Vintage Air 1970-72 Cutlass User manual

1970-72 CUTLASS
w/ FACTORY AIR
564171
904144 REV A 1/9/12, INST 1970-72 CUTLASS w/ AC EVAP KIT PG 1 OF 25
an ISO 9001: 2008 Registered Company

2
904144 REV A 1/9/12, INST 1970-72 CUTLASS w/ AC EVAP KIT 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
FIGURE 1
7. CONDENSER ASSEMBLY, COMPRESSOR & BRACKET, PULLEYS, & PASSENGER
COMPARTMENT
FIGURES 2 & 2a
8. DEFROST DUCT INSTALLATION & HOSE ADAPTER INSTALLATION
FIGURES 3 & 4
9. CENTER LOUVER INSTALLATION
FIGURES 5 & 5a
10. FRESH AIR COVER INSTALLATION & KICK PANEL FRESH AIR CAP INSTALLATION
FIGURES 6, 7, 7a & 7b
11. FIREWALL COVER INSTALLATION & EVAPORATOR INSTALLATION
FIGURES 8 & 9
12. BRACKET INSTALLATION CONT.
FIGURE 10
13. EVAPORATOR INSTALLATION CONT.
FIGURES 11 & 12
14. DRAIN HOSE INSTALLATION LUBRICATING O-RINGS, A/C HOSE INSTALLATION
FIGURES 13 & 14
15. AC & HEATER HOSE ROUTING
FIGURE 15
16. PASSENGER SIDE UNDER DASH LOUVER HOSE ADAPTER INSTALLATION
FIGURES 16,16a & 16b
17. DRIVER SIDE UNDER DASH LOUVER HOSE ADAPTER INSTALLATION
FIGURES 17 & 17a
18. FINAL STEPS, GLOVE BOX AND PASSENGER SIEDE KICK PANEL MODIFICATION
FIGURES 18,19 & 20
19. CONTROL PANEL & DUCT HOSE ROUTING
FIGURES 21 & 21a
20. WIRING DIAGRAM
21. GEN IV WIRING CONNECTION INSTRUCTIONS
22. OPERATION OF CONTROLS
23. TROUBLE SHOOTING INFORMATION
24. TROUBLE SHOOTING INFORMATION CONT.
25. EVAPORATOR KIT PACKING LIST

3
904144 REV A 1/9/12, INST 1970-72 CUTLASS w/ AC EVAP KIT 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
564171
1.
2.
1
1
762171
784156
No. QTY. PART No. DESCRIPTION
ACCESSORY KIT
784156
1
6 VENT EVAP. SUB CASE w/ 204 ECU w/ 4-2 ½”
1970-72 CUTLASS w/ AC ACC. KIT
NOTE: IMAGES MA Y NOT DEPICT ACTUAL PARTS AND QUANTITIES.
REFER TO PACKING LIST FOR ACTUAL PARTS AND QUANTITIES.
2
6 VENT EVAP
SUB CASE
w/ 204 ECU
w/ 4-2 ½”
762171
OFF
DASH
HOT
AC
FAN HI
DEF
FLR
COLD

4
904144 REV A 1/9/12, INST 1970-72 CUTLASS w/ AC EVAP KIT PG 4 OF 25
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.
Service Info:
Safety Switches:
Important Notice—Please Read
Attention: The following system components are capped: Compressor, evaporator, condenser & drier.
Caps may be under pressure with dry nitrogen. 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 OR by running the engine with the heater on before evacuating. Leak check and charge to
specifications.
For Maximum System Performance, Vintage Air Recommends the Following:
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.
Vintage Air Systems Are Designed to Operate With R134a
Refrigerant Only! Use of Any Other Refrigerants Is a Fire Hazard and
Could Damage Either Your Air Conditioning System or Your Vehicle.
Refrigerant Capacity for Vintage Air Systems:
(For other systems, consult manufacturer’s guidelines)
R134a System
Charge with 1.8 lbs. (1 lb., 12 oz.) of refrigerant.
Lubricant Capacities:
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).
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 carry lubrication through the system.
Heater Hose (Not Included With This Kit):
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.
Bolts Passing Through Cowl and/or Firewall:

5
904144 REV A 1/9/12, INST 1970-72 CUTLASS w/ AC EVAP KIT 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 will cause severe damage to the ECU.
When installing ground leads on Gen IV systems, the blower control ground and
ECU ground must be connected directly to the negative battery post.
The heater control valve is a normally open valve. It must be connected to the
ECU to block water flow in MAX A/C mode.
•
•
•

6
904144 REV A 1/9/12, INST 1970-72 CUTLASS w/ AC EVAP KIT PG 6 OF 25
BATTERY, BATTERY TRAY (RETAIN)
DRAIN RADIATOR, REMOVE RADIATOR
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 INDICATES DOING THE
FOLLOWING, REMOVE RIGHT INNER FENDER.
OEM HEATER HOSES, A/C HOSES, HARDLINES AND DRIER (DISCARD). SEE FIGURE 1.
OEM A/C & HEATER WIRING/VACUUM HARNESS MOLDED GROMMET. SEE FIGURE 1.
INSTALL 1 3/4” PLUG IN FIREWALL. SEE FIGURE 1
PASSENGER SIDE GRILL INSERT.
BEFORE STARTING THE INSTALLATION, CHECK THE FUNCTION
OF THE VEHICLE (HORN, LIGHTS,ETC.) FOR PROPER OPERATIONS.
STUDY THE INSTRUCTIONS, ILLUSTRATIONS, & DIAGRAMS.
ENGINE COMPARTMENT
REMOVE THE FOLLOWING
OEM A/C
& HEATER
WIRING/VACUUM
HARNESS
MOLDED GROMMET
317102
1 3/4” PLUG
FIGURE 1

7
904144 REV A 1/9/12, INST 1970-72 CUTLASS w/ AC EVAP KIT PG 7 OF 25
REMOVE GLOVE BOX DOOR (RETAIN) AND GLOVE BOX (DISCARD) (SEE FIGURE 2 BELOW.)
DISCONNECT ALL WIRE AND CABLES FROM CONTROL PANEL AND RADIO.
REMOVE RADIO AND CONTROL PANEL (RETAIN)
ALL HOSE AND DUCTING FROM O.E.M LOUVERS, SEE FIGURE 2 BELOW
OEM UNDER DASH LOUVER ASM AND (2) OEM LOUVERS IN DASH (RETAIN). (SEE FIGURE 2)
OEM DEFROST DUCT ASSEMBLY BY STRAIGHTENING 4 METAL TABS, SEE FIGURE 2 BELOW.
OEM AC/ HEATER ASM. (DISCARD) SEE FIGURE 2 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.
IN MOST INSTANCES THE BELT LENGTHS WILL REMAIN THE SAME.
COMP
RESSOR & BRACKETS
PULLEYS
REMOVE THE FOLLOWING:
DEFROST DUCT
ASM
OEM A/C
HEATER ASM
AC/HEATER
ASSEMBLY &
RELATED
DUCTING
UNDER DASH
LOUVER ASM FIGURE 2
FIGURE 2 a
FRESH AIR
DOOR ASM
PASSENGER
SIDE
KICK PANEL
CONTROL
PANEL
RADIO
GLOVE BOX
& GLOVE BOX
DOOR
METAL
TABS
METAL
TABS

8
904144 REV A 1/9/12, INST 1970-72 CUTLASS w/ AC EVAP KIT PG 8 OF 25
HOSE ADAPTER INSTALLATION
INSTALL S-CLIPS ON HOSE ADAPTERS AS SHOWN IN FIGURE 4 BELOW.
INSTALL DRIVER & PASSENGER SIDE HOSE ADAPTER ON OEM LOUVERS. SEE FIGURE 4 BELOW
ADAPTER
496083
INSTALL
(2) S-CLIPS
DRIVER SIDE PASSENGER SIDE
FIGURE 4
ADAPTER
496082
FIGURE 3
DEFROST DUCT INSTALLATION
INSTALL DEFROST DUCTS UNDER DASH AND ALIGN WITH OEM OPENING. INSTALL THE PASSENGER SIDE
DEFROST DUCT TO COWL USING #10 x 1/2” SHEETMETAL SCREWS. SEE FIGURE 3 BELOW. NOTE: DRIVER
SIDE DEFROST DUCT INSTALLS BEHIND STEERING COLUMN BRACE AND SECURES USING STEERING
COLUMN OEM BOLT AS SHOWN BELOW.
OEM
DEFROST DUCT
OPENING
DEF DUCT
COWL
OEM
BOLT
STEERING
COLUMN BRACE
#10 x 1/2
SHEET METAL
SCREW
DRIVER SIDE
DEFROST DUCT
ASM
496086
PASSENGER SIDE
DEFROST DUCT
ASM
496087
COWL
DEF DUCT
INSTALL
(2) S-CLIPS

