an ISO 9001:2015 Registered Company

1974-76 Chevrolet Corvette with Factory AirEvaporator Kit

(564174)

906417 REV K 01/10/18, PG 1 OF 31

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

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

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906417 REV K 01/10/18, PG 2 OF 31

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..........................................................................................Passenger Compartment Disassembly...................................................................................... Passenger Compartment Disassembly (Cont.), Fresh Air Cover Installation...................................Condenser Assembly & Installation, Compressor & Brackets, Pulleys............................................Defrost Duct Replacement...................................................................................................Passenger and Driver Side A/C Duct Hose Adapter Installation.................................................. Passenger Side Dash Modification, Driver Side Under Dash Louver Hose Adapter......................... Center Louver Assembly......................................................................................................Firewall Modification, Evaporator Bracket Mounting Holes......................................................... Firewall Modification (Cont.), Evaporator Installation...............................................................Evaporator Installation (Cont.).............................................................................................Drain Hose Installation........................................................................................................Firewall Cover....................................................................................................................A/C Hose Installation, Heater Hose & Heater Control Valve Installation, Lubricating O-rings.......... Small Block Hose Routing.................................................................................................... Final Steps........................................................................................................................ Control Panel & Duct Hose Routing........................................................................................ Evaporator Hardline Installation...........................................................................................Wiring Diagram..................................................................................................................Gen IV Wiring Connection Instructions..................................................................................Operation of Controls..........................................................................................................Troubleshooting Guide.........................................................................................................Troubleshooting Guide (Cont.)..............................................................................................Passenger Compartment Modification Templates.....................................................................Firewall Modification Templates............................................................................................Packing List.......................................................................................................................

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Table of Contents

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906417 REV K 01/10/18, PG 3 OF 31

Packing List: Evaporator Kit (564174)

No. 1.2.

Qty.11

Part No.764170784174

DescriptionGen IV Evaporator Sub CaseAccessory Kit

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

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

1

2

Gen IV Evaporator Sub Case764170

Accessory Kit784174

C

HI

OFF

DEF

FLR

PNL

PNL

FLR

H

AC

EC

ON

O

E

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906417 REV K 01/10/18, PG 4 OF 31

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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906417 REV K 01/10/18, PG 5 OF 31

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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906417 REV K 01/10/18, PG 6 OF 31

Engine Compartment Disassembly

1.2.3.4.5.6.7.8.9.

10.11.12.

Disconnect battery.Remove hood to ease installation (retain).Drain radiator.Evacuate the A/C system (if necessary).Remove OEM condenser and drier (discard).Remove OEM A/C lines from compressor to evaporator (discard).Remove OEM compressor and compressor bracket (discard).Remove coolant overflow bottle (retain).Remove OEM blower assembly and cover (discard).Remove OEM evaporator and cover (discard).Remove OEM A/C harness and vacuum harness (discard).Install (2) 1 ½” plugs in firewall as shown in Figure 1a, below.

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

Figure 1

Figure 1a

A/CLines

VacuumHarness

Evaporator& Cover

(2) 1 ½” Plugs

BlowerAssembly& Cover

A/CHarness

CompressorCondenser

Drier

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906417 REV K 01/10/18, PG 7 OF 31

Passenger Compartment Disassembly

1.2.3.4.5.6.7.8.

Remove passenger side dash (retain).Disconnect center dash (retain) and pull forward to remove OEM A/C duct (discard duct).Remove OEM radio (retain).Remove control panel (retain). Refer to control panel conversion kit to assemble control panel.Drop steering column.Disconnect driver side dash and pull forward.Remove the passenger side, center and driver side A/C ducts as shown in Figure 3, below (discard).Remove the floor heater duct as shown (discard).

Perform the Following:

Figure 2

Figure 3

Driver SideDash

CenterDash

SteeringColumn

ControlPanel

Radio

Passenger SideDash

Passenger SideA/C Duct

Driver SideA/C Duct

CenterA/C Duct

FloorHeaterDuct

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906417 REV K 01/10/18, PG 8 OF 31

Fresh Air Cover Installation1.2.

Apply a 1/4” bead of silicone around the back side of the fresh air cap as shown in Figure 4b, below.Attach the fresh air cap to the firewall using a 1/4-20 x 1” bolt and washer. See Figure 4b, below.

Figure 4

Figure 4a

Figure 4b

Passenger Compartment Disassembly (Cont.)

1.2.3.4.

