Vintage Air 1964-66 CHEV PICK-UP User manual

1964-66 CHEV PICK-UP
WITHOUT FACTORY AIR
WITH STANDARD CONTROLS
751165
901136 REV A 10/3/11, INST 64-66 CHEV P-UP wo AC w/ STD EVAP KIT PG 1 OF 24
an ISO 9001:2008 Registered Company

2
901136 REV A 10/3/11, INST 64-66 CHEV P-UP wo AC w/ STD EVAP KIT PG 2 OF 24
PAGES
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, PULLEYS PASSENGER COMPARTMENT
FIGURES 2, 2a & 2b
8. FIREWALL MODIFICATION, BRACKET & EVAPORATOR HARDLINE INSTALLATION
FIGURES 3 & 4
9. BRACKET & EVAPORATOR HARDLINE INSTALLATION CONT.
FIGURE 5
10. EVAPORATOR INSTALLATION
FIGURES 6 & 6a
11. DRAIN HOSE INSTALLATION, LUBRICATING O-RINGS, A/C HOSE INSTALLATION, &
MODIFIED A/C HOSE KIT
FIGURES 7 & 8
12. FIREWALL & OEM HEATER COVER INSTALLATION
FIGURE 9
13. HEATER HOSE & HEATER CONTROL VALVE INSTALLATION
FIGURE 10
14. AC & HEATER HOSE ROUTING
FIGURE 11
15. DRIVER SIDE UNDER DASH LOUVER & CENTER/ PASSENGER SIDE UNDER DASH
LOUVER INSTALLATION
FIGURES 12, 12a, 13, & 13a
16. FINAL STEPS
FIGURES 14 & 14a
17. CONTROL PANEL & DUCT HOSE ROUTING
FIGURE 15
18. WIRING DIAGRAM
19. GEN IV WIRING CONNECTION INSTRUCTIONS
20. OPERATION OF CONTROLS
21. TROUBLE SHOOTING INFORMATION
22. TROUBLE SHOOTING INFORMATION CONT.
23. 64-66 CHEV P-UP FIREWALL TEMPLATE
24. EVAPORATOR KIT PACKING LIST

3
901136 REV A 10/3/11, INST 64-66 CHEV P-UP wo AC w/ STD EVAP KIT PG 3 OF 24
** 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
751165
1.
2.
1
1
744004-VUE
791165
1
ACCESSORY KIT
791165
2
GEN IV 4 VENT EVAPORATOR SUB CASE
ACCESSORY KIT 64-66 CHEV P-UP wo AC w/ STD
NO. QTY. PART NO. DESCRIPTION
EVAPORATOR KIT PACKING LIST
NOTE: IMAGES MA Y NOT DE PICT ACTUAL PARTS AND QUANTITIES.
REFER TO PACKING LIST FOR ACTUAL PARTS AND QUANTITIES.
GEN IV 4 VENT
EVAP. SUB CASE
744004-VUE

