Vintage Air 1968 NOVA User manual

1968 NOVA
WITH AC
565069
905069 REV A 4/21/10, 1968 NOVA w/ AC EVAP INSTR PG 1 OF 25
an ISO 9001: 2008 Registered Company

2
905069 REV A 4/21/10, 1968 NOVA w/ AC EVAP INSTR PG 2 OF 25
PAGES
Table of Contents
1. COVER
2. TABLE OF CONTENTS
3. PACKING LIST / PARTS DISCLAIMER
4. INFORMATION PAGE
5. WIRING NOTICE
6. ENGINE COMPARTMENT, CONDENSER ASSEMBLY, COMPRESSOR & BRACKETS
FIGURES 1 & 1a
7. PASSENGER COMPARTMENT
FIGURE 2
8. KICK PANEL MODIFICATION
FIGURES 3 & 4
9. DEFROST DUCT/ HOSE ADAPTER INSTALLATION
FIGURES 5 & 6
10. FRESH AIR COVER & KICK PANEL FRESH AIR CAP INSTALLATION
FIGURES 7, 8, 8a & 8b
11. FIREWALL COVER & EVAPORATOR BRACKET INSTALLATION
FIGURES 9 & 10
12. EVAPORATOR BRACKET INSTALLATION CONT.
FIGURE 11
13. EVAPORATOR INSTALLATION
FIGURES 12, 13 & 13a
14. OEM CENTER LOUVER INSTALLATION & UNDER DASH CENTER LOUVER INSTALLATION
FIGURES 14, 14a & 15
15. DRAIN HOSE INSTALLATION, LUBRICATING O-RINGS, A/C HOSE INSTALLATION, &
MODIFIED A/C HOSE KIT
FIGURES 16 & 17
16. AC, HEATER HOSE & HEATER CONTROL VALVE INSTALLATION
FIGURE 18
17. FINAL STEPS
FIGURES 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. KICK PANEL MODIFICATION TEMPLATE
25. EVAPORATOR KIT PACKING LIST

3
905069 REV A 4/21/10, 1968 NOVA w/ AC EVAP INSTR 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
565069
EVAPORATOR KIT PACKING LIST
No. QTY. PART No. DESCRIPTION
1.
2.
1
1
744003
784179
GEN IV 4 VENT EVAP. SUB CASE w/ 205 ECU
1968 NOVA w/ AC ACC. KIT
1
ACCESSORY KIT
784179 NOTE: IMAGES MAY NOT DEPICT ACTUAL PARTS AND QUANTITIES.
REFER TO PACKING LIST FOR ACTUAL PARTS AND QUANTITIES
2
GEN IV 4 VENT
EVAP. SUB CASE
w/ 205 ECU
744003

4
905069 REV A 4/21/10, 1968 NOVA w/ AC EVAP INSTR PG 4 OF 25
FOR MAXIMUM SYSTEM PERFORMANCE VINTAGE AIR RECOMMENDS THE FOLLOWING:
THIS KIT DOES NOT CONTAIN HEATER HOSE. YOU MUST PURCHASE 8 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
(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
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 MANUFACTURER G UIDELINES)
IMPORTANT NOTICE-PLEASE READ

