Vintage Air 1966-67 CHEVELLE WITH FACTORY AIR User manual

1966-67 CHEVELLE
WITH FACTORY AIR
564466
904466 REV A 5/8/09 , 1966-67 CHEVELLE w AC EVAP INSTR PG 1 OF 22
an ISO 9001: 2000 Registered Company
SS

2
1966-67 CHEVELLE WITH AC
904466 REV A 5/8/09 , 1966-67 CHEVELLE w AC EVAP INSTR PG 2 OF 22
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. PASSENGER COMPARTMENT, CONDENSER ASSEMBLY, COMPRESSOR & BRACKET
FIGURES 2, 2a, 3
8. DEFROST DUCT INSTALLATION & HOSE ADAPTER INSTALLATION
FIGURES 4, 4a & 5
9. FIREWALL COVER INSTALLATION & EVAPORATOR INSTALLATION
FIGURES 6 & 7
10. BRACKET INSTALLATION
FIGURE 8
11. FRESH AIR COVER INSTALLATION & KICK PANEL FRESH AIR CAP INSTALLATION
FIGURES 9, 10, 10a & 10b
12. EVAPORATOR INSTALLTION CONT.
FIGURES 11 & 12
13. DRAIN HOSE INSTALLATION, LUBRICATING O-RINGS, A/C HOSE INSTALLATION, &
MODIFIED A/C HOSE KIT
FIGURES 13 & 14
14. AC & HEATER HOSE ROUTING
FIGURE 15
15. FINAL STEPS
FIGURES 16, 17 & 18
16. CONTROL PANEL & DUCT HOSE ROUTING
FIGURE 19
17. WIRING DIAGRAM
18. GEN IV WIRING CONNECTION INSTRUCTIONS
19. OPERATION OF CONTROLS
20. TROUBLE SHOOTING INFORMATION
21. TROUBLE SHOOTING INFORMATION CONT.
22. EVAPORATOR KIT PACKING LIST

3
1966-67 CHEVELLE WITH AC
904466 REV A 5/8/09 , 1966-67 CHEVELLE w AC EVAP INSTR PG 3 OF 22
** 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
564466
1.
2.
1
1
762169
784175
1
ACCESSORY KIT
784175
2
GEN IV 4 VENT
w/ 2 & 2 1/2 EVAP
SUB CASE
762169
GEN IV 4 VENT w/ 2 & 2 1/2 EVAP. SUB CASE
1966-67 CHEVELLE w AC ACC. KIT
NOTE: IMAGES MA Y NOT DE PICT ACTUAL PARTS AND QUANTITIES.
REFER TO PACKING LIST FOR ACTUAL PARTS AND QUANTITIES.

4
1966-67 CHEVELLE WITH AC
904466 REV A 5/8/09 , 1966-67 CHEVELLE w AC EVAP INSTR PG 4 OF 22
1966-67 CHEVELLE WITH AC GEN IV
FOR MAXIMUM SYSTEM PERFORMANCE VINTAGE AIR RECOMMENDS THE FOLLOWING:
LUBRICANT CAPACITIES:
134a SYSTEM R-12 SYSTEM
CHARGE WITH 2.0 lbs. OF REFRIGERANTCHARGE WITH 1.8 lbs.
(1lbs. 12ozs) OF REFRIGERANT
NEW COMPRESSOR - NO ADDITIONAL OIL NEEDED
SERVICE INFO:
SAFETY SWITCHES:
ATTENTION:
SYSTEM COMPONENTS: THECOMPRESSOR, 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 RUNN ING 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
(11078-VUS) 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 (11076-VUS) 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 or R-12
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 CAPACITIES FOR VINTAGE AIR SYSTEMS
(FOR OTHER SYSTEMS, CONSULT MANUFACTURER GUIDELINES)

5
1966-67 CHEVELLE WITH AC
904466 REV A 5/8/09 , 1966-67 CHEVELLE w AC EVAP INSTR PG 5 OF 22
THE HEATER CONTROL VALVE IS A NORMALLY OPEN VALVE. IT MUST BE CONNECTED TO
THE ECU TO BLOCK WATER FLOW IN 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
CAPACITA NCE IS NOT TOO SIGNIFICANT, IN COMPARISON TO IGNITION CAPACITORS THAT ARE
MATCHED WITH THE COIL TO REDUCE PITTING OF THE POINTS.
IMPORTANT NOTICE-PLEASE READ
WIRING
GWHEN INSTALLING GROUND LEADS ON EN IV SYSTEMS, THE BLOWER CONTROL GROUND
AND ECU GROUND MUST BE CONNECTED DIRECTLY TO THE NEGATIVE BATTERY POST.

