Vintage Air 1981-87 CHEVROLET PICKUP User manual

1981-87 CHEVROLET PICKUP
with FACTORY AIR
754181
904185 REV D 11/29/22, INST 81-87 CHEV P-UP w/ AC EVAP KIT PG 1 OF 27
an ISO 9001:2015 Registered Company
18865 Goll St. San Antonio, TX 78266
Phone: [phone]
Sales: [email protected]
Tech Support: [email protected]
www.vintageair.com

2
904185 REV D 11/29/22, INST 81-87 CHEV P-UP w/ 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 & BRACKETS
FIGURE 1
7. PASSENGER COMPARTMENT
FIGURES 2, 2a, 2b & 2c
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. A/C & HEATER HOSE ROUTING
FIGURE 13
16. DRIVER AND PASSENGER SIDE CENTER LOUVER HOSE ADAPTER & DRIVER AND
PASSENGER SIDE LOUVER HOSE ADAPTER
FIGURES 14, 14a, 15 & 15a
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. TROUBLESHOOTING INFORMATION
24. TROUBLESHOOTING INFORMATION CONT.
25. GLOVE BOX MODIFICATION TEMPLATE
26. POWER STEERING BRACKET MODIFICATION
27. EVAPORATOR KIT PACKING LIST

3
904185 REV D 11/29/22, INST 81-87 CHEV P-UP w/ 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
754181
1.
2.
1
1
744004-VUE
794180
1
ACCESSORY KIT
794180
2
GEN IV 4-VENT
EVAP SUB CASE
with 204 ECU
744004-VUE
GEN IV 4-VENT EVAP SUB CASE with 204 ECU
ACCESSORY KIT 1981-87 CHEVROLET PICKUP with A/C
No. QTY. PART No. DESCRIPTION
EVAPORATOR KIT PACKING LIST
NOTE: IMAGES MAY NOT DEPICT ACTUAL PARTS AND QUANTITIES.
REFER TO PACKING LIST FOR ACTUAL PARTS AND QUANTITIES.
OFF
DASH
HOT
FLR
A/C
HI
DEF
COLD

4
904185 REV D 11/29/22, INST 81-87 CHEV P-UP w/ AC EVAP KIT PG 4 OF 27
Important Notice—Please Read
For Maximum System Performance, Vintage Air Recommends the Following:
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).
NOTE: Vintage Air systems are designed to operate with R134a refrigerant only.
Use of any other refrigerant could damage your A/C system and/or vehicle, and
possibly cause a fire, in addition to potentially voiding the warranties of the A/C
system and its components.
Refrigerant Capacities:
Vintage Air System: 1.8 lbs. (28.8 oz.) or 816 grams of R134a, charged by weight with a quality charging
station or scale. NOTE: Use of the proper type and amount of refrigerant is critical to system
operation and performance.
Other Systems: Consult manufacturer’s guidelines.
Lubricant Capacities:
Safety Switches
Service Info:
Protect Your Investment: Prior to assembly, it is critical that the compressor, evaporator, A/C hoses and
fittings, hardlines, condenser and receiver/drier remain capped. Removing caps prior to assembly will allow
moisture, insects and debris into the components, possibly leading to reduced performance and/or
premature failure of your A/C system. This is especially important with the receiver/drier.
Additionally, when caps are removed for assembly, BE CAREFUL! Some components are shipped under
pressure with dry nitrogen.
Evacuate the System for 35-45 Minutes: Ensure that system components (Drier, compressor, evaporator
and condenser) are 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.
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 circulate lubricant.
Bolts Passing Through Cowl and/or Firewall:
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.
Heater Hose (not included with this kit):
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.

5
904185 REV D 11/29/22, INST 81-87 CHEV P-UP w/ AC EVAP KIT PG 5 OF 27
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 and 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 and 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 may damage wiring or the compressor relay, and/or cause a
malfunction.
When installing ground leads on Gen IV systems, the blower control ground and ECU
ground must be connected directly to the negative battery post.
For proper system operation, the heater control valve must be connected to the
ECU.
•
•
•