4
901136 REV A 10/3/11, INST 64-66 CHEV P-UP wo AC w/ STD EVAP KIT PG 4 OF 24
FOR MAXIMUM SYSTEM PERFORMANCE VINTAGE AIR RECOMMENDS THE FOLLOWING:
THIS KIT DOES NOT CONTAIN HEATER HOSE. YOU MUST PURCHASE 12 FEET OF 5/8” DIA.
HEATER HOSE FROM VINTAGE AIR (31800-VUD) OR FROM YOUR LOCAL PARTS RETAILER
LUBRICANT CAPACITIES:
134a SYSTEM
CHARGE WITH 1.8 lbs.
(1lbs. 12ozs) OF REFRIGERANT
NEW COMPRESSOR - NO ADDITIONAL OIL NEEDED
SERVICE INFO:
SAFETY SWITCHES:
ATTENTION:
SYSTEM COMPONENTS: THE COMPRESSOR, EVAPORATOR, CONDENSER & DRIER ARE CAPPED.
CAPS MAY BE ; BE CAREFUL REMOVING CAPS. DO NOT REMOVE CAPS
PRIOR TO INSTALLATION. REMOVING CAPS PRIOR TO INSTALLATION WILL CAUSE COMPONENTS TO COLLECT
MOISTURE AND LEAD TO PREMATURE FAILURE AND REDUCED PERFORMANCE.
EVACUATE THE SYSTEM FOR 35-45 MINUTES WITH SYSTEM COMPONENTS (DRIER, COMPRESSOR, EVAPORATOR
AND CONDENSER) AT A TEMPERATURE OF AT LEAST 85° F. ON A COOL DAY THE COMPONENTS CAN BE HEATED
WITH A HEAT GUN BY RUNNING THE ENGINE WITH THE HEATER ON BEFORE EVACUATING. LEAK CHECK
AND CHARGE TO SPECIFICATIONS.
UNDER PRESSURE WITH DRY NITROGEN
OR
YOUR VINTAGE AIR SYSTEM IS EQUIPPED WITH A BINARY PRESSURE SAFETY SWITCH. A BINARY SWITCH
DISENGAGES THE COMPRESSOR CLUTCH IN CASE OF EXTREME LOW PRESSURE CONDITION
(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 MAY BE SUBSTITUTED FOR USE WITH ELECTRIC CONDENSER FANS.
COMPRESSOR SAFETY SWITCHES ARE EXTREMELY IMPORTANT SINCE AN A/C SYSTEM RELIES ON
REFRIGERANT TO CARRY LUBRICATION THROUGH THE SYSTEM.
VINTAGE AIR SYSTEMS ARE DESIGNED TO OPERATE WITH R134a
REFRIGERANT ONLY! USE OF ANY OTHER REFRIGERANTS RISKS A DANGER OF FIRE
AND COULD DAMAGE EITHER YOUR AIR CONDITIONING SYSTEM OR YOUR VEHICLE.
USE OF ANY OTHER REFRIGERANTS WILL VOID ALL WARRANTIES OF
THE AIR CONDITIONING SYSTEM AND COMPONENTS. USE OF THE PROPER
TYPE AND AMOUNT OF REFRIGERANT IS CRITICAL TO PROPER SYSTEM
OPERATION. VINTAGE AIR RECOMMENDS OUR SYSTEMS BE CHARGED BY
WEIGHT WITH A QUALITY CHARGING STATION OR SCALE.
REFRIGERANT CAPACITY FOR VINTAGE AIR SYSTEMS
(FOR OTHER SYSTEMS, CONSULT M ANUFACTURER GUIDELINES)
IMPORTANT NOTICE-PLEASE READ

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901136 REV A 10/3/11, INST 64-66 CHEV P-UP wo AC w/ STD EVAP KIT PG 5 OF 24
THE HEATER CONTROL VALVE IS A NORMALLY OPEN VALVE. IT MUST BE CONNECTED TO
THE ECU TO BLOCK WATER FLOW IN MAX AC MODE.
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 ANY OTHER AUXILIARY DEVICE. SHORTING TO GROUND OR CONNECTING
TO A CONDENSER FAN OR ANY OTHER AUXILIARY DEVICE WILL CAUSE SEVERE DAMAGE
TO THE ECU.
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 TO THE 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 TURNING SOME OF THE VEHICLE'S OTHER SYSTEMS ON AND OFF. MODERN
COMPUTER OPERATED EQUIPMENT CAN BE SENSITIVE TO VOLTAGE SPIKES ON THEIR POWER
LEADS, WHICH CAN CAUSE UNEXPECTED RESETS, STRANGE BEHAVIOR, AND MAY ALSO CAUSE
PERMANENT DAMAGE.
VINTAGE AIR STRIVES TO HARDEN THEIR 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 & TRUCK PARTS
SUPPLIERS. THEY TYPICALLY ARE CYLINDRICAL IN SHAPE, A LITTLE OVER AN INCH LONG, A LITTLE
OVER A HALF INCH IN DIAMETER, THEY HAVE A SINGLE LEAD COMING FROM ONE END OF THE
CYLINDER WITH A TERMINAL ON THE END OF THE WIRE, AND THEY WILL HAVE 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.
IMPORTANT WIRING NOTICE-PLEASE READ
WHEN INSTALLING GROUND LEADS ON GEN IV SYSTEMS, THE BLOWER CONTROL GROUND
AND ECU GROUND MUST BE CONNECTED DIRECTLY TO THE NEGATIVE BATTERY POST.