9
904144 REV A 1/9/12, INST 1970-72 CUTLASS w/ AC EVAP KIT PG 9 OF 25
CENTER LOUVER INSTALLATION
MODIFY OEM CENTER LOUVER ASM AS SHOWN IN FIGURE 5 BELOW.
INSTALL (2) S-CLIPS ON HOSE ADAPTER SEE FIGURE 5a.
INSTALL CENTER LOUVER HOSE ADAPTER ON CENTER LOUVER ASSEMBLY AS SHOWN IN FIGURE 5a BELOW.
CENTER LOUVER
HOSE ADAPTER
496081
(2) S-CLIPS
65980-VUE
CUT & REMOVE
SHADED PORTION
OEM CENTER
LOUVER
ASM
FIGURE 5
FIGURE 5a
4”

10
904144 REV A 1/9/12, INST 1970-72 CUTLASS w/ AC EVAP KIT PG 10 OF 25
1/4-20 x 1 1/2”
BOLT w/
WASHER
FRESH AIR COVER INSTALLATION
SILICONE
FRESH AIR
CAP
496072
(4) GROMMETS
33137-VUI
FIGURE 6
BACK SIDE
OF FRESH AIR
CAP
OEM
HEATER HOLE
IN FIREWALL
ENLARGE
5/16”
ENLARGE
5/16”
GROMMET
33145-VUI
7/8 PLUG
33142-VUI
ENGINE
COMPARTMENT
SIDE OF
FIREWALL
INSTALL (4) GROMMETS IN FRESH AIR CAP. SEE FIGURE 6 BELOW
APPLY A 1/4” BEAD OF SILICONE AROUND THE BACK SIDE OF THE FRESH AIR CAP AS SHOWN IN FIGURE 6
BELOW.
ATTACH FRESH AIR CAP TO FIREWALL USING A 1/4-20 x 1 1/2" BOLT AND WASHER, SEE FIGURE 6 BELOW.
(NOTE: FRESH AIR CAP INSTALLS ON ENGINE SIDE OF FIREWALL.)
INSTALL 7/8 PLUG AND 3/8 GROMMET IN FIREWALL SEE FIGURE 6.
INSTALL (2) 1/2” PLUGS AS SHOWN IN FIGURE 6. (MAY NEED TO ENLARGE TO 1/2“ DIA.)
ENLARGE (2) OEM HOLES TO 5/16” AS SHOWN IN FIGURE 6.
1/2” PLUG
31102-GUR
1/2” PLUG
31102-GUR
FIGURE 7b
FIGURE 7a
FIGURE 7
KICK PANEL FRESH AIR CAP INSTALLATION
INSTALL (4) GROMMETS IN KICK PANEL FRESH AIR CAP, SEE FIGURE 7a BELOW.
ROUTE A/C AND HEATER HOSE THROUGH FRESH AIR CAP AND KICK PANEL
FRESH AIR CAP AS SHOWN IN FIGURE 7 AND 7b, BELOW.
APPLY A 1/4” BEAD OF SILICONE AROUND THE BACK SIDE OF KICK PANEL
FRESH AIR CAP AS SHOWN IN FIGURE 7a, BELOW.
SECURE KICK PANEL FRESH AIR CAP USING OEM SCREWS, AS SHOWN IN
FIGURE 7b BELOW.
(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
904144 REV A 1/9/12, INST 1970-72 CUTLASS w/ AC EVAP KIT PG 11 OF 25
FIREWALL COVER INSTALLATION
APPLY A 1/4” BEAD OF SILICONE AROUND THE BACK SIDE OF THE FIREWALL COVER AS SHOWN IN FIGURE 8,
BELOW.
FROM INSIDE THE CAR, INSTALL FIREWALL COVER ON FIREWALL. SECURE TO FIREWALL FROM ENGINE
COMPARTMENT USING (2) 1/4-20 x 1” HEX BOLTS, FLAT WASHERS. SEE FIGURE 8, BELOW.
NOTE: USE SEAM SEALER OR SILICONE TO FILL GAP BETWEEN COVER AND LIP IN FIREWALL BEFORE
PAINTING.
BACK SIDE
OF FIREWALL
COVER
SILICONE
(2) 1/4-20 x 1”
HEX BOLT 1/4” FLAT
WASHER
FIREWALL
COVER ASM
644106
FIGURE 8
EVAPORATOR INSTALLATION
ON A WORK BENCH INSTALL (2) HEATER FITTINGS WITH PROPERLY LUBRICATED O-RINGS. (SEE FIGURE 14,
PAGE 14, AND FIGURE 10 PAGE 12.)
INSTALL EVAPORATOR FRONT & REAR MOUNTING BRACKETS ON EVAPORATOR USING (6)1/4-20 x 1/2
HEX BOLTS AND TIGHTEN AS SHOWN IN FIGURE 9 BELOW
& FIGURE 10, PAGE 12.
LAY EVAPORATOR SUBCASE ON PASSENGER SIDE
FLOOR BOARD. INSTALL A/C & HEATER HOSE ON
EVAPORATOR AS SHOWN IN FIGURE 14, PAGE 14
AND FIGURE 11, PAGE 13.
(NOTE: WRAP THE #10 FITTING CONNECTIONS
WITH PRESS TAPE. SEE FIGURE 11, PAGE 13.)
(2)1/4-20 x 1/2
HEX BOLT
FRONT
EVAPORATOR
BRACKET
644100
FIGURE 9

