Vintage Air 1981-87 CHEV PICK-UP User manual

1981-87 CHEV PICK-UP
WITHOUT FACTORY AIR
751181
901182 REV A 6/13/11, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 1 OF 27
an ISO 9001:2008 Registered Company

2
901182 REV A 6/13/11, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 2 OF 27
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 & BRACKET, PULLEYS
FIGURE 1
7. PASSENGER COMPARTMENT
FIGURES 2 & 2a
8. DEFROST DUCT INSTALLATION & FRESH AIR CAP INSTALLATION AND FIREWALL
MODIFICATION
FIGURES 3 & 4
9. FIREWALL MODIFICATION CONT. & FIREWALL COVER INSTALLATION
FIGURES 5 & 6
10. BRACKET & EVAPORATOR HARDLINE INSTALLATION
FIGURE 7
11. BRACKET & EVAPORATOR HARDLINE INSTALLATION CONT.
FIGURE 8
12. EVAPORATOR INSTALLATION
FIGURES 9 & 9a 9b
13. DRAIN HOSE INSTALLATION, LUBRICATING O-RINGS, A/C HOSE INSTALLATION, &
MODIFIED A/C HOSE KIT
FIGURES 10 & 11
14. HEATER HOSE & HEATER CONTROL VALVE INSTALLATION
FIGURE 12
15. AC & HEATER HOSE ROUTING
FIGURE 13
16. PASSENGER SIDE LOUVER DASH PANEL INSTALLATION & DRIVER SIDE/ CENTER
LOUVER INSTALLATION
FIGURES 14, 15, 15a, 15b & 15c
17. FINAL STEPS
FIGURE 16
18. GLOVE BOX MODIFICATION
FIGURES 17 & 17a
19. CONTROL PANEL & DUCT HOSE ROUTING
FIGURE 18
20. WIRING DIAGRAM
21. GEN IV WIRING CONNECTION INSTRUCTIONS
22. OPERATION OF CONTROLS
23. TROUBLE SHOOTING INFORMATION
24. TROUBLE SHOOTING INFORMATION CONT.
25. DRIVER SIDE LOUVER TEMPLATE
26. GLOVE BOX MODIFICATION TEMPLATE
27. EVAPORATOR KIT PACKING LIST

3
901182 REV A 6/13/11, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 3 OF 27
** 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
751181
1.
2.
1
1
744004-VUE
791181
1
GEN IV 4 VENT
EVAP SUB CASE
w/204 ECU
744004-VUE
GEN IV 4 VENT EVAP. SUB CASE w/ 204 ECU
ACCESSORY KIT 81-87 CHEV P-UP wo AC
NO. QTY. PART NO. DESCRIPTION
EVAPORATOR KIT PACKING LIST
ACCESSORY KIT
791181
2
NOTE: IMAGES MA Y NOT DE PICT ACTUAL PARTS AND QUANTITIES.
REFER TO PACKING LIST FOR ACTUAL PARTS AND QUANTITIES.
OFF
DASH
HOT
FLR
A/C
HI
DEF
COLD

4
901182 REV A 6/13/11, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 4 OF 27
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
(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 M ANUFACTURER GUIDELINES)
IMPORTANT NOTICE-PLEASE READ

5
901182 REV A 6/13/11, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 5 OF 27
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
901182 REV A 6/13/11, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 6 OF 27
DISCONNECT BATTERY.
DRAIN RADIATOR, REMOVE RADIATOR (RETAIN)
HEATER BLOWER ASSEMBLY AND OEM HEATER HOSES (DISCARD)
NOTE: TO REMOVE THE OEM HEATER BLOWER ASSEMBLY (UNDER HOOD) AND THE AIR
DISTRIBUTION SYSTEM (UNDER DASH). THE FACTORY MANUAL RECOMMENDS THAT YOU REMOVE
RIGHT INNER FENDER FOR ACCESSIBLITY.
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
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