5
905069 REV A 4/21/10, 1968 NOVA w/ AC EVAP INSTR PG 5 OF 25
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
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
905069 REV A 4/21/10, 1968 NOVA w/ AC EVAP INSTR PG 6 OF 25
BEFORE STARTI NG THE INSTALLATION, CHECK THE FUNCTION
OF THE VEHICLE (HORN, LIGHTS,ETC.) FOR PROPER OPERATION S.
STUDY THE INSTRUCTIONS, ILLUSTRATIONS, & DIAGRAMS.
ENGINE COMPARTMENT
BATTERY, BATTERY TRAY (RETAIN).
DRAIN RADIATOR, REMOVE RADIATOR (RETAIN)
OEM CONDENSER AND DRIER (DISCARD). SEE FIGURE 1 BELOW
OEM 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 INDICATES REMOVING RIGHT INNER FENDER PANEL.
OEM HEATER HOSES (DISCARD). SEE FIGURE 1
OEM A/C HOSES AND FIREWALL GROMMET (DISCARD). SEE FIGURE 1
INSTALL 1⅝” PLASTIC PLUG IN FIREWALL (A/C CARS ONLY). SEE FIGURE 1a BELOW
EVACUATE THE A/C SYSTEM IF NECESSARY.
CONDENSER ASSEMBLY & INSTALLATION
REFER TO SEPARATE IN STRUCTIONS IN CLUDED WITH
THE CONDEN SER KIT TO INSTALL THE CONDENSER.
BINARY SWITC H INSTALLATION ( REFER TO CONDENSER IN STRUCTIONS)
REFER TO SEPARATE IN STRUCTIONS INCLUDED WITH THE
BRAC K ET KIT TO INSTALL THE COMPRESSOR BRACKET.
COMPRESSOR & BRACKETS
REMOVE THE FOLLOWING:
DRIER
A/C
HOSES
HEATER
HOSES
INNER FENDER
PANEL
COMPRESSOR
AND
BRACKET
1⅝”
PLASTIC PLUG
317101
GROMMET
FIGURE 1
FIGURE 1a
A/C
HO SES
BATTERY
TRAY
COVER PLATE
640678-FCR
(INCLUDED IN
HOSE KIT)
NOTE: ONCE BATTERY IS REMOVED.
REMOVE A/C HOSES AND GROMMET
FROM BESIDE BATTERY TRAY. RETAIN
THE (4) OEM GROMMET MOUNTING
SCREWS.
(4) O EM
M O UNTING
SCR EWS GR O M M ET
APPLY A BEAD
OF SILICONE
AROUND OPENING
(4) O EM
M O UNTING
SCR EWS

7
905069 REV A 4/21/10, 1968 NOVA w/ AC EVAP INSTR PG 7 OF 25
GLOVE
BOX
CONTROL
PANEL
PASSENGER SIDE
KICK PANEL
FRESH AIR
COVER
PASSENGER SIDE
KICK PANEL
NOTE: REMOVAL OF INSTRUMENT PANEL REQUIRED TO INSTALL THE EVAPORATOR. VINTAGE
AIR RECOMMENDS THAT YOU UTILIZE THE FACTORY SERVICE MANUAL WHEN YOU DISASSEMBLE
AND REASSEMBLE THE INSTRUMENT PANEL.
GLOVE BOX DOOR (RETAIN) SEE FIGURE 2
GLOVE BOX (DISCARD)
A/C HEATER ASSEMBLY AND ALL RELATED DUCTING (DISCARD), RETAIN SCREWS. SEE FIGURE 2
OEM DEFROST DUCT ASM (DISCARD)
LOWER STEERING COLUMN. PROTECT STEERING COLUMN WITH CLOTH
DISCONNECT ALL WIRE AND CABLES FROM INSTRUMENT PANEL SPEEDOMETER, CONTROL PANEL,
AND RADIO.
CONTROL PANEL ASSEMBLY (RETAIN)
REFER TO CONTROL PANEL CONVERSION KIT INSTRUCTIONS FOR INSTALLATION OF CONTROLS.
PASSENGER SIDE KICK PANEL FRESH AIR COVER (RETAIN)
PASSENGER SIDE KICK PANEL (RETAIN)
A/C HEATER ASSEMBLY
& RELATED DUCTING
FIGURE 2
PASSENGER COMPARTMENT
REMOVE THE FOLLOWING
DEFROST DUCT
ASM

8
905069 REV A 4/21/10, 1968 NOVA w/ AC EVAP INSTR PG 8 OF 25
KICK PANEL MODIFICATION
FIGURE 3
FIGURE 4
REMOVE (2) OEM SCREWS FROM THE FRESH AIR DOOR ASM. DISCONNECT AND DISCARD PULL CABLE
ASSEMBLIES FROM THE KICK PANEL. SEE FIGURE 3 BELOW.
REMOVE KICK PANEL BY REMOVING THE (4) OEM SCREWS. SEE FIGURE 3
PLACE TEMPLATE ON KICK PANEL AS SHOWN IN FIGURE 4.
CUT FRESH AIR DOOR ASM USING TEMPLATE PROVIDED ON PAGE 24. SEE FIGURE 4 BELOW.
FRESH AIR
DOOR ASM. TEMPLATE
FRESH AIR
DOOR ASM.
(4) OEM
SCREWS
OEM
SCREWS
FRESH AIR
DOOR ASM
CUT THIS
SECTION
OUT
TEMPLATE
CUT
OUT