12
904144 REV A 1/9/12, INST 1970-72 CUTLASS w/ AC EVAP KIT PG 12 OF 25
REAR
EVAPORATOR
BRACKET
ASM
644104
(2) HEATER
FITTINGS
(2) 1/4-20 x ½”
HEX BOLT
(2) 1/4-20 x ½”
HEX BOLT
BRACKET INSTALLATION CONT.
70-72 CUTLASS
MOUNTING
HOLES
FIGURE 10

13
904144 REV A 1/9/12, INST 1970-72 CUTLASS w/ AC EVAP KIT PG 13 OF 25
FIGURE 11
FIGURE 12
#10 A/C
HOSE
HOSE
CLAMPS
HEATER
HOSE
#6 A/C
HOSE
PRESS
TAPE
KICK PANEL
FRESH AIR
CAP
DRILL 3/16” HOLES IN
COWL AFTER LEVELING
(2) #14 x 3/4
HEX SHEET
METAL SCREW
EVAPORATOR INSTALLATION CONT.
LIFT EVAPORATOR UNIT UP UNDER THE DASHBOARD. SECURE LOOSELY TO THE FIREWALL FROM THE
ENGINE COMPARTMENT SIDE USING (2) 1/4-20 x 1 1/4 HEX BOLT AND FLAT WASHER, SEE FIGURE 12.
VERIFY THAT EVAPORATOR UNIT IS LEVEL AND SQUARE TO THE DASH.
SECURE THE FRONT EVAPORATOR MOUNTING BRACKET TO COWL. USING BRACKET AS TEMPLATE DRILL
(2) 3/16” HOLES IN COWL. SECURE WITH (2) #14 x 3/4 HEX SHEET METAL SCREWS SEE FIGURE 12 BELOW.
THEN TIGHTEN ALL MOUNTING BOLTS. (NOTE: TIGHTEN THE BOLT ON FIREWALL FIRST, THEN THE
FRONT MOUNTING BRACKET.)
(2) 1/4-20 x 1 1/4”
HEX BOLT
182899
(2) 1/4”
FLAT WASHER
18125-VUB