Remove the OEM defrost duct (discard).Remove the heater housing from under the dash.Remove the kick panel vacuum control assembly (discard) (See Figure 4a, below).Using (2) #8 x 1/2” pan head screws, install the kick panel fresh air cap as shown in Figure 4a, below. Prior to final installation, mark and drill (2) 1/8” holes using the kick panel fresh air cap as a template.

Perform the Following:

OEM DefrostDuct

HeaterHousing

Remove

Kick PanelVacuumControl

Assembly

(2) #8 x 1/2”Pan HeadScrews

Kick PanelFresh Air Cap

Drill(2) 1/8” Holes

Silicone Back Side of Fresh Air

Cap

Fresh Air Cap

1/4-20 x 1”Bolt withWasher

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906417 REV K 01/10/18, PG 9 OF 31

Condenser Assembly & Installation

Compressor & Brackets

Pulleys

1.

1.

1.

Refer to separate instructions included with the condenser kit to install the condenser. Refer to Figure 5, below, for condenser location.

Refer to separate instructions included with the bracket kit to install the compressor bracket. Refer to Figure 6, below, for compressor mounting position.

In most instances, existing belt lengths will remain the same (See Figure 6, below). NOTE: Belt routing may vary with different bracket sets. Always refer to instructions included with brackets.

Pulleys (Vintage Air) Short PumpSmall Block Chevrolet (Steel Pulley)22503-VCA - Water Pump Pulley (Double Groove)22506-VCA - Crankshaft Pulley (Double Groove) (with Power Steering, a 3-Groove Crank Pulley is Required)22507-VCA - Crankshaft Pulley (Triple Groove)

Figure 5

Figure 6

Tab“C”

Tab“G”

Tab“A”

Tab“E”

CoreSupport

OEMRadiator

091069-CCL#6 Drier/Core

Support Hardline

091071-CCD#8 Condenser/CoreSupport Hardline

Drier

Compressor

Water PumpPulley

CrankshaftPulley

Generatoror

Alternator

Mount theCompressorUsing Tabs“G” & “C”

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906417 REV K 01/10/18, PG 10 OF 31

Defrost Duct Replacement 1.

2.

3.4.

Remove screws attaching the OEM defrost duct (retain (2) screws attaching the duct to the dash pad) (See Photo 1, below).Remove remaining screws attaching the dash pad to the dash, and remove the dash pad from the vehicle (retain) (See Photo 1, below).Place new defrost duct on the dash pad, in place of the OEM defrost duct (See Photo 2, below).Attach using (2) screws removed in Step #1. Tighten and reinstall the dash pad using the OEM screws previously removed (See Photo 3, below).

Photo 1 Photo 2

Photo 3

DashPad

DashPad

OEM ScrewLocation

OEM ScrewLocation Defrost Duct

625090

OEMScrew

OEMScrew

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906417 REV K 01/10/18, PG 11 OF 31

Figure 7

Figure 8

Figure 8a

Passenger and Driver SideA/C Duct Hose Adapter Installation

1.2.

3.

4.

5.

Remove (2) vent knobs as shown in Figure 7, below (retain).Remove the passenger and driver side vent adapters (discard) as shown in Figure 8, below. NOTE: Retain mounting hardware.Install the inner and outer A/C duct hose adapters as shown in Figure 8, below. Use OEM screws to secure the adapters to the dash.Install the vent knob as shown using a 10-24 x 1 ¼” pan head screw and 3/16” flat washer. NOTE: Thepassenger side installation is shown below in Figure 8. Repeat the same steps for the driver sideinstallation.See Figure 8a, below, for a completely assembled view of the A/C duct hose adapter.

Remove

Vent Knob

RemoveVent Knob

10-24 x 1 ¼”Pan Head Screw 3/16” Flat

Washer

(3) OEMScrews

Vent Knob

Outer A/C DuctHose Adapter

Inner A/C DuctHose Adapter

Vent Adapter

OEMAssembly

AssembledView of

A/C DuctHose Adapter

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906417 REV K 01/10/18, PG 12 OF 31

PASSENGER SIDE DASH

MODIFICATION TEMPLATE

Passenger Side Dash Modification

Driver Side Under Dash Louver Hose Adapter

1.

2.3.

1.

Align the template (provided on Page 29) on the back side of the passenger side dash as shown in Figure 9, below.Using a pencil or scribe, mark along the edge of the template as shown.Remove the template and cut along the dotted line. Remove the plastic portion of the dash. NOTE: Do not cut through the foam dash pad on the back side of the plastic (See Figure 9a, below).

