specializing in “AIR CONDITIONING, PARTS AND SYSTEMS” for your classic vehicle

“PERFECT FIT SERIES”

IN-DASH

HEAT/ COOL/ DEFROST

1970-72 CHEVROLET CHEVELLE/ EL CAMINO

NOTE: INSTRUCTIONS DEPICT CHEVELLE

CONTROL & OPERATING INSTRUCTIONS

The controls on your new “Perfect Fit” system. Offers complete comfort capabilities in virtually every driving condition. This includes Temperature control in all of the modes.

This system also provides the ability to blend the air between Face, Heat, and Defrost modes simultaneously.

TEMPERATURE LEVER

BLOWER SWITCH

FACE / DEFROST DOOR

HEAT / DEFROST DOOR

THE PICTURE YOU SEE ABOVE SHOWS THE CONTROLS IN THE DEFROST

MODE. THIS MEANS THAT ALL OF THE AIR WILL BE DISTRIBUTED

THROUGH THE DEFROST DUCT ASSEMBLY. THIS ALSO HAS THE

TEMPERATURE LEVER IN THE COLD POSITION. WITH THE CONTROLS IN

THIS POSITION YOU WILL GET THE AIR THROUGH THE SYSTEM AT ROOM

TEMPERATURE.

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CAUTION:

ALL OF THE OUTSIDE VENTS MUST BE CLOSED WHEN THE

SYSTEM IS IN THE A/C MODE. THIS WILL ALLOW THE A/C SYSTEM TO

FUCTION AT ITS MAXIMUM PERFORMANCE LEVEL.

THE FOLLOWING SUMMARY WILL DESCRIBE EACH OF THE CONTROL

LEVERS FUNCTION.

FAN SPEED SWITCH

: There are 3 speeds plus Off. When the switch is in the off position it will disconnect the 12V power to the Blower Motor and the A/C Clutch. This will shut down the entire system. When the switch is moved to any of the blower speeds

1,2 or 3 there is 12V supplied to the Micro-Switch which is mounted on the defrost air housing.

HEAT MODE

: When the heat lever is moved towards the right, it will allow the air to go between the floor ducts and the face louvers. Only when the lever is in the far right position will all of the air stop coming out of the face louvers and blow on the floor.

TEMPERATURE CONTROL:

The temperature lever as shown is in the

COLDEST temperature position. As the lever is pushed to the right the temperature of the discharged air will rise to the HOTTEST point.

Note: The temperature lever will function in any of the modes.

DEFROST MODE

: This system allows for Dehumidification of the air in the

Defrost mode. The Heat lever must be in the right position. The bottom lever must be at the far right position in order to get the maximum air flow to the windshield and to trip the Micro-Switch. This will activate the Compressor Clutch.

AIR CONDITIONING MODE:

The picture shows the controls in the

Defrost Mode (air-flow to the windshield).

When Air Conditioning is required the compressor clutch must be activated. This is accomplished by pushing the top lever to the far left position. The bottom lever must be in the far right position to activate the clutch. When the compressor is activated the

Temperature Lever will control the air from maximum cold through maximum heat.

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specializing in “AIR CONDITIONING, PARTS AND SYSTEMS” for your classic vehicle

INSTALLATION INSTRUCTIONS

1970-72 CHEVROLET CHEVELLE/ EL CAMINO

NOTE: INSTRUCTIONS DEPICT CHEVELLE

Congratulations!! You have just purchased the highest quality, best performing A/C system ever designed for you Classic Car. To obtain the high level of performance and dependability our systems are known for, pay close attention to the following instructions.

Before beginning the installation check the box for the correct components.

Evaporator

Face Duct Assembly

Defrost / Heat Duct Assembly

Inlet Air Blockoff Assembly

Firewall Blockoff Assembly

Flex hose 2” dia. x 2ft. – 2ea.

Flex hose 2” dia. x 3ft. – 1ea.

Flex Hose 2 ½”dia. x 2ft. – 2ea.