7
901182 REV A 6/13/11, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 7 OF 27
GLOVE BOX DOOR AND GLOVE BOX ASSEMBLY (RETAIN) (SEE FIGURE 2 BELOW)
UNDER DASH STEERING COLUMN COVER (RETAIN) (SEE FIGURE 2)
INSTRUMENT PANEL BEZEL (RETAIN)
DASH PAD (RETAIN) (SEE FIGURE 2)
DISCONNECT ALL WIRES AND CABLES FROM CONTROL PANEL.
REMOVE CONTROL PANEL (DISCARD) REFER TO CONTROL PANEL CONVERSION KIT INSTRUCTIONS.
ASH TRAY (RETAIN)
OEM HEATER ASSEMBLY (DISCARD) (SEE FIGURE 2a).
DEFROST DUCT ASSEMBLY (DISCARD) (SEE FIGURE 2a.)
NOTE: FOR EASE OF INSTALLING EVAPORATOR UNDER DASH, IT MAYBE HELPFULL TO REMOVE THE
(2) OEM BOLTS UNDER THE DASH ON THE PASSENGER SIDE DOOR PILLAR AND PULL BACK DASH.
PASSENGER COMPARTMENT
REMOVE THE FOLLOWING:
FIGURE 2
CONTROL
PANEL
INTSTRUMENT
PANEL
BEZEL
UNDER DASH
COVER
GLOVE BOX
DOOR &
GLOVE BOX
DASH
PAD
ASH
TRAY
FIGURE 2a
OEM HEATER
ASSEMBLY
DEFROST DUCT
ASSEMBLY
(2) OEM
BOLTS
DASH
BRACE

8
901182 REV A 6/13/11, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 8 OF 27
DEFROST DUCT INSTALLATION
INSTALL (4) #8 U-NUTS IN OEM DEFROST DUCT OPENINGS AS SHOWN BELOW IN FIGURE 3.
INSTALL DRIVER AND PASSENGER SIDE DEFROST DUCTS USING (4) #8 x 1/2” PH PAN HEAD SCREWS
AS SHOWN BELOW. (2) DEFROST
DUCT
623219
FIGURE 3
(4) #8 x 1/2”
PH PAN HEAD
SCREWS
(4) #8 U-NUT
189801
FIGURE 4
APPLY A 1/4” BEAD OF SILICONE AROUND THE BACK SIDE OF THE FRESH AIR CAP AS SHOWN IN FIGURE 4,
BELOW.
ATTACH FRESH AIR CAP TO FIREWALL USING A 1/4-20 x 1” BOLT AND WASHER, SEE FIGURE 4 BELOW.
PLACE FIREWALL COVER ON FIREWALL AND SCURE USING #14 x 3/4“ SHEET METAL SCREW AND
(2) 1/4-20 x 3/4” HEX BOLT w/ 1/4” NUT w/ STAR WASHER AS SHOWN BELOW.
USING FIREWALL COVER AS TEMPLATE, MARK THE HOLES ON FIREWALL AS SHOWN BELOW.
REMOVE FIREWALL COVER.
FRESH AIR CAP AND FIREWALL MODIFICATION
SILICONE
BACK SIDE OF
FRESH AIR CAP
1/4-20 x 1”
BOLT
1/4” FLAT
WASHER
FRESH AIR
CAP
MARK
HOLE
MARK
HOLE
MARK
HOLE
MARK
HOLE
MARK
HOLES
#14 x 3/4”
SHEET METAL
SCREW
OEM
HOLE
MARK
HOLES
OEM
HOLE
1/4-20 x 3/4”
BOLT
1/4” NUT w/
STAR WASHER
1/4-20 x 3/4”
BOLT 1/4” NUT w/
STAR WASHER

9
901182 REV A 6/13/11, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 9 OF 27
FIGURE 5
DRILL HOLES AS SHOWN BELOW IN FIGURE 5
FIREWALL MODIFICATION CONT.
FIGURE 6
APPLY A 1/4” BEAD OF SILICONE AROUND THE BACK SIDE OF THE FIREWALL COVER AS SHOWN BELOW.
INSTALL FIREWALL COVER TO FIREWALL USING 1/4-20 x 3/4” HEX BOLT, 1/4“ FLAT WASHER, 1/4” NUT
w/ STARWASHER AND (7) #14 x 3/4“ SHEET METAL SCREWS AS SHOWN BELOW.
INSTALL GROMMETS AS SHOWN BELOW.
FIREWALL COVER INSTALLATION
LARGE
GROMMET
33137-VUI
GROMMET
33135-VUI
(7) #14 x 3/4”
SHEET METAL
SCREW
1/4-20 x 3/4”
BOLT
1/4-20 x 3/4”
BOLT
1/4” FLAT
WASHER
1/4” FLAT
WASHER
1/4” NUT w/
STAR WASHER
1/4” NUT w/
STAR WASHER
BACK SIDE OF
FIREWALL COVER
644086
SILICONE
DRILL 3/16”
HOLE
DRILL 9/32”
HOLE
DRILL 3/16”
HOLE
DRILL 3/16”
HOLE
OEM
HOLE
OEM
HOLE
OEM
HOLE DRILL 3/16”
HOLE
DRILL 3/8”
HOLE