Install the hose adapter on the driver side under dash louver using a #8 x 1/2” pan head screw as shown in Figure 10, below.

Figure 9Figure 9a

Figure 10

Back Side ofPassenger Side

Dash

Template

RemoveShaded Portion

Foam Pad

Dash

Driver Side LouverHose Adapter

OEM LouverOEM Louver

Driver Side LouverHose Adapter

#8 x 1/2”Pan Head Screw

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906417 REV K 01/10/18, PG 13 OF 31

Photo 4 Photo 5

Photo 6Photo 7

Photo 8 Photo 9

Center Louver Assembly1.2.

3.

4.

5.

Remove the center louver assembly from the center console.On the rear of the center louver assembly, remove (3) OEM screws attaching the center louver vent door to the center louver frame (retain) (See Photo 4, below). Discard the center louver vent door and housing.Making sure the OEM vents are in their original location, install the center louver adapter to the previouslyremoved OEM vent door location as shown in Photos 5 and 6, below.Install the center louver bracket to the center louver adapter by inserting the vent divider blade through the open slot in the center louver adapter as shown in Photo 7, below.Install and tighten the (3) OEM screws as shown in Photos 8 and 9, below.

OEM ScrewLocation

OEM ScrewLocation

Center Louver Adapter625082

Check forProper

Alignment

Center Louver Adapter Slot

Vent Divider Blade(3) OEM

Screws

Attach ScrewHere

Attach ScrewHere

Attach ScrewHere

OEM Vent Door LocationOEM Screw

Location

Center Louver Frame

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906417 REV K 01/10/18, PG 14 OF 31

Evaporator Bracket Mounting Holes1.

2.

Cut out the template provided on Page 29. Place the template under the dash on the inner cowl as shown inFigure 12, below.Once the template is aligned correctly against the dash brace, tape the template into place. Mark the mounting hole locations on the inner cowl. Once the holes are marked in the correct location, drill (2) 3/16” holes in the inner cowl for the front evaporator mounting bracket (See Figure 12, below). NOTE: Some models may have an OEM hole in the inner cowl as shown in Figure 12, below.

Figure 11

Figure 12

Firewall Modification

Inner Cowl

Firewall

Templates

Lower Passenger Side

FirewallLower

Driver SideFirewall

Drill (2)3/8” Holes

Existing OEMHole on

Some Models

Mark & Drill(2) 3/16”

Mounting Holes

Align TemplateAgainst Dash

Brace

Template

1.

2.

Cut out the templates provided on Page 30. Working in the passenger compartment, place the templates on the firewall as shown in Figure 11, below.Once templates are aligned correctly and taped into place, mark the mounting hole locations on the firewall. Once the holes are marked in the correct location, drill (2) 3/8” holes in the firewall for the firewall cover (SeeFigure 11, below).

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906417 REV K 01/10/18, PG 15 OF 31

Firewall Modification (Cont.)1.

2.

3.

Working in the engine compartment, place the supplied firewall cover against the opening in the firewall. Align the firewall cover’s bolt holes with the (2) previously drilled lower holes and (1) upper OEM hole in the firewall (See Figure 13, below).Using a paint pen or marker, and the firewall cover as a template, mark the firewall along the inside edge of the large hole in the firewall cover to indicate the portion of the firewall that will need to be removed to allow clearance for the A/C and heater lines (See Figure 13, below).When the firewall has been marked as shown in Figure 13, below, remove the marked area from the firewall (See Figure 13a, below).

Figure 13Figure 13a

Evaporator Installation

1.

2.

3.4.

5.

6.

7.

On a workbench, install the evaporator rear bracket, and install the evaporator hardlines with properly lubricated O-rings (See Figure 18, Page 19, and Figure 23, Page 23).Install the front mounting bracket on the evaporator using (2) 1/4-20 x 1/2” hex bolts, and tighten as shown in Figure 14, Page 16.Place polyethylene sheet over the stepper motors (See Figure 15, Page 16).Lift evaporator unit up under the dashboard (See Figure 15, Page 16). Secure loosely to the firewall using a 1/4-20 x 1” bolt and washer (See Figure 15, Page 16). 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 flatportions of the case around the drain.Using a #14 x 3/4” sheet metal screw, secure the front evaporator mounting bracket to the inner cowl by aligning the right hole in the front evaporator mounting bracket with the OEM hole in the inner cowl (See Figure 15, Page 16).To secure the left side of the front mounting bracket, with the evaporator mounting bracket in place, drill a 3/16” hole in the inner cowl using the left mounting bracket hole as a guide. Secure the bracket to the inner cowl using a #14 x 3/4” sheet metal screw (See Figure 15, Page 16).Verify that the 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 screws.