Flex Hose 2 ½”dia. x 3ft. – 1ea.

Sack Kit Hardware

Sack Kit Control

Center Air Plenum

IMPORTANT INFORMATION

1.

Before starting, read the instructions carefully and follow proper sequence.

2.

Check condition of engine mounts. Excessive engine movement can damage hoses to A/C, heater, radiator, transcooler, and power steering systems.

3.

Before starting, check vehicle interior electrical functions. i.e. interior lights, radio, horn, etc. When ready to start installation, disconnect battery.

4.

Fittings. Use one or two drops of lubricant on O’rings, threads and rear of bump for O’ring where female nut rides. Do not use thread tape or sealants.

5.

Always use two wrenches to tighten fittings. Try holding in one hand while squeezing together while other hand holds fitting in position.

6.

Shaft seals in a small percentage of compressors will require as much as 3-4 hours run time to become leak free.

7.

Compressors supplied in our complete systems are filled with proper amount of oil.

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8.

Compressor requires technician to hand turn 15-20 revolutions before and after charging with liquid from a charging station before running system. Compressors with damaged reed valves cannot be warranted.

9.

Should you have any technical questions, or are suspect of missing, or defective parts, call us immediately. Our knowledgeable staff will be glad to assist you.

YOU CAN NOW BEGIN THE INSTALLATION

Remove (6) screws at locations shown to remove the dash pad.

In order to remove the heater assembly. It is necessary to remove Blower Housing Assembly from the engine side of the firewall.

Carefully lift vehicle and place support stands under center of the vehicle as shown.

Remove the (8) bolts. Lower the inner fender well on the passenger side.

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Remove (7) screws around the perimeter of the Blower Housing. The lower left screw is located behind the fender well.

Screw location behind fender well

On engine side of Firewall behind Hood hinge assembly is one of the (7) screws holding the blower housing. Remove and retain all of the original hardware.

Hood hinge assembly

Unplug electricals from the blower motor and remove blower assembly from the vehicle.

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Reinstall Inner Fender Well using the original hardware.

Heater Hoses

DRAIN COOLANT FROM RADIATOR.

Remove Heater hoses from heater coil at firewall.

Lower heater box on inside of car to the floor board. To remove heater box from the vehicle (3) control cables and the electrical must be disconnected from the housing. Disconnect (1) control cable and electrical plug located on top of the heater box.

Disconnect (1) control cable located next to the defrost outlet.

Disconnect final control cable located all the way to the left of the heater assembly.

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You can now remove heater assembly from inside of the vehicle.

The blockoff plate above the control head can be removed by (2) screws.

One as shown and the other on driver’s side of the blockoff. Retain original hardware. Remove the center speaker assembly and retain all original hardware.

The control head can be removed by pulling (4) screws behind the dash. There are (2) screws on each side of the control head. The (2) shown are on the passenger side of the control head. Retain original hardware.

The fresh air duct on the passenger side of the vehicle can be removed by cutting duct with a knife and removing it from the vehicle. The driver’s side fresh air duct can also be removed by cutting it.

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Locate behind glove box and on firewall the hole that previously mounted the heater box.

Drill (1) ¾” dia. hole for the drain tube as shown.

DRILL ¾” DIA. HOLE

¾” BETWEEN CENTRES

Locate wire harness that powered the original heater assembly and pull through the control head hole in the dash. Locate the brown wire and cut it at the plug. Attach (1) male insulated spade connector to the brown wire.

¾ “DIA.

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Remove the original defrost duct.

This is done by removing (4) screws at top edge of the dash.

It will be necessary to cut the defrost duct in half to remove it.

DRIVERS SIDE

Attach passenger side defrost template to passenger side of the defrost duct. Cut the duct as shown. Attach ¼ x ½ open cell foam around the duct inlet. Slide passenger side defrost duct adapter over the foamed inlet to the edge of the foam. Pre-Drill duct with a 5/32 drill bit on both sides of the duct. Attach the adapter to the duct using (2) #10 x 5/8 PHP screws.