10
901182 REV A 6/13/11, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 10 OF 27
BRACKET & EVAPORATOR HARDLINE INSTALLATION
ON A WORK BENCH INSTALL EVAPORATOR REAR BRACKET USING (4) 1/4-20 x 1/2” HEX BOLTS.
(SEE FIGURE 8, PAGE 11)
INSTALL #6 EVAP HARDLINE AND (2) HEATER HARDLINES WITH PROPERLY LUBRICATED O-RINGS.
(SEE FIGURE 8, PAGE 11 AND FIGURE 11, PAGE 13.)
INSTALL EVAPORATOR FRONT BRACKET ON EVAPORATOR USING (2)1/4-20 x 1/2” HEX BOLTS AND
TIGHTEN AS SHOWN IN FIGURE 7 BELOW.
FIGURE 7
EVAP FRONT
BRKT
644087
(2)1/4-20 x ½”
HEX BOLT

11
901182 REV A 6/13/11, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 11 OF 27
BRACKET & EVAPORATOR HARDLINE INSTALLATION CONT.
FIGURE 8
#6 LIQUID LINE
091153
TWIST WITH
THIS
WRENCH
LUBRICATE O-RING
(SEE FIGURE 11,
PAGE 13.)
HOLD WITH
THIS WRENCH
HEATER LINE
(EVAP TO WATER PUMP)
091151
ECU MODULE
#10 O-RING
(33859-VUF)
(2) 1/4-20 x ½”
HEX BOLT
(2) 1/4-20 x ½”
HEX BOLT
REAR
EVAPORATOR
BRACKET
644083
HEATER LINE
(EVAP TO INTAKE)
091151
#6 O-RING
(33857-VUF)

12
901182 REV A 6/13/11, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 12 OF 27
INNER
COWL
DRILL (2)
⁄” HOLES (2)#14 x ¾”
SHEET METAL
SCREWS
(2)1/4-20 x 1¼”
HEX BOLT
(2) 1/4” FLAT
WASHER
(2) .563 L
SPACERS
VIEW FROM
PASSENGER SIDE
INSIDE OF CAB
FIGURE 9
FIGURE 9a
FIGURE 9b
NOTE: AFTER INSTALLING
#10 SUCTION LINE
WRAP ALL EXPOSED METAL
(FITTINGS & TUBE) WITH
SUPPLIED PRESS TAPE
PRESS TAPE
#10 O-RING
33859-VUF
#10 SUCTION
LINE
091152
EVAPORATOR INSTALLATION
LIFT EVAPORATOR UNIT UP UNDER THE DASHBOARD. SECURE LOOSELY TO THE FIREWALL USING
(2) 1/4-20 x 1¼” HEX BOLTS, (2) FLAT WASHERS AND (2) .563 L SPACERS. (SEE FIGURE 9.)
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 9a 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.)
INSTALL #10 SUCTION LINE AS SHOWN IN FIGURE 9b BELOW.
NOTE: WRAP THE #10 FITTING CONNECTIONS
WITH PRESS TAPE. SEE FIGURE 9b BELOW.
RE-INSTALL (2) OEM BOLTS UNDER DASH ON
PASSENGER SIDE DOOR PILLAR.

