an ISO 9001:2008 Registered Company

1968-69 Chevrolet Chevelle with Factory AirEvaporator Kit

(564471)

18865 Goll St. San Antonio, TX 78266 Phone: 210-654-7171

Fax: 210-654-3113www.vintageair.com

904471 REV C 04/22/15, PG 1 OF 25

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904471 REV C 04/22/15, PG 2 OF 25

Thank you for purchasing this evaporator kit from Vintage Air. When installing these components as part of a complete SureFit™ system, Vintage Air recommends working from front to back on the vehicle, installing the condenser kit, hose kit, and compressor first, followed by the wiring, evaporator, and finally the control panel.

Cover..................................................................................................................................Table of Contents.................................................................................................................Packing List/Parts Disclaimer..................................................................................................Information Page..................................................................................................................Wiring Notice.......................................................................................................................Engine Compartment Disassembly..........................................................................................Condenser Assembly and Installation, Compressor and Brackets, Pulleys,Passenger Compartment Disassembly..................................................................................... Defrost Duct Installation, Hose Adapter Installation..................................................................Fresh Air Cap Installation, Kick Panel Fresh Air Cap Installation.................................................. Firewall Cover Installation, Evaporator Installation.................................................................. Evaporator Installation (Cont.).............................................................................................Evaporator Installation (Final).............................................................................................. Center Louver Installation................................................................................................... Drain Hose Installation, Lubricating O-rings, A/C Hose Installation............................................ Heater Hose & Heater Control Valve Installation, A/C & Heater Hose Routing 1968 Chevelle......... Heater Hose & Heater Control Valve Installation, A/C & Heater Hose Routing 1969 Chevelle......... Final Steps........................................................................................................................ Control Panel & Duct Hose Routing........................................................................................ Wiring Diagram..................................................................................................................Gen IV Wiring Connection Instruction...................................................................................Operation of Controls..........................................................................................................Troubleshooting Guide.........................................................................................................Troubleshooting Guide (Cont.)..............................................................................................Evaporator Rear Bracket Template........................................................................................Packing List.......................................................................................................................

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Table of Contents

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904471 REV C 04/22/15, PG 3 OF 25

OFF

DASH

HOT

FLR

HI

DEF

COLD

AC

Packing List: Evaporator Kit (564471)

No. 1.2.

Qty.11

Part No.762169784166

DescriptionGen IV Evaporator Sub Case, 4-Vent with 2” & 2 ½”Accessory Kit, 1968-69 Chevrolet Chevelle with Factory Air

** Before beginning installation, open all packages and check contents of shipment. Please report any shortages directly to Vintage Air within 15 days. After 15 days, Vintage Air will not be responsible for missing or damaged items.

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

1

2

Gen IV Evaporator Sub Case 4-Vent

w/ 2” & 2 ½”762169

Accessory Kit784166

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904471 REV C 04/22/15, PG 4 OF 25

Important Notice—Please ReadFor Maximum System Performance, Vintage Air Recommends the Following:

New Vintage Air-supplied Sanden Compressor: No additional oil needed (Compressor is shipped with proper oil charge).All Other Compressors: Consult manufacturer (Some compressors are shipped dry and will need oil added).

NOTE: Vintage Air systems are designed to operate with R134a refrigerant only. Use of any other refrigerant could damage your A/C system and/or vehicle, and possibly cause a fire, in addition to potentially voiding the warranties of the A/C system and its components.

Refrigerant Capacities:Vintage Air System: 1.8 lbs. (1 lb., 12 oz.) of R134a, charged by weight with a quality charging station or scale. NOTE: Use of the proper type and amount of refrigerant is critical to system operation and performance.Other Systems: Consult manufacturer’s guidelines.

Lubricant Capacities:

Safety Switches

Service Info:Protect Your Investment: Prior to assembly, it is critical that the compressor, evaporator, A/C hoses and fittings, hardlines, condenser and receiver/drier remained capped. Removing caps prior to assembly will allow moisture, insects and debris into the components, possibly leading to reduced performance and/or premature failure of your A/C system. This is especially important with the receiver/drier. Additionally, when caps are removed for assembly, BE CAREFUL! Some components are shipped under pressure with dry nitrogen.Evacuate the System for 35-45 Minutes: Ensure that system components (Drier, compressor, evaporator and condenser) are at a temperature of at least 85° F. On a cool day, the components can be heated with a heat gun or by running the engine with the heater on before evacuating. Leak check and charge to specifications.

Your Vintage Air system is equipped with a binary pressure safety switch. A binary switch disengages the compressor clutch in cases of extreme low pressure conditions (Refrigerant Loss) or excessively high head pressure (406 PSI) to prevent compressor damage or hose rupture. A trinary switch combines Hi/Lo pressure protection with an electric fan operation signal at 254 PSI, and should be substituted for use with electric fans. Compressor safety switches are extremely important since an A/C system relies on refrigerant to circulate lubricant.