6
901136 REV A 10/3/11, INST 64-66 CHEV P-UP wo AC w/ STD EVAP KIT PG 6 OF 24
DISCONNECT BATTERY.
DRAIN RADIATOR, REMOVE RADIATOR (RETAIN)
HEATER BLOWER ASSEMBLY AND OEM HEATER HOSES (DISCARD)
ENGINE COMPARTMENT
REMOVE THE FOLLOWING
FIGURE 1
BEFORE STARTING THE INSTALLATION, CHECK THE FUNCTION
OF THE VEHICLE (HORN, LIGHTS,ETC.) FOR PROPER OPERATIONS.
STUDY THE INSTRUCTIONS, ILLUSTRATIONS, & DIAGRAMS.
OEM HEATER
BLOWER
ASSEMBLY
OEM HEATER
HOSES

7
901136 REV A 10/3/11, INST 64-66 CHEV P-UP wo AC w/ STD EVAP KIT PG 7 OF 24
REMOVE GLOVE BOX DOOR (RETAIN) AND GLOVE BOX (DISCARD).
DISCONNECT ALL WIRES AND CABLES FROM CONTROL PANEL .
REMOVE CONTROL PANEL (RETAIN).
REMOVE OEM DUCT HOSE FROM DEFROST DUCTS (SEE FIGURE 2 BELOW.)
OEM HEATER ASSEMBLY.
REMOVE PASSENGER SIDE FRESH AIR DOOR ASM (DISCARD) (RETAIN SCREWS) (SEE FIGURE 2a).
INSTALL PASSENGER SIDE FRESH AIR COVER USING OEM SCREWS AS SHOWN IN FIGURE 2b BELOW.
INSTALL HOSE ADAPTERS ON OEM DEFROST DUCTS USING (2) S-CLIPS AS SHOWN IN FIGURE 2 BELOW.
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
AND BRACKET.
COMPRESSOR & BRACKETS
REMOVE THE FOLLOWING:
FIGURE 2
OEM HEATER
ASSEMBLY
CONTROL
PANEL
BACKSIDE OF
PASSENGER SIDE
FRESH AIR COVER
OEM DUCT
HOSE
HOSE
ADAPTER
49168-VCI
(2) S-CLIPS
65980-VUE
GLOVE BOX
&
DOOR
FIGURE 2a
FIGURE 2b
PASSENGER SIDE
FRESH AIR
DOOR ASM PASSENGER SIDE
FRESH AIR
COVER
644095
(6) OEM
SCREWS
SILICONE
HOSE
ADAPTER
49168-VCI
(2) S-CLIPS
65980-VUE