6
1966-67 CHEVELLE WITH AC
904466 REV A 5/8/09 , 1966-67 CHEVELLE w AC EVAP INSTR PG 6 OF 22
BEFORE STARTING THE INSTALLATION, CHECK THE FUNCTION
OF THE VEHICLE (HORN, LIGHTS,ETC.) FOR PROPER OPERATIONS.
STUDY THE INSTRUCTIONS, ILLUSTRATIONS, & DIAGRAMS.
BATTERY, BATTERY TRAY (RETAIN)
DRAIN RADIATOR, REMOVE RADIATOR (RETAIN)
EVACUATE THE A/C SYSTEM IF NECESSARY
O.E.M. CONDENSER AND DRIER (DISCARD) SEE FIGURE 1
O.E.M. A/C LINES FROM COMPRESSOR TO EVAPORATOR (DISCARD) SEE FIGURE 1
O.E.M. COMPRESSOR AND BRACKET (DISCARD) SEE FIGURE 1
EVAPORATOR BLOWER ASSEMBLY (DISCARD)
TO REMOVE THE EVAPORATOR AND BLOWER ASSEMBLY (UNDER HOOD) AND THE AIR
DISTRIBUTION SYSTEM (UNDER DASH) THE FACTORY MANUAL RECOMMENDS REMOVING
THE RIGHT INNER FENDER.
OEM HEATER HOSES, A/C HOSES, AND HARDLINES (DISCARD). SEE FIGURE 1.
ENGINE COMPARTMENT
REMOVE THE FOLLOWING
(ONLY FOR 67 CHEVELLE w/ AC)
ONCE BATTERY IS REMOVED, REMOVE
A/C HOSES AND GROMMET FROM BESIDE
BATTERY TRAY. (RETAIN THE (4) OEM
GROMMET MOUNTING SCREWS)
NOTE:
INNER FENDER
COVER
640678-FCR
APPLY A BEAD
OF SILICONE
AROUND OPENING
A/C
HO SES
BATTERY
TRAY
(4) OEM
MOUNTING
SCREWS GROMMET
(4) OEM
MOUNTING
SCREWS
67 CHEVELLE
EVAPORATOR
BLOWER
HOUSING
COMPRESSOR
CONDENSER
DRIER
FIGURE 1

7
1966-67 CHEVELLE WITH AC
904466 REV A 5/8/09 , 1966-67 CHEVELLE w AC EVAP INSTR PG 7 OF 22
REMOVE GLOVE BOX DOOR (RETAIN) AND GLOVE BOX (DISCARD).
DISCONNECT ALL WIRE AND CABLES FROM CONTROL PANEL AND RADIO.
ALL HOSE AND DUCTING FROM O.E.M LOUVERS, SEE FIGURE 2 BELOW
O.E.M DEFROST DUCT ASSEMBLY, SEE FIGURE 3 BELOW.
O.E.M AC/ HEATER ASM SEE FIGURE 3 BELOW
PASSENGER SIDE KICK PANEL/ FRESH AIR DOOR ASM AS SHOWN IN FIGURE 2a
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:
REMOVAL OF DASHBOARD REQUIRED TO INSTALL THE EVAPORATOR. VINTAGE AIR
RECOMMENDS THAT YOU UTILIZE THE FACTORY SERVICE MANUAL WHEN YOU DISASSEMBLE
AND REASSEMBLE THE DASHBOARD.
NOTE:
DEFROST DUCT
ASM
OEM A/C HEATER ASM
CONTROL
PANEL
AC/HEATER ASSEMBLY
GLOVE BOX
& RELATED DUCTING
FIGURE 2
FIGURE 2 a
FIGURE 3
FRESH AIR
DOOR ASM