Bolts Passing Through Cowl and/or Firewall:To ensure a watertight seal between the passenger compartment and the vehicle exterior, for all bolts passing through the cowl and/or firewall, Vintage Air recommends coating the threads with silicone prior to installation.

Heater Hose (Not Included With This Kit):Heater hose may be purchased from Vintage Air (Part# 31800-VUD) or your local parts retailer. Routing and required length will vary based on installer preference.

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904471 REV C 04/22/15, PG 5 OF 25

Important Wiring Notice—Please Read

Some Vehicles May Have Had Some or All of Their Radio Interference Capacitors Removed. There Should Be a Capacitor Found At Each of the Following Locations:

1. On the positive terminal of the ignition coil.2. If there is a generator, on the armature terminal of the generator.3. If there is a generator, on the battery terminal of the voltage regulator.

Most alternators have a capacitor installed internally to eliminate what is called “whining” as the engine is revved. If whining is heard in the radio, or just to be extra cautious, a radio interference capacitor can be added to the battery terminal of the alternator.

It is also important that the battery lead is in good shape and that the ground leads are not compromised. There should be a heavy ground from the battery to the engine block, and additional grounds to the body and chassis.

If these precautions are not observed, it is possible for voltage spikes to be present on the battery leads. These spikes come from ignition systems, charging systems, and from switching some of the vehicle’s other systems on and off. Modern computer-operated equipment can be sensitive to voltage spikes on the power leads, which can cause unexpected resets, strange behavior, and/or permanent damage.

Vintage Air strives to harden our products against these types of electrical noise, but there is a point where a vehicle’s electrical system can be degraded so much that nothing can help.

Radio interference capacitors should be available at most auto and truck parts suppliers. They typically are cylindrical in shape, a little over an inch long, a little over a half inch in diameter, and they have a single lead coming from one end of the cylinder with a terminal on the end of the wire, as well as a mounting clip which is screwed into a good ground on the vehicle. The specific value of the capacitance is not too significant in comparison to ignition capacitors that are matched with the coil to reduce pitting of the points.

Care must be taken, when installing the compressor lead, not to short it to ground. The compressor lead must not be connected to a condenser fan or to any other auxiliary device. Shorting to ground or connecting to a condenser fan or any other auxiliary device may damage wiring, the compressor relay, and/or cause a malfunction.

When installing ground leads on Gen IV systems, the blower control ground and ECU ground must be connected directly to the negative battery post.

For proper system operation, the heater control valve must be connected to the ECU.

•

•

•

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904471 REV C 04/22/15, PG 6 OF 25

Engine Compartment Disassembly

1.2.3.4.5.6.7.8.

9.10.11.

Disconnect battery.Remove battery and battery tray (retain).Drain radiator.Evacuate the A/C system if necessary.Remove the OEM condenser and drier (discard) (See Figure 1, below).Remove OEM A/C lines from compressor to evaporator (discard) (See Figure 1, below).Remove OEM compressor and bracket (discard) (See Figure 1, below).Remove evaporator blower assembly (discard). NOTE: To remove the evaporator and blower assembly (under hood) and the air distribution system (under dash), the factory manual recommends removing the passenger side inner fender.Remove OEM heater hoses, A/C hoses, hardlines and drier (discard) (See Figure 1, below).Remove A/C and heater wiring/vacuum harness molded grommet (See Figure 1, below).Install a 1 ¾” plug in the firewall as shown in Figure 1, below.

NOTE: Before starting the installation, check the function of the vehicle (horn, lights, etc.) for proper operation, and study the instructions, illustrations, & diagrams.Perform the Following:

Figure 11 ¾” Plug317102

OEM A/C & HeaterWiring/Vacuum Harness

Molded Grommet

BatteryTray

A/C Hoses

Grommet

(4) OEMMounting Screws

(4) OEMMounting Screws

NOTE: On 1968 models only, once the battery is removed, remove A/C hoses and grommet from beside the battery tray (Retain the (4) OEM grommet mounting screws).

1968 Chevelle

1969 Chevelle Shown

Cover Plate640678-FCR

(Included in StandardHose Kit)

Apply a BeadOf Silicone

Around Opening

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904471 REV C 04/22/15, PG 7 OF 25

Condenser Assembly and Installation1.2.

Refer to separate instructions included with the condenser kit to install the condenser.Binary switch installation (Refer to condenser instructions).

Compressor and Brackets1. Refer to separate instructions included with the bracket kit to install the compressor bracket.

Pulleys1. In most instances, the belt lengths will remain the same.

Passenger Compartment Disassembly

1.2.3.4.5.6.7.8.9.

Remove the dash pad by removing (6) OEM screws (retain) (See Figure 2, below).Lower the steering column. Protect the steering column with a cloth.Disconnect all wires and cables from the instrument panel, speedometer, control panel and radio.Remove the instrument panel retaining screws at the top, bottom and side of panel.Remove all hoses and ducting from the OEM louvers (See Figure 2, below).Remove the (2) OEM under dash louver assemblies (discard) (See Figure 2, below).Remove the OEM defrost duct assembly by removing the (4) screws (See Figure 3, below).Remove the OEM A/C and heater assembly (discard) (See Figure 3, below).Remove the passenger side kick panel/fresh air door assembly as shown in Figure 2a, below.