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.

Mark and Cut Along

Dotted Line

3/8” DrilledHole

3/8” DrilledHole

OEM Hole

Passenger Side Engine Compartment

View

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906417 REV K 01/10/18, PG 16 OF 31

FIGURE 7

Figure 14

Figure 15

10-32 x 1/2”Screw

LeftMounting

HoleRight

MountingHole

Evaporator FrontBracket

643071-PCA

(2) 1/4-20 x 1/2”Hex Bolts

4-VentA/C Plenum

1/4-20 x 1”Bolt & Washer

(Install Bolt & WasherFrom Engine

Compartment Side)

Place PolyethyleneSheet Over theStepper Motors

Once Bracket isin Place, Drill a 3/16”

Mounting Hole

(2) #14 x 3/4”Sheet Metal Screws

NOTE: InstallThis Screw First

OEMHole

InnerCowl

Evaporator Installation (Cont.)

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906417 REV K 01/10/18, PG 17 OF 31

Figure 16

Drain Hose Installation1.

2.

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 16, below).Install the drain hose to the bottom of the evaporator unit, and route through the firewall (See Figure 16, below).

DrainHose

Drain

1”

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906417 REV K 01/10/18, PG 18 OF 31

S B

Y

Figure 17

Firewall Cover1.2.3.

4.5.

Apply a 1/4” bead of silicone around the back side of the firewall cover as shown in Figure 17, below.Pass the lines through the firewall cover, and secure with (2) 7/16” panel retainers (See Figure 17, below).Once the firewall cover is in place, locate the hole on the left side of the firewall cover. Drill a 3/8” hole through the firewall. Install a 7/16” panel retainer to secure the left side of the firewall cover to the firewall (See Figure 17, below).Install (2) grommets in the firewall cover cap as shown in Figure 17, below.Apply a 1/4” bead of silicone around the back side of the firewall cover cap as shown in Figure 17, below.Using (2) #8 x 1/2” pan head screws, install the firewall cover cap as shown.

Back Sideof FirewallCover Cap

Drill 3/8”Hole

FirewallCap

Silicone

Back Sideof Firewall

Cover

Silicone

(3) 7/16”Panel

Retainers

LargeGrommet #10 Suction

Line

#6 LiquidLine

1 ¼” x 1” with 3/8” Hole

Grommet

(2) #8 x 1/2”Pan Head Screws

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906417 REV K 01/10/18, PG 19 OF 31

A/C Hose Installation

Heater Hose & Heater Control Valve Installation

1.

2.

3.

1.

2.

Locate the #8 compressor A/C hose. Lubricate (2) #8 O-rings (See Figure 18, below) and connect the 135° female fitting to the #8 discharge port on the compressor. Then route the 45° female fitting to the #8 condenser hardline coming through the core support (See Figure 19, Page 20). Tighten each fitting connection as shown in Figure 18, below.Locate the #10 compressor A/C hose. Lubricate (2) #10 O-rings (See Figure 18, below) and connect the 45° female fitting with 134a service port to the #10 suction port on the compressor. Then route the straight fitting to the #10 evaporator hardline coming through the firewall (See Figure 19, Page 20). Tighten each fitting connection as shown in Figure 18, below. NOTE: Wrap the #10 fitting connections at the firewall with press tape (See Figure 19, Page 20).Locate the #6 A/C hose. Lubricate (2) #6 O-rings (See Figure 18, below) and connect the 90° fitting to the #6 hardline coming through the core support from the drier. Attach the straight fitting with 134a service port to the #6 evaporator hardline coming through the firewall (See Figure 19, Page 20). Tighten each fitting connection as shown in Figure 18, below. Use a #6 Adel clamp to secure the #6 A/C hose to the inner fender well as shown in Figure 19, Page 20. Secure the Adel clamp to the inner fender using a 10-32 x 1/2” machine screw and nut.

