564173-PCZ
an ISO 9001:2008 Registered Company
1974-76 Chevrolet Corvette
with Factory Air
Evaporator Kit
(564174)
18865 Goll St. San Antonio, TX 78266
Phone: 210-654-7171
Fax: 210-654-3113
www.vintageair.com
906417 REV J 06/22/15, PG 1 OF 31
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Table of Contents
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.................................................................................................................................. 1
Table of Contents................................................................................................................. 2
Packing List/Parts Disclaimer.................................................................................................. 3
Information Page.................................................................................................................. 4
Wiring Notice....................................................................................................................... 5
Engine Compartment Disassembly.......................................................................................... 6
Passenger Compartment Disassembly...................................................................................... 7
Passenger Compartment Disassembly (Cont.), Fresh Air Cover Installation................................... 8
Condenser Assembly & Installation, Compressor & Brackets, Pulleys............................................ 9
Defrost Duct Replacement................................................................................................... 10
Passenger and Driver Side A/C Duct Hose Adapter Installation.................................................. 11
Passenger Side Dash Modification, Driver Side Under Dash Louver Hose Adapter......................... 12
Center Louver Assembly...................................................................................................... 13
Firewall Modification, Evaporator Bracket Mounting Holes......................................................... 14
Firewall Modification (Cont.), Evaporator Installation............................................................... 15
Evaporator Installation (Cont.)............................................................................................. 16
Drain Hose Installation........................................................................................................ 17
Firewall Cover.................................................................................................................... 18
A/C Hose Installation, Heater Hose & Heater Control Valve Installation, Lubricating O-rings.......... 19
Small Block Hose Routing.................................................................................................... 20
Final Steps........................................................................................................................ 21
Control Panel & Duct Hose Routing........................................................................................ 22
Evaporator Hardline Installation........................................................................................... 23
Wiring Diagram.................................................................................................................. 24
Gen IV Wiring Connection Instructions.................................................................................. 25
Operation of Controls.......................................................................................................... 26
Troubleshooting Guide......................................................................................................... 27
Troubleshooting Guide (Cont.).............................................................................................. 28
Passenger Compartment Modification Templates..................................................................... 29
Firewall Modification Templates............................................................................................ 30
Packing List....................................................................................................................... 31
2
906417 REV J 06/22/15, PG 2 OF 31
Packing List:
Evaporator Kit (564174)
www.vintageair.com
No.
1.
2.
Qty.
1
1
Part No.
764170
784174
Description
Gen IV Evaporator Sub Case
Accessory 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.
1
Gen IV Evaporator
Sub Case
764170
2
OFF
HI
DE
F
C
A
C
FLR
PN
L
E
C
O
N
O
PN
L
FLR
H
Accessory Kit
784174
NOTE: Images may not depict actual parts and quantities.
Refer to packing list for actual parts and quantities.
3
906417 REV J 06/22/15, PG 3 OF 31
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Important Notice—Please Read
For Maximum System Performance, Vintage Air Recommends the Following:
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:
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).
Safety Switches
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.
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.
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.
4
906417 REV J 06/22/15, PG 4 OF 31
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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.
5
906417 REV J 06/22/15, PG 5 OF 31
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Engine Compartment Disassembly
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:
1. Disconnect battery.
2. Remove hood to ease installation (retain).
3. Drain radiator.
4. Evacuate the A/C system (if necessary).
5. Remove OEM condenser and drier (discard).
6. Remove OEM A/C lines from compressor to evaporator (discard).
7. Remove OEM compressor and compressor bracket (discard).
8. Remove coolant overflow bottle (retain).
9. Remove OEM blower assembly and cover (discard).
10. Remove OEM evaporator and cover (discard).
11. Remove OEM A/C harness and vacuum harness (discard).
12. Install (2) 1 ½” plugs in firewall as shown in Figure 1a, below.
(2) 1 ½” Plugs
Figure 1a
Vacuum
Harness
Evaporator
& Cover
A/C
Harness
A/C
Lines
Compressor
Condenser
Blower
Assembly
& Cover
Drier
Figure 1
6
906417 REV J 06/22/15, PG 6 OF 31
Passenger Compartment
Disassembly
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Perform the Following:
1. Remove passenger side dash (retain).
2. Disconnect center dash (retain) and pull forward to remove OEM A/C duct (discard duct).
3. Remove OEM radio (retain).
4. Remove control panel (retain). Refer to control panel conversion kit to assemble control panel.
5. Drop steering column.
6. Disconnect driver side dash and pull forward.
7. Remove the passenger side, center and driver side A/C ducts as shown in Figure 3, below (discard).
8. Remove the floor heater duct as shown (discard).
Driver Side
Dash
Center
Dash
Control
Panel
Steering
Column
Radio
Figure 2
Passenger Side
Dash
Driver Side
A/C Duct
Center
A/C Duct
Floor
Heater
Duct
Figure 3
7
Passenger Side
A/C Duct
906417 REV J 06/22/15, PG 7 OF 31
Passenger Compartment
Disassembly (Cont.)
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Perform the Following:
1. Remove the OEM defrost duct (discard).
2. Remove the heater housing from under the dash.
3. Remove the kick panel vacuum control assembly (discard) (See Figure 4a, below).
4. 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.
OEM Defrost
Duct
Kick Panel
Vacuum
Control
Assembly
Remove
Figure 4a
Heater
Housing
Drill
(2) 1/8” Holes
(2) #8 x 1/2”
Pan Head
Screws
Figure 4
Kick Panel
Fresh Air Cap
Fresh Air Cover Installation
1. Apply a 1/4” bead of silicone around the back side of the fresh air cap as shown in Figure 4b, below.
2. Attach the fresh air cap to the firewall using a 1/4-20 x 1” bolt and washer. See Figure 4b, below.
Silicone
Back Side of
Fresh Air
Cap
Figure 4b
1/4-20 x 1”
Bolt with
Washer
Fresh Air Cap
8
906417 REV J 06/22/15, PG 8 OF 31
Condenser Assembly & Installation
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1. Refer to separate instructions included with the condenser kit to install the condenser. Refer to Figure 5,
below, for condenser location.
Core
Support
OEM
Radiator
091071-CCD
#8 Condenser/Core
Support Hardline
Figure 5
091069-CCL
#6 Drier/Core
Support Hardline
Drier
Compressor & Brackets
1. Refer to separate instructions included with the bracket kit to install the compressor bracket. Refer to Figure
6, below, for compressor mounting position.
Pulleys
1. 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 Pump
Small 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)
Tab
“E”
Tab
“A”
Compressor
Generator
or
Alternator
Tab
“G”
Mount the
Compressor
Using Tabs
“G” & “C”
9
Tab
“C”
Figure 6
Water Pump
Pulley
Crankshaft
Pulley
906417 REV J 06/22/15, PG 9 OF 31
Defrost Duct Replacement
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1. Remove screws attaching the OEM defrost duct (retain (2) screws attaching the duct to the dash pad) (See
Photo 1, below).
2. Remove remaining screws attaching the dash pad to the dash, and remove the dash pad from the
vehicle (retain) (See Photo 1, below).
3. Place new defrost duct on the dash pad, in place of the OEM defrost duct (See Photo 2, below).
4. Attach using (2) screws removed in Step #1. Tighten and reinstall the dash pad using the OEM screws
previously removed (See Photo 3, below).
Dash
Pad
Dash
Pad
OEM Screw
Location
OEM Screw
Location
Defrost Duct
625090
Photo 1
Photo 2
OEM
Screw
OEM
Screw
Photo 3
10
906417 REV J 06/22/15, PG 10 OF 31
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Passenger and Driver Side
A/C Duct Hose Adapter Installation
1. Remove (2) vent knobs as shown in Figure 7, below (retain).
2. Remove the passenger and driver side vent adapters (discard) as shown in Figure 8, below. NOTE: Retain
mounting hardware.
3. 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.
4. Install the vent knob as shown using a 10-24 x 1 ¼” pan head screw and 3/16” flat washer. NOTE: The
passenger side installation is shown below in Figure 8. Repeat the same steps for the driver side
installation.