Perform the Following:

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

Figure 2

Figure 3

Figure 2aDefrost Duct

Assembly

Fresh AirDoor Assembly

A/C & Heater Assembly

InstrumentPanel

ControlPanel

A/C & Heater Assembly& Related Ducting

PassengerSide

Kick Panel

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904471 REV C 04/22/15, PG 8 OF 25

Defrost Duct Installation1. Install the defrost ducts under the dash, aligning them with the OEM opening. Secure the defrost ducts to the

cowl using #10 x 1/2” sheet metal screws as shown in Figure 4, below.

Figure 4

Figure 5

OEMLouver

Hose Adapter49870-VCI

Hose Adapter49870-VCI

Install(3) S-clips

#10 x 1/2”Sheet Metal

Screw

Driver SideDefrost Duct

Assembly626673

Cowl

OEMDefrost Duct

Opening

DefrostDuct

Driver Side Defrost Duct

Assembly626673

Passenger SideDefrost Duct

Assembly626674

Passenger SideDefrost Duct

Assembly626674

Hose Adapter Installation1.2.

Install (3) S-clips onto the hose adapters as shown in Figure 5, below.Install the driver and passenger side hose adapters outside the OEM louvers (See Figure 5, below).

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904471 REV C 04/22/15, PG 9 OF 25

Fresh Air Cap Installation1.2.3.

4.5.

Install (4) grommets into fresh air cap (See Figure 6, below).Apply a 1/4” bead of silicone around the back side of the fresh air cap as shown in Figure 6, below.Attach the fresh air cap to the firewall using a 1/4-20 x 1 ½” bolt and washer (See Figure 6, below). NOTE: Fresh air cap installs on the engine side of the firewall.Install a 5/8” plug and grommet in the firewall. See Figure 6, below.Using the template on Page 24, drill a 5/16” hole in the firewall as shown in Figure 6, below.

Figure 6

Figure 7

Figure 7a

Figure 7b#6 A/CHose #6 A/C

Hose

#10 A/CHose

#10 A/CHose

(5) OEMScrews

(2) Heater Hoses

1/4-20 x 1 ½”Bolt with Washer

(4) Grommets33137-VUI

Fresh AirCap

Silicone

Silicone

Enlarge Existing Holein Firewall to 5/16”

OEM Heater Holein Firewall

Back Sideof Fresh Air

Cap

Back Side ofKick Panel

Fresh Air Cap

EngineCompartment

Side ofFirewall

NOTE: Firewall covermounting holes mustbe enlarged.

FIREWALL TEMPLATE

68-69 CHEVELLEw/ AC TEMPLATEFIREWALL/EVAP. BRKT

Drill5/16”Hole

Grommet33145-VUI

5/8” Plug33142-VUI

(4) Grommets33137-VUI

(2) Heater Hoses

Kick Panel Fresh Air Cap Installation1.2.

3.

4.

Install (4) grommets into the kick panel fresh air cap (See Figure 7a, below).Route A/C and heater hoses through the fresh air cap and kick panel fresh air cap as shown in Figures 7 and 7b, below.Apply a 1/4” bead of silicone around the back side of the kick panel fresh air cap as shown in Figure 7a, below.Secure kick panel fresh air cap using OEM screws as shown in Figure 7b, below.

Enlarge Existing Holein Firewall to 5/16”

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904471 REV C 04/22/15, PG 10 OF 25

Figure 8

Figure 9

Front EvaporatorBracket647065

1/4-20 x 1/2”Hex Bolt

(3) 1/4-20Nuts with

Star Washers

Firewall Cover Installation1.2.

Apply a 1/4” bead of silicone around the back side of the firewall cover as shown in Figure 8, below.From inside the car, install the firewall cover onto the firewall using (3) 1/4-20 X 1” hex bolts, (3) flat washers and (3) 1/4-20 nuts with star washers (See Figure 8, below).

Silicone

Back Side ofFirewall Cover

(3) 1/4” x 3/4”Flat Washers

(3) 1/4-20 x 1”Hex Bolts

Firewall Cover648170

Evaporator Installation1.

2.

3.

4.

On a workbench install (2) heater fittings with properly lubricated O-rings (See Figure 15, Page 14, and Figure 10, Page 11).Install a 1/4-20 x 1” hex bolt and a 1/4-20 x 1 ½” hex bolt with 1/2” spacer and (2) 1/4” push nut bolt retainers on evaporator rear bracket as shown in Figure 10, Page 11.Install the evaporator front and rear mounting brackets onto the evaporator using (5) 1/4-20 x 1/2” hex bolts and tighten as shown in Figure 9, below, and Figure 10, Page 11.Lay the evaporator sub case on the passenger side floorboard. Install the A/C and heater hoses onto the evaporator as shown in Figure 11, Page 12, and hose installation instructions on Page 14. NOTE: Wrap the #10 fitting connections with press tape (See Figure 11, Page 12).