13
901182 REV A 6/13/11, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 13 OF 27
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 10
EVAPORATOR
CASE
1”
LOCATE THE #8 COMPRESSOR A/C HOSE. LUBRICATE (2) #8 O-RINGS (SEE FIGURE 11, ABOVE) AND CONNECT
THE 90° FEMALE FITTING TO THE #8 DISCHARGE PORT ON THE COMPRESSOR. ROUTE THE STRAIGHT FEMALE
FITTING w/ 134a SERVICE PORT TO THE #8 CONDENSER HARDLINE COMING THROUGH CORE SUPPORT.
SEE FIGURE 13, PAGE 15. TIGHTEN EACH FITTING CONNECTION AS SHOWN.
LOCATE THE #10 COMPRESSOR A/C HOSE. LUBRICATE (2) #10 O-RINGS (SEE FIGURE 11, ABOVE) AND
CONNECT THE #10 135° FEMALE FITTING w/134a SERVICE PORT TO THE #10 SUCTION PORT ON THE
COMPRESSOR. ROUTE THE STRAIGHT FEMALE FITTING TO THE #10 EVAPORATOR. SEE FIGURE 12, PAGE 14
AND FIGURE 13, PAGE 15. TIGHTEN EACH FITTING CONNECTION AS SHOWN.
INSTALL #6 A/C LIQUID LINE AS SHOWN IN FIGURE 13, PAGE 15.
A
/C HOSE INSTALLATION
STANDARD HOSE KIT
LUBRICATING O-RINGS
REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH MODIFIED HOSE KIT.
MODIFIED A/C HOSE KIT
DRAIN
HOSE
1”
#6O-RING
#8 O-RING#10O -RING
HOLDWITH
THIS W RENCH
FORA PROPERSEALOFFITTINGS:
INSTALL SUPPLIEDO-RINGSAS SHOWN
ANDLUBRICATE WITH SUPPLIEDOIL.
O-RING
SUPPLIEDOIL
FORO-RINGS
MALE
INSERTFEMALE
NUT
O-RING
TWIST WITH
THIS WRENCH
FIGURE 11
O-RING, INSTALLES
OVER MALE INSERT
TO SWAGED LIP

14
901182 REV A 6/13/11, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 14 OF 27
ROUTE HEATER HOSE FROM WATER PUMP TO THE HEATER LINE COMING THROUGH THE FIREWALL AS
SHOWN IN FIGURE 12, 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.
FIGURE 12
O-RINGS
HEATER
HOSE
NOTE: FLOW ARROW DECAL
ON HEATER CONTROL VALVE.
HEATER HOSE & HEATER CONTROL VALVE INSTALLATION
#6 LIQUID
LINE
FROM HEATER CORE
TO WATER PUMP
HEATER
HOSE
#10 SUCTION
LINE
FROM HTR CNTRL VLV
TO HEATER CORE
FROM INTAKE
MANIFOLD

15
901182 REV A 6/13/11, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 15 OF 27
FIGURE 13
TIE
WRAP
HEATER
HOSE
FROMINT
AKE
MANIFOLD
#2 ADEL
CLAMP
31600-VUD
#6 LIQUID
HARDLINE
091150
NOTE: VINTAGE AIR SYSTEMS REQUIRE
(2) 5/8” HOSE NIPPLES (NOT SUPPLIED)
AC & HEATER HOSE ROUTING
HEATER HOSE
(HEATER CNTRL
VALVE/INTAKE)
#8 DISCHARGE
HOSE
096004 #10 SUCTION
HOSE
096005
#10 ADEL
CLAMP
31601-VUD
FROM HTR CNTRL VLV
TO HEATER CORE
#6 COND/ DRIER
HARDLINE
091154
(NOTE FLOW DIRECTION SPECIFIED
ON HEATER CONTROL VALVE LABEL)
FLOW SHOULD BE OPPOSITE
DIRECTION OF MOLDED ARROW
ON VALVE
OUT
COMPRESSOR
SAFETY SWITCH
(BINARY TYPE)
SCREW ON DRIER
(REFER TO
CONDENSER
INSTRUCTIONS)
#6 CORE/ EVAP
LIQUID
HARDLINE
091149
#8 COND HARDLINE
091156
IN
#6 DRIER/
CORE SUPPORT
HARD LINE
091155