5. See Figure 8a, below, for a completely assembled view of the A/C duct hose adapter.
Remove
Vent Knob
Remove
Vent Knob
Figure 7
Vent Adapter
OEM
Assembly
Outer A/C Duct
Hose Adapter
Inner A/C Duct
Hose Adapter
Figure 8
(3) OEM
Screws
Vent Knob
10-24 x 1 ¼”
Pan Head Screw
Assembled
View of
A/C Duct
Hose Adapter
3/16” Flat
Washer
Figure 8a
11
906417 REV J 06/22/15, PG 11 OF 31
Passenger Side Dash Modification
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1. Align the template (provided on Page 29) on the back side of the passenger side dash as shown in Figure 9,
below.
2. Using a pencil or scribe, mark along the edge of the template as shown.
3. 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).
PA
MO SSENGE
DIFIC
R
ATIO SIDE
N TE DASH
MP
LATE
Back Side of
Passenger Side
Dash
Template
Remove
Shaded Portion
Figure 9
Figure 9a
Foam Pad
Driver Side Under Dash Louver Hose Adapter
1. 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.
Dash
OEM Louver
OEM Louver
Driver Side Louver
Hose Adapter
Driver Side Louver
Hose Adapter
Figure 10
12
#8 x 1/2”
Pan Head Screw
906417 REV J 06/22/15, PG 12 OF 31
Center Louver Assembly
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1. Remove the center louver assembly from the center console.
2. 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.
3. Making sure the OEM vents are in their original location, install the center louver adapter to the previously
removed OEM vent door location as shown in Photos 5 and 6, below.
4. 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.
5. Install and tighten the (3) OEM screws as shown in Photos 8 and 9, below.
Center Louver
Adapter
625082
OEM Screw
Location
OEM Screw
Location
Center Louver
Frame
OEM Vent
Door Location
OEM Screw
Location
Photo 4
Photo 5
Center Louver
Adapter Slot
Check for
Proper
Alignment
Vent Divider
Blade
(3) OEM
Screws
Photo 6
Photo 7
Attach Screw
Here
Attach Screw
Here
Attach Screw
Here
Photo 8
Photo 9
13
906417 REV J 06/22/15, PG 13 OF 31
Firewall Modification
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1. 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.
2. 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 (See
Figure 11, below).
Firewall
Drill (2)
3/8” Holes
Lower
Driver Side
Firewall
Templates
Lower
Passenger Side
Firewall
Figure 11
Evaporator Bracket Mounting Holes
1. Cut out the template provided on Page 29. Place the template under the dash on the inner cowl as shown in
Figure 12, below.
2. 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.
Mark & Drill
(2) 3/16”
Mounting Holes
Existing OEM
Hole on
Some Models
Align Template
Against Dash
Brace
Inner Cowl
Template
Figure 12
14
906417 REV J 06/22/15, PG 14 OF 31
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Firewall Modification (Cont.)
1. 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).
2. 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).
3. When the firewall has been marked as shown in Figure 13, below, remove the marked area from the firewall
(See Figure 13a, below).
OEM
Hole
3/8” Drilled
Hole
Mark and
Cut Along
Dotted Line
3/8” Drilled
Hole
Figure 13
Passenger Side
Engine Compartment
View
Figure 13a
Evaporator Installation
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.
1. 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).
2. 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.
3. Place polyethylene sheet over the stepper motors (See Figure 15, Page 16).
4. 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 flat
portions of the case around the drain.
5. 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).
6. 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).
7. 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.
15
906417 REV J 06/22/15, PG 15 OF 31
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Evaporator Installation (Cont.)
Evaporator Front
Bracket
643071-PCA
Figure 14
10-32 x 1/2”
Screw
4-Vent
A/C Plenum
(2) 1/4-20 x 1/2”
Hex Bolts
OEM
Hole
Inner
Cowl
1/4-20 x 1”
Bolt & Washer
(Install Bolt & Washer
From Engine
Compartment Side)
FIGURE 7
Left
Mounting
Hole
Right
Mounting
Hole
Once Bracket is
in Place, Drill a 3/16”
Mounting Hole
NOTE: Install
This Screw First
Place Polyethylene
Sheet Over the
Stepper Motors
(2) #14 x 3/4”
Sheet Metal Screws
Figure 15
16
906417 REV J 06/22/15, PG 16 OF 31
Drain Hose Installation
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1. 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).
2. Install the drain hose to the bottom of the evaporator unit, and route through the firewall (See Figure 16,
below).
