1967-72 chevrolet pickup - vintage air home · 1967-72 chevrolet pickup without factory air with...

1967-72 CHEVROLET PICKUP without FACTORY AIR

with FACTORY CONTROLS751171

901150 REV C 7/30/14, INST 67-72 CHEV P-UP wo AC w/ FACTORY AIR CONTROLS EVAP KIT PG 1 OF 24

an ISO 9001:2008 Registered Company


PAGES

Table of Contents

1. COVER 2. TABLE OF CONTENTS 3. PACKING LIST/PARTS DISCLAIMER 4. INFORMATION PAGE 5. WIRING NOTICE 6. ENGINE COMPARTMENT FIGURE 1 7. CONDENSER ASSEMBLY, COMPRESSOR & BRACKET, PASSENGER COMPARTMENT FIGURE 2 8. DEFROST DUCT AND LOUVER INSTALLATION FIGURES 3, 3a & 3b 9. FRESH AIR CAP AND FIREWALL COVER INSTALLATION/BRACKET & EVAPORATOR HARDLINE INSTALLATION FIGURES 4 & 510. BRACKET & EVAPORATOR HARDLINE INSTALLATION CONT. FIGURE 611. EVAPORATOR INSTALLATION FIGURES 7 & 7a12. DRAIN HOSE INSTALLATION, LUBRICATING O-RINGS, A/C HOSE INSTALLATION & MODIFIED A/C HOSE KIT FIGURES 8 & 913. HEATER HOSE & HEATER CONTROL VALVE INSTALLATION FIGURE 1014. A/C & HEATER HOSE ROUTING FIGURE 1115. FINAL STEPS FIGURES 12 & 12a16. CONTROL PANEL & DUCT HOSE ROUTING FIGURE 1317. WIRING DIAGRAM18. GEN IV WIRING CONNECTION INSTRUCTIONS19. OPERATION OF CONTROLS20. TROUBLESHOOTING INFORMATION21. TROUBLESHOOTING INFORMATION CONT.22. DRIVER/PASSENGER SIDE LOUVER TEMPLATE23. CENTER LOUVER TEMPLATE24. 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 KIT751171

1.2.

11

744005791171

1

ACCESSORY KIT791171

2

GEN IV 3-VENTEVAP SUB CASE

w/ 204 ECU744005

GEN IV 3-VENT EVAP. SUB CASE w/204 ECU ACCESSORY KIT 1967-72 CHEVROLET PICKUP wo A/Cw/ FACTORY AIR CONTROLS

No. QTY. PART No. DESCRIPTION

EVAPORATOR KIT PACKING LIST

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

COLD HOT

DASH

TEMP

MODE

FANFLOOR DEF

OFF LO HI


Use of Any Other Refrigerants Will Void All Warranties of the Air Conditioning System and Components. Use of the Proper Type and

Amount of Refrigerant Is Critical to Proper System Operation. VintageAir Recommends Our Systems Be Charged By Weight With a Quality

Charging Station or Scale.

Service Info:

Safety Switches:

Important Notice—Please Read

Attention: The following system components are capped: Compressor, evaporator, condenser & drier. Caps may be under pressure with dry nitrogen. Be careful removing caps. Do not remove caps prior to installation. Removing caps prior to installation will cause components to collect moisture and lead to premature failure and reduced performance.

Evacuate the system for 35-45 minutes with system components (Drier, compressor, evaporator and condenser) 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.

For Maximum System Performance, Vintage Air Recommends the Following:

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.

Vintage Air Systems Are Designed to Operate With R134a Refrigerant Only! Use of Any Other Refrigerants Is a Fire Hazard and Could Damage Either Your Air Conditioning System or Your Vehicle.

Refrigerant Capacity for Vintage Air Systems:(For other systems, consult manufacturer’s guidelines)

R134a SystemCharge with 1.8 lbs. (1 lb., 12 oz.) of refrigerant.

Lubricant Capacities: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).

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.

Heater Hose (Not Included With This Kit):

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.

Bolts Passing Through Cowl and/or Firewall:


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.

•

•

•


DISCONNECT BATTERY.DRAIN RADIATOR, REMOVE RADIATOR (RETAIN). HEATER BLOWER ASSEMBLY AND OEM HEATER HOSES (DISCARD).NOTE: TO REMOVE THE OEM HEATER BLOWER ASSEMBLY (UNDER HOOD) AND THE AIR DISTRIBUTION SYSTEM (UNDER DASH), THE FACTORY MANUAL RECOMMENDS THAT YOU REMOVETHE RIGHT INNER FENDER FOR ACCESSIBLITY.

