Vintage Air 561065 User manual

1964-65 CHEVELLE
WITHOUT FACTORY AIR
561065
901163 REV A 6/24/09, 1964-65 CHEVELLE wo AC EVAP INSTR PG 1 OF 23
an ISO 9001: 2000 Registered Company

2
1964-65 CHEVELLE WITHOUT AC
901163 REV A 6/24/09 , 1964-65 CHEVELLE wo AC EVAP INSTR PG 2 OF 23
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, PASSENGER COMPARTMENT,
FIGURES 2 & 3
8. KICK PANEL MODIFICATION & DEFROST DUCT 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
16. CONTROL PANEL & DUCT HOSE ROUTING
FIGURE 18
17. DRIVER SIDE UNDER DASH LOUVER & CENTER & PASSENGER SIDE LOUVER
INSTALLATION
FIGURES 19, 19a, 20 & 20a
18. WIRING DIAGRAM
19. GEN IV WIRING CONNECTION INSTRUCTIONS
20. OPERATION OF CONTROLS
21. TROUBLE SHOOTING INFORMATION
22. TROUBLE SHOOTING INFORMATION CONT.
23. EVAPORATOR KIT PACKING LIST

3
1964-65 CHEVELLE WITHOUT AC
901163 REV A 6/24/09 , 1964-65 CHEVELLE wo AC EVAP INSTR PG 3 OF 23
** 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
561065
1.
2.
1
1
744004-VUE
784159
1
ACCESSORY KIT
784159
2
GEN IV MAGNUM
EVAP SUB CASE
744004-VUE
GEN IV MAGNUM EVAP. SUB CASE
1964-65 CHEVELLE wo AC ACC. KIT
NOTE: IMAGES MA Y NOT DE PICT ACTUAL PARTS AND QUANTITIES.
REFER TO PACKING LIST FOR ACTUAL PARTS AND QUANTITIES.

4
1964-65 CHEVELLE WITHOUT AC
901163 REV A 6/24/09 , 1964-65 CHEVELLE wo AC EVAP INSTR PG 4 OF 23
1964-65 CHEVELLE wo 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
1964-65 CHEVELLE WITHOUT AC
901163 REV A 6/24/09 , 1964-65 CHEVELLE wo AC EVAP INSTR PG 5 OF 23
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 NOTICE-PLEASE READ
WIRING
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
1964-65 CHEVELLE WITHOUT AC
901163 REV A 6/24/09 , 1964-65 CHEVELLE wo AC EVAP INSTR PG 6 OF 23
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
FIGURE 1
BATTERY
TRAY
INNER
FENDER
OEM
BLOWER MOTOR
ASSEMBLY
HEATER
HOSES
BATTERY, BATTERY TRAY (RETAIN)
DRAIN RADIATOR, REMOVE RADIATOR (RETAIN)
TO REMOVE THE OEM BLOWER MOTOR ASSEMBLY (UNDER HOOD) AND THE AIR
DISTRIBUTION SYSTEM (UNDER DASH) THE FACTORY MANUAL INDICATES DOING THE
FOLLOWING, REMOVE RIGHT INNER FENDER.
OEM HEATER HOSES (DISCARD). SEE FIGURE 1.
OEM HEATER WIRING (DISCARD) SEE FIGURE 1.

7
1964-65 CHEVELLE WITHOUT AC
901163 REV A 6/24/09 , 1964-65 CHEVELLE wo AC EVAP INSTR PG 7 OF 23
REMOVE GLOVE BOX DOOR (RETAIN) AND GLOVE BOX (DISCARD).
DISCONNECT ALL WIRE AND CABLES FROM CONTROL PANEL AND RADIO.
REMOVE CONTROL PANEL AND RADIO.
REMOVE OEM HEATER ASSEMBLY.
REMOVE O.E.M DEFROST DUCT ASSEMBLY, SEE FIGURE 3 BELOW.
REMOVE 3 SPOT WELDS ON DEF DUCT BY CHISEL OR DIE GRINDER.
SEE FIGURE 3 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 BRACKET.
COMPRESSOR & BRACKETS
REMOVE THE FOLLOWING:
FIGURE 3
DEFROST
DUCT
RADIO
CONTROL
PANEL
OEM
HEATER
ASSEMBLY
GLOVE
BOX
FIGURE 2