9
905069 REV A 4/21/10, 1968 NOVA w/ AC EVAP INSTR PG 9 OF 25
INSTALL DEFROST DUCTS UNDER DASH AS SHOWN IN FIGURE 5 BELOW. ALIGN DEFROST DUCTS WITH
DEFROST OPENING IN DASH, HOLD IN PLACE. USE BRACKET AS TEMPLATE AND DRILL 7/64” HOLE. SECURE
USING #10 x ½” SHEETMETAL SCREW.
DRIVER SIDE
DEFROST DUCT
(2) #10 x ½”
SHEET METAL
SCREWS
PASSENGER SIDE
DEFROST DUCT
DEFROST DUCT INSTALLATION
FIGURE 5
HOSE ADAPTER INSTALLATION
INSTALL S-CLIPS ON HOSE ADAPTERS AS SHOWN IN FIGURE 6 BELOW.
INSTALL DRIVER & PASSENGER SIDE HOSE ADAPTERS ON OEM LOUVERS. SEE BELOW
FIGURE 6
OEM
LOUVER
HOSE
ADAPTER
49870-VCI
(3) S-CLIPS
65980-VUE
OEM
LOUVER
HOSE
ADAPTER
49870-VCI
(3) S-CLIPS
65980-VUE

10
905069 REV A 4/21/10, 1968 NOVA w/ AC EVAP INSTR PG 10 OF 25
1/4-20 x 1 1/2”
BOLT w/
WASHER
FRESH AIR COVER INSTALLATION
SILICONE
FRESH AIR
CAP
(4) GROMMETS
33137-VUI
FIGURE 7
BACK SIDE
OF FRESH AIR
CAP
OEM
GROMMET
33139-VUI
7/8 PLUG
317100
HEATER HOLE
IN FIREWALL
ENGINE
COMPARTMENT
SIDE OF
FIREWALL
INSTALL (4) GROMMETS IN FRESH AIR CAP. SEE FIGURE 7 BELOW
APPLY A 1/4” BEAD OF SILICONE AROUND THE BACK SIDE OF THE FRESH AIR CAP AS SHOWN BELOW.
ATTACH FRESH AIR CAP TO FIREWALL USING A 1/4-20 x 1 1/2" BOLT AND WASHER, SEE BELOW.
(NOTE: FRESH AIR CAP INSTALLS ON ENGINE SIDE OF FIREWALL.)
INSTALL 7/8 PLUG AND GROMMET IN FIREWALL AS SHOWN.
FIGURE 8b
FIGURE 8a
FIGURE 8
KICK PANEL FRESH AIR CAP INSTALLATION
INSTALL (4) GROMMETS IN KICK PANEL FRESH AIR CAP, SEE FIGURE 8a BELOW.
ROUTE A/C AND HEATER HOSE THROUGH FRESH AIR CAP AND KICK
PANEL FRESH AIR CAP AS SHOWN IN FIGURE 8 AND 8b, BELOW.
APPLY A 1/4” BEAD OF SILICONE AROUND THE BACK SIDE OF KICK PANEL
FRESH AIR CAP AS SHOWN IN FIGURE 8a, BELOW.
SECURE KICK PANEL FRESH AIR CAP USING OEM SCREWS, AS SHOWN IN
FIGURE 8b BELOW.
RE-INSTALL KICK PANEL WITH OEM SCREWS.
(5) OEM
SCREWS
SILICONE
BACKSIDE OF
KICK PANEL
FRESH AIR CAP
#10 A/C
HOSE
#6 A/C
HOSE
(2)HEATER
HOSES
#10 A/C
HOSE
#6 A/C
HOSE
(2) HEATER
HOSE
(4)GROMMETS
33137-VUI