1”
Drain
Drain
Hose
Figure 16
17
906417 REV J 06/22/15, PG 17 OF 31
Firewall Cover
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1. Apply a 1/4” bead of silicone around the back side of the firewall cover as shown in Figure 17, below.
2. Pass the lines through the firewall cover, and secure with (2) 7/16” panel retainers (See Figure 17, below).
3. 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).
4. Install (2) grommets in the firewall cover cap as shown in Figure 17, below.
5. 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 Side
of Firewall
Cover
Figure 17
Silicone
SB
Y
Drill 3/8”
Hole
(3) 7/16”
Panel
Retainers
Large
Grommet
Firewall
Cap
Silicone
1 ¼” x 1”
with 3/8” Hole
Grommet
Back Side
of Firewall
Cover Cap
18
#10 Suction
Line
#6 Liquid
Line
(2) #8 x 1/2”
Pan Head
Screws
906417 REV J 06/22/15, PG 18 OF 31
A/C Hose Installation
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Standard Hose Kit:
1. 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.
2. 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).
3. 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.
Modified Hose Kit:
1. Refer to separate instructions included with modified hose kit.
Heater Hose & Heater Control Valve Installation
1. 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.
2. 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.
Lubricating O-rings
Male
O-ring Insert
Female Nut
#6 O-ring
#8 O-ring
#10 O-ring
For a proper seal of fittings: Install supplied
O-rings as shown, and lubricate with supplied
oil.
O-ring
Supplied Oil
for O-rings
NOTE: Standard torque specifications:
#6: 11 to 13 ft-lb.
#8: 15 to 20 ft-lb.
#10: 21 to 27 ft-lb.
O-ring Installs
Over Male Insert
to Swaged Lip
Figure18
##
Figure
Twist With
This Wrench
Hold With
This Wrench
19
906417 REV J 06/22/15, PG 19 OF 31
20
906417 REV J 06/22/15, PG 20 OF 31
Firewall
Cover
Press
Tape
ECU
Module
Heater
Control
Valve
www.vintageair.com
Evaporator
Sub Case
Press
Tape
#6 A/C Hose
(Drier/Evaporator)
#8 A/C
Discharge Hose
(Compressor/
Condenser Hardline)
#10 A/C
Suction Hose
(Compressor/Evaporator)
Out
FLOW
In
Binary
Switch
Figure 19
Small Block Hose Routing
Final Steps
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1. Install the driver side louver adapter assembly as shown in Figure 21, below.
2. Install the duct hoses as shown in Figure 22, Page 22.
3. Reinstall the center dash assembly.
4. Reinstall the control panel assembly. Refer to control panel instructions. NOTE: Controls must be calibrated
for proper operation. Refer to control panel instructions.
5. Plug the control panel harness into the ECU module on the sub case as shown in Figure 22, Page 22.
6. Plug the wiring harnesses into the ECU module on the sub case. Wire according to wiring diagrams on Pages
24 & 25.
7. Reinstall all previously removed items.
8. 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.
9. Double check all fittings, brackets and belts for tightness.
10. Vintage Air recommends that all A/C systems be serviced by a licensed automotive A/C technician.
11. Evacuate the system for a minimum of 45 minutes prior to charging, and perform a leak check prior to
servicing.
12. Charge the system to the capacities stated on Page 4 of this instruction manual.
13. See Operation of Controls procedures on Page 26.
ECU
Module
#10 x 3/4”
Sheet Metal
Screw
Press
Tape
Firewall
Cover
#10
Suction
Line
(Insulated)
Driver Side Louver
Adapter Assembly
496137
O-ring
#10 Suction
Hose
Expansion
Valve
Firewall
Cover Cap
Figure 20
TO
WAT
ER
FRO
Heater
Hose
M
HT
RC
Figure 21
PUM
P
NT
RL
NOTE: Flow Direction Follows
Molded Arrow on Valve.