8
901136 REV A 10/3/11, INST 64-66 CHEV P-UP wo AC w/ STD EVAP KIT PG 8 OF 24
BRACKET & EVAPORATOR HARDLINE INSTALLATION
ON A WORK BENCH INSTALL EVAPORATOR REAR BRACKET USING (4) 1/4-20 x 1/2” HEX BOLTS.
INSTALL HARDLINES WITH PROPERLY LUBRICATED O-RINGS. (SEE FIGURE 5, PAGE 9,
AND FIGURE 8, PAGE 11.)
NOTE: WRAP THE #10 FITTING CONNECTIONS WITH PRESS TAPE.
SEE FIGURE 5, PAGE 9.
INSTALL EVAPORATOR FRONT BRACKET ON
EVAPORATOR USING (2)1/4-20 x 1/2” HEX BOLTS
AND TIGHTEN AS SHOWN IN FIGURE 4 BELOW.
FIREWALL MODIFICATION
USING TEMPLATE PROVIDED ON PAGE 23, ALIGN TEMPLATE ON ENGINE SIDE OF FIREWALL WITH OEM
HOLES AND MARK AND DRILL 9/32” HOLE IN FIREWALL. (SEE FIGURE 3 BELOW.)
(2)1/4-20 x 1/2”
HEX BOLT
DRILL
9/32
FRONT
EVAPORATOR
BRACKET
644094
FIGURE 4
FIGURE 3
60 -66 CHEV. P/UP
FIREWALL DRILL TEMPLATE
FOR REAR EVAP BRKT
OEM
HOLE
OEM
HOLE
DRILL 9/32”
HOLE

9
901136 REV A 10/3/11, INST 64-66 CHEV P-UP wo AC w/ STD EVAP KIT PG 9 OF 24
REAR
EVAPORATOR
BRACKET ASM
644073
BRACKET & EVAPORATOR HARDLINE INSTALLATION CONT.
FIGURE 5
(2) 1/4-20 x 1/2”
HEX BOLT
#6 LIQUID LINE
095008
TWIST WITH
THIS
WRENCH LUBRICATE O-RING
(SEE FIGURE 8,
PAGE 11.)
HOLD WITH
THIS WRENCH
HEATER LINE
(EVAP TO WATER PUMP)
095010
ECU MODULE
#10 O-RING
33859-VUF
NOTE: AFTER INSTALLING
#10 SUCTION LINE
WRAP ALL EXPOSED METAL
(FITTINGS & TUBE)
WITH SUPPLIED
PRESS TAPE
#6 LIQUID LINE
095008
PRESS TAPE
HEATER LINE
(EVAP TO INTAKE)
095011
#6
O-RING
33857-VUF
(2) 1/4-20 x 1/2”
HEX BOLT
#10 O-RING
(33859-VUF)
#10 SUCTION
LINE
095009

10
901136 REV A 10/3/11, INST 64-66 CHEV P-UP wo AC w/ STD EVAP KIT PG 10 OF 24
INNER
COWL
MOUNT EVAPORATOR
TO FIREWALL
USING THESE HOLES
DRILL (2)
⁄” HOLES
(2)#14 x ¾”
SHEET METAL
SCREWS
(2) 1/4-20 x 1 1/4”
HEX BOLT
182899
(2) 1/4”
FLAT WASHER
18125-VUB
VIEW FROM
PASSENGER SIDE
INSIDE OF CAB
FIGURE 6
FIGURE 6a
.750 OD x .312 ID x .625 L
NYLN SPACER
180391
EVAPORATOR INSTALLATION
LIFT EVAPORATOR UNIT UP UNDER THE DASHBOARD. SECURE LOOSELY TO THE FIREWALL USING
(2) 1/4-20 x 1 1/4” HEX BOLTS, (2) FLAT WASHERS. SEE FIGURE 6.
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, BLOCK THE UNIT
UP, THEN DRILL FOR FRONT BRACKET SCREWS.
SECURE THE FRONT EVAPORATOR MOUNTING BRACKET TO COWL USING (2) #14 x 3/4” HEX SHEET
METAL SCREWS SEE FIGURE 6a BELOW.
VERIFY THAT EVAPORATOR UNIT IS LEVEL AND SQUARE TO THE DASH, THEN TIGHTEN ALL MOUNTING
BOLTS. (NOTE: TIGHTEN THE BOLT ON FIREWALL FIRST, THEN THE FRONT MOUNTING BRACKET.)