16
901182 REV A 6/13/11, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 16 OF 27
PASSENGER SIDE LOUVER DASH PANEL INSTALLATION
REMOVE PASSENGER SIDE DASH TRIM FROM DASH PAD. (SEE FIGURE 14)
INSTALL PASSENGER SIDE LOUVER DASH PANEL USING (7) NUTS. (SEE FIGURE 14)
DRIVER SIDE/ CENTER LOUVER INSTALLATION
USING DRIVER SIDE LOUVER TEMPLATE PROVIDED ON PAGE 25, MARK AND CUT INSTRUMENT PANEL BEZEL
AS SHOWN IN FIGURE 15 BELOW.
CUT AND REMOVE PACKAGE TRAY AS SHOWN IN FIGURE 15a.
INSTALL DRIVER SIDE LOUVER AND CENTER LOUVER AS SHOWN IN FIGURE 15b.
DRILL (4) 3/32” HOLES IN DRIVER SIDE LOUVER AND SECURE USING (4) #4 PH PAN HEAD SCREWS.
(SEE FIGURE 15c.)
DRILL (4) 3/32” HOLES IN DRIVER SIDE CENTER LOUVER AND SECURE USING (4) #4 PH PAN HEAD SCREWS.
(SEE FIGURE 15c.)
PACKAGE
TRAY
DASH
INSTRUMENT
BEZEL
DRIVER SIDE
LOUVER
49178-VCL
PACKAGE
TRAY
(4) #4
PH PAN HEAD
SCREWS
DRILL (4)
3/32” HOLES
DRILL (4)
3/32” HOLES
CUT ALONG
EDGE
AS SHOWN
PLACE DRIVER-SIDE
LOUVER TEMPLATE LOCATED
ON PAGE 25 HERE
FIGURE 14
FIGURE 15
FIGURE 15a
FIGURE 15b
FIGURE 15c
(4) #4
PH PAN HEAD
SCREWS
PASSENGER SIDE
LOUVER DASH PANEL
49176-VCL
OEM PASSENGER SIDE
DASH TRIM
1973-87
CHEVY TRUCK
NON AIR
DRIVER SIDE VENT
TEMPLATE
CENTER
LOUVER
49179-VCL
DRIVER SIDE
CENTER LOUVER
49179-VCL
LOUVER
PLATE ADAPTER
49180-VCL

17
901182 REV A 6/13/11, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 17 OF 27
INSTALL DUCT HOSES AS SHOWN IN FIGURE 18, PAGE 19.
ROUTE A/C WIRES THROUGH 3/8” GROMMET 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 18, PAGE 19
(WIRE ACCORDING TO WIRING DIAGRAM ON PAGE 20 AND 21.)
MODIFY GLOVE BOX AS SHOWN ON PAGE 18.
REINSTALL GLOVE BOX.
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 22.
FINAL STEPS
FIGURE 16
3/8” GROMMET
33144-VUI

18
901182 REV A 6/13/11, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 18 OF 27
GLOVE BOX MODIFICATION
USE GLOVE BOX MODIFICATION TEMPLATE PROVIDED ON PAGE 26.
PLACE TEMPLATE ON THE OUTSIDE OF THE GLOVE BOX. MARK THE OUTSIDE OF THE GLOVE BOX ALONG
THE FRONT OF THE TEMPLATE AS SHOWN IN FIGURE 17 BELOW.
PLACE THE SAME TEMPLATE ON THE OUTSIDE OF THE GLOVE BOX ON THE OPPOSITE SIDE. MARK THE OUTSIDE
OF THE GLOVE BOX ALONG THE FRONT OF THE TEMPLATE AS SHOWN BELOW.
MARK THE BOTTOM OF THE BOX CONNECTING EACH END OF TEMPLATE.
CUT THE BOX ON THE LINES YOU HAVE MARKED. DISCARD THE FRONT PORTION OF THE BOX.
INSTALL THE NEW SUPPLIED GLOVE BOX BY PRESSING THE S-CLIPS ONTO THE OEM PORTION OF THE BOX.
AS SHOWN IN FIGURE 17a BELOW.
OEM wo AC
GLOVE BOX
MODIFIED GLOVE
BOX
DISCARD FRONT
PORTION OF
BOX
FACTORY AIR
GLOVE BOX
TEMPLATE
CUT BOX WITH A
HACK SAW BLADE
ON THESE THREE
FRONT LINES ONLY
OEM wo AC
GLOVE BOX
DISCARD FRONT
PORTION OF
BOX
FACTORY AIR
GLOVE BOX
TEMPLATE
CUT BOX WITH A
HACK SAW BLADE
ON THESE THREE
FRONT LINES ONLY
FIGURE 17
FIGURE 17a

19
901182 REV A 6/13/11, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 19 OF 27
CONTROL PANEL & DUCT HOSE ROUTING
FIGURE 18
PLUG
FROM
CONTROL
WIRING
HARNESS
232007-VU
R
PLUG
FROM
WIRING
HARNESS
232001-VUR
PASS. SIDE
DEF. DUCT
2” x 12”
DRIVER SIDE
DEF DUCT
2” x 28”
OFF
DASH
HOT
FLR
A/C
HI
DEF
COLD
PASS SIDE
LOUVER
2 ½” x 45”
CENTER DRIVER
SIDE LOUVER
2 ½” x 28”
DRIVER SIDE
LOUVER
2 ½” x 26”
CENTER PASS
SIDE LOUVER
2 ½” x 15”

20
901182 REV A 6/13/11, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 20 OF 27
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