Route a piece of heater hose from the water pump to the heater line coming through the firewall as shown in Figure 20, Page 21. Secure using hose clamps.Route a piece of heater hose from the intake to the heater line coming through the firewall as shown in Figure 20, Page 21. NOTE: Install heater control valve in line with the intake manifold (pressure side) heater hose, and secure using hose clamps as shown in Figure 20, Page 21. Also note proper flow direction.

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 18

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20 906417 REV K 01/10/18, PG 20 OF 31

FLO

W

Fig

ure

19

Ou

t

Sm

all

Blo

ck H

ose

Ro

uti

ng

Evap

orat

orSub

Cas

e

Fire

wal

lCov

er

ECU

Mod

ule

Pres

sTa

pe

Pres

sTa

pe

Hea

ter

Con

trol

Valv

e

#10

A/C

Suc

tion

Hos

e(C

ompr

esso

r/Ev

apor

ator

)

#6

A/C

Hos

e(D

rier

/Eva

pora

tor)

#8

A/C

Dis

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(Com

pres

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Bin

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Switc

h

In

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906417 REV K 01/10/18, PG 21 OF 31

FROM INTAKE

TO WATER PUMP FROM HTR CNTRL VLV

Figure 20

Figure 21

NOTE: Flow Direction FollowsMolded Arrow on Valve.

Final Steps1.

2.3.4.

5.6.

7.8.

9.10.11.

12.13.

Using the supplied tie wraps and a #10 x 3/4” sheet metal screw, install the driver side louver adapter assembly as shown in Figure 21, below. NOTE: Use the tie wraps to raise and secure the louver adapter assembly.Install the duct hoses as shown in Figure 22, Page 22.Reinstall the center dash assembly.Reinstall the control panel assembly. Refer to control panel instructions. NOTE: Controls must be calibrated for proper operation. Refer to control panel instructions.Plug the control panel harness into the ECU module on the sub case as shown in Figure 22, Page 22.Plug the wiring harnesses into the ECU module on the sub case. Wire according to wiring diagrams on Pages 24 & 25.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 26.

ECUModule

PressTape

#10Suction

Line(Insulated)

ExpansionValve

FirewallCover Cap

FirewallCover

HeaterHose

#6 A/CHose

#10 SuctionHose

O-ring

#10 x 3/4”Sheet Metal

Screw

Driver Side LouverAdapter Assembly

496137

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906417 REV K 01/10/18, PG 22 OF 31

Figure 22

Flow

Control Panel & Duct Hose Routing

Control PanelWiring Harness232002-VUA

PassengerSide Louver2 ½” x 30”

PassengerSide Louver2 ½” x 20”

(Evaporator Side)

Passenger SideDuct Extension

Assembly605173-PCA

Defrost Duct2 ½” x 15”

Driver Side2 ½” x 10”

Driver Side Center Louver

2 ½” x 18”

Passenger Side Center Louver

2 ½” x 18”

Driver SideLower Right

Louver2” x 12”

2 ½” x 12”

Plug FromWiring Harness232001-VUR

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23 906417 REV K 01/10/18, PG 23 OF 31

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etal

(fi

ttin

gs

&tu

be)

wit

h s

up

plie

d p

ress

tap

e.

Evap

ora

tor

Hard

lin

e I

nst

all

ati

on

#10

O-r

ing

(2)

#10

O-r

ings

ECU

Mod

ule

Pres

s Ta

pe#

6 O

-rin

g

#10

Suc

tion

Line

(091

51-P

CS)

Hea

ter

Line

(Hea

ter

to W

ater

Pum

p)09

152-

PCH

Hea

ter

Line

(Hea

ter

to I

ntak

e)09

153-

PCH

(2)

1/4-

20 x

1/2

” Bol

ts(L

ocat

ed o

n Sub

Cas

e)

Hol

d w

ithTh

is W

renc

h

Twis

t w

ithTh

is W

renc

h

Lubr

icat

e O

-rin

g (S

ee F

igur

e 18

, Pa

ge 1

9

#6

Liqu

id L

ine

(091

50-P

CL)

24

www.vintageair.com

906417 REV K 01/10/18, PG 24 OF 31

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

REVISION C 10/06/17

25

www.vintageair.com

906417 REV K 01/10/18, PG 25 OF 31

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.

26

www.vintageair.com

906417 REV K 01/10/18, PG 26 OF 31

C

C C

HI

HI HI

OFF

OFF OFF

DEF

DEF DEF

FLR

FLR FLR

PNL

PNL PNL

PNL

PNL PNL

FLR

FLR FLR

H

H H

CONO

E

CONO

E

CONO

E

AC

AC

AC

BlowerSpeed

ThermostatDialMode

Dial

Blower SpeedThis lever controlsthe blower speed,

from off to hi.