ENGINE COMPARTMENTREMOVE THE FOLLOWING:

FIGURE 1

BEFORE STARTING THE INSTALLATION, CHECK THE FUNCTIONOF THE VEHICLE (HORN, LIGHTS,ETC.) FOR PROPER OPERATIONS.

STUDY THE INSTRUCTIONS, ILLUSTRATIONS, & DIAGRAMS.

OEM HEATER BLOWER ASSEMBLY


REMOVE GLOVE BOX DOOR (RETAIN) AND GLOVE BOX (DISCARD).DISCONNECT ALL WIRES AND CABLES FROM CONTROL PANEL AND RADIO. ALL HOSE AND DUCTING FROM DEFROST DUCTS (SEE FIGURE 2, BELOW).OEM HEATER ASSEMBLY.

PASSENGER COMPARTMENT

CONDENSER ASSEMBLY & INSTALLATIONREFER TO SEPARATE INSTRUCTIONS INCLUDED WITH THE CONDENSER KIT TO INSTALL THE CONDENSER.BINARY SWITCH INSTALLATION (REFER TO CONDENSER INSTRUCTIONS).

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

COMPRESSOR & BRACKETS

REMOVE THE FOLLOWING:

FIGURE 2

OEM HEATER ASSEMBLY& RELATED DUCTING

OEM DEFROST DUCT ASM

CONTROL PANEL

RADIO

GLOVE BOXDOOR


DEFROST DUCT AND LOUVER INSTALLATIONINSTALL S-CLIPS ON DEFROST DUCT HOSE ADAPTERS AND ATTACH TO OEM DEFROSTER DUCTS AS SHOWN IN FIGURE 3, BELOW.INSTALL CENTER LOUVER IN DASH AS SHOWN IN FIGURE 3b, BELOW. USE TEMPLATE PROVIDED ON PAGE 23. INSTALL DRIVER/PASSENGER SIDE LOUVER IN DASH AS SHOWN IN FIGURE 3a, BELOW. USE TEMPLATE PROVIDED ON PAGE 22.

HOSE ADAPTER

BALL LOUVER

49053-VUL

DASH

PASSENGER SIDEOVAL DEFROST

ADAPTER49167-VCI

(2) S-CLIPS

(2) S-CLIPS

DRIVER SIDEROUND DEFROST

ADAPTER49168-VCI

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

(2) 1/4” FLAT WASHERS

DASH

OEM DEFROST DUCTS

FIGURE 3

FIGURE 3b

FIGURE 3a


BRACKET & EVAPORATOR HARDLINE INSTALLATIONON A WORK BENCH INSTALL EVAPORATOR REAR BRACKET USING (4) 1/4-20 x 1/2” HEX BOLTS.INSTALL HARDLINES WITH PROPERLY LUBRICATED O-RINGS. (SEE FIGURE 9, PAGE 12, AND FIGURE 6, PAGE 10.) NOTE: WRAP THE #10 FITTING CONNECTIONS WITH PRESS TAPE. SEE FIGURE 6, PAGE 10.INSTALL EVAPORATOR FRONT BRACKET ON EVAPORATOR USING (2) 1/4-20 x 1/2” HEX BOLTS AND TIGHTEN AS SHOWN IN FIGURE 5.

(2) 1/4-20 x 1/2”HEX BOLTS

FRONTEVAPORATOR

BRACKET644080

FIGURE 5

FIGURE 4

APPLY A 1/4” BEAD OF SILICONE AROUND THE BACK SIDE OF THE FRESH AIR CAP AS SHOWN IN FIGURE 4, BELOW.ATTACH FRESH AIR CAP TO FIREWALL USING A 1/4-20 x 1” BOLT AND WASHER, SEE FIGURE BELOW.APPLY A 1/4” BEAD OF SILICONE AROUND THE BACK SIDE OF THE FIREWALL COVER AS SHOWN BELOW.INSTALL FIREWALL COVER TO FIREWALL USING (2) 1/4-20 x 1” HEX BOLTS, (2) FLAT WASHERS AND 1/4” NUTS w/ STAR WASHERS IN THE OEM HOLES AS SHOWN BELOW.USE FIREWALL COVER AS TEMPLATE TO DRILL (6) 3/16” HOLES IN FIREWALL, AND THEN SECURE USING #14 x 3/4” SHEET METAL SCREWS AS SHOWN BELOW.USING FIREWALL COVER AS TEMPLATE, DRILL (2) 9/32” HOLES IN FIREWALL AS SHOWN BELOW.INSTALL GROMMETS AS SHOWN BELOW.