11
905069 REV A 4/21/10, 1968 NOVA w/ AC EVAP INSTR PG 11 OF 25
APPLY A 1/4“ BEAD OF SILICONE AROUND THE BACK SIDE OF THE FIREWALL COVER AS SHOWN IN FIGURE 9.
SECURE FIREWALL COVER TO FIREWALL USING (3) 1/4-20 x 1” HEX BOLT w/ FLAT WASHER.
(NOTE: FIREWALL COVER INSTALLS FROM INSIDE PASSENGER COMPARTMENT.)
FIREWALL COVER INSTALLATION
NOTE: FIREWALL COVER
MOUNTING HOLES MUST
BE ENLARGED, ENLARGE
EXISTING HOLES IN
FIREWALL TO 5/16”
FIGURE 9 FIREWALL
COVER
648228
VIEW SHOWN FROM
INSIDE CAR, THROUGH
DASH
SILICONE
BACK SIDE
OF FIREWALL
COVER
(3) 1/4-20 x 1”
HEX BOLT
w/ WASHER
EVAPORATOR BRACKET INSTALLATION
(2)1/4-20 x ½”
HEX BOLT
FIGURE 10
ON A WORK BENCH INSTALL EVAPORATOR FRONT & REAR MOUNTING BRACKETS ON EVAPORATOR
USING (4)1/4-20 x 1/2” HEX BOLTS AND TIGHTEN AS SHOWN IN FIGURE 10 BELOW & FIGURE 11, PAGE 12.
LAY EVAPORATOR SUBCASE ON PASSENGER SIDE FLOOR BOARD. INSTALL A/C & HEATER HOSE ON
EVAPORATOR AS SHOWN IN FIGURE 12, PAGE 13 AND
HOSE INSTALLATION ON PAGE 16.
(NOTE: WRAP THE #10 FITTING CONNECTIONS
WITH PRESS TAPE. SEE FIGURE 12, PAGE 13.)

12
905069 REV A 4/21/10, 1968 NOVA w/ AC EVAP INSTR PG 12 OF 25
REAR
EVAPORATOR
BRACKET
643170-FCB
(2) 1/4-20 x 1/2”
HEX BOLTS
(2) HEATER
FITTINGS
EVAPORATOR BRACKET INSTALLATION CONT.
FIGURE 11
18040-VUB
3/4” NYLON
SPACER
189125-MUR
1/4” PUSH NUT
BOLT RETAINER
BRACKET
18289-VUB
1/4-20 x 1 1/2”
HEX BOLT
w/ 18125-VUB
FLAT WASHER

13
905069 REV A 4/21/10, 1968 NOVA w/ AC EVAP INSTR PG 13 OF 25
LIFT EVAPORATOR UNIT UP UNDER THE DASHBOARD. SECURE LOOSELY TO THE FIREWALL FROM THE ENGINE
COMPARTMENT SIDE USING 1/4-20 NUT w/ STARWASHER AND FLAT WASHER. SEE FIGURE 13 BELOW.
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.
USING (2) #14 x ¾SHEET METAL SCREW SECURE THE FRONT EVAPORATOR MOUNTING BRACKET TO THE INNER
COWL. SEE FIGURE 13a 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 SCREWS.)
INNER COWL
DRILL (2)
⁄” HOLES (2)#14 x ¾”
SHEET METAL
SCREWS
FIGURE 12
FIGURE 13
FIGURE 13a
EVAPORATOR INSTALLATION
#10 A/C
HOSE
HOSE
CLAMPS
1/4-20 NUT
w/ STAR WASHER
w/ FLAT WASHER
HEATER
HOSE
#6 A/C
HOSE
PRESS
TAPE
KICK PANEL
FRESH AIR
CAP

14
905069 REV A 4/21/10, 1968 NOVA w/ AC EVAP INSTR PG 14 OF 25
OEM CENTER LOUVER INSTALLATION
REMOVE OEM CENTER LOUVER ASSEMBLY FROM DASH.
INSTALL CENTER LOUVER HOSE ADAPTER IN CENTER LOUVER ASSEMBLY SEE FIGURE 14 BELOW.
INSTALL CENTER LOUVER ASSEMBLY IN DASH USING (3) OEM SCREWS. SEE FIGURE 14 BELOW.
INSTALL OEM CENTER LOUVER IN LOUVER ASSEMBLY AS SHOWN BELOW IN FIGURE 14a.
DRIVER SIDE UNDER DASH CENTER LOUVER INSTALLATION
INSTALL UNDER DASH CENTER LOUVER BEZEL USING (2) #10 x 1/2” SHEET METAL SCREWS
AS SHOWN IN FIGURE 15 BELOW.
INSTALL LOUVER IN UNDER DASH CENTER LOUVER BEZEL. SEE FIGURE BELOW.
CENTER LOUVER
HOSE ADAPTER
629965
DASH
OEM
CENTER LOUVER
ASSEMBLY
(3) OEM
SCREWS
OEM
CENTER
LOUVER
FIGURE 14
FIGURE 15
(2)#10 x 1/2”
SHEET METAL
SCREWS
UNDER DASH
LOUVER BEZEL
494052
LOUVER
49157-VUL
FIGURE 14a