8
1964-65 CHEVELLE WITHOUT AC
901163 REV A 6/24/09 , 1964-65 CHEVELLE wo AC EVAP INSTR PG 8 OF 23
FIGURE 5
DEFROST DUCT INSTALLATION
INSTALL DEFROST DUCTS UNDER DASH AND ALIGN WITH OEM OPENING. INSTALL DEFROST DUCT
TO COWL USING (2) #10 x 1/2” SHEETMETAL SCREWS. NOTE APPLY SILICONE ON SCREWS TO
INSURE LEAK FREE INSTALLATION. SEE FIGURE 5 BELOW.
KICK PANEL MODIFICATION
REMOVE KICK PANEL.
REMOVE KICK PANEL FRESH AIR DOOR ASM BY REMOVING (5) OEM SCREWS.
DISCONNECT PULL CABLE ASSEMBLY FROM UNDER DASH (DISCARD). SEE FIGURE 4 BELOW
MODIFY PASSENGER SIDE KICK PANEL AS SHOWN IN FIGURE 4a BELOW
OEM
DEFROST DUCT
OPENING
(2) #10 x 1/2
SHEET METAL
SCREW
DEFROST
DUCT
FIGURE 4 FIGURE 4a
FRESH AIR
DOOR ASM
5”
3”
CUT

9
1964-65 CHEVELLE WITHOUT AC
901163 REV A 6/24/09 , 1964-65 CHEVELLE wo AC EVAP INSTR PG 9 OF 23
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 1/2”
HEX BOLT
FRONT
EVAPORATOR
BRACKET
647065
FIGURE 7
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 (3) 1/4-20 x 1” HEX BOLTS, FLAT
WASHERS AND 1/4-20 NUT WITH STAR WASHER, SEE FIGURE 6, BELOW.
FIGURE 6
(3) 1/4-20 x 1”
HEX BOLTS
HOLE
NOT USED
(3) 1/4 x 3/4
FLAT WASHER
(3) 1/4-20
NUTS WITH
STAR WASHER
BACK SIDE
OF FIREWALL
COVER
SILICONE
FIREWALL
COVER
648169

10
1964-65 CHEVELLE WITHOUT AC
901163 REV A 6/24/09 , 1964-65 CHEVELLE wo AC EVAP INSTR PG 10 OF 23
REAR
EVAPORATOR
BRACKET
643059
(2) HEATER
FITTINGS
(2) 1/4-20 x 1/2”
HEX BOLT
BRACKET INSTALLATION
FIGURE 8
(2) 1/4-20 x 1/2”
18290-VUB
1/4-20 x 1”
HEX BOLT
189125-MUR
1/4 PUSH NUT
BOLT RETAINER
18290-VUB
1/4-20 x 1”
HEX BOLT
189125-MUR
1/4 PUSH NUT
BOLT RETAINER
HEX BOLT

11
1964-65 CHEVELLE WITHOUT AC
901163 REV A 6/24/09 , 1964-65 CHEVELLE wo AC EVAP INSTR PG 11 OF 23
FRESH AIR COVER INSTALLATION
FIGURE 10b
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 FRESH AIR CAP 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 OEM SCREWS,
AS SHOWN IN FIGURE 10b 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
1/4-20 x 1 1/2”
BOLT w/
WASHER
SILICONE
FRESH AIR
CAP
(4) GROMMETS
33137-VUI
FIGURE 9
BACK SIDE
OF FRESH AIR
CAP
ENGINE
COMPARTMENT
SIDE OF
FIREWALL
INSTALL (4) GROMMETS IN FRESH AIR CAP. SEE FIGURE 9 BELOW
APPLY A 1/4” BEAD OF SILICONE AROUND THE BACK SIDE OF THE FRESH AIR CAP AS SHOWN IN
FIGURE 9 BELOW.
ATTACH FRESH AIR CAP TO FIREWALL USING A 1/4-20 x 1 1/2" BOLT AND WASHER, SEE FIGURE 9
BELOW. (NOTE: FRESH AIR CAP INSTALLS ON ENGINE SIDE
OF FIREWALL.)
FIGURE 10a

12
1964-65 CHEVELLE WITHOUT AC
901163 REV A 6/24/09 , 1964-65 CHEVELLE wo AC EVAP INSTR PG 12 OF 23
(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
1964-65 CHEVELLE WITHOUT AC
901163 REV A 6/24/09 , 1964-65 CHEVELLE wo AC EVAP INSTR PG 13 OF 23
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”
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,INSTALES
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
DRAIN
HOSE
1”