11
901136 REV A 10/3/11, INST 64-66 CHEV P-UP wo AC w/ STD EVAP KIT PG 11 OF 24
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.
INSTALL DRAIN HOSE TO BOTTOM OF
EVAPORATOR UNIT AND ROUTE THROUGH
FIREWALL. INSTALL 1/2” 90° DRAIN ELBOW
ON DRAIN HOSE.
DRAIN HOSE INSTALLATION
FIGURE 7
EVAPORATOR
CASE
1”
LOCATE THE #8 COMPRESSOR A/C HOSE. LUBRICATE (2) #8 O-RINGS (SEE FIGURE 8, 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 11, PAGE 14. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN FIGURE 8 ABOVE.
LOCATE THE #10 COMPRESSOR A/C HOSE. LUBRICATE (2) #10 O-RINGS (SEE FIGURE 8, ABOVE) AND CONNECT
THE #10 135° FEMALE FITTING w/134a SERVICE PORT TO THE #10 SUCTION PORT ON THE COMPRESSOR.
ROUTE THE 45° FEMALE FITTING TO THE #10 EVAPORATOR. SEE FIGURE 10, PAGE 13 AND FIGURE 11, PAGE 14.
TIGHTEN EACH FITTING CONNECTION AS SHOWN IN FIGURE 8 ABOVE.
LOCATE THE #6 EVAPORATOR/ DRIER HARDLINE. LUBRICATE (2) #6 O-RINGS (SEE FIGURE 8, ABOVE) AND
CONNECT THE HARDLINE TO THE #6 DRIER HARDLINE COMING THROUGH CORE SUPPORT. ATTACH THE
OTHER END OF THE HARDLINE TO THE #6 EVAPORATOR. HARDLINE COMING THROUGH THE FIREWALL.
SEE FIGURE 10, PAGE 13 AND FIGURE 11, PAGE 14. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN
FIGURE 8 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,INSTALES
OVERMALEINSERT
TOSWAGEDLIP
MALE
INSERTFEMALE
NUT
O-RING
TWIST WITH
THIS WRENCH
FIGURE 8
REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH MODIFIED HOSE KIT.
MODIFIED A/C HOSE KIT
DRAIN
HOSE
1”

12
901136 REV A 10/3/11, INST 64-66 CHEV P-UP wo AC w/ STD EVAP KIT PG 12 OF 24
APPLY A 1/4” BEAD OF SILICONE ON THE BACK SIDE OF OEM HEATER COVER AS SHOWN BELOW.
INSTALL OEM HEATER COVER USING (4) OEM SCREWS AS SHOWN IN FIGURE 9 BELOW.
INSTALL GROMMETS IN FIREWALL COVER AS SHOWN BELOW.
APPLY A 1/4” BEAD OF SILICONE ON THE BACK SIDE OF FIREWALL COVER AS SHOWN BELOW.
INSTALL FIREWALL COVER USING (3) #10 x 1/2” SHEET METAL SCREWS AS SHOWN IN FIGURE 9 BELOW.
FIREWALL
COVER
644093
OEM HEATER
COVER
644092
FIREWALL & OEM HEATER COVER INSTALLATION
FIGURE 9
(3) #10 x 1/2”
SHEET METAL
SCREWS
18247-VUB
(4) OEM
SCREWS
SILICONE SILICONE
LARGE
GROMMET
33137-VUI
GROMMET
33135-VUI
BACK SIDE
OF FIREWALL
COVER
BACK SIDE
OF OEM HEATER
COVER