VLV
#6 A/C
Hose
FR
OM
IN
TA
K
E
21
906417 REV J 06/22/15, PG 21 OF 31
www.vintageair.com
Control Panel & Duct Hose Routing
Control Panel
Wiring Harness
232002-VUA
Passenger
Side Louver
2 ½” x 30”
Passenger Side
Duct Extension
Assembly
605173-PCA
Passenger
Side Louver
2 ½” x 20”
(Evaporator Side)
Flow
Driver Side
Center Louver
2 ½” x 18”
Plug From
Wiring Harness
232001-VUR
Defrost Duct
2 ½” x 15”
Driver Side
2 ½” x 10”
2 ½” x 12”
Passenger Side
Center Louver
2 ½” x 18”
Figure 22
Driver Side
Lower Right
Louver
2” x 12”
22
906417 REV J 06/22/15, PG 22 OF 31
23
906417 REV J 06/22/15, PG 23 OF 31
Figure 23
Press Tape
#6 O-ring
#10 O-ring
Heater Line
(Heater to Intake)
09153-PCH
Heater Line
(Heater to Water Pump)
09152-PCH
#10 Suction
Line
(09151-PCS)
NOTE: After installing the
#10 suction line, wrap all
exposed metal (fittings &
tube) with supplied press
tape.
www.vintageair.com
Twist with
This Wrench
#6 Liquid Line
(09150-PCL)
ECU Module
(See Figure 18,
Page 19
FIGURE
8 O-ring
Lubricate
Hold with
This Wrench
(2) 1/4-20 x 1/2” Bolts
(Located on Sub Case)
(2) #10 O-rings
Evaporator Hardline Installation
Wiring Diagram
www.vintageair.com
232007-VUR
TAN
ORA
BLK
WHT
RED
WHT/RED
WHT/YEL
JF8
WHT/GRN
AC ANNUNCIATOR
BACKLIGHT POS
BACKLIGHT NEG
GND
5V-SW
TEMP WIPER
MODE WIPER
FAN WIPER
PRE-WIRED
VIEWED FROM WIRE SIDE
232002-VUA
A/C
(IF USED)
GEN IV ECU
GEN IV WIRING DIAGRAM
REV D, 5/6/2014
TEMP
MODE
FAN
PROGRAM
* DASH LAMP
(IF USED)
*** WIDE OPEN
THROTTLE
SWITCH
(OPTIONAL)
** CIRCUIT
BREAKER
30 AMP
HEATER
CONTROL VALVE
• Dash Lamp Is Used Only With Type 232007-VUR Harness.
• 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).
• Wide Open Throttle Switch Contacts Close Only at Full Throttle, Which Disables A/C
Compressor.
24
906417 REV J 06/22/15, PG 24 OF 31
Gen IV Wiring
Connection Instruction
www.vintageair.com
WIRING
HARNESS
CONTROL
WIRING
HARNESS
RED
&
WHITE
A/C
COMPRESSOR
RELAY
RED
BLUE
NOTE:
MOUNT RELAY
IN DESIRED
LOCATION
UNDER DASH
RED
WH
IT
E
Ignition Switch:
VIOLET
Violet 12V Ign Switch Source (Key On
Accessory) Position Must Be Switched.
+12V
NOTE:
WIRING YELLOW & ORANGE (IGNITION HOT
HARNESS COMING FROM
TERMINAL)
HARNESS ARE NOT
USED.
YELLOW
RUN
BAT
IGNITION
SWITCH
ORANGE
TAN
DASH BACK LIGHT+0-12v
GRAY
GRAY WIRE IS USED FOR
PROGRAMING CONTROLS
IF APPLICABLE
RED
GREEN
RED
GREEN
FIREWALL
BLACK BLUE
Heater Control Valve:
RED
LATCH
WIRING
HARNESS
WHITE
CHASSIS GROUND
NOTE: HEATER CONTROL
VALVE CONNECTION AND
CHASSIS GROUND MAY BE
LOCATED ON EITHER SIDE
OF THE FIREWALL. ENSURE
CONNECTOR IS LATCHED
FIRMLY.
HEATER
CONTROL VALVE
K
BLAC
BLUE
COMPRESSOR
WHITE
NOTE: CONNECT WHITE
WIRES DIRECTLY TO
(-) BATTERY TERMINAL
WHITE
RED
RED
CIRCUIT BREAKER
30 AMP
Install With Servo Motor Facing Down,
As Shown. Note Flow Direction Arrow
Molded Into Valve Body, And Install
Accordingly.
Binary/Trinary & Compressor:
Binary: Connect As Shown (Typical
Compressor Wiring). Be Sure
Compressor Body Is Grounded.