6
904185 REV D 11/29/22, INST 81-87 CHEV P-UP w/ AC EVAP KIT PG 6 OF 27
DISCONNECT BATTERY.
DRAIN RADIATOR, REMOVE RADIATOR (RETAIN).
EVACUATE THE A/C SYSTEM IF NECESSARY.
OEM CONDENSER AND DRIER (DISCARD). SEE FIGURE 1.
OEM A/C LINES FROM COMPRESSOR TO EVAPORATOR (DISCARD).
OEM COMPRESSOR AND BRACKET (DISCARD).
EVAPORATOR BLOWER ASSEMBLY (DISCARD).
NOTE: TO REMOVE THE EVAPORATOR AND BLOWER ASSEMBLY (UNDER HOOD) AND THE AIR
DISTRIBUTION SYSTEM (UNDER DASH), THE FACTORY MANUAL RECOMMENDS THAT YOU REMOVE
RIGHT INNER FENDER FOR ACCESSIBILITY.
OEM HEATER HOSES, A/C HOSES AND HARDLINES (DISCARD). SEE FIGURE 1.
ENGINE COMP
ARTMENT
REMOVE THE FOLLOWING:
FIGURE 1
EVAPORATOR
BLOWER
HOUSING
COMPRESSOR
DRIER &
CONDENSER
BEFORE STARTING THE INSTALLATION, CHECK THE FUNCTION
OF THE VEHICLE (HORN, LIGHTS,ETC.) FOR PROPER OPERATIONS.
STUDY THE INSTRUCTIONS, ILLUSTRATIONS & DIAGRAMS.
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
904185 REV D 11/29/22, INST 81-87 CHEV P-UP w/ 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).
ALL HOSE AND DUCTING FROM OEM LOUVERS (SEE FIGURE 2, BELOW).
A/C & HEATER ASSEMBLY (DISCARD) (SEE FIGURE 2a).
DEFROST DUCT ASSEMBLY (DISCARD) (SEE FIGURE 2a, BELOW).
PASSENGER SIDE KICK PANEL ASSEMBLY (RETAIN KICK PANEL COVER & KICK PANEL
CAP, BUT DISCARD DOOR & ACTUATOR). SEE FIGURE 2b.
APPLY 1/4” BEAD OF SILICONE ON BACK SIDE OF KICK PANEL BLOCK-OFF PLATE.
INSTALL KICK PANEL BLOCK-OFF PLATE USING (2) #8 x 1/2” PH PAN HEAD
SCREWS (SEE FIGURE 2c).
NOTE: FOR EASE OF INSTALLING EVAPORATOR UNDER DASH, IT MAY BE
HELPFUL TO REMOVE THE (2) OEM BOLTS UNDER THE DASH ON THE
PASSENGER SIDE DOOR PILLAR AND PULL BACK DASH.
PASSENGER COMPARTMENT
REMOVE THE FOLLOWING:
FRESH AIR
DOOR ASSEMBLY
KICK PANEL
COVER
KICK
PANEL
CAP
FIGURE 2
FIGURE 2a
FIGURE 2b
FIGURE 2c
CONTROL
PANEL
INSTRUMENT
PANEL
BEZEL DEFROST DUCT
ASSEMBLY
A/C & HEATER
ASSEMBLY
ALL HOSE
AND RELATED
DUCTING
FROM LOUVERS
UNDER DASH
COVER
GLOVE BOX
DOOR &
GLOVE BOX
DASH
PAD
ASH
TRAY
(2) OEM
BOLTS
KICK PANEL
COVER
(2) #8 x 1/2”
PH P
AN HEAD
SCREWS
KICK PANEL
BLOCK OFF
PLATE
62438-LCE SILICONE
BA
CK SIDE

8
904185 REV D 11/29/22, INST 81-87 CHEV P-UP w/ 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
DUCTS
623219
FIGURE 3
FIGURE 4
(4) #8 x 1/2”
PH PAN HEAD
SCREWS
(4) #8 U-NUTS
189801
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 SECURE USING (2) #14 x 3/4“ SHEET METAL SCREWS AS SHOWN
BELOW.
USING FIREWALL COVER AS TEMPLATE, MARK THE HOLES ON FIREWALL AS SHOWN BELOW.
REMOVE FIREWALL COVER.
FRESH AIR CAP AND FIREW
ALL MODIFICATION
SILICONE
BACK SIDE OF
FRESH AIR CAP
1/4-20 x 1”
BOLT
1/4” FLAT
WASHER
FRESH AIR
CAP
MARK
HOLES
MARK
HOLE
MARK
HOLE
MARK
HOLE
MARK
HOLES
MARK
HOLES #14 x 3/4”
SHEET METAL
SCREW
OEM
HOLES
OEM
HOLE
OEM
HOLE
#14 x 3/4”
SHEET METAL
SCREW