13
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#10 SUCTION
LINE
HEATER
HOSE
NOTE: FLOW ARROW DECAL
ON HEATER CONTROL VALVE.
ROUTE HEATER HOSE FROM WATER PUMP TO THE HEATER LINE COMING THROUGH THE FIREWALL AS
SHOWN IN FIGURE 10, BELOW. SECURE USING HOSE CLAMPS. NOTE: A SMALL AMOUNT OF SILICONE
SPRAY WILL EASE HEATER HOSE INSTALLATION.
ROUTE HEATER HOSE FROM THE INTAKE TO THE HEATER LINE COMING THROUGH THE FIREWALL AS SHOWN
BELOW. NOTE: INSTALL HEATER CONTROL VALVE IN-LINE WITH INTAKE MANIFOLD (PRESSURE SIDE) HEATER
HOSE, SECURE USING HOSE CLAMPS AS SHOWN. NOTE PROPER FLOW DIRECTION.
HOSE SHOULD PROTRUDE THROUGH THE FIREWALL COVER SLIGHTLY TO CLOSE THE GAP BETWEEN THE
ALUMINUM LINE AND THE FIREWALL COVER. SEAL ANY REMAINING GAP WITH RTV SILICONE.
HEATER HOSE & HEATER CONTROL VALVE INSTALLATION
LIQUID
LINE FIGURE 10
HEATER
HOSE
FROM INTAKE
MANIFOLD
FROM EVAPORATOR TO WATER PUMP
FROM HTR CNTRL VLV
TO EVAPORATOR

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901136 REV A 10/3/11, INST 64-66 CHEV P-UP wo AC w/ STD EVAP KIT PG 14 OF 24
FIGURE 11
TIE WRAP
#8 DISCHARGE
HOSE
095100
NOTE: VINTAGE AIR SYSTEMS REQUIRE
(2) 5/8” HOSE NIPPLES (NOT SUPPLIED)
HEATER
HOSE
FROM HTR CNTRL VLV
TO EVAPORATOR
FROM EVAPORATOR
TO WATER PUMP
AC & HEATER HOSE ROUTING
#6 DRIER/CORE
HARDLINE
095013
#6 COND/DRIER
HARDLINE
095015
NOTE: DIRECTION OF WATER FLOW. INSTALL HEATER CONTROL VALVE AS SHOWN.
FROM INTAKE MANIFOLD
#6 LIQUID
HARDLINE
095012
COMPRESSOR
SAFETY SWITCH (BINARY TYPE)
SCREW ON DRIER (REFER TO
CONDENSER INSTRUCTIONS)
#10 SUCTION
HOSE
095101
HEATER HOSE
(HEATER CNTRL
VALVE/ INTAKE
#8 COND/COMP
HARDLINE
095014

15
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(4) S-CLIPS
(2) 10-32 x 1/2”
PAN HEAD
SCREW
CENTER/ PASSENGER
SIDE UNDERDASH
LOUVER
EVAPORATOR
PLENUM
(2) #10 X 1/2
HEX SHEET
METAL SCREWS
18247-VUB
LOCATE DRIVER SIDE LOUVER HOUSING UNDER DASH AND DRILL (2) 1/8” HOLES.
SECURE LOUVER HOUSING TO DASH USING (2) #10 x 1/2 HEX SHEET METAL SCREWS AS SHOWN
IN FIGURE 12 BELOW.
INSTALL LOUVER IN UNDER DASH HOUSING AS SHOWN IN FIGURE 12a.
DRIVER SIDE UNDER DASH LOUVER INSTALLATION
DR SIDE
UNDER DASH
LOUVER HOUSING
494052
FIGURE 12
LOUVER
49057-VUL
FIGURE 12a
(3)#10 x 1/2
HEX SHEET
METAL SCREWS
LOCATE CENTER/ PASSENGER SIDE LOUVER ASM UNDER DASH AND DRILL (3) 1/8” HOLES.
SECURE LOUVER ASM UNDER DASH USING (3) #10 x 1/2 HEX SHEET METAL SCREWS AS SHOWN IN
FIGURE 13 BELOW.
INSTALL LOUVERS IN CENTER/ PASSENGER SIDE UNDER DASH LOUVER ASM AS SHOWN IN FIGURE 13a.
INSTALL (3) 1/2” PLASTIC PLUG AS SHOWN BELOW.
CENTER/ PASSENGER SIDE UNDER DASH LOUVER INSTALLATION
CENTER/ PASSENGER
SIDE UNDER DASH
LOUVER ASM
496069
FIGURE 13
FIGURE 13a
(3) LOUVERS
490570 (3) 1/2”
PLASTIC PLUG
31102-GUR