FRESH AIR CAP AND FIREWALL COVER INSTALLATION

SILICONE

BACK SIDEOF FRESH AIR

CAP

BACK SIDEOF FIREWALL

COVER648218

1/4-20 x 1”BOLT

SILICONE

1/4” FLATWASHER 1/4-20 x 1”

BOLT

1/4-20 x 1”BOLT

DRILL9/32” HOLE

DRILL9/32” HOLE

1/4” FLAT WASHER

1/4” NUT w/ STAR WASHER


OEM HOLE

(6) #14 x 3/4”SHEET METAL

SCREWS

LARGE GROMMET33137-VUI

GROMMET33135-VUI

3/8” GROMMET33144-VUI

1/4” FLAT WASHERFRESH AIR

CAP

OEM HOLE


REAREVAPORATORBRACKET ASM

644073

BRACKET & EVAPORATOR HARDLINE INSTALLATION CONT.

FIGURE 6

(2) 1/4-20 x 1/2”HEX BOLTS

(2) 1/4-20 x 1/2”HEX BOLTS

#6 LIQUID LINE095002

TWIST WITHTHIS

WRENCHLUBRICATE O-RING

(SEE FIGURE 9,PAGE 12.)

HOLD WITH THIS WRENCH

HEATER LINE(EVAP TO WATER PUMP)

095004

ECU MODULE

#10 O-RING33859-VUF

NOTE: AFTER INSTALLING#10 SUCTION LINE

WRAP ALL EXPOSED METAL(FITTINGS & TUBE)WITH SUPPLIED

PRESS TAPE.

#10 O-RING(33859-VUF)

#10 SUCTIONLINE

095003

#6 LIQUID LINE095002

PRESS TAPE

HEATER LINE(EVAP TO INTAKE)

095005

#6 O-RING

33857-VUF


INNER COWL

DRILL (2)3/16” HOLES

(2) #14 x 3/4”SHEET METAL

SCREWS

1/4-20 x 1”HEX BOLT

1/4-20 x 1”HEX BOLT

FLAT WASHER

1/4”FLAT

WASHER


VIEW FROMPASSENGER SIDEINSIDE OF CAB

FIGURE 7

FIGURE 7a

EVAPORATOR INSTALLATION

LIFT EVAPORATOR UNIT UP UNDER THE DASHBOARD. SECURE LOOSELY TO THE FIREWALL USING (2) 1/4-20 x 1” HEX BOLTS, (2) FLAT WASHERS AND 1/4” NUTS w/ STAR WASHERS. SEE FIGURE 7.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 AROUNDTHE DRAIN, BLOCK THE UNIT UP, THEN DRILL FOR FRONT BRACKET SCREWS.SECURE THE FRONT EVAPORATOR MOUNTING BRACKET TO COWL USING (2) #14 x 3/4” HEX SHEET METAL SCREWS. SEE FIGURE 7a, BELOW.VERIFY THAT EVAPORATOR UNIT IS LEVEL AND SQUARE TO THE DASH, THEN TIGHTEN ALL MOUNTING BOLTS. NOTE: TIGHTEN THE BOLT ON FIREWALL FIRST, THEN THE FRONT MOUNTING BRACKET.


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. INSTALL DRAIN HOSE TO BOTTOM OFEVAPORATOR UNIT AND ROUTE THROUGHFIREWALL. INSTALL 1/2” 90° DRAIN ELBOW ON DRAIN HOSE.

DRAIN HOSE INSTALLATION

FIGURE 8EVAPORATORCASE1”

LOCATE THE #8 COMPRESSOR A/C HOSE. LUBRICATE (2) #8 O-RINGS (SEE FIGURE 9, ABOVE) AND CONNECTTHE 135° FEMALE FITTING w/134a SERVICE PORT TO THE #8 DISCHARGE PORT ON THE COMPRESSOR. ROUTE THE STRAIGHT FEMALE FITTING TO THE #8 CONDENSER HARDLINE COMING THROUGH CORE SUPPORT. SEE FIGURE 11, PAGE 14. TIGHTEN EACH FITTING CONNECTION AS SHOWN.