14
904144 REV A 1/9/12, INST 1970-72 CUTLASS w/ AC EVAP KIT PG 14 OF 25
LOCATE THE #8 COMPRESSOR A/C HOSE. LUBRICATE (2) #8 O-RINGS (SEE FIGURE 14, ABOVE) AND CONNECT
THE 90° FEMALE FITTING w/ 134a SERVICE PORT TO THE #8 DISCHARGE PORT ON THE COMPRESSOR. ROUTE
THE 90° FEMALE FITTING TO THE #8 CONDENSER HARDLINE COMING THROUGH CORE SUPPORT. SEE
FIGURE 15, PAGE 15. 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 CONNEC
T
THE #10 135° 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 13 AND FIGURE 15, PAGE 15. 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 #6 HARDLINE COMING THROUGH THE CORE SUPPORT FROM DRIER. ROUTE
THE 90° FEMALE FITTING TO THE #6 EVAPORATOR. SEE FIGURE 11, PAGE 13 AND FIGURE 15 PAGE 15. TIGHTEN
EACH FITTING CONNECTION AS SHOWN IN FIGURE 14, ABOVE.
A/C HOSE INSTALLATION
STANDARD HOSE KIT
LUBRICATING O-RINGS
FIGURE 14
LOCATE EVAPORATOR DRAIN ON BOTTOM
OF EVAPORATOR CASE.
IN-LINE WITH DRAIN, LIGHTLY MAKE A MARK
ON THE FIREWALL MEASURE 1” DOWN AND
2 1/2” TO THE LEFT 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. SEE FIGURE 13.
DRAIN HOSE INSTALLATION
FIGURE 13
EVAPORATOR
O-RING
O-RING, INSTALLS
OVER MALE INSERT
TO SWAGED LIP
SUPPLIED OIL
FOR O-RINGS
FEMALE
NUT
MALE
INSERT
O-RING
#6 O-RING
#8 O-RING #10 O-RING 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.
CASE
1”
2 1/2” DRAIN
HOSE
1”
2 1/2”
REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH MODIFIED HOSE KIT.
MODIFIED A/C HOSE KIT

15
904144 REV A 1/9/12, INST 1970-72 CUTLASS w/ AC EVAP KIT PG 15 OF 25
AC & HEATER HOSE ROUTING
FIGURE 15
FROM HTR CNTRL VLV
TO EVAPORATOR
HEATER
HOSE
FROM EVAPORATOR
TO WATER PUMP
(4) TIE WRAPS
#6 DRIER/ CORE
HARDLINE
091180
#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 13 AND FIGURE 15 BELOW. SECURE USING HOSE CLAMPS.
NOTE: OEM WATER PUMP OUTLET IS 3/4”. A 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 11 PAGE 13 AND FIGURE 15, BELOW. 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.
FROMINT
AKE
MANIFOLD
NOTE: OEM WATER PUMP OUTLET IS 3/4“. A 3/4 x 5/8
REDUCER FITTING IS REQUIRED (NOT SUPPLED)
HEATER HOSE
(HEATER CNTRL
VALVE/ INTAKE)
#8 CONDENSER/
COMP HARDLINE
091179
COMPRESSOR
SAFETY SWITCH
(BINARY TYPE)
SCREW ON DRIER
(REFER TO
CONDENSER
INSTRUCTIONS)
#8 DISCHARGE
HOSE
096069
#10 SUCTION
HOSE
096076

16
904144 REV A 1/9/12, INST 1970-72 CUTLASS w/ AC EVAP KIT PG 16 OF 25
CUT AND REMOVE OEM PASSENGER SIDE UNDER DASH LOUVER HOSE ADAPTER AS SHOWN BELOW IN
FIGURE 16 BELOW.
INSTALL SUPPLIED FOAM AROUND THE OEM PASSENGER SIDE UNDER DASH LOUVER HOSE ADAPTER AS
SHOWN IN FIGURE 16a.
INSTALL HOSE ADAPTER ON OEM PASSENGER SIDE UNDER DASH LOUVER USING (2) #8 x 1/2” PAN
HEAD SCREWS AS SHOWN BELOW IN FIGURE 16b.
CUT &
REMOVE
CUT FOAM
3/8 x 5” LONG
AND INSTALL
PASSENGER SIDE
UNDER DASH LOUVER
HOSE ADAPTER
496084
(2) #8 x 1/2”
PAN HEAD
SCREW
3/4”
FIGURE 16
FIGURE 16a
FIGURE 16b
PASSENGER SIDE UNDER DASH LOUVER HOSE ADAPTER INSTALLATION