PASSENGER SIDE

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The driver’s side defrost duct can be modified using the driver’s side template and adapter.

Cut off 17” of 2” flex hose and attach to the passenger side defrost adapter with (2) #10 x

5/8 PHP screws

Cut off 20” of 2” flex hose and attach to

Drivers side defrost adapter with (2) #10 x

5/8 PHP screws

All of the modifications to the vehicle are complete we will now begin the installation of the Unit.

Attach 30” of 2 ½” flex hose to the passenger side louver adapter using (2) #10 x 5/8 php. Press louver adapter over the back of the original passenger side louver.

Make sure that the flange on the dash inserts into the s-clips. Press air inlet blockoff over the air inlet making sure that the s-clips are inserted correctly.

Driver’s side louver and air inlet blockoff can be installed the same way. Attach 32” of 2” duct hose to the driver’s side louver adapter.

Remove (2) dash mounting bolts at locations shown.

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Set evaporator on floorboard of the vehicle.

Have one person carefully flex the dash towards rear of the car while another person slides unit behind the glove box.

Insert stud on top mounting bracket through hole that original heater mounted to. Attach (1) ¼-20 flange nut to the stud. The drain tube should insert through the previously drilled ¾” hole.

Reattach dash to the mounting points.

Remove #10 x ¾ hex head screw that is located behind bottom edge of dash on the evaporator.

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Attach the front support bracket with the previously removed hex head screw.

Remove screw from dash support bracket. Attach front support bracket with screw to the dash support.

Attach suction tube to the evaporator using (1) #10 o-ring and a few drops of mineral oil. Attach the liquid tube to the TXV using (1) #6 o-ring and a few drops of mineral oil.

LIQUID TUBE

SUCTION TUBE

Locate Sensing Coil attached to the TXV and utilizing

Bulb Clamp, attach it to the Suction Tube.

CAUTION: SYSTEM WILL NOT FUNCTION

PROPERLY IF SENSING COIL IS NOT CLAMPED

IN THE CORRECT POSITION. SEE PICTURE.

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Wrap Suction Tube and Sensing Coil with refrigerant tape provided. Be sure that all of the exposed metal is covered.

Locate in hardware sack kit is rear unit support bracket, and (2) #10 x 5/8” pan head

Philips screws.

Using a non powered screw driver. Install screws through bracket and into Evaporator housing. Do not over tighten.

NOTE LOCATION OF BRACKET.

Locate the Inlet Blockoff Plate.

Attach the blockoff behind the Hood Hinge assembly. Use the original hardware.

HOOD HINGE ASSEMBLY

Locate the Firewall Blockoff plate, and

(6) #10 x ¾” hex head tek screws.

On engine side of firewall attach over hookup tubes from the evaporator using (6) #10 x ¾” hex washer head

Tek screws.

Locate refrigeration tape provided and seal around the hookup tubes.

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Locate the Water Valve and (3) worm gear clamps.

Supply line from engine is attached to the upper heater hookup tube. Cut 6” off the end of the return line and install the water valve using (3) worn gear clamps as shown above.

Note: It is recommended that you replace heater hoses from the engine to the hookup tubes.

Remove the original blower switch. Using original switch mounting hardware install the switch assembly as shown. Press chrome knob onto switch lever.

Remove three original cables from the control head and retain all original hardware.

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Attach face/defrost cable to the control head using a cable clip. This will be the middle sized cable in the kit. This cable will be placed on the control lever labeled OFF to AIR on face of the control head.

The shortest cable supplied in kit will be installed onto the final mounting point using a cable clip and the original hardware.

Install longest of the (3) cables supplied in kit onto the middle mounting point of control head using original hardware and cable attachment bracket in the control sack kit.

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Slide the loop on the cables over the levers.

Press (3) push nuts onto the levers to hold the cables in place.

Attach wire harness to switch on control head per the wiring diagram.

WIRING DIAGRAM 1970 CHEVY CHEVELLE

Reinstall control head using the original hardware. Set the center air plenum into place above the control head.