LOCATE THE #10 COMPRESSOR A/C HOSE. LUBRICATE (2) #10 O-RINGS (SEE FIGURE 9, ABOVE) AND CONNECT THE #10 135° 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 10, PAGE 13, AND FIGURE 11, PAGE 14. TIGHTEN EACH FITTING CONNECTION AS SHOWN. LOCATE THE #6 EVAPORATOR A/C HOSE. LUBRICATE (2) #6 O-RINGS (SEE FIGURE 9, ABOVE) AND CONNECT THE STRAIGHT FEMALE FITTING TO THE #6 CONDENSER HARDLINE COMING THROUGH CORE SUPPORT. ROUTE THE 90° FEMALE FITTING TO THE #6 EVAPORATOR. SEE FIGURE 10, PAGE 13, AND FIGURE 11, PAGE 14. TIGHTEN EACH FITTING CONNECTION AS SHOWN.

A/C HOSE INSTALLATIONSTANDARD HOSE KIT

LUBRICATING O-RINGS

FIGURE 9

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

DRAINHOSE

FEMALENUT

TWIST WITHTHIS WRENCH

HOLD WITHTHIS WRENCH

SUPPLIED OILFOR O-RINGS O-RING, INSTALLS

OVER MALE INSERTTO SWAGED LIP

MALEINSERTO-RING

#6 O-RING

#8 O-RING #10 O-RING

O-RING

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

1”


ROUTE HEATER HOSE FROM WATER PUMP TO THE HEATER LINE COMING THROUGH THE FIREWALL AS SHOWN IN FIGURE 10, BELOW. SECURE USING HOSE CLAMPS. NOTE: A SMALL AMOUNT OF SILICONESPRAY WILL EASE HEATER HOSE INSTALLATION.

ROUTE HEATER HOSE FROM THE INTAKE TO THE HEATER LINE COMING THROUGH THE FIREWALL AS SHOWN BELOW. NOTE: INSTALL HEATER CONTROL VALVE IN LINE WITH INTAKE MANIFOLD (PRESSURE SIDE)HEATER HOSE. SECURE USING HOSE CLAMPS AS SHOWN. NOTE PROPER FLOW DIRECTION.

HOSE SHOULD PROTRUDE THROUGH THE FIREWALL COVER SLIGHTLY TO CLOSE THE GAP BETWEEN THE ALUMINUM LINE AND THE FIREWALL COVER. SEAL ANY REMAINING GAP WITH RTV SILICONE.

#10 SUCTIONLINE

FIGURE 10

O-RINGS

HEATERHOSE NOTE: FLOW DIRECTION FOLLOWS

MOLDED ARROW ON VALVE.

HEATER HOSE & HEATER CONTROL VALVE INSTALLATION

LIQUIDLINE

FROM HTR CNTRL VLVTO EVAPORATOR

FROM EVAPORATORTO WATER PUMP

FROM INTAKEMANIFOLD


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35056-L

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ATER

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FRO

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096003

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SM

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VA

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INSTALL DUCT HOSES AS SHOWN IN FIGURE 13, PAGE 16.ROUTE A/C WIRES THROUGH 3/8” GROMMET AS SHOWN IN FIGURE 12(12 VOLT/GROUND/BINARY SWITCH/HEATER VALVE).INSTALL CONTROL PANEL ASSEMBLY.PLUG THE WIRING HARNESS IN THE ECU MODULE ON SUB CASE AS SHOWN IN FIGURE 13, PAGE 16(WIRE ACCORDING TO WIRING DIAGRAM ON PAGE 17 AND 18).INSTALL NEW GLOVE BOX USING OEM SCREWS (SEE FIGURE 12a). INSTALL GLOVE BOX DOOR.REINSTALL ALL PREVIOUSLY REMOVED ITEMS, 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 19.

FINAL STEPS

FIGURE 12a

FIGURE 12

GLOVE BOX496067

GROMMET33144-VUI

WIRING HARNESS(12 VOLT/GROUNDS/BINARY SWITCH)

WIRING HARNESS(HEATER CONTROL VALVE)


CONTROL PANEL & DUCT HOSE ROUTING

FIGURE 13

PLUGFROM

CONTROLWIRING

HARNESS232002-VUA

PLUGFROM

WIRINGHARNESS

232001-VURPASSENGER SIDE

LOUVER2 ½” x 36”

DRIVER SIDELOUVER

2 ½” x 48”

CENTERLOUVER

2 ½” x 18”

PASS. SIDEDEF. DUCT2” x 12”

DRIVER SIDEDEF DUCT2” x 24”


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.