8
1966-67 CHEVELLE WITH AC
904466 REV A 5/8/09 , 1966-67 CHEVELLE w AC EVAP INSTR PG 8 OF 22
FIGURE 4
FIGURE 4a
DEFROST DUCT INSTALLATION
INSTALL DEFROST DUCTS UNDER DASH AND ALIGN WITH OEM OPENING. INSTALL THE DRIVER/
PASSENGER SIDE DEFROST DUCT TO COWL USING #10 x 1/2” SHEETMETAL SCREWS. SEE FIGURE
4 BELOW. NOTE: 66 CHEVELLE DRIVER SIDE DEFROST DUCT INSTALLS BEHIND STEERING COLUMN
BRACKET AND SECURES USING STEERING COLUMN OEM BOLT AS SHOWN IN FIGURE 4a.
OEM
DEFROST DUCT
OPENING
DEF DUCT
COWL
66 CHEVELLE
DRIVER SIDE
SHOWN
STEERING
COLUMN BRKT
DEF DUCT
#10 x 1/2
SHEET METAL
SCREW
HOSE ADAPTER INSTALLATION
INSTALL S-CLIPS ON HOSE ADAPTERS AS SHOWN IN FIGURE 5 BELOW.
INSTALL CENTER LOUVER HOSE ADAPTER OUTSIDE OEM CENTER LOUVER ASSEMBLY AS SHOWN
IN FIGURE 5 BELOW.
INSTALL DRIVER & PASSENGER SIDE HOSE ADAPTERS OUTSIDE OEM LOUVERS. SEE FIGURE 5 BELOW
RE-INSTALL LOUVERS IN DASH.
FIGURE 5
OEM
LOUVER
HOSE
ADAPTER
49870-VCI
(2) S-CLIPS
65980-VUE
(3) S-CLIPS
65980-VUE

9
1966-67 CHEVELLE WITH AC
904466 REV A 5/8/09 , 1966-67 CHEVELLE w AC EVAP INSTR PG 9 OF 22
FIREWALL COVER INSTALLATION
APPLY A 1/4” BEAD OF SILICONE AROUND THE BACK SIDE OF THE FIREWALL COVER AS SHOWN IN
FIGURE 6, BELOW.
FROM INSIDE THE CAR, INSTALL FIREWALL COVER ON FIREWALL USING (2) 1/4-20 x 1” HEX BOLTS, FLAT
WASHERS AND 1/4-20 NUT WITH STAR WASHER, SEE FIGURE 6, BELOW.
EVAPORATOR INSTALLATION
ON A WORK BENCH INSTALL (2) HEATER FITTINGS WITH PROPERLY LUBRICATED O-RINGS. (SEE FIGURE 14,
PAGE 13, AND FIGURE 8 PAGE 10.)
INSTALL (2) 1/4-20 x 1” HEX BOLT AND (2) 1/4 PUSH NUT BOLT RETAINERS ON EVAP REAR BRKT AS
SHOWN IN FIGURE 8, PAGE 10.
INSTALL EVAPORATOR FRONT & REAR MOUNTING BRACKETS
ON EVAPORATOR USING (6)1/4-20 x 1/2” HEX BOLTS AND
TIGHTEN AS SHOWN IN FIGURE 7 BELOW & FIGURE 8,
PAGE 10.
LAY EVAPORATOR SUBCASE ON PASSENGER SIDE
FLOOR BOARD. INSTALL A/C & HEATER HOSE
ON EVAPORATOR AS SHOWN IN FIGURE 11,
PAGE 12 AND HOSE INSTALLATION ON
PAGE 14.
(NOTE: WRAP THE #10 FITTING
CONNECTIONS WITH PRESS TAPE.
SEE FIGURE 11, PAGE 12.)
(2)1/4-20 x ½”
HEX BOLT
FRONT
EVAPORATOR
BRACKET
647065
FIGURE 7
FIGURE 6
(2) 1/4-20 x 1”
HEX BOLTS
FIREWALL
COVER
648169
HOLE
NOT USED
(2) 1/4 x 3/4
FLAT WASHER
(2) 1/4-20
NUTS WITH
STAR WASHER
BACK SIDE
OF FIREWALL
COVER
SILICONE

10
1966-67 CHEVELLE WITH AC
904466 REV A 5/8/09 , 1966-67 CHEVELLE w AC EVAP INSTR PG 10 OF 22
REAR
EVAPORATOR
BRACKET
643059
(2) HEATER
FITTINGS
(2) 1/4-20 x ½”
HEX BOLT
BRACKET INSTALLATION
FIGURE 8
(2) 1/4-20 x ½”
18290-VUB
1/4-20 x 1”
HEX BOLT
189125-MUR
1/4 PUSH NUT
BOLT RETAINE
R
18290-VUB
1/4-20 x 1”
HEX BOLT
189125-MUR
1/4 PUSH NUT
BOLT RETAINER
HEX BOLT