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904471 REV C 04/22/15, PG 11 OF 25

Figure 10

Evaporator Installation (Cont.)

(2) 1/4-20 x 1/2”Hex Bolts

(2) 1/4-20 x 1/2”Hex Bolts

1/4” Push NutBolt Retainer

1/4” Push NutBolt Retainer

1/2” Spacer1/4-20 x 1 ½”

Hex Bolt

1/4-20 x 1”Hex Bolt

1968-69 ChevelleMounting Holes

Rear EvaporatorBracket

655000-VUB

(2) HeaterFittings

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904471 REV C 04/22/15, PG 12 OF 25

Evaporator Installation (Final)

1.

2.

3.

4.

Lift evaporator unit up under the dashboard. Secure loosely to firewall from the engine compartment side using (2) 1/4-20 nuts and flat washers as shown in Figure 12, below. NOTE: To ensure proper drainage, it is very important that the evaporator is level, both left-right and fore-aft. Check for level on the flat portions of the case around the drain.Using the OEM bolt, secure the front evaporator mounting bracket between the dash bracket and cowl bracket as shown in Figure 12a, below.Verify that evaporator unit is level and square to the dash; then tighten all mounting bolts. NOTE: Tighten the bolt on the firewall first. Then tighten the front mounting bracket.Once evaporator is in place, route the A/C & heater hoses out the kick panel fresh air cap and through the fresh air cap.

NOTE: To ensure a watertight seal between the passenger compartment and the vehicle exterior, for all bolts passing through the firewall, Vintage Air recommends coating the threads with silicone prior to installation.

Figure 11

Figure 12

Figure 12a

Kick PanelFresh Air

Cap

OEMBolt

HeaterHose

#10 A/CHose

#6 A/CHose

(2) 1/4-20 Nutswith Flat Washers

PressTape

FrontEvaporator

Bracket647065

NOTE: Coat bolt threads withsilicone before installing nutsand washers.

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904471 REV C 04/22/15, PG 13 OF 25

Figure 13

Figure 13a

1968 Center Louver Installation1.2.

Install (4) S-clips on the hose adapter as shown in Figure 13, below.Install center louver hose adapter outside the OEM center louver assembly as shown in Figure 13, below.

Install(4) S-clips

DoorFlap

1969 Center Louver Installation1.2.3.

Remove the center louver door flap (See Figure 13a, below).Install (4) S-clips on the hose adapter as shown in Figure 13a, below.Install the center louver hose adapter outside the OEM center louver assembly as shown in Figure 13a, below.

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904471 REV C 04/22/15, PG 14 OF 25

Figure 14

Drain Hose Installation1.2.

3.

Locate the evaporator drain on the bottom of the evaporator case.In line with the drain, lightly make a mark on the firewall. Measure 1” down and drill a 5/8” hole through the firewall (See Figure 14, below).Install the drain hose to the outlet on the bottom of the evaporator unit and route it through the firewall (See Figure 14, below).

A/C Hose Installation

1.

2.

3.

Locate the #8 compressor A/C hose. Lubricate (2) #8 O-rings (See Figure 15, above) and connect the 135° female fitting with 134a service port to the #8 discharge port on the compressor. Then route the straight female fitting to the #8 condenser hardline coming through the core support (See Figure 16, Page 15, and Figure 16a, Page 16). Tighten each fitting connection as shown in Figure 15, above.Locate the #10 compressor A/C hose. Lubricate (2) #10 O-rings (See Figure 15, above) and connect the #10 135° female fitting with 134a service port to the #10 suction port on the compressor. Then route the 90° female fitting to the #10 fitting on the evaporator (See Figure 11, Page 12, Figure 16, Page 15, and Figure 16a, Page 16). Tighten each fitting connection as shown in Figure 15, above.Locate the #6 evaporator A/C hose. Lubricate (2) #6 O-rings (See Figure 15, above) and connect the straight female fitting to the #6 hardline coming through the core support from the drier. Then route the 90° female fitting to the #6 fitting on the evaporator (See Figure 11, Page 12, Figure 16, Page 15, and Figure 16a, Page 16). Tighten each fitting connection as shown in Figure 15, above.

Standard Hose Kit:

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

Figure ##

O-ring Installs Over Male Insert to Swaged Lip

O-ring#6 O-ring

#8 O-ring #10 O-ring

O-ring

Supplied Oil for O-rings

Male Insert

Female Nut

Hold With This Wrench

Twist With This Wrench

Lubricating O-rings For a proper seal of fittings: Install supplied O-rings as shown, and lubricate with supplied oil.

NOTE: Standard torque specifications:#6: 11 to 13 ft-lb.#8: 15 to 20 ft-lb.

#10: 21 to 27 ft-lb.

Figure 15

DrainHose

EvaporatorCase 1”1”

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904471 REV C 04/22/15, PG 15 OF 25

Heater Hose & Heater Control Valve Installation

A/

C &

Hea

ter

Hos

e R

outi

ng

19

68

Ch

evel

le S

how

n

1.

