER HARDLINE COMING THROUGH CORE SUPPORT. SEE FIGURE 21, PAGE 19. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN FIGURE 20, ABOVE.

LOCATE THE #10 COMPRESSOR A/C HOSE. LUBRICATE (2) #10 O-RINGS (SEE FIGURE 20, ABOVE) AND CONNECT THE #10 45° FEMALE FITTING w/134a SERVICE PORT TO THE #10 SUCTION PORT ON THE COMPRESSOR. ROUTE THE 90° FEMALE FITTING TO THE #10 EVAPORATOR. SEE FIGURE 17, PAGE 17, AND FIGURE 21, PAGE 19. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN FIGURE 20, ABOVE.

LOCATE THE #6 EVAPORATOR A/C HOSE. LUBRICATE (2) #6 O-RINGS (SEE FIGURE 20, ABOVE) AND CONNECT THE 90° FEMALE FITTING TO THE DRIER. ROUTE THE 90° FEMALE FITTING TO THE #6 EVAPORATOR. SEE FIGURE 17, PAGE 17, AND FIGURE 21, PAGE 19. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN FIGURE 20, ABOVE.

A/C HOSE INSTALLATIONSTANDARD HOSE KIT

LUBRICATING O-RINGS

FIGURE 20

LOCATE EVAPORATOR DRAIN ON BOTTOM OF EVAPORATOR CASE.IN LINE WITH DRAIN, LIGHTLY MAKE A MARKON THE FIREWALL. MEASURE 1” DOWN ANDDRILL A 5/8” HOLE THROUGH THE FIREWALL. SEE FIGURE 19, BELOW.INSTALL DRAIN HOSE TO BOTTOM OFEVAPORATOR UNIT AND ROUTE THROUGHFIREWALL. INSTALL 1/2” 90° DRAIN ELBOW ON DRAIN HOSE. SEE FIGURE 19.

DRAIN HOSE INSTALLATION

FIGURE 19

EVAPORATORCASE

#6 O-RING

O-RING

O-RING

FOR A PROPER SEAL OF FITTINGS:INSTALL SUPPLIED O-RINGS AS SHOWNAND LUBRICATE WITH SUPPLIED OIL.

TWIST WITHTHIS WRENCHHOLD WITH

THIS WRENCH

MALEINSERT

SUPPLIED OILFOR O-RINGS O-RING, INSTALLS

OVER MALE INSERTTO SWAGED LIP

FEMALENUT

#8 O-RING #10 O-RING

1”

REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH MODIFIED HOSE KIT. MODIFIED A/C HOSE KIT

DRAINHOSE

1”


CO

MPR

ESSO

RSA

FETY

SW

ITC

H(B

INA

RY T

YPE)

SCRE

W-O

N D

RIER

(REF

ER T

OC

ON

DEN

SER

INST

RUC

TIO

NS)

FIG

UR

E 21

HEATER HOSE & HEATER CONTROL VALVE INSTALLATION

ROUTE A PIECE OF HEATER HOSE FROM THE WATER PUMP TO THE TOP HEATER FITTING OF HEATER CORE AS SHOWN IN FIGURE 17, PAGE 17, AND FIGURE 21, BELOW. SECURE USING HOSE CLAMPS.

ROUTE A PIECE OF HEATER HOSE FROM THE INTAKE TO THE BOTTOM HEATER FITTING OF HEATER COREAS SHOWN IN FIGURE 17, PAGE 17, AND FIGURE 21, BELOW. NOTE: INSTALL HEATER CONTROL VALVE IN LINE WITH INTAKE MANIFOLD (PRESSURE SIDE) HEATER HOSE. SECURE USING HOSE CLAMPS AS SHOWN IN FIGURE 21, BELOW. NOTE PROPER FLOW DIRECTION.

#8

CO

ND

ENSE

R/C

OM

P H

ARD

LIN

E0

91

16

7

#6

HA

RDLI

NE

DRI

ER/C

ON

DEN

SER

09

11

66

FRO

M E

VAPO

RATO

R

TO W

ATER

PU

MP

A/C

& H

EATE

R H

OSE

RO

UTI

NG

1966-6

7 C

HEV

ELLE

SH

OW

NN

OTE

: V

INTA

GE

AIR

SYS

TEM

S R

EQU

IRE

(2)

5/8

” H

OSE

NIP

PLE

S (N

OT

SUP

PLI

ED).

NO

TE:

FLO

W D

IREC

TIO

N F

OLL

OW

SM

OLD

ED A

RR

OW

ON

VA

LVE.