Mode DialRoll the dial up or down

to the “PNL”, “FLR” or “DEF”legends in the “AC” range

of the mode dial.

Thermostat DialRoll the thermostatdial all the way up

for maximum cooling.Roll the dial downto decrease the

amount of cooling.

Blower SpeedThis lever controlsthe blower speed,

from off to hi.

Mode DialRoll the dial down

to the “PNL” or “FLR”legends in the “ECONO”range of the mode dial.

Thermostat DialRoll the thermostat

dial all the way downfor maximum heating.

Roll the dial up todecrease the amount

of heating.

Blower SpeedThis lever controlsthe blower speed,

from off to hi.

Mode DialRoll the dial up to

the “DEF” legend inthe “AC” range of the

mode dial.

Thermostat DialRoll the thermostat

dial all the way downfor maximum heating.

Roll the dial up todecrease the amount

of heating.

A/C Operation

Defrost OperationHeat Operation

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

Mode Dial: “AC” & “ECONO” RangesThe “AC” and “ECONO” ranges of the mode dial operate indentically. However, when the mode dial is in the “ECONO” range, the A/C compressor is switched off. NOTE: When the mode dial is moved from one range to the other, the blower will momentarily change speeds, before returning to normal, to indicate the change.

Operation of Controls

ww

w.v

inta

gea

ir.c

om

27 906417 REV K 01/10/18, PG 27 OF 31

Sym

pto

m

C

on

dit

ion

C

heck

s

Act

ion

s

N

ote

s

Blo

wer

sta

ys o

n hi

gh s

peed

whe

n ig

nitio

n is

on.

1a.

No

othe

r fu

nctio

ns w

ork.

Che

ck f

or d

amag

ed p

ins

or

wires

in c

ontr

ol h

ead

plug

.Ve

rify

tha

t al

l pin

s ar

e in

sert

ed in

to p

lug.

Ens

ure

that

no

pins

are

ben

t or

dam

aged

in E

CU

.Che

ck f

or d

amag

ed g

roun

d w

ire

(whi

te)

in c

ontr

ol h

ead

harn

ess.

Verify

con

tinui

ty t

o ch

assi

s gr

ound

with

whi

te c

ontr

ol

head

wire

at v

ario

us p

oint

s.

Loss

of gr

ound

on

this

wire

rend

ers

cont

rol h

ead

inop

erab

le.

All

othe

r fu

nctio

ns w

ork.

Che

ck f

or d

amag

ed b

low

er

switc

h or

pot

entio

met

er a

nd

asso

ciat

ed w

irin

g.

Blo

wer

sta

ys o

n hi

gh s

peed

whe

n ig

nitio

n is

on

or o

ff.

Unp

lug

3-w

ire

BSC c

ontr

ol

conn

ecto

r fr

om E

CU

. If

blo

wer

sh

uts

off,

ECU

is e

ither

im

prop

erly

wired

or

dam

aged

.

Be

sure

the

sm

all,

20 G

A w

hite

gro

und

wire

is c

onne

cted

to

the

bat

tery

gro

und

post

. If

it is

, re

plac

e th

e EC

U.

Unp

lug

3-w

ire

BSC c

ontr

ol

conn

ecto

r fr

om E

CU

. If

blo

wer

st

ays

runn

ing,

BSC is

eith

er

impr

oper

ly w

ired

or

dam

aged

.

Che

ck t

o en

sure

tha

t no

BSC w

irin

g is

dam

aged

or

shor

ted

to v

ehic

le g

roun

d. T

he B

SC o

pera

tes

the

blow

er

by g

roun

d si

de p

ulse

wid

th m

odul

atio

n sw

itchi

ng.

The

posi

tive

wire

to t

he b

low

er w

ill a

lway

s be

hot

. If

the

“g

roun

d” s

ide

of t

he b

low

er is

sho

rted

to

chas

sis

grou

nd,

the

blow

er w

ill r

un o

n H

I.

Repl

ace

BSC (

This

will

req

uire

rem

oval

of ev

apor

ator

fr

om v

ehic

le).

No

othe

r pa

rt r

epla

cem

ents

sh

ould

be

nece

ssar

y.

Com

pres

sor

will

no

t tu

rn o

n (A

ll ot

her

func

tions

w

ork)

.

2.