16
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INSTALL DUCT HOSES AS SHOWN IN FIGURE 15, PAGE 17.
ROUTE A/C WIRES THROUGH 3/8” GROMMET AS SHOWN ON FIGURE 14
(12 VOLT/GROUND/BINARY SWITCH/HEATER VALVE).
INSTALL CONTROL PANEL ASM.
PLUG THE WIRING HARNESS IN THE ECU MODULE ON SUB CASE AS SHOWN IN FIGURE 15, PAGE 17
(WIRE ACCORDING TO WIRING DIAGRAM ON PAGE 18 AND 19.)
INSTALL NEW GLOVE BOX USING OEM SCREWS, (SEE FIGURE 14a.)
INSTALL GLOVE BOX DOOR
REINSTALL ALL PREVIOUSLY REMOVED ITEMS, INNER FENDER.
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 PAGE 20.
FINAL STEPS
FIGURE 14a
FIGURE 14
GROMMET
33144-VUI
PLUG
317098
GLOVE BOX
496066

17
901136 REV A 10/3/11, INST 64-66 CHEV P-UP wo AC w/ STD EVAP KIT PG 17 OF 24
CONTROL PANEL & DUCT HOSE ROUTING
FIGURE 15
PLUG
FROM
CONTROL
WIRING
HARNESS
232002-VU
A
PLUG
FROM
WIRING
HARNESS
232001-VUR
PASS. SIDE
DEF. DUCT
2” x 13”
DRIVER SIDE
DEF DUCT
2” x 26”
DRIVER SIDE
LOUVER
2 ½” x 42”
PASSENGER SIDE
LOUVER
2 ½” x 13”
DR SIDE
CENTER LOUVER
2 ½” x 18”
PASS SIDE
CENTER LOUVER
2 ½” x 16”

18
901136 REV A 10/3/11, INST 64-66 CHEV P-UP wo AC w/ STD EVAP KIT PG 18 OF 24
WHT/GRN
WHT/YEL
WHT/RED
RED
WHT
BACKLIGH T NEG
FAN WIPER
MODE WIPER
TEMP WIPER
5V-SW
GND
BACKLIGH T POS
AC ANNUNCIATOR
PRE-WIRED
GEN IV WIRING DIAGRAM
REV C, 11/24/2009
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 ONLY USED WITH TYPE 232007-VUR HARNESS
** WARNING: ALWAYS MOUNT CIRCUIT BREAKER UNDER THE HOOD IN THE ENGINE COMPARTMENT
AND AS CLOSE TO THE BATTERY AS POSSIBLE.
*** WIDE OPEN THROTTLE SWITCH CONTACTS CLOSE ONLY AT FULL THROTTLE, WHICH DISABLES AC
COMPRESSOR.
JF8
BLK
ORA
TAN
VIEWED FROM WIRE SIDE