11
1966-67 CHEVELLE WITH AC
904466 REV A 5/8/09 , 1966-67 CHEVELLE w AC EVAP INSTR PG 11 OF 22
FRESH AIR COVER INSTALLATION
FIGURE 10
KICK PANEL FRESH AIR CAP INSTALLATION
INSTALL (4) GROMMETS IN KICK PANEL FRESH AIR CAP, SEE FIGURE 10a
BELOW.
ROUTE A/C AND HEATER HOSE THROUGH AC BLOCK-OFF PLATE AND
KICK PANEL FRESH AIR CAP AS SHOWN IN FIGURE 10 AND 10b, BELOW.
APPLY A 1/4” BEAD OF SILICONE AROUND THE BACK SIDE
OF KICK PANEL FRESH AIR CAP AS SHOWN IN FIGURE 10a, BELOW.
SECURE KICK PANEL FRESH AIR CAP USING (8) #8 x 1 1/4” PH PAN
HEAD SCREWS, AS SHOWN IN FIGURE 10b BELOW.
#10 A/C
HOSE
#6 A/C
HOSE
(2) HEATER
HOSE
FIGURE 9
INSTALL (4) GROMMETS IN AC BLOCK-OFF PLATE AS SHOWN IN FIGURE 9 BELOW.
APPLY A 1/4” BEAD OF SILICONE AROUND THE BACK SIDE OF THE AC BLOCK-OFF PLATE AS
SHOWN IN FIGURE 9 BELOW.
INSTALL THE AC BLOCK-OFF PLATE USING (8) #14 x 3/4 SHEET METAL
SCREWS AS SHOWN IN FIGURE 9 BELOW.
APPLY A 1/4” BEAD OF SILICONE AROUND THE BACK SIDE OF
THE HEATER/ BLOWER COVER AS SHOWN IN
FIGURE 9 BELOW.
INSTALL THE HEATER/ BLOWER COVER
USING (4) #14 x 3/4” SHEET METAL
SCREWS, SHOWN IN FIGURE 9.
DRILL (2) 3/16 AND (2) 5/16 HOLES IN
FIREWALL USING THE HEATER BLOWER
COVER AS TEMPLATE. INSTALL (2) #14
x 3/4” SHEET METAL SCREWS AND (1) 1/4
- 20 x 1” BOLT w/FLAT WASHER AND 1/4
NUT w/ STAR WASHER. SEE FIGURE 9,
BELOW.
DRILL 3/16
HOLE
IN FIREWALL
(6) #14 x 3/4
SHEETMETAL
SCREWS
DRILL 3/16
HOLE
IN FIREWALL
1/4”
NUT/w
STAR WASHER
DRILL (2) 5/16
HOLES
IN FIREWALL
1/4-20 x 1”
BOLT w/
FLAT WASHER
(8) #14 x 3/4
SHEET METAL
SCREWS
(4) GROMMETS
(8) #8 x 1 1/4”
PH PAN HEAD
SCREWS
#10 A/C
HOSE
#6 A/C
HOSE
(2)HEATER
HOSES FIGURE 10b
FIGURE 10a
SILICONE
SILICONE
SILICONE
BACKSIDE OF
KICK PANEL
FRESH AIR CAP
(4)GROMMETS
33137-VUI

12
1966-67 CHEVELLE WITH AC
904466 REV A 5/8/09 , 1966-67 CHEVELLE w AC EVAP INSTR PG 12 OF 22
(2) 1/4-20 NUT
w/ FLAT WASHER
FIGURE 12
EVAPORATOR INSTALLATION CONT.
KICK PANEL
FRESH AIR
CAP
LIFT EVAPORATOR UNIT UP UNDER THE DASHBOARD. SECURE LOOSELY TO THE
FIREWALL FROM THE ENGINE COMPARTMENT SIDE USING (2) 1/4-20 NUT AND FLAT WASHER,
SEE FIGURE 12.
SECURE THE FRONT EVAPORATOR MOUNTING BRACKET TO COWL USING (2) #14 x 3/4 HEX SHEET METAL
SCREWS SEE FIGURE 12 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.)
FIGURE 11
HEATER
HOSE
#6 A/C
HOSE
PRESS
TAPE
#10 A/C
HOSE
(2) #14 x 3/4”
SHEETMETAL
SCREW