15
905069 REV A 4/21/10, 1968 NOVA w/ AC EVAP INSTR PG 15 OF 25
DRAIN HOSE INSTALLATION
FIGURE 16
O-RING MALE
INSERT
FEMALE
NUT
SUPPLIED OIL
FOR O-RINGS
O-RING
SLIDE OVER
MALE INSERT TO
SWAGED LIP
TWIST WITH
THIS
WRENCH
HOLD WITH
THIS
WRENCH
FOR A PROPER SEAL OF FITTINGS:
INSTALL SUPPLIED O-RINGS AS SHOWN
AND LUBRICATE WITH SUPPLIED OIL.
LOCATE EVAPORATOR DRAIN ON BOTTOM OF EVAPORATOR CASE.
IN-LINE WITH THE DRAIN, LIGHTLY MAKE A MARK ON
THE FIREWALL. MEASURE ONE INCH DOWN AND DRILL
A 5/8” HOLE THROUGH THE FIREWALL. SEE FIGURE 16.
INSTALL DRAIN HOSE TO BOTTOM OF EVAPORATOR
UNIT AND ROUTE THROUGH FIREWALL. INSTALL
½” 90° DRAIN ELBOW ON DRAIN HOSE AS SHOWN.
O-RING
#6 O-RING
#8 O-RING #10 O-RING
FIGURE 17
LUBRICATING O-RINGS
DRAIN
DRAIN
HOSE
1”
LOCATE THE #8 COMPRESSOR A/C HOSE. LUBRICATE (2) #8 O-RINGS (SEE FIGURE 17, 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 18,
PAGE 16. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN FIGURE 17 ABOVE.
LOCATE THE #10 COMPRESSOR A/C HOSE. LUBRICATE (2) #10 O-RINGS (SEE FIGURE 17, 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 12 PAGE 13 AND
FIGURE 18, PAGE 16. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN 17 ABOVE.
LOCATE THE #6 EVAPORATOR A/C HOSE. LUBRICATE (2) #6 O-RINGS (SEE FIGURE 17 , ABOVE) AND
CONNECT THE 90° FEMALE FITTING TO THE DRIER. ROUTE THE 90° FEMALE FITTING TO THE #6 EVAPORATOR.
SEE FIGURE 12, PAGE 13 AND FIGURE 18 PAGE 16. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN
FIGURE 17, ABOVE.
A/C HOSE INSTALLATION
STANDARD HOSE KIT
REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH MODIFIED HOSE KIT.
MODIFIED A/C HOSE KIT

16
905069 REV A 4/21/10, 1968 NOVA w/ AC EVAP INSTR PG 16 OF 25
AC, HEATER HOSE & HEATER CONTROL VALVE INSTALLATION
ROUTE HEATER HOSE FROM THE WATER PUMP TO THE TOP HEATER FITTING OF HEATER CORE AS SHOWN
IN FIGURE 12 PAGE 13 AND FIGURE 18 BELOW. SECURE USING HOSE CLAMPS.
ROUTE HEATER HOSE FROM THE INTAKE TO THE BOTTOM HEATER FITTING OF HEATER CORE AS SHOWN IN
FIGURE 12 PAGE 13 AND FIGURE 18 BELOW. NOTE: INSTALL HEATER CONTROL VALVE IN-LINE WITH INTAKE
MANIFOLD (PRESSURE SIDE) HEATER HOSE, SECURE USING HOSE CLAMPS AS SHOWN BELOW.
(NOTE PROPER FLOW DIRECTION. IS OPPOSITE OF ARROW MOLDED INTO VALVE BODY.)
NOTE:
VINTAGEAIRSYSTEMSREQUIRE
(2)5/8HOSENIPPLES(NO
TSUPPLIED)
COMPRESSOR
SAFETY SWITCH
(BINARY TYPE)
SCREW ON DRIER
(REFER TO
CONDENSER
INSTRUCTIONS)
AC & HEATER HOSE ROUTING
FIGURE 18
(4) TIE WRAPS
HEATERHOSE
(HEA
TECNTRL
VALVE/INTAKE)
R
#8 DISCHARGE
HOSE
096067
68 NOVA SHOWN
#6 HOSE
096066
FROM HTR CNTRL VLV
TO EVAPORATOR
HEATER
HOSE
FROM EVAPORATOR
TO WATER PUMP
FROMINT
AKE
MANIFOLD
#6 HARDLINE
DRIER/COND
091164
#8 HARDLINE
COND/COMP
091163
#10 SUCTION
HOSE
096068