Syst

em is

not

cha

rged

.Sy

stem

mus

t be

cha

rged

for

co

mpr

esso

r to

eng

age.

Cha

rge

syst

em o

r by

pass

pre

ssur

e sw

itch.

Dan

ger

: N

ever

byp

ass

safe

ty s

wit

ch w

ith

en

gin

e ru

nn

ing

. S

erio

us

inju

ry c

an r

esu

lt.

Syst

em is

cha

rged

.

1b

.

Tro

ub

lesh

oo

tin

g G

uid

e

Che

ck f

or f

aulty

A/C

po

tent

iom

eter

or

asso

ciat

ed

wirin

g (N

ot a

pplic

able

to

3-po

t co

ntro

ls).

Che

ck f

or d

isco

nnec

ted

or

faul

ty t

herm

isto

r.

Che

ck c

ontin

uity

to

grou

nd o

n w

hite

con

trol

hea

d w

ire.

Che

ck f

or 5

V o

n re

d co

ntro

l hea

d w

ire.

Che

ck 2

-pin

con

nect

or a

t EC

U h

ousi

ng.

To c

heck

for

pro

per

pot

func

tion,

che

ck v

olta

ge a

t w

hite

/blu

e w

ire.

Vol

tage

sh

ould

be

betw

een

0V a

nd

5V,

and

will

var

y w

ith p

ot

leve

r po

sitio

n.

Dis

conn

ecte

d or

fau

lty

ther

mis

tor

will

cau

se

com

pres

sor

to b

e di

sabl

ed.

Red

wire

at A

/C p

ot s

houl

d ha

ve a

ppro

xim

atel

y 5V

w

ith ig

nitio

n on

. W

hite

w

ire

will

hav

e co

ntin

uity

to

chas

sis

grou

nd.

Whi

te/

Blu

e w

ire

shou

ld v

ary

betw

een

0V a

nd 5

V w

hen

leve

r is

mov

ed u

p or

dow

n.

3. Com

pres

sor

will

no

t tu

rn o

ff

(All

othe

r fu

nctio

ns

wor

k).

Che

ck f

or f

aulty

A/C

po

tent

iom

eter

or

asso

ciat

ed

wirin

g.

Che

ck f

or f

aulty

A/C

rel

ay.

Repa

ir o

r re

plac

e po

t/co

ntro

l wirin

g.

Repl

ace

rela

y.

See

blo

wer

sw

itch

chec

k pr

oced

ure.

ww

w.v

inta

gea

ir.c

om

28 906417 REV K 01/10/18, PG 28 OF 31

Sym

pto

m

C

on

dit

ion

Ch

eck

s

Act

ion

s

N

ote

s

Syst

em w

ill n

ot

turn

on,

or

runs

in

term

itten

tly.

4.

Wor

ks w

hen

engi

ne is

not

runn

ing;

shu

ts o

ff w

hen

engi

ne is

sta

rted

(T

ypic

ally

ear

ly G

en I

V,

but

poss

ible

on

all

vers

ions

).

Noi

se in

terf

eren

ce f

rom

eith

er

igni

tion

or a

ltern

ator

.

Inst

all c

apac

itors

on

igni

tion

coil

and

alte

rnat

or.

Ensu

re

good

gro

und

at a

ll po

ints

. Re

loca

te c

oil a

nd a

ssoc

iate

d w

irin

g aw

ay f

rom

ECU

and

ECU

wirin

g. C

heck

for

bur

ned

or lo

ose

plug

wires

.

Verify

con

nect

ions

on

pow

er

lead

, ig

nitio

n le

ad,

and

both

whi

te g

roun

d w

ires

.

Verify

pro

per

met

er f

unct

ion

by c

heck

ing

the

cond

ition

of

a kn

own

good

bat

tery

.

Igni

tion

nois

e (r

adia

ted

orco

nduc

ted)

will

cau

se t

he

syst

em t

o sh

ut d

own

due

tohi

gh v

olta

ge s

pike

s. I

f th

isis

sus

pect

ed,

chec

k w

ith a

qu

ality

osc

illos

cope

. Spi

kes

grea

ter

than

16V

will

shu

t do

wn

the

ECU

. In

stal

l a

radi

o ca

paci

tor

at t

he

posi

tive

post

of th

e ig

nitio

nco

il (S

ee r

adio

cap

acito

r in

stal

latio

n bu

lletin

). A

fa

ulty

alte

rnat

or o

r w

orn

out

batt

ery

can

also

res

ult

in t

his

cond

ition

.