13
1966-67 CHEVELLE WITH AC
904466 REV A 5/8/09 , 1966-67 CHEVELLE w AC EVAP INSTR PG 13 OF 22
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 13 BELOW.
INSTALL DRAIN HOSE TO BOTTOM OF
EVAPORATOR UNIT AND ROUTE THROUGH
FIREWALL. INSTALL 1/2” 90° DRAIN ELBOW
ON DRAIN HOSE SEE FIGURE 13.
DRAIN HOSE INSTALLATION
FIGURE 13
EVAPORATOR
CASE
1”
DRAIN
HOSE
1”
LOCATE THE #8 COMPRESSOR A/C HOSE. LUBRICATE (2) #8 O-RINGS (SEE FIGURE 14, ABOVE) AND CONNECT
THE 90° FEMALE FITTING TO THE #8 DISCHARGE PORT ON THE COMPRESSOR. ROUTE THE 45° FEMALE
FITTING w/ 134a SERVICE PORT TO THE #8 CONDENSER HARDLINE COMING THROUGH CORE SUPPORT.
SEE FIGURE 15 PAGE 14. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN FIGURE 14 ABOVE.
LOCATE THE #10 COMPRESSOR A/C HOSE. LUBRICATE (2) #10 O-RINGS (SEE FIGURE 14, ABOVE) AND
CONNECT THE #10 45° 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 11 PAGE 12 AND
FIGURE 15 PAGE 14. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN 14 ABOVE.
LOCATE THE #6 EVAPORATOR A/C HOSE. LUBRICATE (2) #6 O-RINGS (SEE FIGURE 14, ABOVE) AND CONNECT
THE 90° FEMALE FITTING TO THE DRIER. ROUTE THE 90° FEMALE FITTING TO THE #6 EVAPORATOR.
SEE FIGURE 11, PAGE 12 AND FIGURE 15 PAGE 14. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN
FIGURE 14, 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 14
REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH MODIFIED HOSE KIT.
MODIFIED A/C HOSE KIT

14
1966-67 CHEVELLE WITH AC
904466 REV A 5/8/09 , 1966-67 CHEVELLE w AC EVAP INSTR PG 14 OF 22
NOTE:
VINTAGEAIRSYSTEMSREQUIRE
(2)5/8HOSENIPPLES(NO
TSUPPLIED)
COMPRESSOR
SAFETY SWITCH
(BINARY TYPE)
SCREW ON DRIER
(REFER TO
CONDENSER
INSTRUCTIONS)
AC & HEATER HOSE ROUTING
FIGURE 15
(4) TIE WRAPS
HEATERHOSE
(HEA
TECNTRL
VALVE/INTAKE)
R
#8 DISCHARGE
HOSE
096067
#10 SUCTION
HOSE
096068
66-67 CHEVELLE SHOWN
#8 CONDENSER/
COMP HARDLINE
091167
#6 HARDLINE
DRIER/ CONDENSER
091166
#6 HOSE
096066
HEATER HOSE & HEATER CONTROL VALVE INSTALLATION
ROUTE A PIECE OF HEATER HOSE FROM THE WATER PUMP TO THE TOP HEATER FITTING OF HEATER CORE
AS SHOWN IN FIGURE 11 PAGE 12 AND FIGURE 15 BELOW. SECURE USING HOSE CLAMPS
ROUTE A PIECE OF HEATER HOSE FROM THE INTAKE TO THE BOTTOM HEATER FITTING OF HEATER CORE
AS SHOWN IN FIGURE 11 PAGE 12 AND FIGURE 15, BELOW. NOTE: INSTALL HEATER CONTROL VALVE
IN-LINE WITH INTAKE MANIFOLD (PRESSURE SIDE) HEATER HOSE, SECURE USING HOSE CLAMPS AS
SHOWN IN FIGURE 15, BELOW. NOTE: PROPER FLOW DIRECTION.
FROM HTR CNTRL VLV
TO EVAPORATOR
HEATER
HOSE
FROM EVAPORATOR
TO WATER PUMP
FROMINT
AKE
MANIFOLD

15
1966-67 CHEVELLE WITH AC
904466 REV A 5/8/09 , 1966-67 CHEVELLE w AC EVAP INSTR PG 15 OF 22
INSTALL DUCT HOSES AS SHOWN IN FIGURE 19, PAGE 16.
ROUTE A/C WIRES THROUGH 3/8 GROMMENT AS SHOWN ON FIGURE 16
(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 19, PAGE 16
(WIRE ACCORDING TO WIRING DIAGRAM ON PAGE 17 AND 18.)
INSTALL NEW GLOVE BOX USING (4) #8 x 1/2” PH PAN HEAD SCREWS, SEE FIGURE 17.
MODIFY PASSENGER SIDE KICK PANEL AS SHOWN IN FIGURE 18 BELOW.
REINSTALL ALL PREVIOUSLY REMOVED ITEMS (BATTERY TRAY, BATTERY & 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 19.
FINAL STEPS
FIGURE 16
FIGURE 17
GROMMET
33144-VUI
(4) #8 x 1/2”
PH PAN
HEAD
SCREWS
GLOVE BOX
625666
FIGURE 18
PASSENGER
SIDE
KICK PANEL
CUT & REMOVE
2 3/4 2 1/4