17
905069 REV A 4/21/10, 1968 NOVA w/ AC EVAP INSTR PG 17 OF 25
INSTALL DUCT HOSES AS SHOWN IN FIGURE 20, PAGE 18. EXTEND DUCT HOSE TO A TAUT CONDITION, THEN CUT
TO LENGTH AS NOTED. THERE SHOULD BE LITTLE OR NO SLACK IN HOSE ONCE INSTALLED.
ROUTE A/C WIRES THROUGH ⅜” GROMMET AS SHOWN IN FIGURE 19 BELOW.
(12 VOLT/ GROUND/ BINARY SWITCH/ HEATER VALVE).
RE-INSTALL CONTROL PANEL ASSEMBLY.
(NOTE: CONTROLS MUST BE CALIBRATED FOR PROPER OPERATION. REFER TO CONTROL PANEL INSTRUCTIONS)
PLUG THE WIRING HARNESS IN TO THE ECU MODULE ON SUB CASE AS SHOWN IN FIGURE 20, PAGE 18
(WIRE ACCORDING TO WIRING DIAGRAM ON PAGE 19 AND 20)
MODIFY PASSENGER SIDE KICK PANEL FRESH AIR COVER AS SHOWN IN FIGURE 19b.
REINSTALL PASSENGER SIDE KICK PANEL FRESH AIR COVER.
INSTALL NEW GLOVE BOX AND GLOVE BOX DOOR USING OEM SCREWS SEE FIGURE 19a.
REINSTALL ALL PREVIOUSLY REMOVED ITEMS (BATTERY, RADIATOR, RADIO)
FILL RADIATOR WITH AT LEAST A 50/50 MIXTURE OF APPROVED ANTIFREEZE AND DISTILLED WATER OR PRE MIX
ANTIFREEZE. 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 A/C 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 CAPACITY STATED ON THE INFORMATION (PAGE 4) OF THIS INSTRUCTION
MANUAL.
SEE OPERATION OF CONTROLS PROCEDURES PAGE 21.
FINAL STEPS
FIGURE 19
FIGURE 19a
GROMMET
33139-VUI
FIGURE 19b
PASSENGER
SIDE
KICK PANEL
FRESH AIR COVER
3⅛”
4⅞”
GLOVE BOX
629964

18
905069 REV A 4/21/10, 1968 NOVA w/ AC EVAP INSTR PG 18 OF 25
FIGURE 20
CONTROL PANEL & DUCT HOSE ROUTING
PLUG
FROM
CONTROL
WIRING
HARNESS
232006-VUR
PLUG
FROM
WIRING
HARNESS
232001-VUR
PASS. SIDE
LOUVER
2 ½” x 40”
DRIVER SIDE
LOUVER
2 ½” x 36”
CENTER LOUVER
UNDER DASH
2 ½” x 18”
CENTER LOUVER
IN DASH
2 ½” x 20”
PASS. SIDE
DEF. DUCT
2” x 12”
DRIVER SIDE
DEF DUCT
2” x 20”

19
905069 REV A 4/21/10, 1968 NOVA w/ AC EVAP INSTR 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 C, 11/24/2009
GEN IV ECU
PROGRAM
WIRING DIAGRAM
232006-VUR
TEMP
MODE
FAN
A/C
(IF USED)
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 C 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

20
905069 REV A 4/21/10, 1968 NOVA w/ AC EVAP INSTR PG 20 OF 25