#8 D

ISC

HA

RGE

HO

SE0960

67

#10 S

UC

TIO

NH

OSE

096068

(4)

TIE

WRA

PS

HEA

TER

HO

SE

#6 H

OSE

096066

FRO

MH

EATE

R C

ON

TRO

LVA

LVE

TO E

VA

PORA

TOR

HEA

TER

HO

SE(H

EATE

R C

ON

TRO

LVA

LVE/

INTA

KE)

FR

OM

INTA

KEM

AN

IFO

LD


INSTALL DUCT HOSES AS SHOWN IN FIGURE 24, PAGE 21.ROUTE A/C WIRES THROUGH 3/8” GROMMET AS SHOWN IN FIGURE 22(12 VOLT/GROUND/BINARY SWITCH/HEATER VALVE).INSTALL CONTROL PANEL ASSEMBLY.PLUG THE WIRING HARNESSES INTO THE ECU MODULE ON THE SUB CASE AS SHOWN IN FIGURE 24, PAGE 21 (WIRE ACCORDING TO WIRING DIAGRAMS ON PAGES 22 AND 23).INSTALL NEW GLOVE BOX USING (4) #8 x 1/2” PH PAN HEAD SCREWS. SEE FIGURE 23. REINSTALL ALL PREVIOUSLY REMOVED ITEMS (BATTERY TRAY, BATTERY & INNER FENDER).FILL RADIATOR WITH AT LEAST A 50/50 MIXTURE OF APPROVED ANTIFREEZE AND DISTILLED WATER. IT IS THEOWNER'S RESPONSIBILITY TO KEEP THE FREEZE PROTECTION AT THE PROPER LEVEL FOR THE CLIMATE INWHICH THE VEHICLE IS OPERATED. FAILURE TO FOLLOW ANTIFREEZE RECOMMENDATIONS WILL CAUSEHEATER 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 CERTIFIED AUTOMOTIVE AIRCONDITIONING TECHNICIAN. EVACUATE THE SYSTEM FOR A MINIMUM OF 45 MINUTES PRIOR TO CHARGING, AND LEAK CHECK PRIORTO SERVICING. CHARGE THE SYSTEM TO THE CAPACITIES STATED ON THE INFORMATION PAGE (PAGE 4) OF THISINSTRUCTION MANUAL. SEE OPERATION OF CONTROLS PROCEDURES, PAGE 24.

FINAL STEPS

FIGURE 22

FIGURE 23

GROMMET33144-VUI

(4) #8 x 1/2”PH PAN HEAD

SCREWS

GLOVE BOX625666


CONTROL PANEL & DUCT HOSE ROUTING

CONTROL PANELHARNESS

FROM ECU232002-VUA

PLUGFROM

WIRINGHARNESS

232001-VUR

DRIVER SIDE LOUVER

2 ½” x 36”

PASS. SIDE LOUVER

2 ½” x 48”

DEFROST DUCTDR. SIDE2” x 30”

DEFROST DUCTPASS. SIDE2” x 12”

FIGURE 24

CENTER LOUVER2” x 15”


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


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.


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. NOTE: For proper control panel function, refer to control panel instructions for calibration procedure.

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

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).

OFF

AIR FAN

TEMPERATURE

DEFROSTER DE-ICE

ON

HOT

OFF

AIR FAN

TEMPERATURE

DEFROSTER DE-ICE

ON

HOT

OFF

AIR FAN

TEMPERATURE

DEFROSTER DE-ICE

ON

HOT

OFF

AIR FAN

TEMPERATURE

DEFROSTER DE-ICE

ON

HOT


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

.


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.

27

CUT ALONGDOTTED LINE

66 CHEVELLE KICK PANELMODIFICATION TEMPLATE


CUT THIS AREA

28



CUT THIS AREA

67 CHEVELLE KICK PANELMODIFICATION TEMPLATE


** 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.

EVAPORATOR KITEVAPORATOR KIT PACKING LIST

No. QTY. PART No. DESCRIPTION

561066

1.2.

11

762169784161

1

ACCESSORY KIT784161

2

GEN IV 4-VENTwith 2” & 2 ½”

EVAPORATOR SUB CASE762169

GEN IV 4-VENT with 2” & 2 ½” EVAPORATOR SUB CASE 1966-67 CHEVELLE without A/C ACCESSORY KIT

NOTE: IMAGES MAY NOT DEPICT ACTUAL PARTS AND QUANTITIES.REFER TO PACKING LIST FOR ACTUAL PARTS AND QUANTITIES.

1966-67 chevelle - vintage air home - vintage air · 2017-10-16 · 2 901162 rev d 4/21/15, 1966-67...

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