16
1966-67 CHEVELLE WITH AC
904466 REV A 5/8/09 , 1966-67 CHEVELLE w AC EVAP INSTR PG 16 OF 22
PLUG
FROM
WIRING
HARNESS
232001-VUR
DRIVER SIDE
LOUVER
2 ½” x 36”
PASS. SIDE
LOUVER
2 ½” x 48”
DEFROST DUCT
DR. SIDE
2” x 30”
DEFROST DUCT
PASS. SIDE
2” x 12”
FIGURE 19
CONTROL PANEL & DUCT HOSE ROUTING
CENTER
LOUVER
2” x 15”
CONTROL PANEL
HARNESS
FROM ECU
232006-V UR

17
1966-67 CHEVELLE WITH AC
904466 REV A 5/8/09 , 1966-67 CHEVELLE w AC EVAP INSTR PG 17 OF 22
W
IRING DIAGRAM
85 8586 86
GROUND
DASH/FLOOR
DEFROST/PLENUM
TEMPERTURE BLEND
COMPRESSOR
30 AMP
BLK
BLK
DK BLU
DK BLU
RED
RED
REDRED RED
RED
RED
RED
GRY
GRN
LT BLUYEL/BLK
GRN
WHT
WHT
WHT
ORA
VIO
VIO
WHT
ORA
GRY
RED
WHT
N/A TACH
DASH LAMP
(NOT USED)
PRGM
JM8
JM9
JM1
JM2
JM6
JM5
JM4
JM3
GRY
BLK
BLK
YEL
VIEWED FROM BOARD TOP SIDE
NOT USED
JF8
TAN
GENIV WIRING DIAGRAM
REVISI ON B, 2006-05-04
CMPR
= CHASSIS
NOTE:
BATTERY
BLOWER MOTOR
BSC
GEN-IV ECU
CIRCUIT
BREAKER
HCV
30 30
87 87
RELAYRELAY
HEATER
CONTROL
VALVE
BAT
RU N
IGNITION
+ 12v
SWITCH
WIDE OPEN
THROTTLE
SWITCH
(OPTIONAL)
EVAPORATOR
TEMPERATURE
SENSOR
STEPPER
RED
GRN
GRN
YEL
BLK
BLU
STEPPER
RED
GRN
GRN
YEL
BLK
BLU
STEPPER
RED
GRN
GRN
YEL
BLK
BLU
RED
RED
RED
RED
WHT
WHT
WHT
WHT
WHT/GRN
WHT/YEL
WHT/RED
WHT/BLUNA
DASH
FLR
DEF
FAN
COLD
HOT
JF8
VIEWED FROM
WIRE SIDE
SWITCH CONTACTS
WIDE OPEN THROTTLE
CLOSE ONLY AT
FULL THROTTLE,
WHICH DISABLES
AC COMPRESSOR
OPTIONAL:
BINARY
DRIE R
OR TRIN ARY
SAFETY
SWITCH
WARNING: ALWAYS MOUNT CIRCUIT
BREAKER UNDE R THE HOOD IN THE ENGINE
COMPARTMEN T AND AS CLOSE TO
THE BATTERY AS POSSIBLE.

18
1966-67 CHEVELLE WITH AC
904466 REV A 5/8/09 , 1966-67 CHEVELLE w AC EVAP INSTR PG 18 OF 22
HEATER
CONTROL
VALVE RELAY
HEATER
CONTROL
VALVE
REFER TO CONTROL
PANEL INSTRUCTIONS
AND PLUG IN ACCORDINGLY
BINARY
SAFETY
SWITCH
NOTE:
IF USING TRINARY
SAFETY SWITCH- REFER TO
WIRING SCHEMATIC SUPPLIED
WITH TRINAY SAFETY SWITCH
FOR PROPER WIRING INSTRUCTIONS
(IGNITION HOT
TERMINAL)
NOTE :
CONNECT WHITE
WIR ES DIRECTLY TO
( ) BATTERY TERMINAL
CONNECT
CONNECT
BACK SIDE
OF EVAPORATOR
FRONT SIDE
OF EVAPORATOR
CONNECT
(SUPPLIED
GROUND
WIRE, NOT
PART OF
HARNESS)
CIRCUIT BREAKER
30 AMP
CONNECT
CONNECT
CONNECT
CONNECT
CONNECT
NOTE:
MOUNT RELAYS
IN DESIRED
LOCATION
UNDER DASH
NOTE:
YELLOW, ORANGE
& TAN COMING FROM
HARNESS ARE
GRAY WIRE IS USED
FOR PROGRAMING
CONTROLS IF APPLICABLE
NOT USED.
GEN IV WIRING
CONNECTION
INSTRUCTIONS
CONTROL
WIRING
WIRING
HARNESS
HARNESS
A/C
COMPRESSOR
RELAY
GROUND
+
+
-
WHT
GRN
BLUE
BLACK
BLUE
RED
RED
RED
RED
RED
WHT
WHTWHT
WHT
WHT
VIOLET
WHT
WHT
CHASSIS
BATTERY
COMPRESSOR
BAT
RUN
IGNITION
12 V
SWITCH
WARNING:
ALWAYS MOUNT CIRCUIT
BREAKER UNDER THE HOOD
IN THE ENGINE COMPARTMENT
AND AS CLOSE TO THE BATTERY AS POSSIBLE.