17
904144 REV A 1/9/12, INST 1970-72 CUTLASS w/ AC EVAP KIT PG 17 OF 25
INSTALL SUPPLIED FOAM AROUND THE OEM DRIVER SIDE UNDER DASH LOUVER HOSE ADAPTER AS
SHOWN IN FIGURE 17.
INSTALL HOSE ADAPTER ON OEM DRIVER SIDE UNDER DASH LOUVER USING (2) #8 x 1/2” PAN
HEAD SCREWS AS SHOWN BELOW IN FIGURE 17a.
DRIVER SIDE
UNDER DASH LOUVER
HOSE ADAPTER
496085
(2) #8 x 1/2”
PAN HEAD
SCREW
FIGURE 17
FIGURE 17a
DRIVER SIDE UNDER DASH LOUVER HOSE ADAPTER INSTALLATION
CUT FOAM
3/8 x 9 ½” LONG
AND INSTALL

18
904144 REV A 1/9/12, INST 1970-72 CUTLASS w/ AC EVAP KIT PG 18 OF 25
GL
OVE BOX AND PASSENGER SIDE KICK PANEL MODIFICATION
INSTALL DUCT HOSES AS SHOWN IN FIGURE 21, PAGE 19
ROUTE A/C WIRES THROUGH 3/8 GROMMET AS SHOWN ON FIGURE 18
(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 21, PAGE 19
(WIRE ACCORDING TO WIRING DIAGRAM ON PAGE 20 AND 21.)
INSTALL U-NUTS IN GLOVE BOX TOP/ BOTTOM. SEE FIGURE 19 BELOW.
INSTALL GLOVE BOX BOTTOM IN GLOVE BOX COMPARTMENT USING OEM SCREWS.
INSTALL GLOVE BOX TOP USING (4) S-CLIPS AND OEM SCREWS. SEE FIGURE 19 BELOW.
MODIFY PASSENGER SIDE KICK PANEL AS SHOWN IN FIGURE 20 BELOW.
REINSTALL ALL PREVIOUSLY REMOVED ITEMS (BATTERY TRAY, BATTERY, INNER FENDER AND RADIATOR).
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 22.
FINAL STEPS
FIGURE 18
FIGURE 19
FIGURE 20
GROMMET
33145-VUI
(4) S-CLIPS
(2) U-NUT #8
189801
GLOVE BOX
TOP
496077
PASSENGER
SIDE
KICK PANEL
GLOVE BOX
BOTTOM
496078
OEM
SCREWS
CUT &
REMOVE
1”
CUT &
REMOVE
5”

19
904144 REV A 1/9/12, INST 1970-72 CUTLASS w/ AC EVAP KIT PG 19 OF 25
FIGURE 21
FIGURE 21a
CONTROL PANEL & DUCT HOSE ROUTING
PLUG
FROM
WIRING
HARNESS
232001-VUR
FROM
CONTROLS
DRIVER SIDE
LOUVER
2 ½” x 42”
DRIVER SIDE
CENTER LOUVER
IN DASH
2 ½” x 20”
PASSENGER SIDE
CENTER LOUVER
IN DASH
2 ½” x 16”
PASSENGER SIDE
CENTER LOUVER
UNDER DASH
2” x 21”
DRIVER SIDE
CENTER LOUVER
UNDER DASH
2” x 26”
PASS. SIDE
DEF. DUCT
2” x 13”
DRIVER SIDE
DEF DUCT
2” x 30”
PLUG
FROM
CONTROL
WIRING
HARNESS
232002-VUA
PASS. SIDE
LOUVER
2 ½” x 66”
ROUTE PASSENGER SIDE DUCT HOSE AS SHOWN BELOW.
TIE WRAP DUCT HOSE TO DASH BRACE FOR GLOVE BOX ARM CLEARANCE.
TIE
WRAP
DASH
BRACE
GLOVE BOX
ARM

20
904144 REV A 1/9/12, INST 1970-72 CUTLASS w/ AC EVAP KIT PG 20 OF 25
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 Used Only 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 A/C
Compressor.
JF8
BLK
ORA
TAN
VIEWED FROM WIRE SIDE
•
•
•