14
1964-65 CHEVELLE WITHOUT AC
901163 REV A 6/24/09 , 1964-65 CHEVELLE wo AC EVAP INSTR PG 14 OF 23
NOTE:
VINT
AGEAIRSYSTEMSREQUIRE
(2)5/8HOSENIPPLES(NO
TSU
PPLIED)
COMPRESSOR
SAFETY SWITCH
(BINARY TYPE)
SCREW ON DRIER
(REFER TO
CONDENSER
INSTRUCTIONS)
AC & HEATER HOSE ROUTING
FIGURE 15
(4) TIE WRAPS
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.
HEATERHOSE
(HEATECNTRL
VALVE/INTAKE)
R
#8 DISCHARGE
HOSE
096067
#10 SUCTION
HOSE
096068
64-67 CHEVELLE SHOWN
#8 CONDENSER/
COMP HARDLINE
091167
#6 HARDLINE
DRIER/ CONDENSER
091166
#6 HOSE
096066
FROM HTR CNTRL VLV
TO EVAPORATOR
HEATER
HOSE
FROM EVAPORATOR
TO WATER PUMP
FROMINT
AKE
MANIFOLD

15
1964-65 CHEVELLE WITHOUT AC
901163 REV A 6/24/09 , 1964-65 CHEVELLE wo AC EVAP INSTR PG 15 OF 23
INSTALL DUCT HOSES AS SHOWN IN FIGURE 18, 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 18, PAGE 16
(WIRE ACCORDING TO WIRING DIAGRAM ON PAGE 18 AND 19.)
INSTALL NEW GLOVE BOX USING (4) #8 x 1/2” PH PAN HEAD SCREWS, SEE FIGURE 17.
REINSTALL KICK PANEL.
INSTALL LOUVERS AS SHOWN ON PAGE 17.
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 20.
FINAL STEPS
FIGURE 16
GROMMET
33144-VUI
FIGURE 17
GLOVE BOX
625663
(4) #8 x 1/2”
PH PAN
HEAD
SCREWS

16
1964-65 CHEVELLE WITHOUT AC
901163 REV A 6/24/09 , 1964-65 CHEVELLE wo AC EVAP INSTR PG 16 OF 23
CONTROL PANEL & DUCT HOSE ROUTING
CONTROL PANEL
HARNESS
FROM ECU
232006-V UR
PLUG
FROM
WIRING
HARNESS
232001-VUR
DRIVER SIDE
UNDERDASH LOUVER
2 1/2” x 30”
PASS. SIDE
UDERDASH LOUVER
2 1/2” x 44”
DEFROST DUCT
DR. SIDE
2” x 20”
DEFROST DUCT
PASS. SIDE
2” x 12”
FIGURE 18
CENTER
UNDERDASH
LOUVER
2 1/2” x 16”

17
1964-65 CHEVELLE WITHOUT AC
901163 REV A 6/24/09 , 1964-65 CHEVELLE wo AC EVAP INSTR PG 17 OF 23
(2)10/32 X 3/4”
PAN HEAD
SCREWS
(3)10/32 X 3/4”
PAN HEAD
SCREWS
(2) LOUVERS
49157-VUL
BALL LOUVER
49053-VUL
(2)10/32
NUTS w/
STARWASHER
(3) 10/32
NUTS w/
STARWASHER
PLACE LOUVER HOUSING UNDER DASH AND ALIGN WITH OEM HOLES IN DASH.
SECURE LOUVER HOUSING UNDER DASH USING (2) 10/32 x 3/4” PAN HEAD SCREWS, (4) 3/16 FLAT
WASHERS, (2) 10/32 NUTS w/ STARWASHER AS SHOWN IN FIGURE 19 BELOW.
INSTALL LOUVER IN UNDER DASH HOUSING AS SHOWN IN FIGURE 19a.
DRIVER SIDE UNDER DASH LOUVER INSTALLATION
PLACE PS SIDE LOUVER BEZEL UNDER DASH AND ALIGN WITH OEM HOLES IN DASH.
SECURE LOUVER BEZEL UNDER DASH USING (3) 10/32 x 3/4” PAN HEAD SCREWS, (6) 3/16 FLAT
WASHERS, (3) 10/32 NUTS w/ STARWASHER AS SHOWN IN FIGURE 20 BELOW.
INSTALL LOUVERS IN PS SIDE UNDER DASH LOUVER BEZEL AS SHOWN IN FIGURE 20a.
CENTER/ PASSENGER SIDE UNDER DASH INSTALLATION
(4) 3/16 FLAT
WASHERS
DR SIDE
UNDER DASH
LOUVER HOUSING
626662
PS SIDE
UNDER DASH
LOUVER BEZEL
626661
BALL LOUVER
49053-VUL
(6) 3/16 FLAT
WASHERS
FIGURE 19
FIGURE 19a
FIGURE 20
FIGURE 20a