BINARY
SAFETY
SWITCH
BLUE
Dash Light:
Tan Wire Used Only With Vintage Air
Supplied Control Panel With LED Back
Light.
Circuit Breaker/Battery:
White Must Run To (-) Battery. Red May
Run To (+) Battery Or Starter. Mount
Circuit Breaker As Close to Battery As
Possible.
RED
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).
+
Trinary Switch: Connect According To
Trinary Switch Wiring Diagram.
-
BATTERY
25
906417 REV J 06/22/15, PG 25 OF 31
Operation of Controls
www.vintageair.com
NOTE: For proper control panel function, refer to control panel instructions for calibration procedure.
A/C Operation
Blower Speed
This lever controls
the blower speed,
from off to hi.
OFF
Thermostat Dial
Roll the thermostat
dial all the way up
for maximum cooling.
Roll the dial down
to decrease the
amount of cooling.
HI
DEF
A
C
Mode Dial
Roll the dial up or down
to the “PNL”, “FLR” or “DEF”
legends in the “AC” range
of the mode dial.
Blower
Speed
C
FLR
PNL
PNL
E
C
O
N
O
Mode
Dial
FLR
H
Thermostat
Dial
Heat Operation
OFF
HI
DEF
A
C
C
FLR
PNL
PNL
E
C
O
N
O
FLR
H
Defrost Operation
Blower Speed
This lever controls
the blower speed,
from off to hi.
Blower Speed
This lever controls
the blower speed,
from off to hi.
Thermostat Dial
Roll the thermostat
dial all the way down
for maximum heating.
Roll the dial up to
decrease the amount
of heating.
Thermostat Dial
Roll the thermostat
dial all the way down
for maximum heating.
Roll the dial up to
decrease the amount
of heating.
Mode Dial
Roll the dial down
to the “PNL” or “FLR”
legends in the “ECONO”
range of the mode dial.
Mode Dial
Roll the dial up to
the “DEF” legend in
the “AC” range of the
mode dial.
OFF
HI
DEF
A
C
C
FLR
PNL
PNL
E
C
O
N
O
FLR
H
Mode Dial: “AC” & “ECONO” Ranges
The “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.
26
906417 REV J 06/22/15, PG 26 OF 31
27
906417 REV J 06/22/15, PG 27 OF 31
Symptom
Compressor will
not turn off
(All other functions
work).
3.
Compressor will
not turn on
(All other functions
work).
2.
Blower stays on
high speed when
ignition is on or off.
1b.
Blower stays on
high speed when
ignition is on.
1a.
System is charged.
System is not charged.
All other functions work.
No other functions work.
Condition
www.vintageair.com
Repair or replace pot/control wiring.
Replace relay.
Check for faulty A/C relay.
Check 2-pin connector at ECU housing.
Check continuity to ground on white control head wire.
Check for 5V on red control head wire.
Charge system or bypass pressure switch.
Replace BSC (This will require removal of evaporator
from vehicle).
Check to ensure that no BSC wiring is damaged or
shorted to vehicle ground. The BSC operates the blower
by ground side pulse width modulation switching. The
positive wire to the blower will always be hot. If the
“ground” side of the blower is shorted to chassis ground,
the blower will run on HI.
Be sure the small, 20 GA white ground wire is connected
to the battery ground post. If it is, replace the ECU.
Verify continuity to chassis ground with white control
head wire at various points.
Verify that all pins are inserted into plug. Ensure that no
pins are bent or damaged in ECU.
Actions
Check for faulty A/C
potentiometer or associated
wiring.
Check for disconnected or
faulty thermistor.
Check for faulty A/C
potentiometer or associated
wiring (Not applicable to 3-pot
controls).
System must be charged for
compressor to engage.
Unplug 3-wire BSC control
connector from ECU. If blower
stays running, BSC is either
improperly wired or damaged.
Unplug 3-wire BSC control
connector from ECU. If blower
shuts off, ECU is either
improperly wired or damaged.
Check for damaged ground
wire (white) in control head
harness.
Check for damaged blower
switch or potentiometer and
associated wiring.
Check for damaged pins or
wires in control head plug.
Checks
Red wire at A/C pot should
have approximately 5V
with ignition on. White
wire will have continuity to
chassis ground. White/
Blue wire should vary
between 0V and 5V when
lever is moved up or down.