19
901136 REV A 10/3/11, INST 64-66 CHEV P-UP wo AC w/ STD EVAP KIT PG 19 OF 24
RED
CIRCUIT BREAKER
30 AMP
+
+
-
BLACK
RED
WHITE
RED
CHASSIS
GROUND
HEATER
CONTROL
VALVE
A/C
COMPRESSOR
RELAY HEATER
CONTROL
VALVE RELAY
IGNITION SWITCH:
DASH LIGHT:
NOTE:
MOUNT RELAYS
IN DESIRED
LOCATION
UNDER DASH
GREEN
FIREWALL
BLUE
BLUE
RED
&
WHITE
VIOLET
(IGNITION HOT
TERMINAL)
IGNITION
SWITCH
DASH BACK LIGHT+0-12v
TAN
GRAY
GREEN
RED
BLUE
WHITE
WHITE
WARNING:
ALWAYS MOUNT CIRCUIT
BREAKER UNDER THE HOOD
IN THE ENGINE COMPARTMENT
AND AS CLOSE TO THE
BATTERY AS POSSIBLE
RED
RED
WHITE
COMPRESSOR
BATTERY
NOTE: CONNECT WHITE
WIRES DIRECTLY TO
(-) BATTERY TERMINAL
CONNECT
CONNECT
CONNECT
CONNECT
CONNECT
CONNECT
BAT
RUN
12 V
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.
RELAY:
GREEN WIRE IS HEATER CONTROL
VALVE.
BLUE WIRE IS A/C COMPRESSOR.
BINARY- CONNECT AS SHOWN TYPICAL
COMPRESSOR WIRING. BE SURE
COMPRESSOR BODY IS GROUNDED.
TRINARY SWITCH- CONNECT
ACCORDING TO TRINARY SWITCH
WIRING DIAGRAM
INSTALL SOLENOID POINTING DOWN.
NORMAL TO GET VERY HOT DURING
OPERATION.
WHITE GROUND WIRE (NOT PART OF
HARNESS) SUPPLIED IN KIT.
NORMALLY OPEN VALVE MUST BE
CONNECTED FOR PROPER SYSTEM
OPERATION.
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
GEN IV WIRING CONNECTION INSTRUCTION
GRAY WIRE IS USED FOR
PROGRAMING CONTROLS
IF APPLICABLE
WIRING
HARNESS

20
901136 REV A 10/3/11, INST 64-66 CHEV P-UP wo AC w/ STD EVAP KIT PG 20 OF 24
MODE
KNOB
OPERATION OF CONTROLS
DEFROST/ DE-FOG MODE
AC MODE
TEMPERATURE
KNOB
BLOWER
SPEED
ROTATE KNOB RIGHT
TO DESIRED BLOWER
SPEED FROM OFF TO HI
BLOWER SPEED
ROTATE THE KNOB TO
THE CENTER TO DIRECT
AIR FLOW TO THE FLOOR.
MODE KNOB
TEMPERATURE KNOB
THIS KNOB CONTROLS
THE BLOWER SPEED,
FROM OFF TO HI
BLOWER SPEED
ROTATE THE KNOB TO
THE LEFT TO DIRECT AIR
FLOW TO THE DASH VENTS
MODE KNOB
TEMPERATURE KNOB
IN A/C MODE ROTATE
THE TEMPERATURE KNOB
ALL THE WAY RIGHT TO
THE COLD POSITION TO
ENGAGE COMPRESSOR.
(ROTATE KNOB LEFT OR
RIGHT TO ADJUST
DESIRED TEMPERATURE)
IN HEAT MODE ROTATE
THE TEMPERATURE KNOB
ALL THE WAY LEFT TO THE
HOT POSTION. (ROTATE
KNOB LEFT OR RIGHT TO
ADJUST DESIRED
TEMPERATURE)
ROTATE KNOB RIGHT
TO DESIRED BLOWER
SPEED FROM OFF TO HI
BLOWER SPEED
ROTATE THE KNOB TO
THE RIGHT TO DIRECT
AIR FLOW TO THE
DEFROST VENTS
MODE KNOB
TEMPERATURE KNOB
ROTATE KNOB LEFT OR
RIGHT TO ADJUST
DESIRED TEMPERATURE
(COMPRESSOR IS
AUTOMATICALLY
ENGAGED)
THE TEMPERATURE KNOB TOGGLES BETWEEN A/C AND HEAT MODES. FOR A/C MODE ROTATE THE
TEMPERATURE KNOB ALL THE WAY RIGHT FOR HEAT MODE ROTATE THE KNOB ALL THE WAY TO THE
LEFT TO DISENGAGE THE COMPRESSOR, THEN MOVE THE KNOB TO SELECT DESIRED TEMPERATURE.
NOTE: EACH TIME THE SYSTEM TOGGLES BETWEEN MODES, THE BLOWER WILL MOMENTARILY
CHANGE SPEEDS.
ALL SWITCHES ARE VARIABLE BETWEEN POSITIONS, SYSTEM WILL PERFORM A BLEND BETWEEN THE
FUNCTIONS.
HEAT MODE