18
1964-65 CHEVELLE WITHOUT AC
901163 REV A 6/24/09 , 1964-65 CHEVELLE wo AC EVAP INSTR PG 18 OF 23
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 TRINARY
SAFETY
SWITCH
WARNING: ALWAYS MOUNT CIRCUIT
BREAKER UNDE R THE HOOD IN THE ENGINE
COMPARTMEN T AND AS CLOSE TO
THE BATTERY AS POSSIBLE.

19
1964-65 CHEVELLE WITHOUT AC
901163 REV A 6/24/09 , 1964-65 CHEVELLE wo AC EVAP INSTR PG 19 OF 23
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
HARNE SS 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 TH E BATTERY AS POSSIBLE.

20
1964-65 CHEVELLE WITHOUT AC
901163 REV A 6/24/09 , 1964-65 CHEVELLE wo AC EVAP INSTR PG 20 OF 23
OPERATION OF CONTROLS
BLOWER SPEED
SLIDE THE FAN LEVER
UP OR DOWN
TO SELECT DESIRE
FAN SPEED
(SLIDE LEVER ALL THE WAY
DOWN FOR MAXIMUM
FAN SPEED)
BLOWER SPEED
SLIDE THE FAN LEVER
UP OR DOWN TO
SELECT DESIRE FAN
SPEED (SLIDE LEVER ALL
THE WAY DOWN
FOR MAXIMUM
FAN SPEED)
DEFROST MODE
THERMOSTAT LEVER
IN A/C MODE SLIDE THE
TEMP LEVER ALL THE WAY
UP TO ENGAGE
COMPRESSOR FOR
MAXIMUM COOLING.
(SLIDE LEVER UP OR DOWN TO
ADJUST DESIRED TEMPERATURE)
THERMOSTAT LEVER
IN DEF MODE SLIDE THE
TEMP LEVER ALL THE WAY
UP TO
(SLIDE LEVER UP OR DOWN TO
ADJUST DESIRED TEMPERATURE)
ENGAGE COMPRESSOR
FOR MAXIMUM COOLING.
MODE LEVER
SLIDE THE MODE LEVER ALL THE
WAY UP FOR DASH MODE
MODE LEVER
SLIDE THE MODE LEVER
ALL THE WAY DOWN
FOR DEFROST MODE
(SLIDE LEVER UP OR DOWN
TO BLEND BETWEEN DESIRED
MODE POSITIONS)
NOTE: CONTROLS MUST BE CALIBRATED PRIOR TO FI RST OPERATION- REFER TO CONTROL PANEL
INSTRUCTIONS
A/C MODE
BLOWER SPEED
THIS LEVER CONTROLS
THE BLOWER SPEED,
FROM OFF TO HI
SYSTEM OFF
THERMOSTAT LEVER
THIS LEVER CONTROLS
THE TEMPERATURE
FROM HOT TO COLD
MODE LEVER
THE MODE POSITIONS
FROM DASH TO FLOOR
TO DEFROST
THIS LEVER CONTROLS
BLOWER SPEED
SLIDE THE FAN LEVER
UP OR DOWN TO
SELECT DESIRE FAN
SPEED (SLIDE LEVER ALL
THE WAY DOWN
FOR MAXIMUM
FAN SPEED)
HEAT MODE
THERMOSTAT LEVER
IN HEAT MODE SLIDE THE
TEMP LEVER ALL THE WAY
DOWN FOR MAXIMUM HEATING.
(SLIDE LEVER UP OR DOWN TO
ADJUST DESIRED TEMPERATURE)
MODE LEVER
SLIDE THE MODE LEVER
TO THE CENTER FOR
FLOOR MODE
(SLIDE LEVER UP OR DOWN
TO BLEND BETWEEN DESIRED
MODE POSITIONS)
AIR
DEF TEMP
AIR
DEF
TEMP
AIR
DEF
TEMP
MODE
LEVERTHERMOSTAT
LEVER
AIR
DEF TEMP
BLOWER
SPEED