2.

Route a piece of heater hose from the water pump to the top heater fitting of heater core as shown in Figure 11, Page 12, and Figure 16, below. Secure using hose clamps.Route a piece of heater hose from the intake to the bottom heater fitting of the heater core as shown in Figure 11, Page 12, and Figure 16, below. NOTE: Install heater control valve in line with intake manifold (pressure side) heater hose. Secure using hose clamps as shown in Figure 16, below. Also note proper flow direction.

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ure

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904471 REV C 04/22/15, PG 16 OF 25

Heater Hose & Heater Control Valve Installation

1.

2.

Route a piece of heater hose from the water pump to the top heater fitting of heater core as shown in Figure 11, Page 12, and Figure 16a, below. Secure using hose clamps.Route a piece of heater hose from the intake to the bottom heater fitting of the heater core as shown in Figure 11, Page 12, and Figure 16a, below. NOTE: Install heater control valve in line with intake manifold (pressure side) heater hose. Secure using hose clamps as shown in Figure 16a, below. Also note proper flow direction.

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ure

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17

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904471 REV C 04/22/15, PG 17 OF 25

Cut & Remove1 ½”

Glove Box62567-VCE

OEMScrews

3/8”Grommet

PassengerSide

Kick Panel

Figure 17

Figure 18

Figure 19

Final Steps1.2.

3.4.

5.6.7.8.

9.10.11.

12.13.

Install duct hoses as shown in Figure 20, Page 18.Route A/C wires (12 volt/grounds/binary switch/heater valve) through 3/8” grommet as shown in Figure 17, below.Install control panel assembly. Refer to control panel instructions.Plug the wiring harnesses into the ECU module on the sub case as shown in Figure 20, Page 18. Wire according to the wiring diagrams on Pages 19 and 20.Install new glove box.Modify passenger side kick panel as shown in Figure 19, below.Reinstall all previously removed items.Fill radiator with at least a 50/50 mixture of approved antifreeze and distilled water. It is the owner’s responsibility to keep the freeze protection at the proper level for the climate in which the vehicle is operated. Failure to follow antifreeze recommendations will cause heater core to corrode prematurely and possibly burst in A/C mode and/or freezing weather, voiding your warranty.Double check all fittings, brackets and belts for tightness.Vintage Air recommends that all A/C systems be serviced by a licensed automotive A/C technician.Evacuate the system for a minimum of 45 minutes prior to charging, and perform a leak check prior to servicing.Charge the system to the capacities stated on Page 4 of this instruction manual.See Operation of Controls procedures on Page 21.

Glove BoxDoor

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904471 REV C 04/22/15, PG 18 OF 25

Figure 20

Control Panel & Duct Hose Routing

PlugFromWiring

Harness231001-VUR

Center Louver2” x 20”

Defrost DuctPassenger Side

2” x 12”

Passenger SideLouver

2 ½” x 36”

Driver SideLouver

2 ½” x 32”

Defrost DuctDriver Side

2” x 18”

Control PanelHarness From ECU

232007-VUR

Back Sideof PC BoardAssembly

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904471 REV C 04/22/15, PG 19 OF 25

WHT/GRN

WHT/YELWHT/RED

RED

WHTBACKLIGHT NEG

FAN WIPER

MODE WIPER

TEMP WIPER

5V-SW

GND

BACKLIGHT POS

AC ANNUNCIATOR

PRE-WIRED

GEN IV WIRING DIAGRAMREV D, 5/6/2014

GEN IV ECU

PROGRAM

Wiring Diagram

TEMP

MODE

FAN

A/C(IF USED)

232007-VUR

232002-VUA

** CIRCUITBREAKER30 AMP

*** WIDE OPENTHROTTLESWITCH

(OPTIONAL)

* DASH LAMP(IF USED)

Dash Lamp Is Used Only With Type 232007-VUR Harness.Warning: Always Mount Circuit Breaker As Close to the Battery As Possible. (NOTE: Wire BetweenBattery and Circuit Breaker Is Unprotected and Should Be Carefully Routed to Avoid a ShortCircuit).Wide Open Throttle Switch Contacts Close Only at Full Throttle, Which Disables A/C Compressor.

JF8

BLK

ORA

TAN

VIEWED FROM WIRE SIDE

••

•

HEATERCONTROL VALVE

20

www.vintageair.com

904471 REV C 04/22/15, PG 20 OF 25

RED

CIRCUIT BREAKER30 AMP

+

+

-

BLACK

REDWHITE

RED

CHASSIS GROUND

A/CCOMPRESSOR

RELAY

Ignition Switch:

Dash Light:

NOTE: MOUNT RELAYIN DESIRED LOCATION

UNDER DASH

GREEN

FIREWALL

BLUE

BLUE

RED &

WHITE

VIOLET

(IGNITION HOTTERMINAL)

IGNITION SWITCH

DASH BACK LIGHT+0-12vTAN

GRAY

BLUE

WHITE

WHITE

REDRED

WHITE

COMPRESSOR

BATTERY

NOTE: CONNECT WHITEWIRES DIRECTLY TO

(-) BATTERY TERMINAL

BATRUN

12V

RED GREEN

RED

RED

BLUE

LATCH

BLACK

BINARYSAFETYSWITCH

YELLOW

ORANGE

WIRING HARNESS

Violet 12V Ign Switch Source (Key On Accessory) Position Must Be Switched.