BLOWER SPEEDADJUST TO DESIRED

SPEED

TEMPERATURE LEVERSLIDE THE TEMPERATURE LEVER ALL THE WAY RIGHT

TO THE HOT POSITION.(SLIDE LEVER LEFT OR RIGHT TO DESIRED TEMPERATURE)

SLIDE THE LEVER TOTHE CENTER POSITION

MODE LEVER

BLOWER SPEEDADJUST TO DESIRED

SPEED

SLIDE THE LEVER TO THE LEFT POSITION

MODE LEVER

TEMPERATURE LEVERADJUST TO DESIRED

SPEED

BLOWER SPEED

SLIDE THE LEVER TOTHE RIGHT POSITION

MODE LEVER

DEFROST/DE-FOG MODEHEAT MODE

A/C MODE

MODELEVER

NOT USED

OPERATION OF CONTROLSNOTE: CONTROLS MUST BE CALIBRATED FOR PROPER OPERATION. SEE CALIBRATION INSTRUCTIONSINCLUDED WITH CONTROLS KIT FOR CALIBRATION PROCEDURE.

THE TEMPERATURE LEVER TOGGLES BETWEEN A/C AND HEAT MODES. FOR A/C MODE SLIDE THE TEMPERATURE LEVER ALL THE WAY LEFT TO ENGAGE THE COMPRESSOR, THEN MOVE THE LEVER TO SELECT THE DESIRED TEMPERATURE. FOR HEAT MODE SLIDE THE LEVER RIGHT TO DISENGAGE THE COMPRESSOR, THEN MOVE THE LEVER TO SELECT DESIRED TEMPERATURE.

NOTE: EACH TIME THE SYSTEM TOGGLES BETWEEN MODES, THE BLOWER WILL MOMENTARILY CHANGE SPEEDS.

ALL SWITCHES ARE VARIABLE BETWEEN POSITIONS, SYSTEM WILL PERFORM A BLEND BETWEEN THE FUNCTIONS.

ADJUST LEVER TODESIRED TEMPERATURE.

(COMPRESSOR IS AUTOMATICALLY

ENGAGED)

TEMPERATURE LEVERIN A/C MODE SLIDE THE TEMPERATURE LEVER ALL

THE WAY TO THE LEFT TO ENGAGE COMPRESSOR.(SLIDE LEVER LEFT OR RIGHT

TO ADJUST DESIRED TEMPERATURE)

COLD HOT

DASH

TEMP

MODE

FANFLOOR DEF

OFF LO HI

BLOWERSPEED

TEMPERATURELEVER

COLD HOT

DASH

TEMP

MODE

FANFLOOR DEF

OFF LO HI

COLD HOT

DASH

TEMP

MODE

FANFLOOR DEF

OFF LO HI


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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.


TEMPLATE FOR DRIVER SIDE

TEMPLATE FOR PASSENGER SIDE

END OF DASHDRIVER SIDE

DRILL2 ½”

DIAMETERHOLE

DRILL2 ½”

DIAMETERHOLE

BOTTOM EDGEOF DASH FACE

BOTTOM EDGEOF DASH FACE

END OF DASHPASSENGER SIDE

DRIVER/PASSENGER SIDE LOUVER TEMPLATE


5 ½”

1 �¼” Center Louver Dimensions

Top of Radio Opening

1 1/16”

CENTER LOUVER DIMENSIONS


1

ACCESSORY KIT791171

GEN IV 3-VENTEVAP SUB CASE

w/ 204 ECU744005

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

CHECK BY:PACKED BY:

DATE:

EVAPORATOR KIT751171

1.2.

11

744005791171

GEN IV 3-VENT EVAP. SUB CASE w/ 204 ECUACCESSORY KIT 1967-72 CHEVROLET PICKUP wo A/Cw/ FACTORY AIR CONTROLS

No. QTY. PART No. DESCRIPTION

EVAPORATOR KIT PACKING LIST

2

COLD HOT

DASH

TEMP

MODE

FANFLOOR DEF

OFF LO HI

1967-72 chevrolet pickup - vintage air home · 1967-72 chevrolet pickup without factory air with...

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