Disconnected or faulty
thermistor will cause
compressor to be
disabled.
To check for proper pot
function, check voltage at
white/blue wire. Voltage
should be between 0V and
5V, and will vary with pot
lever position.
Danger: Never bypass
safety switch with
engine running. Serious
injury can result.
No other part replacements
should be necessary.
See blower switch check
procedure.
Loss of ground on this wire
renders control head
inoperable.
Notes
Troubleshooting Guide
28
906417 REV J 06/22/15, PG 28 OF 31
Symptom
8.
When ignition is
turned on, blower
momentarily
comes on, then
shuts off. This
occurs with the
blower switch in
the OFF position.
Erratic functions of
blower, mode,
temp, etc.
7.
Blower turns on
and off rapidly.
6.
Loss of mode door
function.
5.
System will not
turn on, or runs
intermittently.
4.
This is an indicator that the
system has been reset. Be
sure the red power wire is on
the battery post, and not on a
switched source. Also, if the
system is pulled below 7V for
even a split second, the
system will reset.
Run red power wire directly to battery.
Repair or replace.
Charge battery.
Check for faulty battery or
alternator.
Battery voltage is less
than 12V.
Check for damaged switch or
pot and associated wiring.
Ensure all system grounds and power connections are
clean and tight.
Verify proper meter function by checking the condition of
a known good battery.
Check for positive power at heater valve green wire and
blower red wire. Check for ground on control head white
wire.
Install capacitors on ignition coil and alternator. Ensure
good ground at all points. Relocate coil and associated
wiring away from ECU and ECU wiring. Check for burned
or loose plug wires.
Actions
Check for at least 12V at
circuit breaker.
Check for damaged stepper
motor or wiring.
Check for obstructed or
binding mode doors.
Check for damaged mode
switch or potentiometer and
associated wiring.
Verify battery voltage is
greater than 10 volts and less
than 16.
Verify connections on power
lead, ignition lead, and both
white ground wires.
Noise interference from either
ignition or alternator.
Checks
Battery voltage is at least
12V.
Partial function of mode
doors.
No mode change at all.
Will not turn on under
any conditions.
Works when engine is not
running; shuts off when
engine is started
(Typically early Gen IV,
but possible on all
versions).
Condition
www.vintageair.com
System shuts off blower at
10V. Poor connections or
weak battery can cause
shutdown at up to 11V.
Typically caused by
evaporator housing
installed in a bind in the
vehicle. Be sure all
mounting locations line up
and don’t have to be forced
into position.
Ignition noise (radiated or
conducted) will cause the
system to shut down due to
high voltage spikes. If this
is suspected, check with a
quality oscilloscope. Spikes
greater than 16V will shut
down the ECU. Install a
radio capacitor at the
positive post of the ignition
coil (See radio capacitor
installation bulletin). A
faulty alternator or worn
out battery can also result
in this condition.
Notes
Troubleshooting Guide (Cont.)
29
Drill 3/16”
Hole
Cut Along Dotted Line
Front Evaporator Bracket
Mounting Template
5 ½”
Fold Along Line
Cut Along Dotted Line
Drill 3/16”
Hole
Passenger Side Dash
Modification Template
www.vintageair.com
Passenger Compartment
Modification Templates
906417 REV J 06/22/15, PG 29 OF 31
Firewall Modification Templates
www.vintageair.com
Drill 3/8”
Hole
OEM
Hole
Lower Passenger Side
Firewall Template
Drill 3/8”
Hole
OEM
Hole
Lower Driver Side
Firewall Template
30
906417 REV J 06/22/15, PG 30 OF 31
Packing List:
Evaporator Kit (564174)
www.vintageair.com
Part No.
No.
Qty.
764170
1.
1
784174
2.
1
Description
Gen IV Evaporator Sub Case
Accessory Kit
Checked By:
Packed By:
Date:
1
Gen IV Evaporator
Sub Case
764170
2
OFF
HI
DE
F
C
A
C
FLR
PN
L
E
C
O
N
O
PN
L
FLR
H
Accessory Kit
784174
NOTE: Images may not depict actual parts and quantities.
Refer to packing list for actual parts and quantities.
31
906417 REV J 06/22/15, PG 31 OF 31
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