Will

not

tur

n on

und

er

any

cond

ition

s.Ve

rify

bat

tery

vol

tage

is

grea

ter

than

10

volts

and

less

than

16.

Loss

of m

ode

door

fu

nctio

n.

No

mod

e ch

ange

at

all.

Che

ck f

or d

amag

ed m

ode

switc

h or

pot

entio

met

er a

nd

asso

ciat

ed w

irin

g.

Part

ial f

unct

ion

of m

ode

door

s.

Typi

cally

cau

sed

by

evap

orat

or h

ousi

ng

inst

alle

d in

a b

ind

in t

he

vehi

cle.

Be

sure

all

mou

ntin

g lo

catio

ns li

ne u

p an

d do

n’t

have

to

be for

ced

into

pos

ition

.

Blo

wer

tur

ns o

n an

d of

f ra

pidl

y.

6.

Bat

tery

vol

tage

is a

t le

ast

12V.

Che

ck f

or a

t le

ast

12V a

t ci

rcui

t br

eake

r.En

sure

all

syst

em g

roun

ds a

nd p

ower

con

nect

ions

are

cl

ean

and

tight

.

Bat

tery

vol

tage

is le

ss

than

12V

.

5.

Tro

ub

lesh

oo

tin

g G

uid

e (

Co

nt.

)

Che

ck f

or f

aulty

bat

tery

or

alte

rnat

or.

Cha

rge

batt

ery.

Syst

em s

huts

off b

low

er a

t 10

V. P

oor

conn

ectio

ns o

r w

eak

batt

ery

can

caus

e sh

utdo

wn

at u

p to

11V

.

7. Whe

n ig

nitio

n is

tu

rned

on,

blo

wer

m

omen

tarily

co

mes

on,

the

n sh

uts

off.

This

oc

curs

with

the

bl

ower

sw

itch

in

the

OFF

pos

ition

.

This

is a

n in

dica

tor

that

the

sy

stem

has

bee

n re

set.

Be

sure

the

red

pow

er w

ire

is o

nth

e ba

tter

y po

st,

and

not

on a

sw

itche

d so

urce

. Als

o, if

the

sy

stem

is p

ulle

d be

low

7V f

orev

en a

spl

it se

cond

, th

e sy

stem

will

res

et.

Run

red

pow

er w

ire

dire

ctly

to

batt

ery.

Che

ck f

or p

ositi

ve p

ower

at

heat

er v

alve

gre

en w

ire

and

blow

er r

ed w

ire.

Che

ck f

or g

roun

d on

con

trol

hea

d w

hite

w

ire.

Che

ck f

or o

bstr

ucte

d or

bi

ndin

g m

ode

door

s.Che

ck f

or d

amag

ed s

tepp

er

mot

or o

r w

irin

g.

Erra

tic fun

ctio

ns o

fbl

ower

, m

ode,

te

mp,

etc

.

Che

ck f

or d

amag

ed s

witc

h or

po

t an

d as

soci

ated

wirin

g.Re

pair o

r re

plac

e.

8.

29

www.vintageair.com

906417 REV K 01/10/18, PG 29 OF 31

Passenger CompartmentModification Templates

Drill

3/16

”H

ole

Fron

t Ev

apor

ator

Bra

cket

M

oun

tin

g T

emp

late

Pas

sen

ger

Sid

e D

ash

Mod

ifica

tion

Tem

pla

te

Fold

Alo

ng L

ine

Cut

Alo

ng D

otte

d Li

ne

Cut

Alo

ng D

otte

d Li

ne

Drill

3/16

”H

ole

5 ½

”

30

www.vintageair.com

906417 REV K 01/10/18, PG 30 OF 31

Drill 3/8”Hole

Drill 3/8”Hole

OEMHole

OEMHole

Lower Passenger Side Firewall Template

Lower Driver Side Firewall Template

Firewall Modification Templates

31

www.vintageair.com

906417 REV K 01/10/18, PG 31 OF 31

Packing List: Evaporator Kit (564174)

No. 1.2.

Qty.11

Part No.764170784174

DescriptionGen IV Evaporator Sub CaseAccessory Kit

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

1

2

Gen IV Evaporator Sub Case764170

Accessory Kit784174

Checked By:Packed By:

Date:

C

HI

OFF

DEF

FLR

PNL

PNL

FLR

H

AC

EC

ON

O

E