Tan Wire Used Only With Vintage Air Supplied Control Panel With LED Back Light.

Binary: Connect As Shown (Typical Compressor Wiring). Be Sure Compressor Body Is Grounded.

Trinary Switch: Connect According To Trinary Switch Wiring Diagram.

Install With Servo Motor Facing Down, As Shown. Note Flow Direction Arrow Molded Into Valve Body, And Install Accordingly.

White Must Run To (-) Battery. Red May Run To (+) Battery Or Starter. Mount Circuit Breaker As Close to Battery As Possible.

Heater Control Valve:

Binary/Trinary & Compressor:

Circuit Breaker/Battery:

CONTROL WIRING HARNESS

NOTE: YELLOW & ORANGE

COMING FROM HARNESS ARE NOT

USED.

WIRING HARNESS

GRAY WIRE IS USED FOR PROGRAMING CONTROLS

IF APPLICABLE

WIRING HARNESS

Gen IV Wiring Connection Instruction

HEATERCONTROL VALVE

WARNING: ALWAYS MOUNT CIRCUIT BREAKER

AS CLOSE TO THE BATTERY AS POSSIBLE. (NOTE: WIRE BETWEEN BATTERY AND CIRCUIT BREAKER IS UNPROTECTED

AND SHOULD BE CAREFULLY ROUTED TO AVOID A SHORT CIRCUIT).

NOTE: HEATER CONTROL VALVE CONNECTION AND CHASSIS GROUND MAY BE LOCATED ON EITHER SIDE OF THE FIREWALL. ENSURECONNECTOR IS LATCHED

FIRMLY.

21

www.vintageair.com

904471 REV C 04/22/15, PG 21 OF 25

Operation of Controls

Adjust to desiredspeed.

Blower SpeedAdjust to desired

speed.

Adjust to desiredmode position (DASH position recommended).

Adjust to desiredspeed.

Adjust to DEFROST position for maximum defrost, or between FLOOR and DEFROST positions for a bi-level

blend (Compressor is automatically engaged).

Adjust to desired temperature.

For A/C operation, adjust tocoldest position to engage

compressor (Adjust between HOT and COLD to reachdesired temperature).

A/C Operation

Heat Operation

Defrost/De-fog Operation

On Gen IV systems with three lever/knob controls, the temperature control toggles between heat and A/C operations. To activate A/C, move the temperature lever/knob all the way to cold and then back it off to the desired vent temperature. For heat operation, move the temperature lever/knob all the way to hot and then adjust to the desired vent temperature. The blower will momentarily change speed, each time you toggle between operations, to indicate the change.

Blower Speed

Blower Speed

This lever/knob controlsblower speed, from

OFF to HI.

This lever/knob controls the mode positions,from DASH to FLOORto DEFROST, with a blend in between.

This lever/knob controlsthe temperature,

from HOT to COLD.

Blower Speed

Mode Control

Temperature Control

Blower Speed

TemperatureControl

A/C Light(When Lit, Compressor

is Engaged)

ModeControl

Temperature Control

Temperature Control

Temperature Control

Mode Control

Mode Control

Mode Control

For maximum heating, adjust to hottest position (Adjust between HOT and COLD to reach desired temperature).Adjust to desired

mode position(FLOOR position recommended).

DASH

HOT

DASH

HOT

DASH

HOT

DASH

HOT

ww

w.v

inta

gea

ir.c

om

22 904471 REV C 04/22/15, PG 22 OF 25

Sym

pto

m

C

on

dit

ion

C

heck

s

Act

ion

s

N

ote

s

Blo

wer

sta

ys o

n

hig

h s

pee

d w

hen

ig

nitio

n is

on.

1a.

No o

ther

funct

ions

work

.

Chec

k fo

r dam

aged

pin

s or

wires

in c

ontr

ol hea

d p

lug.

Ver

ify

that

all

pin

s ar

e in

sert

ed into

plu

g.

Ensu

re t

hat

no

pin

s ar

e ben

t or

dam

aged

in E

CU

.

Chec

k fo

r dam

aged

gro

und

wire

(white)

in c

ontr

ol hea

d

har

nes

s.

Ver

ify

continuity

to c

has

sis

gro

und w

ith w

hite

contr

ol

hea

d w

ire

at v

ario

us

poin

ts.

Loss

of gro

und o

n t

his

wire

render

s co

ntr

ol hea

d

inoper

able

.