19
1966-67 CHEVELLE WITH AC
904466 REV A 5/8/09 , 1966-67 CHEVELLE w AC EVAP INSTR PG 19 OF 22
COLD
A/C
INSIDE AIR
FAN
HI TEMPERATURE
OUTLETS
HOT
OUTSIDE
HEATER
OFF DEFROSTER DE-ICE
COLD
A/C
INSIDE AIR
FAN
HI TEMPERATURE
OUTLETS
HOT
OUTSIDE
HEATER
OFF DEFROSTER DE-ICE
COLD
A/C
INSIDE AIR
FAN
HI TEMPERATURE
OUTLETS
HOT
OUTSIDE
HEATER
OFF DEFROSTER DE-ICE
COLD
A/C
INSIDE AIR
FAN
HI TEMPERATURE
OUTLETS
HOT
OUTSIDE
HEATER
OFF DEFROSTER DE-ICE
OPERATION OF CONTROLS
A/C MODE
DEFROST/ DE-FOG MODE
HEAT MODE
SYSTEM OFF
BLOWER SPEED
THIS LEVER CONTROLS
THE BLOWER SPEED,
FROM OFF TO HI
THERMOSTAT LEVER
IN A/C MODE SLIDE THE
THERMOSTAT LEVER ALL THE WAY
LEFT TO THE COLD POSTION,
FOR MAXIMUM COOLING
(SLIDE LEVER LEFT OR RIGHT TO
ADJUST DESIRED TEMPERATURE)
MODE
SLIDE THE LEVER TO
THE “DASH“ POSITION
LEVER
BLOWER SPEED
SLIDE LEVER RIGHT
TO DESIRED BLOWER SPEED,
FROM OFF TO HI
THERMOSTAT
IN A/C MODE SLIDE THE
THERMOSTAT LEVER ALL THE
WAY LEFT TO THE COLD POSITION
TO ENGAGE COMPRESSOR,
FOR MAXIMUM COOLING
(SLIDE LEVER LEFT OR RIGHT TO
ADJUST DESIRED TEMPERATURE)
LEVER
MODE
SLIDE THE LEVER TO THE LEFT
FOR “DASH” POSTION
SLIDE THE LEVER TO THE CENTER
FOR “FLR” POSTIONSLIDE THE LEVER TO THE RIGHT
FOR “DEF” POSTION
LEVER
BLOWER SPEED
SLIDE LEVER RIGHT
TO DESIRED BLOWER SPEED,
FROM OFF TO HI
THERMOSTAT
IN HEAT MODE SLIDE THE
THERMOSTAT LEVER ALL THE
WAY RIGHT TO THE HOT POSITION,
FOR MAXIMUM HEATING
( (SLIDE LEVER LEFT OR RIGHT TO
ADJUST DESIRED TEMPERATURE)
LEVER
MODE LEVER
BLOWER SPEED
SLIDE LEVER RIGHT
TO DESIRED BLOWER SPEED,
FROM OFF TO HI
MODE LEVER
THERMOSTAT
IN DEF MODE SLIDE THE
THERMOSTAT LEVER ALL THE WAY
LEFT TO THE COLD POSITION
TO ENGAGE COMPRESSOR.
FOR MAXIMUM COOLING
(SLIDE LEVER LEFT OR RIGHT TO
ADJUST DESIRED TEMPERATURE)
LEVER
BLOWER SPEED
NOT
USED
MODE
LEVER
THERMOSTAT
LEVER
THE COLD LEVER TOGGLES BETWEEN COLD AND HOT MODES. SLIDE THE
FOR A/C MODE
FOR HEAT MODE
SLIDE THE COLD LEVER ALL THE WAY TO THE RIGHT TO DISENGAGE THE COMPRESSOR. SLIDE THE COLD
TO THE LEFT TO ENGAGE THE COMPRESSOR. SLIDE THE COLD LEVER TO THE RIGHT TO SELECT DESIRED TEMPERATURE.
LEVER TO THE LEFT TO SELECT DESIRED TEMPERATURE.
ALL SWITCHES ARE VARIABLE BETWEEN POSITIONS, SYSTEM WILL PERFORM A BLEND BETWEEN THE FUNCTIONS.
COLD LEVER ALL THE WAY

