Vintage Air 1967-68 CAMARO w/o Factory Air Gen IV User manual

an ISO 9001:2008 Registered Company
1967-68 Chevrolet Camaro
without Factory Air
Control Panel Conversion Kit
475168
18865 Goll St. San Antonio, TX 78266
Phone: [phone]
Fax: [phone]
www.vintageair.com
905168 REV G 4/13/15, PG 1 OF 17

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905168 REV G 4/13/15, PG 2 OF 17
Table of Contents
Cover.................................................................................................................................
Table of Contents.................................................................................................................
Packing List/Parts Disclaimer...................................................................................................
Removing OEM Control Panel, Placard Installation...................................................................
Placard Installation (Cont.)...................................................................................................
Cable Converter Assembly Modification, Cable Converter Assembly Mounting Clamp Installation....
Dash/Floor/Defrost Cable Converter Assembly Installation........................................................
Dash/Floor/Defrost Control Harness.......................................................................................
Cold/Hot Cable Converter Assembly Installation, Cold/Hot Control Harness.................................
Cold/Hot Control Harness (Cont.), Off/Hi Cable Converter Assembly Installation........................
Off/Hi Control Harness.......................................................................................................
Final Steps.......................................................................................................................
Control Panel Calibration Procedure.....................................................................................
Control Panel Calibration Procedure (Cont.)..........................................................................
Wiring Diagram..................................................................................................................
Operation of Controls.........................................................................................................
Packing List......................................................................................................................
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Thank you for purchasing this control panel 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.

3
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905168 REV G 4/13/15, PG 3 OF 17
Control Panel Conversion Kit
1967-68 Chevrolet Camaro
without Factory Air
1
No. Qty. Part No. Description
Label, Control Panel Mode
Cable Converter Assembly
Control Harness, Gen IV Universal
Push-on Ring, 3/16”
Clamp, Cable Converter
Tie Wrap, 4”
Ground Wire
Screw, #8 x 1/2”, Pan Head
Label Backing
1.
2.
3.
4.
5.
6.
7.
8.
9.
1
3
1
3
3
5
1
4
1
484168
112002-SUA
232002-VUA
65976-VUE
491010-VUR
21301-VUP
231520
18235-VUB
484170
Packing List: (475168)
4567
89
23
** 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.
DASH
HOT
HI

4
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905168 REV G 4/13/15, PG 4 OF 17
Remove (4) OEM screws from the dash bezel,
under the dash (retain) (See Figure 1, below).
Remove the OEM control panel from the dash (retain).
Disconnect the cables and wires from the back side
of the OEM controls (discard).
Remove the (2) screws securing the OEM fan switch to
the top of the control panel. Remove the fan switch
from the control panel (discard).
Removing OEM Control Panel
1.
2.
3.
4.
Perform the Following:
Control
Panel
ON
COLD
DASH FLR DEF
HOT
OFF
Placard Installation
NOTE: The OEM control panel placard can be used with this system. However, the bottom of the placard
will not depict actual mode settings. The actual mode settings are shown on the replacement placard
mode label that comes with this kit. To use the replacement placard mode label, you must modify parts
of the control panel assembly as described below. We leave it up to you, the customer, to decide if you
would like to use the OEM placard or the replacement placard mode label.
To Use the Replacement Placard Mode Label:
Remove the (3) lever knobs (See Figure 2, below).
Remove the (4) control panel face plate mounting rivets. Drill out the rivets using a 9/64” drill bit (See
Figure 2, below).
Remove the OEM control panel face plate, placard and OEM backing plate from the control panel. Orient the
OEM backing plate as shown in Figure 2, below. Using a suitable method, cut along the inside edge of the
flange as shown.
1.
2.
3.
Remove (4)
OEM Screws
Control Panel
Face Plate
(2) Rivets
(2) Rivets
Cut Along
Inside Edge of
Flange
After Edge of Backing
Plate is Removed
(3) Knobs
Figure 1
Figure 2

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905168 REV G 4/13/15, PG 5 OF 17
Locate the OEM placard. Turn the placard over, and apply the white backing labels to the back side of the OEM
placard as shown in Figure 3a, below. NOTE: These white stickers are applied to the back side of the
control panel placard to balance the amount of light across the face of the control panel.
Install replacement placard mode label on the front side of the OEM placard.
Remove OEM light baffle (discard).
Install OEM backing plate, placard and control panel face plate. Secure control panel face plate to control panel
using (4) #8 x 1/2” pan head screws.
Reinstall knobs.
DASH
HOT
DEFROSTER
TEMPERATURE
DE-ICE
HOT
ON
FAN
AIR
OFF
OFF
HI
DASH
HOT
HI
ON
HOT
FAN
TEMPERATURE
DEFROSTR
COLD
OFF
OFF
Placard Installation (Cont.)
1.
2.
3.
4.
5.
Front Side of
OEM Placard
Backing
Labels
Back Side of
OEM Placard
Replacement
Mode Label
Control
Panel
Control Panel
Face Plate
(3) Knobs
Figure 3
Figure 3a
Bottom Side
of Control Panel
Shown
Placard
(4) #8 x 1/2”
Pan Head
Screws
OEM Light
Baffle
OEM Backing
Plate

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905168 REV G 4/13/15, PG 6 OF 17
Locate the (3) cable converter assemblies. Using a pair of wire cutters, cut the cable converter actuator rods as
shown in Figure 4, below.
Cable Converter Assembly
Modification
1.
Install cable converter assembly mounting clamps. NOTE: Orient clamps in relation to the (3) housing
snaps on the cable converter assembly (See Figure 5, below).
Cable Converter Assembly
Mounting Clamp Installation
1.
Cut at Each Side
of Hole as Shown
Off/Hi Lever
Cut at 2nd Hole
(Remove Shaded Portion)
Cold/Hot Lever
Cut at 6th Hole
(Remove Shaded Portion)
Dash/Floor/Defrost Lever
Cut at 3rd Hole
(Remove Shaded Portion)
Cable Converter
Actuator Rod
Cable Converter
Assembly Mounting
Clamp
Cable Converter
Assembly
Off/Hi
Cable Converter Assembly
Orient Cable Converter Assemblies and Install Mounting Clamps as Shown.
Cold/Hot
Cable Converter Assembly
Dash/Floor/Defrost
Cable Converter Assembly
Figure 4
Figure 5

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905168 REV G 4/13/15, PG 7 OF 17
Turn control panel over, with bottom side facing up.
Install the cable converter assembly onto the Dash/Floor/Defrost lever (See Figure 6, below).
Install the cable converter push rod onto the OEM cable mounting stud on the lever.
Secure the cable converter assembly onto the OEM control panel using the OEM screw in the OEM cable clamp
mounting location (See Figure 6, below).
Since the cable converter assembly can slide back and forth in the clamp before the screw is tightened, position
the cable converter assembly such that the flat part of the rod is as close to flush as possible with the end of
the housing at the lever’s innermost position (See Figure 6, below).
Secure the cable converter lever push rod onto the OEM cable mounting stud using a 3/16” push-on ring as
shown in Figure 6, below.
Dash/Floor/Defrost Cable Converter
Assembly Installation
1.
2.
3.
4.
5.
6.
3/16” Push-on
Ring
OEM Cable
Mounting Stud
OEM Cable
Mounting Location
End of Rod
Flat Section
End of
Housing
NOTE: Do not allow rod to
separate housing when rod
is in innermost position.
Rod Shown
in Approximately
Innermost
Position
Flush
1/8” Max
Bottom Side of
Control Panel
OEM Screw
Dash/Floor/Defrost
Cable Converter
Assembly
Figure 6

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905168 REV G 4/13/15, PG 8 OF 17
Remove OEM fan switch actuator stud (See Figure 7 and photos, below). NOTE: Fan switch actuator stud
removal is required to allow clearance for duct hoses. Failure to remove the stud will result in a
punctured duct hose.
Locate the control panel wiring harness, and plug the corresponding wire into the correct cable converter
assembly as shown in Figure 7, below.
Once the wires are correctly plugged into the cable converter assembly, secure the wires to the cable converter
assembly using the supplied tie wraps. The tie wrap must be located between the end of the wire jacket and
the step in the cable converter housing, forcing a bend in each wire as it passes over the step in the cable
converter housing. The head of the tie wrap must fall on the edge of the housing to remain tight. Ensure that
the tie wraps are tight enough that the wires cannot move (See Figure 8, below).
Dash/Floor/Defrost
Control Harness
1.
2.
3.
OEM Cable
Mounting Stud
Bottom Side of
Control Panel
Dash/Floor/Defrost
Cable Converter
Assembly
Force Bend
in Wires
Over Step
Step in
Cable Converter
Housing
Tie Wrap
Tie Wrap
Wire
Jacket
Wire
Jacket
Cable Converter
Assembly
Cable Converter
Clamp
Dash/Floor/Defrost
Cable Converter
Assembly
Red
White/Yellow
White
OEM Fan Switch
Actuator Stud
Before Stud Removal
After Stud Removal
Figure 7
Figure 8

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905168 REV G 4/13/15, PG 9 OF 17
Install the cable converter assembly onto the Cold/Hot lever.
Install the cable converter push rod onto the OEM cable mounting stud on the lever.
Secure the cable converter assembly onto the OEM control panel using the OEM screw in the OEM cable clamp
mounting location (See Figure 9, below).
Since the cable converter assembly can slide back and forth in the clamp before the screw is tightened, position
the cable converter assembly such that the flat part of the rod is as close to flush as possible with the end of
the housing at the lever’s innermost position.
Secure the cable converter lever push rod onto the OEM cable mounting stud using a 3/16” push-on ring as
shown in Figure 9, below.
Locate the control panel wiring harness, and plug the corresponding wire into the correct cable converter
assembly as shown in Figure 10, below.
Cold/Hot Cable Converter Assembly
& Control Harness Installation
1.
2.
3.
4.
5.
6.
Bottom Side of
Control Panel
Cold/Hot
Cable Converter
Assembly
Cold/Hot Cable Converter
Assembly
Red
White/Red
White
Figure 9
Figure 10

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905168 REV G 4/13/15, PG 10 OF 17
Install the cable converter assembly onto the Off/Hi lever.
Install the cable converter push rod onto the OEM cable mounting stud on the lever.
Secure the cable converter assembly onto the OEM control panel using the OEM screw in the OEM cable clamp
mounting location (See Figure 12, below).
Since the cable converter assembly can slide back and forth in the clamp before the screw is tightened, position
the cable converter assembly such that the flat part of the rod is as close to flush as possible with the end of
the housing at the lever’s innermost position.
Secure the cable converter lever push rod onto the OEM cable mounting stud using a 3/16” push-on ring as
shown in Figure 12, below.
Off/Hi Cable Converter Assembly
Installation
1.
2.
3.
4.
5.
Cold/Hot Control Harness (Cont.)
Once the wires are correctly plugged into the cable converter assembly, secure the wires to the cable converter
assembly using the supplied tie wraps. The tie wrap must be located between the end of the wire jacket and
the step in the cable converter housing, forcing a bend in each wire as it passes over the step in the cable
converter housing. The head of the tie wrap must fall on the edge of the housing to remain tight. Ensure that
the tie wraps are tight enough that the wires cannot move (See Figure 11, below).
1.
Force Bend
in Wires
Over Step
Step in
Cable Converter
Housing
Cable Converter
Clamp
Cable Converter
Assembly
Tie Wrap
Tie Wrap
Wire
Jacket
Wire
Jacket
Figure 11
Figure 12

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905168 REV G 4/13/15, PG 11 OF 17
Locate the control panel wiring harness, and plug the corresponding wire into the correct cable converter
assembly (See Figure 13, below).
Once the wires are correctly plugged into the cable converter assembly, secure the wires to the cable converter
assembly using the supplied tie wraps. The tie wrap must be located between the end of the wire jacket and
the step in the cable converter housing, forcing a bend in each wire as it passes over the step in the cable
converter housing. The head of the tie wrap must fall on the edge of the housing to remain tight. Ensure that
the tie wraps are tight enough that the wires cannot move (See Figure 14, below).
Off/Hi Control Harness
1.
2.
Off/Hi
Cable Converter
Assembly
Wire
Jacket Wire
Jacket Tie Wrap
Force Bend
in Wires
Over Step
Step in
Cable Converter
Housing
Cable Converter
Assembly
Cable Converter
Clamp
Tie Wrap
Off/Hi Cable Converter
Assembly
Red
White
White/Green
Figure 13
Figure 14

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905168 REV G 4/13/15, PG 12 OF 17
Final Steps
Using the supplied tie wraps, tie the wires to the control panel. Confirm that wires are secured and do not
interfere with lever operation or cable converter assembly.
Install control panel into dash using OEM screws. To ease installation, rotate control panel slightly and pass the
cable converter assemblies through the dash opening first. As the cable converter assemblies pass through the
dash opening, rotate the control panel back the opposite direction to fit control panel into the dash. NOTE:
Make sure cable converter assemblies clear the duct hose behind the left side of the dash opening.
Do not force the control panel into the dash. Forcing the control panel into the dash will damage the
cable converter assemblies and/or duct hose.
Plug the wiring harnesses into the ECU module on the sub case.
Wire according to the wiring diagram on Page 16.
Calibration procedure and operation instructions:
A. Calibrating the control panel will set the range of travel for the cable converters connected to the OEM
control panel levers. Performing this procedure will set the limits of the cable converters at their highest
and lowest points.
B. Locate the gray wire with an unused connector in the wiring harness near the two cable harness relays.
This wire is labeled PROGRAM on the wiring diagram.
C. It will be necessary to ground the gray wire for approximately five seconds while moving the controls, so
it is sometimes helpful to attach one end of the white jumper to the vehicle’s ground (for example, the
chassis) and have the other end ready to connect to the gray PROGRAM wire when the procedure requires
it.
D. To calibrate the control panel, follow the calibration procedures on Pages 14 & 15.
1.
2.
3.
4.
5.
NOTE: Tie the unused wire to the
control panel approximately as
shown. Ensure that the wire does
not interfere with levers or cable
converter assemblies.
Unused Red,
White/Blue,
White Wire Tie Wrap
Plug From Control
Wiring Harness
232002-VUA
Plug
From Wiring
Harness
232001-VUR

13
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905168 REV G 4/13/15, PG 13 OF 17
On Vintage Air Gen IV systems using factory controls, it is necessary to calibrate the system to your specific
control panel. This procedure ensures that the stroke of your control panel levers or knobs is translated into
precise control of the fan speed, temperature blend and mode door position. Please carefully read and understand
these procedures before beginning. The procedure may be repeated as many times as necessary to get it right.
In preparation for calibration, you will need to attach the supplied white ground jumper wire to a suitable chassis
ground. This jumper wire must be easily connected to the gray programming wire located in the main Gen IV wiring
harness next to the relays. During the calibration procedure, you will connect the white jumper to the gray program
wire, which will “teach” the Gen IV ECU the upper limits of the control levers or knobs. The blower will momentarily
change speeds, signaling that the upper limits have been “learned”. You will move the levers or knobs to opposite
extreme positions of their travel and then disconnect the white jumper. The blower will again change speeds,
signaling that the lower limits have been learned and that the calibration procedure is complete.
Control Panel
Calibration Procedure
Gray
Program Wire
White Jumper
Cable

14
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905168 REV G 4/13/15, PG 14 OF 17
1. Turn on the ignition switch (Do not start the engine).
2. Move the control levers/knobs to the position
shown.
3. Connect the white jumper wire to the gray program
wire. Wait for the blower speed to change (Approximately
5 seconds).
4. Move the control levers/knobs to the positions
shown.
5. Disconnect the white jumper wire from the gray
program wire. The blower speed will change,
indicating completion of the calibration procedure.
6. Confirm proper operation of controls. Repeat
procedure if necessary. When finished, tape
over program wire connector with electrical tape to
prevent accidental contact with chassis ground.
Control Panel
Calibration Procedure (Cont.)
DASH
HOT
HI
DASH
HOT
HI
OFF
ON
START

15
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905168 REV G 4/13/15, PG 15 OF 17
WHT/GRN
WHT/YEL
WHT/RED
RED
WHT
BACKLIGHT NEG
FAN WIPER
MODE WIPER
TEMP WIPER
5V-SW
GND
BACKLIGHT POS
AC ANNUNCIATOR
PRE-WIRED
GEN IV WIRING DIAGRAM
REV D, 5/6/2014
GEN IV ECU
PROGRAM
Wiring Diagram
TEMP
MODE
FAN
A/C
(IF USED)
232007-VUR
232002-VUA
** CIRCUIT
BREAKER
30 AMP
*** WIDE OPEN
THROTTLE
SWITCH
(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 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.
JF8
BLK
ORA
TAN
VIEWED FROM WIRE SIDE
•
•
•
HEATER
CONTROL VALVE
To AC Request on ECM

16
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905168 REV G 4/13/15, PG 16 OF 17
Operation of Controls
Adjust to desired
speed.
Blower Speed
Adjust to desired
speed.
Adjust to desired
mode position
(DASH position
recommended).
Adjust to desired
speed.
Adjust to DEFROST position for maximum defrost, or
between FLOOR and DEFROST positions for a bi-level
blend (Compressor is automatically engaged).
Adjust to desired
temperature.
For A/C operation, adjust to
coldest position to engage
compressor (Adjust between
HOT and COLD to reach
desired temperature).
A/C Operation
Heat Operation
Defrost/De-fog Operation
On Gen IV systems with three lever/knob controls, the temperature control toggles between heat and A/C
operations. To activate A/C, move the temperature lever/knob all the way to cold and then back it off to the desired
vent temperature. For heat operation, move the temperature lever/knob all the way to hot and then adjust to the
desired vent temperature. The blower will momentarily change speed, each time you toggle between operations, to
indicate the change. NOTE: For proper control panel function, refer to control panel instructions for
calibration procedure.
Blower Speed
Blower Speed
This lever/knob controls
blower speed, from
OFF to HI.
This lever/knob controls
the mode positions,
from DASH to FLOOR
to DEFROST, with a
blend in between.
This lever/knob controls
the temperature,
from HOT to COLD.
Blower Speed
Mode Control
Temperature Control
Blower
Speed
Temperature
Control
Mode
Control
Temperature Control
Temperature Control
Temperature Control
Mode Control
Mode Control
Mode Control
For maximum heating, adjust
to hottest position (Adjust
between HOT and COLD to
reach desired temperature).
Adjust to desired
mode position
(FLOOR position
recommended).
DASH
DASH
DASH
HOT
HOT
HOT
HI
HI
HI
DASH
HOT
HI

www.vintageair.com
Control Panel Conversion Kit
1967-68 Chevrolet Camaro
without Factory Air
1
No. Qty. Part No. Description
Label, Control Panel Mode
Cable Converter Assembly
Control Harness, Gen IV Universal
Push-on Ring, 3/16”
Clamp, Cable Converter
Tie Wrap, 4”
Ground Wire
Screw, #8 x 1/2”, Pan Head
Label Backing
1.
2.
3.
4.
5.
6.
7.
8.
9.
1
3
1
3
3
5
1
4
1
484168
112002-SUA
232002-VUA
65976-VUE
491010-VUR
21301-VUP
231520
18235-VUB
484170
Packing List: (475168)
4567
89
23
NOTE: Images may not depict actual parts and quantities.
Refer to packing list for actual parts and quantities.
DASH
HOT
HI
Checked By:
Packed By:
Date:
905168 REV G 4/13/15, PG 17 OF 17