All

oth

er f

unct

ions

work

.Chec

k fo

r dam

aged

blo

wer

sw

itch

or

pote

ntiom

eter

and

asso

ciat

ed w

irin

g.

Blo

wer

sta

ys o

n

hig

h s

pee

d w

hen

ig

nitio

n is

on o

r off.

Unplu

g 3

-wire

BSC c

ontr

ol

connec

tor

from

ECU

. If

blo

wer

sh

uts

off,

ECU

is

eith

er

impro

per

ly w

ired

or

dam

aged

.

Be

sure

the

smal

l, 2

0 G

A w

hite

gro

und w

ire

is c

onnec

ted

to t

he

bat

tery

gro

und p

ost

. If

it

is,

repla

ce t

he

ECU

.

Unplu

g 3

-wire

BSC c

ontr

ol

connec

tor

from

ECU

. If

blo

wer

st

ays

runnin

g,

BSC is

eith

er

impro

per

ly w

ired

or

dam

aged

.

Chec

k to

ensu

re t

hat

no B

SC w

irin

g is

dam

aged

or

short

ed t

o v

ehic

le g

round.

The

BSC o

per

ates

the

blo

wer

by

gro

und s

ide

puls

e w

idth

modula

tion s

witch

ing.

The

posi

tive

wire

to t

he

blo

wer

will

alw

ays

be

hot.

If th

e “g

round”

side

of

the

blo

wer

is

short

ed t

o c

has

sis

gro

und,

the

blo

wer

will

run o

n H

I.

Rep

lace

BSC (

This

will

req

uire

rem

oval

of

evap

ora

tor

from

veh

icle

).N

o o

ther

par

t re

pla

cem

ents

sh

ould

be

nec

essa

ry.

Com

pre

ssor

will

not

turn

on

(All

oth

er funct

ions

work

).

2.

Sys

tem

is

not

char

ged

.Sys

tem

must

be

char

ged

for

com

pre

ssor

to e

ngag

e.Char

ge

syst

em o

r byp

ass

pre

ssure

sw

itch

.

Dan

ger:

Never

byp

ass

sa

fety

sw

itch

wit

h

en

gin

e r

un

nin

g.

Seri

ou

s in

jury

can

resu

lt.

Sys

tem

is

char

ged

.

1b

.

Tro

ub

lesh

oo

tin

g G

uid

e

Chec

k fo

r fa

ulty

A/C

pote

ntiom

eter

or

asso

ciat

ed

wirin

g (

Not

applic

able

to 3

-pot

contr

ols

).

Chec

k fo

r dis

connec

ted o

r fa

ulty

ther

mis

tor.

Chec

k co

ntinuity

to g

round o

n w

hite

contr

ol hea

d w

ire.

Chec

k fo

r 5V o

n r

ed c

ontr

ol hea

d w

ire.

Chec

k 2-p

in c

onnec

tor

at E

CU

housi

ng.

To c

hec

k fo

r pro

per

pot

funct

ion,

chec

k vo

ltag

e at

w

hite/

blu

e w

ire.

Voltag

e sh

ould

be

bet

wee

n 0

V a

nd

5V,

and w

ill v

ary

with p

ot

leve

r posi

tion.

Dis

connec

ted o

r fa

ulty

ther

mis

tor

will

cau

se

com

pre

ssor

to b

e dis

able

d.

Red

wire

at A

/C p

ot

should

hav

e ap

pro

xim

atel

y 5V

with ignitio

n o

n.

White

wire

will

hav

e co

ntinuity

to

chas

sis

gro

und.

White/

Blu

e w

ire

should

var

y bet

wee

n 0

V a

nd 5

V w

hen

le

ver

is m

oved

up o

r dow

n.

3. Com

pre

ssor

will

not

turn

off

(A

ll oth

er funct

ions

work

).

Chec

k fo

r fa

ulty

A/C

pote

ntiom

eter

or

asso

ciat

ed

wirin

g.

Chec

k fo

r fa

ulty

A/C

rel

ay.

Rep

air

or

repla

ce p

ot/

contr

ol w

irin

g.

Rep

lace

rel

ay.

See

blo

wer

sw

itch

chec

k pro

cedure

.

ww

w.v

inta

gea

ir.c

om

23 904471 REV C 04/22/15, PG 23 OF 25

Sym

pto

m

C

on

dit

ion

Ch

eck

s

Act

ion

s

N

ote

s

Sys

tem

will

not

turn

on,

or

runs

inte

rmitte

ntly.

4.

Work

s w

hen

engin

e is

not

runnin

g;

shuts

off w

hen

en

gin

e is

sta

rted

(T

ypic

ally

ear

ly G

en I

V,

but

poss

ible

on a

ll ve

rsio

ns)

.

Nois

e in

terf

eren

ce f

rom

either

ig

nitio

n o

r al

tern

ator.

Inst

all ca

pac

itors

on ignitio

n c

oil

and a

lter

nat

or. E

nsu

re

good g

round a

t al

l poin

ts.

Rel

oca

te c

oil

and a

ssoci

ated

w

irin

g a

way

fro

m E

CU

and E

CU

wirin

g.