20
1966-67 CHEVELLE WITH AC
904466 REV A 5/8/09 , 1966-67 CHEVELLE w AC EVAP INSTR PG 20 OF 22
TROUBLESHOOTINGINFORMATION
SYMPTOM CONDITION CHECKS ACTIONS NOTES
1. BLOWER STAYS ON HIGH
SPEED WHEN IGNITION IS ON
NO OTHER FUNCTIONS WORK CHECKFOR DAMAGED PINS OR WIRESIN CONTROL
HEAD PLUG.
VERIFYALL PINS ARE INSERTED INTO PLUG. INSURE NO PINSARE BENT OR DAMAGED IN ECU.
CHECK FOR DAMAGED GROUND WIRE (WHITE) IN
CONTROL HEAD HARNESS.
VERIFY CONTINUITY TO CHASSIS GROUND WITH WHITE
CONTROL HEAD WIRE AT VARIOUS POINTS.
LOSS OF GROUND ON THIS WIRE WILL RENDER
CONTROL HEAD INOPERABLE
ALL OTHER FUNCTIONS WORK CHECK FOR DAMAGED BLOWER SWITCH OR POT
ANDASSOCIATED WIRING.
SEE BLOWER SWITCH CHECK PROCEDURE
BLOWER STAYS ON HIGH
SPEED WHEN IGNITION IS ON OR OFF.
UN-PLUG 3 WIRE BSC CONTROLCONNECTOR FROM ECU. IF BLOWER SHUTSOFF, ECU IS EITHER
IMPROPERLY WIRED, OR DAMAGED.
BE SURE SMALL, 20GA. WHITE GROUND WIRE IS CONNECTED TO THE BATTERY GROUND POST. IF IT IS,
REPLACE ECU.
UN-PLUG3 WIRE BSC CONTROL CONNECTOR
FROM ECU. IF BLOWER STAYS RUNNING, THE BSC
IS EITHER IMPROPERLY WIRED, OR DAMAGED.
CHECK TO INSURE THAT NO BSC WIRING IS DAMAGED OR
SHORTED TO VEHICLE GROUND. THE BSC OPERATES
THE BLOWER BY GROUND SIDE PWM SWITCHING. THE
POSITIVE WIRE TO THE BLOWER WILLALWAYS BE HOT. IF THE "GROUND" SIDE OF THE BLOWER IS SHORTED TO
CHASSIS GROUND, THE BLOWER WILL RUN ON HI.
REPLACE BSC. (THIS WILL REQUIRE EVAPORATOR TO BE
REMOVED FROM VEHICLE. )
NO OTHER PART REPLACEMENTS SHOULD BE
NECESSARY.
2. COMPRESSOR WILL NOT TURN
ON (ALL OTHER FUNCTIONS
WORK)
SYSTEM IS NOT CHARGED SYSTEM MUST BE CHARGED FOR COMP. TO
ENGAGE.
CHARGE SYSTEM OR BYPASS PRESSURE SWITCH .
DANGER- NEVER BYPASS SAFETY SWITCH WITH ENGINE RUNNING, SERIOUS INJURY CAN RESULT
CHECK FOR FAULTY A/C POT OR ASSOC. WIRING
(NOT APPLICABLE TO 3 POT CONTROLS)
CHECK CONTINUITY TO GROUND ON WHITE CONTROL
HEAD WIRE. CHECK FOR 5V ON RED CONTROL HEAD
WIRE.
TO CHECK FOR PROPER POT FUNCTION, CHECK
VOLTAGE AT WHITE/BLUE WIRE. VOLTAGE
SHOULD BE BETWEEN 0AND 5V, AND WILL VARY
WITH POT LEVER POSITION.
CHECK FOR DISCONNECTED OR FAULTY
THERMISTOR.
CHECK TWO PIN CONNECTOR AT ECU HOUSING.
DISCONNECTED OR FAULTY THERMISTOR WILL
CAUSE COMPRESSOR TO BE DISABLED.
3. COMPRESSOR WILL NOT TURN
OFF (ALL OTHER FUNCTIONS
WORK)
CHECK FOR FAULTY A/C POT OR ASSOC. WIRING REPAIR/REPLACE POT/CONTROLWIRING RED WIRE @ A/C POT SHOULD HAVE APPROX. 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 AND DO
WN.
CHECK FOR FAULTY A/C RELAY REPLACE RELAY