Center Air Plenum

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Connect power wire (brown / from the original harness) to the

Red / White stripe from the new harness supplied.

Attach support bracket on center air plenum to the dash support.

Center air plenum

Reinstall the front speakers.

Attach wire harness to the resistor block, blower motor, and thermostat per the wiring diagram on the previous page.

Ground blower motor using the ring terminal attached to black wire on the wire harness. Use (1) #10 x ¾ hex head self tapping screw behind dash on the passenger side wall.

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Locate the Defrost / Heat Duct Assembly.

Attach to evaporator using (2) #10 x 5/8 pan head Philips screws. Be sure that S-clips are pressed over the rear flange. This helps secure the duct assembly.

Insert defrost heat cable (bottom lever on control head) into second hole from end of the defrost heat duct crank arm. Attach cable to bracket using (1) #8 x ½ PHP screw. Plug (2) blue wire leads from wire harness into micro switch as indicated by the white arrows. Check the lever on control head to insure that when door is in defrost position the micro switch is engaged.

Install defrost ducts using the original hardware.

PASSENGER SIDE

DRIVERS SIDE

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To Driver’s Side

Defrost Duct

Route the face defrost cable (top cable on the control head) around dash support and insert cable into 3 rd

hole from end of crank arm on the defrost face door. Attach cable to the cable attachment bracket using (1) #8 x ½ PHP screw.

To Passenger’s

Side Defrost Duct

Route the defrost flex hose.

Power pack blower

Route the final control cable (the longest cable) over top of unit and through firewall under the blower. Also insert long blue clutch wire through firewall at the same location.

Use a small piece of refrigeration tape to seal the firewall.

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Locate the center air distribution duct.

Attach to evaporator using (2) #10 x 5/8 pan head Philips screws. Be sure that S-clips are pressed over the rear flange. This helps secure the duct assembly.

Attach 16” of 2 ½” flex hose to rear hose adapter on the center air plenum.

Attach 22” of 2 ½” flex hose to front hose adapter of the center air plenum. Attach duct hose to the hose adapter using (2)

#10 x 5/8 PHP screws.

Route the flex hoses as shown.

From the rear hose adapter on the center air plenum.

From the front hose adapter on the center air plenum

From the driver’s side louver. Route the hose up and behind the instrument panel.

From the passenger’s side louver (see routing below.)

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Route the passenger side louver flex hose over the glove box

.

Caution:

Carefully check under Instrument Panel for all cables, electrical harness, or Flex Hose that might interfere with the safe operation of the vehicle.

Install dash pad using the original hardware

.

Apply a small bead of adhesive to all (4) clips on the

(2) chrome louvers in the hardware sack kit. Insert louvers into dash opening above the control head.

Installation of the interior components is complete. We will now install under hood portion of the system.

Drain and remove the radiator and fan shroud.

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Locate the condenser, (4) condenser mounting brackets, and (8) #10 x 3/8 hex head screws.

Attach brackets to the condenser as shown.

TOP

3

RD

HOLE FROM BOTTOM

Using (2) #10 x 3/8 hex head screws attach the drier and drier bracket to the condenser so that the condenser-drier tube fits properly.

Slide condenser in front of the bulkhead and behind the hood latch assembly. Attach condenser to the existing holes in the bulkhead using (6) 5/16 x ½ hex head bolts.

Locate the discharge tube and (1) #8 o-ring. Apply a few drops of lubricating oil to o-ring fitting on discharge tube and attach tube to top fitting on the condenser utilizing a 1” wrench on the tube fitting and a 7/8” backup wrench on the condenser fitting. The tube should travel along the top edge of the condenser.

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Locate (2) discharge bulkhead flat washers. Slide one flat washer over bulkhead fitting and insert the bulkhead fitting through existing hole on driver’s side of the bulkhead. Attach bulkhead nut on engine side of the bulkhead.

BULKHEAD FITTING

Locate the liquid bulkhead tube, (1) #6 o-ring, and hi/low pressure switch. Attach liquid tube to the drier using (1) #6 o-ring and few drops of lubricating oil and a ¾” open end wrench.

Attach bulkhead fitting on the liquid tube to original hole on passenger side of the bulkhead. Use one bulkhead flat washer on each side of the bulkhead.

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Plug in hi/low pressure switch wires into top of the hi/low pressure switch.

Route the (2) white wires through the grommet along with #6 refrigerant hose. One of the wires attaches to Blue Clutch wire from thermostat and the other to the compressor clutch.

INSTALL THE COMPRESSOR ADAPTOR KIT AND COMPRESSOR AT THIS

TIME PER THE MANUFACTURERS DIRECTIONS.

NOTE: THIS INSTALL IS CORRECT FOR A 350CID V8 ENGINE, WITH

ALTERNATOR ON PASSENGER SIDE OF VEHICLE.

IF YOUR VEHICLE IS EQUIPTED WITH A DIFFERENT ENGINE PACKAGE

IT WILL BE NECESSARY TO ROUTE THE HOSES DIFFERENT

Locate the #8 discharge hose. Attach straight fitting to the previously installed bulkhead fitting on driver’s side of the vehicle.

Route hose to the compressor and attach the

90 degrees fitting with service port to appropriate outlet on the compressor. .

Attach using (1) #10 o-ring and a few drops of lubricating oil.

Attach 90 degree fitting with service port on #10 suction hose to the compressor.

Attach using (1) #10 o-ring and a few drops of lubricating oil.

DISCHARGE

SUCTION

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Attach 90 deg. end of the #10 suction hose that does not have the service port to

#10 fitting at the firewall. Attach using

(1) #10 o-ring and a few drops of mineral oil.

Tighten securely.

Locate the #6 liquid hose. Attach the 45 degree fitting to the firewall using (1) #6 o-ring and a few drops of mineral oil.

Route the liquid hose across fender well and behind the battery. Attach 90 degree fitting on liquid hose to bulkhead fitting next to radiator on passenger side of the vehicle using (1) #6 o-ring and a few drops of lubricating oil.

Reinstall the battery, radiator and fan shroud using original hardware.

THE ENGINE COMPARTMENT OF YOUR SYSTEM IS COMPLETE.

THE UNIT IS READY FOR EVACUATION AND CHARGING.

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THIS SHOULD BE DONE BY A QUALIFIED AND CERTIFIED AIR

CONDITIONING TECHNICIAN.

NOTE:

COMPRESSOR IS SUPPLIED WITH THE

CORRECT OIL CHARGE. DO NOT ADD OIL TO SYSTEM.

134A SYSTEMS 24 oz OF REFRIGERANT

Congratulations you have completed the install of your

CLASSIC AUTO AIR PERFECT FIT SERIES climate control system.

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IMPORTANT

CAUTION: WATER VALVE MUST BE INSTALLED PER

THE INSTRUCTIONS.

Classic Auto Air has done extensive testing on the correct method to install the water valve in order to get a repeatable and progressive temperature control.

Locate the bottom connection from the evaporator/heater unit off of the firewall and attach a 6” piece of

5/8” dia. heater hose with the supplied hose clamp. Next attach the inlet side of the water valve using another supplied hose clamp, (make sure the arrow on the water valve points toward the engine) Attach a heater hose from the outlet side of the water valve and route to the connection on the water pump.

NOTE: WATER VALVE = WATER PUMP

FROM HEATER CORE TO WATER PUMP

COOLANT FLOW

CAUTION: WATER VALVE MUST BE INSTALLED ON HEATER LINE ROUTED TO

WATER PUMP.

NOTE:

COMPRESSOR PURCHASED WITH KIT IS

SUPPLIED WITH THE CORRECT OIL CHARGE. DO NOT

ADD OIL TO SYSTEM.

134A SYSTEMS 24 oz OF REFRIGERANT

Recommend that power fuse is 25amp minimum

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