Chec

k fo

r burn

edor

loose

plu

g w

ires

.

Ver

ify

connec

tions

on p

ow

er

lead

, ig

nitio

n lea

d,

and b

oth

white

gro

und w

ires

.

Ver

ify

pro

per

met

er f

unct

ion b

y ch

ecki

ng t

he

conditio

n o

f a

know

n g

ood b

atte

ry.

Ignitio

n n

ois

e (r

adia

ted o

rco

nduct

ed)

will

cau

se t

he

syst

em t

o s

hut

dow

n d

ue

tohig

h v

oltag

e sp

ikes

. If

this

is s

usp

ecte

d,

chec

k w

ith a

qual

ity

osc

illosc

ope.

Spik

esgre

ater

than

16V w

ill s

hut

dow

n t

he

ECU

. In

stal

l a

radio

cap

acitor

at t

he

posi

tive

post

of th

e ig

nitio

nco

il (S

ee r

adio

cap

acitor

inst

alla

tion b

ulle

tin).

A

faulty

alte

rnat

or

or

worn

out

bat

tery

can

als

o r

esult

in t

his

conditio

n.

Will

not

turn

on u

nder

an

y co

nditio

ns.

Ver

ify

bat

tery

voltag

e is

gre

ater

than

10 v

olts

and les

sth

an 1

6.

Loss

of m

ode

door

funct

ion.

No m

ode

chan

ge

at a

ll.Chec

k fo

r dam

aged

mode

switch

or

pote

ntiom

eter

and

asso

ciat

ed w

irin

g.

Part

ial fu

nct

ion o

f m

ode

doors

.

Typic

ally

cau

sed b

y ev

apora

tor

housi

ng

inst

alle

d in a

bin

d in t

he

vehic

le.

Be

sure

all

mounting loca

tions

line

up

and d

on’t h

ave

to b

e fo

rced

in

to p

osi

tion.

Blo

wer

turn

s on

and o

ff r

apid

ly.

6.

Bat

tery

voltag

e is

at

leas

t 12V.

Chec

k fo

r at

lea

st 1

2V a

t ci

rcuit b

reak

er.

Ensu

re a

ll sy

stem

gro

unds

and p

ow

er c

onnec

tions

are

clea

n a

nd t

ight.

Bat

tery

voltag

e is

les

s th

an 1

2V.

5.

Tro

ub

lesh

oo

tin

g G

uid

e (

Co

nt.

)

Chec

k fo

r fa

ulty

bat

tery

or

alte

rnat

or.

Char

ge

bat

tery

.

Sys

tem

shuts

off b

low

er a

t 10V.

Poor

connec

tions

or

wea

k bat

tery

can

cau

se

shutd

ow

n a

t up t

o 1

1V.

7. When

ignitio

n is

turn

ed o

n,

blo

wer

m

om

enta

rily

co

mes

on,

then

sh

uts

off.

This

occ

urs

with t

he

blo

wer

sw

itch

in

the

OFF

posi

tion.

This

is

an indic

ator

that

the

syst

em h

as b

een r

eset

. Be

sure

the

red p

ow

er w

ire

is o

nth

e bat

tery

post

, an

d n

ot

on a

sw

itch

ed s

ourc

e. A

lso,

if

the

syst

em is

pulle

d b

elow

7V f

or

even

a s

plit

sec

ond,

the

syst

em w

ill r

eset

.

Run r

ed p

ow

er w

ire

direc

tly

to b

atte

ry.

Chec

k fo

r posi

tive

pow

er a

t hea

ter

valv

e gre

en w

ire

and

blo

wer

red

wire.

Chec

k fo

r gro

und o

n c

ontr

ol hea

d w

hite

wire.

Chec

k fo

r obst

ruct

ed o

r bin

din

g m

ode

doors

.

Chec

k fo

r dam

aged

ste

pper

m

oto

r or

wirin

g.

Err

atic

funct

ions

of

blo

wer

, m

ode,

te

mp,

etc.

Chec

k fo

r dam

aged

sw

itch

or

pot

and a

ssoci

ated

wirin

g.

Rep

air

or

repla

ce.

8.

24

www.vintageair.com

904471 REV C 04/22/15, PG 24 OF 25

EvaporatorRear Bracket

Template

Enlarge OEM Hole

5/16”

Drill5/16”

FirewallOpening

Firewall

25

www.vintageair.com

904471 REV C 04/22/15, PG 25 OF 25

OFF

DASH

HOT

FLR

HI

DEF

COLD

AC

Packing List: Evaporator Kit (564471)

No. 1.2.

Qty.11

Part No.762169784166

DescriptionGen IV Evaporator Sub Case, 4-Vent with 2” & 2 ½”Accessory Kit, 1968-69 Chevrolet Chevelle with Factory Air

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

1

2

Gen IV Evaporator Sub Case 4-Vent

w/ 2” & 2 ½”762169

Accessory Kit784166

Checked By:Packed By:

Date: