Vintage Air 561163 User manual

1963-66 CORVETTE
WITHOUT FACTORY A/C
561163
901142 REV D 5/16/17, INST 63-66 COVETTE EVAP wo AC PG 1 OF 25
an ISO 9001:2008 Registered Company
18865 Goll St. San Antonio, TX 78266
Phone: [phone]
Sales: [email protected]
Tech Support: [email protected]
www.vintageair.com

2
901142 REV D 5/16/17, INST 63-66 CORVETTE EVAP wo AC PG 2 OF 25
PA
GES
Table of Contents
1. COVER
2. TABLE OF CONTENTS
3. PACKING LIST / PARTS DISCLAIMER
4. INFORMATION PAGE
5. WIRING NOTICE
6. ENGINE COMPARTMENT
FIGURE 1
7. CONDENSER ASSEMBLY, COMPRESSOR & BRACKET, PASSENGER COMPARTMENT
FIGURES 2 & 2a
8. DEFROST DUCT INSTALLATION, FIREWALL BLOWER COVER INSTALLATION
FIGURES 3, 3a & 4
9. FIREWALL COVER INSTALLATION
FIGURE 5
10. KICK PANEL COVER INSTALLATION, EVAPORATOR INSTALLATION
FIGURES 6, 6a, 6b, 6c & 7
11. BRACKET INSTALLATION
FIGURE 8
12. EVAPORATOR INSTALLATION CONT.
FIGURES 9 & 10
13. FIREWALL BLOWER COVER INSTALLATION CONT., LUBRICATING O-RINGS,
A/C HOSE INSTALLATION & MODIFIED A/C HOSE KIT
FIGURES 11, 11a & 12
14. 63-65 VETTE AC & HEATER HOSE ROUTING
FIGURE 13
15. DRAIN HOSE INSTALLATION CENTER CONSOLE TRIM MODIFICATION
FIGURE 14 & 15
16. PASSENGER SIDE UNDER DASH LOUVER INSTALLATION, DRIVER SIDE UNDER
DASH LOUVER INSTALLATION
FIGURES 16 & 17
17. DRIVER & PASSENGER SIDE CONSOLE PANEL INSTALLATION, FINAL STEPS
FIGURES 18, 19, 19a & 19b
18. CONTROL PANEL & DUCT HOSE ROUTING
FIGURE 20
19. WIRING DIAGRAM
20. GEN IV WIRING CONNECTION INSTRUCTIONS
21. OPERATION OF CONTROLS
22. TROUBLE SHOOTING INFORMATION
23. TROUBLE SHOOTING INFORMATION CONT.
24. POWER ANTENNA SWITCH INSTALLATION
25. EVAPORATOR KIT PACKING LIST

3
901142 REV D 5/16/17, INST 63-66 CORVETTE EVAP wo AC PG 3 OF 25
** 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.
EVAPORATOR KIT
561163
EVAPORATOR KIT PACKING LIST
1.
No. QTY. PART No. DESCRIPTION
2.
1
1
744009
781063
1
ACCESSORY KIT
781063
2
63-67 VETTE
EVAP SUB CASE
744009
63-67 VETTE EVAP SUB CASE
ACC KIT 63-66 VETTE
NOTE: IMAGES MA Y NOT DE PICT ACTUAL PARTS AND QUANTITIES.
REFER TO PACKING LIST FOR ACTUAL PARTS AND QUANTITIES.

4
901142 REV D 5/16/17, INST 63-66 CORVETTE EVAP wo AC PG 4 OF 25
Important Notice—Please Read
For 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.

5
901142 REV D 5/16/17, INST 63-66 CORVETTE EVAP wo AC PG 5 OF 25
Important Wiring Notice—Please Read
Some Vehicles May Have Had Some or All of Their Radio Interference Capacitors Removed.
There Should Be a Capacitor Found At Each of the Following Locations:
1. On the positive terminal of the ignition coil.
2. If there is a generator, on the armature terminal of the generator.
3. If there is a generator, on the battery terminal of the voltage regulator.
Most alternators have a capacitor installed internally to eliminate what is called “whining” as
the engine is revved. If whining is heard in the radio, or just to be extra cautious, a radio
interference capacitor can be added to the battery terminal of the alternator.
It is also important that the battery lead is in good shape and that the ground leads are not
compromised. There should be a heavy ground from the battery to the engine block, and
additional grounds to the body and chassis.
If these precautions are not observed, it is possible for voltage spikes to be present on the
battery leads. These spikes come from ignition systems, charging systems, and from
switching some of the vehicle’s other systems on and off. Modern computer-operated
equipment can be sensitive to voltage spikes on the power leads, which can cause unexpected
resets, strange behavior, and/or permanent damage.
Vintage Air strives to harden our products against these types of electrical noise, but there is
a point where a vehicle’s electrical system can be degraded so much that nothing can help.
Radio interference capacitors should be available at most auto and truck parts suppliers. They
typically are cylindrical in shape, a little over an inch long, a little over a half inch in diameter,
and they have a single lead coming from one end of the cylinder with a terminal on the end of
the wire, as well as a mounting clip which is screwed into a good ground on the vehicle. The
specific value of the capacitance is not too significant in comparison to ignition capacitors that
are matched with the coil to reduce pitting of the points.
Care must be taken, when installing the compressor lead, not to short it to ground.
The compressor lead must not be connected to a condenser fan or to any other
auxiliary device. Shorting to ground or connecting to a condenser fan or any other
auxiliary device may damage wiring, the compressor relay, and/or cause a
malfunction.
When installing ground leads on Gen IV systems, the blower control ground and ECU
ground must be connected directly to the negative battery post.
For proper system operation, the heater control valve must be connected to the
ECU.
•
•
•

6
901142 REV D 5/16/17, INST 63-66 CORVETTE EVAP wo AC PG 6 OF 25
EN
GINE COMPARTMENT
REMOVE THE FOLLOWING
FIGURE 1
HOOD FOR EASE OF INSTALLATION
DRAIN RADIATOR.
DISCONNECT BATTERY AND REMOVE, IF MOUNTED ON PASSENGER SIDE.
IF MOUNTED ON DRIVER SIDE, DISCONNECT (-) TERMINAL.
OEM BLOWER MOTOR ASSEMBLY (UNDER HOOD) (DISCARD).
OEM HEATER HOSES (DISCARD). SEE FIGURE 1.
REMOVE OEM RADIATOR EXPANSION TANK (RETAIN) (IF EQUIPPED).
OEM HEATER
HOSES
OEM RADIATOR
EXPANSION
TANK
OEM
BLOWER
MOTOR
ASSEMBLY
BEFORE STARTING THE INSTALLATION, CHECK THE FUNCTION
OF THE VEHICLE (HORN, LIGHTS,ETC.) FOR PROPER OPERATIONS.
STUDY THE INSTRUCTIONS, ILLUSTRATIONS, & DIAGRA MS.
BATTERY

7
901142 REV D 5/16/17, INST 63-66 CORVETTE EVAP wo AC PG 7 OF 25
GLOVE BOX, DOOR AND MOUNTING PANEL (DISCARD GLOVE BOX) (RETAIN HARDWARE). (SEE FIGURE 2)
RIGHT AND LEFT SIDE CONSOLE PANELS. (DISCARD) (RETAIN SCREWS)
HEAT DISTRIBUTION DUCTS.(DISCARD)
OEM HEATER. (DISCARD)
OEM DEFROST DUCT. (DISCARD) (RETAIN NUTS)
REMOVE OEM CONTROL KNOBS AND BEZELS (RETAIN) SEE FIGURE 2a.
DISCONNECT ALL WIRES AND CABLE FROM CONTROL PANEL. (DISCARD)
REMOVE RADIO AND CLOCK (RETAIN).
PASSENGER SIDE KICK PANEL (RETAIN).
REMOVE OEM PASSENGER SIDE FRESH AIR CABLE AND KICK PANEL
ASSEMBLY (DISCARD)
LOOSEN OEM DRIVER SIDE FRESH AIR CABLE ASSEMBLY FROM DASH,
FOR LATER INSTALLATION.
REMOVE OEM CENTER CONSOLE FLOOR
TRIM (RETAIN) (63 MODELS ONLY)
REMOVE CENTER FLOOR CONSOLE (RETAIN)
PASSENGER COMPARTMENT
CONDENSER ASSEMBLY & INSTALLATION
REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH THE CONDENSER KIT TO INSTALL THE CONDENSER.
BINARY SWITCH INSTALLATION (REFER TO CONDENSER INSTRUCTIONS)
REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH THE BRACKET KIT TO INSTALL THE COMPRESSOR
BRACKET.
COMPRESSOR & BRACKETS
REMOVE THE FOLLOWING:
FIGURE 2a
GLOVE BOX
DEFROST
DUCT
OEM
HEATER
GLOVE
BOX
DOOR
MOUNTING
PANEL
FIGURE 2
CONTROL
PANEL
HEAT DISTRIBUTION
DUCT
OEM PASSENGER SIDE
FRESH AIR CABLE
ASSEMBLY
OEM DRIVER SIDE
FRESH AIR CABLE
ASSEMBLY
RADIO
LEFT & RIGHT
CONSOLE
PANELS
CENTER
CONSOLE
FLOOR
TRIM

8
901142 REV D 5/16/17, INST 63-66 CORVETTE EVAP wo AC PG 8 OF 25
FIGURE 3
FIGURE 3a
FIGURE 4
DEFROST DUCT INSTALLATION
INSTALL DEFROST DUCT UNDER DASH AS SHOWN IN FIGURE 3 BELOW. SECURE USING OEM NUTS.
NOTE: DEFROST DUCT MOUNTING HOLES TOWARDS FIREWALL AS SHOWN BELOW IN FIGURE 3a.
OEM
DEFROST DUCT
OPENING
DEFROST DUCT
MOUNTING
HOLES
TOP VIEW
DEFROST DUCT
(2) OEM
NUTS
DEFROST
DUCT
491634
FIREWALL BLOWER COVER INSTALLATION
INSTALL (4) GROMMETS IN FIREWALL BLOWER COVER. SEE FIGURE 4a BELOW
ROUTE #10 HOSE THROUGH FIREWALL BLOWER COVER AS SHOWN BELOW.
DO NOT ATTACH TO FIREWALL AT THIS TIME.
(4) GROMMETS
33137-VUI
FIREWALL
BLOWER
COVER
644042

9
901142 REV D 5/16/17, INST 63-66 CORVETTE EVAP wo AC PG 9 OF 25
FIREWALL COVER INSTALLATION
APPLY A 1/4” BEAD OF SILICONE AROUND THE BACK SIDE OF THE FIREWALL COVER AS SHOWN IN
FIGURE 5, BELOW.
FROM INSIDE THE CAR, INSTALL FIREWALL COVER ON FIREWALL USING (2) 1/4-20 x 1¼” HEX BOLTS AND
(2) FLAT WASHERS, SEE FIGURE 5, BELOW. (NOTE: USE SEAM SEALER TO FILL GAP BETWEEN COVER & LIP
IN FIREWALL BEFORE PAINTING.)
INSTALL 3/8 GROMMET IN FIREWALL COVER AS SHOWN BELOW.
FIGURE 5
(2) 1/4-20 x 1¼”
HEX BOLTS
(2) 1/4 x 3/4
FLAT WASHER
GROMMET
33144-VUI
BACK SIDE
OF FIREWALL
COVERSILICONE
FIREWALL
COVER

10
901142 REV D 5/16/17, INST 63-66 CORVETTE EVAP wo AC PG 10 OF 25
(2)1/4-20 x 1/2”
HEX BOLT
DR FRONT
EVAPORATOR
BRACKET
644044
PS FRONT
EVAPORATOR
BRACKET
644045
FIGURE 7
EVAPORATOR INSTALLATION
ON A WORK BENCH INSTALL (2) HEATER FITTINGS WITH PROPERLY LUBRICATED O-RINGS. (SEE FIGURE 12,
PAGE 13, AND FIGURE 8, PAGE 11.) FOR HEATER HOSE ROUTING SEE PAGE 12, 14 AND PAGE 15.
INSTALL EVAPORATOR REAR MOUNTING BRACKET ON EVAPORATOR USING
(2)1/4-20 x 1/2 HEX BOLTS AS SHOWN IN FIGURE 8, PAGE 11.
LAY EVAPORATOR SUBCASE ON PASSENGER SIDE FLOOR
BOARD. INSTALL #6 AC HOSE & HEATER HOSE ON
EVAPORATOR AS SHOWN IN FIGURE 9, PAGE 12.
FOR EVAPORATOR INSTALLATION IT MAY BE NECESSARY
TO PULL BACK CARPET FROM FIREWALL AS SHOWN
BELOW. AFTER EVAPORATOR IS INSTALLED PUSH
CARPET BACK IN PLACE.
THIS WILL BE A VERY CLOSE FIT. TAKE CARE
NOT TO DAMAGE STEPPER MOTORS DURING
INSTALLATION.
FIGURE 6c
KICK PANEL COVER INSTALLATION
INSTALL (4) GROMMETS IN KICK PANEL COVER, SEE FIGURE 6b BELOW.
REMOVE TAB FROM KICK PANEL AS SHOWN IN FIGURE 6a.
ROUTE A/C AND HEATER HOSE THROUGH FIREWALL BLOWER COVER
AND KICK PANEL COVER AS SHOWN IN FIGURE 6 AND 6c, BELOW.
APPLY A 1/4” BEAD OF SILICONE AROUND THE BACK SIDE OF KICK
PANEL COVER AS SHOWN IN FIGURE 6b, BELOW.
SECURE KICK PANEL COVER USING OEM SCREWS, AS SHOWN IN
FIGURE 6c BELOW.
(4) OEM
SCREWS
SILICONE
BACK SIDE OF
KICK PANEL
FRESH AIR COVER
#10 A/C
HOSE
#6 A/C
HOSE
REMOVE
TAB
UPPER
HEATER
HOSE
LOWER
HEATER
HOSE
LOWER
HEATER
HOSE
UPPER
HEATER
HOSE
(4)GROMMETS
33137-VUI
FIGURE 6b
FIGURE 6a
#6 A/C
HOSE
FIREWALL
BLOWER COVER
#10 A/C
HOSE FIGURE 6
PULL BACK
CARPET

11
901142 REV D 5/16/17, INST 63-66 CORVETTE EVAP wo AC PG 11 OF 25
BRACKET INSTALLATION
FIGURE 6
1/4-20 x 1
HEX BOLT
18290-VUB
1/4-20 x 1
HEX BOLT
18290-VUB
1/4 PUSH NUT
BOLT RETAINER
189125-MUR
1/4 PUSH NUT
BOLT RETAINER
189125-MUR
PS REAR
EVAPORATOR
BRACKET
644054
DS REAR
EVAPORATOR
BRACKET
644053
(2) HEATER
FITTINGS
(2) 1/4-20 x 1/2
HEX BOLT
(2) 1/4-20 x 1/2
HEX BOLT
REAR
EVAPORATOR
BRACKET
644040
(2) HEATER
FITTINGS
BRACKET INSTALLATION
FIGURE 8
(2) 1/4-20 x 1/2”
HEX BOLT

12
901142 REV D 5/16/17, INST 63-66 CORVETTE EVAP wo AC PG 12 OF 25
FIGURE 10
FIGURE 9
(2) 1/4-20 x 1¼”
BOLT
(2) 1/4” FLAT
WASHERS
EVAPORATOR INSTALLATION CONT.
KICK PANEL
COVER
PASSENGER SIDE
DASH BRACE
(2) #14 x 3/4
SHEET METAL
SCREWS
DRILL
3/16”
HOLE
OEM
HOLE
LIFT EVAPORATOR UNIT UP UNDER THE DASHBOARD. SECURE TO THE FIREWALL FROM THE ENGINE
COMPARTMENT SIDE USING (2) 1/4-20 x 1¼” BOLTS AND (2) 1/4” FLAT WASHERS, SEE FIGURE 10 BELOW.
INSTALL EVAPORATOR DRIVER/ PASSENGER FRONT MOUNTING BRACKETS ON EVAPORATOR USING
(2) 1/4-20 x 1/2“ HEX BOLTS AS SHOWN IN FIGURE 7, PAGE 10.
SECURE PASSENGER SIDE FRONT MOUNTING BRACKET TO PASSENGER SIDE DASH BRACE USING
#14 x 3/4” HEX SHEET METAL SCREW IN OEM HOLE. NOTE: IN SOME MODELS IT MAY REQUIRE TO DRILL
3/16” HOLE, USE DIMENSION BELOW. (SEE FIGURE 10 BELOW.)
DRILL 3/16“ HOLE IN PASSENGER SIDE DASH BRACE USING DRIVER SIDE FRONT MOUNTING BRACKET AS
TEMPLATE. (SEE FIGURE 10 BELOW).
SECURE DRIVER SIDE FRONT MOUNTING BRACKET TO PASSENGER SIDE DASH BRACE USING #14 x 3/4”
HEX SHEET METAL SCREW. (SEE FIGURE 10 BELOW.)
VERIFY THAT EVAPORATOR UNIT IS LEVEL AND SQUARE TO THE DASH, THEN TIGHTEN ALL MOUNTING
BOLTS. (NOTE: TIGHTEN THE BOLTS ON FIREWALL FIRST, THEN THE FRONT MOUNTING BRACKETS.)
CONNECT #10 AC HOSE TO EVAPORATOR AS SHOWN IN FIGURE 10.
(NOTE: WRAP THE #10 FITTING CONNECTION
WITH PRESS TAPE. SEE FIGURE 10.)
#10 A/C
HOSE
NOTE: THIS HEATER
HOSE TO RADIATOR
EXPANSION TANK
(IF EQUIPPED)
OR WATER PUMP
(IF EQUIPPED) OR
WATER PUMP
PRESS
TAPE
#6 A/C
HOSE
HEATER
HOSE
45”
THIS END TO
EVAPORATOR
TOP FITTING
NOTE: HEATER HOSE MODIFICATION
REFER TO FIGURE 9
OPTION 1
GATES 18084
3/4” TO 5/8“ x 60” HEATER HOSE
NOTE: CUT TO LENGTH
OPTION 2
3/4” x 5/8” REDUCER FITTING
REQUIRED
(NOT SUPPLIED)
THIS END TO
RADIATOR
EXPANSION TANK
3/4” 5/8”
7 ¾”

13
901142 REV D 5/16/17, INST 63-66 CORVETTE EVAP wo AC PG 13 OF 25
LOCATE THE #8 COMPRESSOR A/C HOSE. LUBRICATE (2) #8 O-RINGS (SEE FIGURE 12, ABOVE) AND CONNECT
THE 135° FEMALE FITTING TO THE #8 DISCHARGE PORT ON THE COMPRESSOR. ROUTE THE STRAIGHT FEMALE
FITTING w/ 134a SERVICE PORT TO THE #8 CONDENSER HARDLINE COMING THROUGH CORE SUPPORT.
SEE FIGURE 13 PAGE 14. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN FIGURE 12 ABOVE.
LOCATE THE #10 COMPRESSOR A/C HOSE. LUBRICATE (2) #10 O-RINGS (SEE FIGURE 12, ABOVE) AND
CONNECT THE #10 STRAIGHT FEMALE FITTING w/134a SERVICE PORT TO THE #10 SUCTION PORT ON THE
COMPRESSOR. ROUTE THE 90° FEMALE FITTING TO THE #10 EVAPORATOR. SEE FIGURE 10, PAGE 12 AND
FIGURE 13, PAGE 14. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN 12 ABOVE.
LOCATE THE #6 EVAPORATOR A/C HOSE. LUBRICATE (2) #6 O-RINGS (SEE FIGURE 12, ABOVE) AND CONNECT
THE 90° FEMALE FITTING TO THE DRIER HARDLINE. ROUTE THE 90° FEMALE FITTING TO THE #6 EVAPORATOR.
SEE FIGURE 9, PAGE 12 AND FIGURE 13, PAGE 14. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN
FIGURE 12, ABOVE.
A/
C HOSE INSTALLATION
STANDARD HOSE KIT
LUBRICATING O-RINGS
#6O-RING
#8 O-RING#10O -RING
HOLDWITH
THIS W RENCH
FORA PROPERSEALOFFITTINGS:
INSTALL SUPPLIEDO-RINGSAS SHOWN
ANDLUBRICATE WITH SUPPLIEDOIL.
O-RING
SUPPLIEDOIL
FORO-RINGSO-RING,INSTALLS
OVERMALEINSERT
TOSWAGEDLIP
MALE
INSERTFEMALE
NUT
O-RING
TWIST WITH
THIS WRENCH
FIGURE 12
REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH MODIFIED HOSE KIT.
MODIFIED A/C HOSE KIT
FIGURE 11a
FIGURE 11
FIREWALL BLOWER COVER INSTALLATION CONT.
APPLY A 1/4” BEAD OF SILICONE AROUND THE BACK SIDE OF THE FIREWALL BLOWER COVER AS SHOWN
IN FIGURE 11a BELOW.
ATTACH FIREWALL BLOWER COVER TO FIREWALL USING (3) 1/4” NUT w/ STAR WASHERS AND
(3) FLAT WASHERS. SEE FIGURE 11 BELOW.
(3) 1/4” NUT
w/ STAR WASHERS
(3) 1/4” FLAT
WASHERS
FIREWALL
BLOWER
COVER
SILICONE
LOWER
HEATER
HOSE
UPPER HEATER
HOSE
#6 A/C
HOSE
#10 A/C
HOSE

14
901142 REV D 5/16/17, INST 63-66 CORVETTE EVAP wo AC PG 14 OF 25
HEATER HOSE
(HEATER CNTRL
VALVE/ INTAKE)
HEATER HOSE & HEATER CONTROL VALVE INSTALLATION
ROUTE A PIECE OF HEATER HOSE FROM THE RADIATOR EXPANSION TANK (IF EQUIPPED) OR WATER PUMP
TO THE TOP HEATER FITTING OF HEATER CORE AS SHOWN IN FIGURE 9, PAGE 12 AND FIGURE 13 BELOW.
SECURE USING HOSE CLAMPS.
NOTE: OEM RADIATOR EXPANSION TANK OUTLET IS 3/4”. (OPTION 1)
USE GATES HEATER HOSE PART # 18084 3/4” x 5/8” x 60” (REFER TO PAGE 12) FOR HEATER HOSE
MODIFICATION. (OPTION 2) 3/4 x 5/8 REDUCER FITTING IS REQUIRED (NOT SUPPLIED)
ROUTE A PIECE OF HEATER HOSE FROM THE INTAKE TO THE BOTTOM HEATER FITTING OF HEATER CORE
AS SHOWN IN FIGURE 9, PAGE 12 AND FIGURE 13, BELOW. INSTALL HEATER CONTROL VALVE
IN-LINE WITH INTAKE MANIFOLD (PRESSURE SIDE) HEATER HOSE, SECURE USING HOSE CLAMPS AS
SHOWN IN FIGURE 13, BELOW. NOTE PROPER FLOW DIRECTION.
FROM HTR CNTRL VL
V
TO HEATER CORE
HEATER
HOSE
FROM HEATER
TO RADIATOR
EXPANSION
TANK
(IF EQUIPPED)
OR WATER PUMP
FROM INTAKE
MANIFOLD
#6 DRIER/
CORE SUPPORT
HARD LINE
63-65 VETTE
091079
66-67 VETTE
091081
#10
SUCTION
HOSE
096050
AC & HEATER HOSE ROUTING
FIGURE 13
NOTE: VINTAGE AIR SYSTEM REQUIRES
5/8” HOSE NIPPLE (NOT SUPPLED)
OUT
COMPRESSOR
SAFETY SWITCH
(BINARY TYPE)
SCREW ON DRIER
(REFER TO
CONDENSER
INSTRUCTIONS)
#6 DRIER/
CONDENSER
HARD LINE
35130-VCG
#8
DISCHARGE
HOSE
096049
HEATER HOSE
(HEATER CORE/
RADIATOR EXPANSION
TANK) (IF EQUIPPED)
OR WATER PUMP
#6 AC
HOSE
096048
#8 CONDENSER/
COMP HARD LINE
63-65 VETTE
091180
66-67 VETTE
091082
IN

15
901142 REV D 5/16/17, INST 63-66 CORVETTE EVAP wo AC PG 15 OF 25
REMOVE THE CENTER CONSOLE FLOOR TRIM AND PASSENGER SIDE CENTER CONSOLE FLOOR PLATE.
CUT & REMOVE 6” FROM CENTER CONSOLE FLOOR TRIM AS SHOWN BELOW IN FIGURE 15.
CUT & REMOVE 2” FROM CENTER CONSOLE FLOOR PLATE AS SHOWN BELOW.
REINSTALL CENTER CONSOLE FLOOR PLATE AND FLOOR TRIM.
INSTALL CONTROL SWITCHES AND WIRING. (SEE CONTROL PANEL INSTRUCTIONS)
CENTER CONSOLE TRIM MODIFICATION
FIGURE 15
6”
2”
PASSENGER SIDE
CENTER CONSOLE
FLOOR PLATE
(63 MODELS ONLY)
CENTER CONSOLE
FLOOR TRIM
CUT
& REMOVE
CUT
& REMOVE
PASSENGER SIDE
CENTER CONSOLE
FLOOR PLATE
CENTER
CONSOLE
FLOOR TRIM
LOCATE EVAPORATOR DRAIN ON BOTTOM
OF EVAPORATOR CASE.
IN-LINE WITH DRAIN, LIGHTLY MAKE A MARK
ON THE FIREWALL MEASURE 1” DOWN AND
DRILL A 5/8” HOLE THROUGH THE FIREWALL.
SEE FIGURE 14 BELOW.
INSTALL DRAIN HOSE TO BOTTOM OF
EVAPORATOR UNIT AND ROUTE THROUGH
FIREWALL. INSTALL 1/2” 90° DRAIN ELBOW
ON DRAIN HOSE SEE FIGURE 14.
DRAIN HOSE INSTALLATION
EVAPORATOR
CASE
DRAIN
HOSE
1”
1”
FIGURE 14

16
901142 REV D 5/16/17, INST 63-66 CORVETTE EVAP wo AC PG 16 OF 25
LOOSEN THE (2) OEM NUTS FROM STEERING COLUMN BRACKET. DROP STEERING COLUMN FROM DASH
BRACE. SLIDE BRACKET BETWEEN DASH BRACE AND STEERING COLUMN BRACKET.
ADJUST AND SECURE LOUVER HOUSING TO UNDER DASH STEERING COLUMN BRACKET USING OEM
NUTS AS SHOWN IN FIGURE 17 BELOW.
DRIVER SIDE UNDER DASH LOUVER INSTALLATION
FIGURE 17
(2) OEM
NUTS
STEERING
COLUMN
DRIVER SIDE
LOUVER BRACKET
(2) OEM
NUTS
DASH
BRACE
DASH
BRACE
STEERING COLUMN
BRACKET
DRIVER SIDE
LOUVER ASM
491630
ALIGN PASSENGER SIDE UNDER DASH LOUVER TO DASH BRACE USING PASSENGER SIDE FRONT EVAP
BRACKET AND #14 x 3/4” SHEET METAL SCREW, DRILL (2) 1/8“ HOLES IN DASH BRACE AND SECURE USING
(2) #10 x 1/2” SHEET METAL SCREW AS SHOWN BELOW IN FIGURE 16.
INSTALL 1/2” PLASTIC PLUG IN LOUVER ASM.
PASSENGER SIDE UNDER DASH LOUVER INSTALLATION
FIGURE 16
DASH
BRACE
PASSENGER SIDE
FRONT EVAP
BRACKET
#14 x 3/4”
SHEET METAL
SCREW
DRILL 1/8”
HOLE
DRILL 1/8”
HOLE
(2) #10 x 1/2”
SHEET METAL
SCREW
(2)1/2”
PLASTIC PLUG
PASSENGER SIDE
LOUVER ASM
491631

17
901142 REV D 5/16/17, INST 63-66 CORVETTE EVAP wo AC PG 17 OF 25
INSTALL DUCT HOSES AS SHOWN IN FIGURE 20, PAGE 18.
ROUTE A/C WIRES THROUGH 3/8” GROMMET AS SHOWN IN FIGURE 19 BELOW.
(12 VOLT/ GROUND/ BINARY SWITCH/ HEATER VALVE).
PLUG THE WIRING HARNESS IN THE ECU MODULE ON SUB CASE AS SHOWN IN FIGURE 20, PAGE 18
(WIRE ACCORDING TO WIRING DIAGRAM ON PAGE 19 AND 20.)
INSTALL (9) #8 U-NUTS IN GLOVE BOX AS SHOWN IN FIGURE 19a.
INSTALL NEW GLOVE BOX USING OEM SCREWS.
REINSTALL CENTER FLOOR CONSOLE.
REINSTALL KICK PANEL.
RELOCATE OEM DRIVER SIDE FRESH AIR CABLE ASSEMBLY TO OEM PASSENGER SIDE MOUNTING
LOCATION SEE FIGURE 19 BELOW.
REINSTALL ALL PREVIOUSLY REMOVED ITEMS.
FILL RADIATOR WITH AT LEAST A 50/50 MIXTURE OF APPROVED ANTIFREEZE AND DISTILLED WATER. IT IS THE
OWNER'S RESPONSIBILITY TO KEEP THE FREEZE PROTECTION AT THE PROPER LEVEL FOR THE CLIMATE IN
WHICH THE VEHICLE IS OPERATED. FAILURE TO FOLLOW ANTIFREEZE RECOMMENDATIONS WILL CAUSE
HEATER CORE TO CORRODE PREMATURELY AND POSSIBLY BURST IN AC MODE AND/OR FREEZING WEATHER,
VOIDING YOUR WARRANTY.
DOUBLE CHECK ALL FITTINGS, BRACKETS AND BELTS FOR TIGHTNESS.
VINTAGE AIR RECOMMENDS THAT ALL AC SYSTEMS BE SERVICED BY A CERTIFIED AUTOMOTIVE AIR
CONDITIONING TECHNICIAN.
EVACUATE THE SYSTEM FOR A MINIMUM OF 45 MINUTES PRIOR TO CHARGING AND LEAK CHECK PRIOR
TO SERVICING.
CHARGE THE SYSTEM TO THE CAPACITIES STATED ON THE INFORMATION PAGE (PAGE 4) OF THIS
INSTRUCTION MANUAL.
SEE OPERATION OF CONTROLS PROCEDURES ON PAGE 21.
FINAL STEPS
FIGURE 19b
FIGURE 19
FIGURE 19a
3/8” GROMMET
33144-VUI
OEM DRIVER SIDE
FRESH AIR CABLE
ASSEMBLY
(9) #8 U-NUTS
189801
INSTALL POWER ANTENNA SWITCH (65 AND 66 VETTE ONLY) REFER TO PAGE 24.
INSTALL CONTROL SWITCHES AND WIRING. (SEE CONTROL PANEL INSTRUCTIONS)
INSTALL DRIVER AND PASSENGER SIDE CONSOLE PANELS USING OEM SCREWS AS SHOWN BELOW IN
FIGURE 18. NOTE: LOWER MOUNTING HOLE MUST BE DRILLED IN OEM CONSOLE TO MOUNT NEW
CONSOLE. USE DRIVER/ PASSENGER CONSOLE PANEL AS GUIDE TO DRILL 3/16” HOLE IN CONSOLE.
RELOCATE OEM J NUT AND ATTACH AS SHOWN.
DRIVER & PASSENGER SIDE CONSOLE PANEL INSTALLATION
DR SIDE
CONSOLE PANEL
491632
OEM
SCREWS
DRILL
3/16”
OEM
CONSOLE
OEM
HOLE
OEM
HOLE
PASS SIDE
CONSOLE PANEL
491633
OEM
SCREWS
DRILL
3/16”
OEM
HOLE
OEM
HOLE
FIGURE 18

18
901142 REV D 5/16/17, INST 63-66 CORVETTE EVAP wo AC PG 18 OF 25
DRIVER SIDE
UNDER DASH
LOUVER
2 ½” x 18”
PASS. SIDE
CONSOLE
LOUVER
2 ½” x 16”
DRIVER SIDE
CONSOLE
LOUVER
2 ½” x 8”
CONTROL PANEL & DUCT HOSE ROUTING
DEFROST DUCT
DR. SIDE
3” x 12”
FIGURE 20
PLUG
FROM
CONTROL
WIRING
HARNESS
232002-VUA
PLUG
FROM
WIRING
HARNESS
232001-VUR
PASS. SIDE
UNDER DASH
LOUVER
2 ½” x 16”
12 1
2
3
4
5
6
7
8
9
10
11
108
104
100
96
92
88
A
I
R
-
P
U
L
L
-
D
E
F
T
U
N
I
N
G
F
A
N
T
E
M
P
P
U
L
L
V
O
L
T
O
N
E

19
901142 REV D 5/16/17, INST 63-66 CORVETTE EVAP wo AC PG 19 OF 25
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

20
901142 REV D 5/16/17, INST 63-66 CORVETTE EVAP wo AC PG 20 OF 25
RED
CIRCUIT BREAKER
30 AMP
+
+
-
BLACK
RED
WHITE
RED
CHASSIS GROUND
A/C
COMPRESSOR
RELAY
Ignition Switch:
Dash Light:
NOTE:
MOUNT RELAY
IN DESIRED
LOCATION
UNDER DASH
GREEN
FIREWALL
BLUE
BLUE
RED
&
WHITE
VIOLET
(IGNITION HOT
TERMINAL)
IGNITION
SWITCH
DASH BACK LIGHT+0-12v
TAN
GRAY
BLUE
WHITE
WHITE
RED
RED
WHITE
COMPRESSOR
BATTERY
NOTE: CONNECT WHITE
WIRES DIRECTLY TO
(-) BATTERY TERMINAL
BAT
RUN
12V
RED
GREEN
RED
RED
BLUE
LATCH
BLACK
BINARY
SAFETY
SWITCH
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
HEATER
CONTROL 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. ENSURE
CONNECTOR IS LATCHED
FIRMLY.