9
904185 REV D 11/29/22, INST 81-87 CHEV P-UP w/ AC EVAP KIT PG 9 OF 27
FIGURE 5
DRILL HOLES INTO FIREWALL 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 THE FIREWALL COVER ONTO THE FIREWALL USING A 1/4-20 x 3/4” HEX BOLT, 1/4“ FLAT WASHER,
1/4” NUT WITH STAR WASHER AND (8) #14 x 3/4“ SHEET METAL SCREWS AS SHOWN BELOW.
INSTALL GROMMETS INTO THE FIREWALL COVER AS SHOWN BELOW.
FIREWALL COVER INSTALLATION
LARGE
GROMMET
33137-VUI
FIREWALL COVER
644086
GROMMET
33135-VUI
(8) #14 x 3/4”
SHEET METAL
SCREWS
1/4-20 x 3/4”
BOLT 1/4” FLAT
WASHER
1/4” NUT w/
STAR WASHER
BACK SIDE OF
FIREWALL COVER
644086
SILICONE
GROMMET
33144-VUI
DRILL (2) 3/16”
HOLES
DRILL (3) 3/16”
HOLES
DRILL (2) 2”
HOLES
DRILL 3/16”
HOLE
(2) OEM
HOLES
OEM
HOLE
DRILL (3) 1 ⅛”
HOLES
(2) OEM
HEATER
HOLES

10
904185 REV D 11/29/22, INST 81-87 CHEV P-UP w/ AC EVAP KIT PG 10 OF 27
BRACKET & EVAPORATOR HARDLINE INSTALLATION
ON A WORKBENCH, 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
EV
AP FRONT
BRKT
644087
(2) 1/4-20 x 1/2”
HEX BOLTS

11
904185 REV D 11/29/22, INST 81-87 CHEV P-UP w/ 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 1/2”
HEX BOLTS
(2) 1/4-20 x 1/2”
HEX BOLTS
REAR
EVAPORATOR
BRACKET
644083
HEATER LINE
(EVAP TO INTAKE)
091151
#6 O-RING
(33857-VUF)

12
904185 REV D 11/29/22, INST 81-87 CHEV P-UP w/ AC EVAP KIT PG 12 OF 27
INNER
COWL
DRILL (2)
3/16” HOLES
(2) #14 x 3/4”
SHEET METAL
SCREWS
(2) 1/4-20 x 1 ¼”
HEX BOLTS
(2) 1/4” FLAT
WASHERS
(2) .563 L
SPACERS
VIEW FROM
PASSENGER SIDE
INSIDE OF CAB
FIGURE 9
FIGURE 9b
FIGURE 9a
EVAPORATOR INSTALLATION
LIFT EVAPORATOR UNIT UP UNDER THE DASHBOARD. SECURE LOOSELY TO THE FIREWALL USING
(2) 1/4-20 x 1 ¼” 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 TIGHTEN 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.
REINSTALL (2) OEM BOLTS UNDER DASH ON
PASSENGER SIDE DOOR PILLAR.
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

13
904185 REV D 11/29/22, INST 81-87 CHEV P-UP w/ 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
LUBRICA
TING O-RINGS
FIGURE 11
REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH MODIFIED HOSE KIT.
MODIFIED A/C HOSE KIT
DRAIN
HOSE
O-RING
O-RING
SUPPLIED OIL
FOR O-RINGS O-RING, INSTALLS
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.
#6 O-RING
#8 O-RING #10 O-RING
MALE
INSERT FEMALE
NUT
1”

14
904185 REV D 11/29/22, INST 81-87 CHEV P-UP w/ 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
NOTE: FLOW DIRECTION FOLLOWS
MOLDED ARROW ON VALVE.
HEATER HOSE & HEATER CONTROL VALVE INSTALLATION
#6 LIQUID
LINE
FROM HEATER CORE
TO WATER PUMP
#10 SUCTION
LINE
HEATER
HOSE
HEATER
HOSE
FROM HTR CNTRL VLV
TO HEATER CORE
FROM INTAKE
MANIFOLD

15
904185 REV D 11/29/22, INST 81-87 CHEV P-UP w/ AC EVAP KIT PG 15 OF 27
FIGURE 13
TIE
WRAP
HE
ATER
HOSE
#2 ADEL
CLAMP
31600-VUD
#6 LIQUID
HARDLINE
091150
NOTE: VINTAGE AIR SYSTEMS REQUIRE
(2) 5/8” HOSE NIPPLES (NOT SUPPLIED).
A/C & HEATER HOSE ROUTING
HEATER HOSE
(HEATER CONTROL
VALVE/INTAKE)
#8 DISCHARGE
HOSE
096004 #10 SUCTION
HOSE
096005
#10 ADEL
CLAMP
31601-VUD
FROM
HEATER CONTROL VALVE
TO HEATER CORE
#6 CONDENSER/DRIER
HARDLINE
091154
NOTE: FLOW DIRECTION FOLLOWS MOLDED ARROW ON VALVE.
OUT
COMPRESSOR
SAFETY SWITCH
(BINARY TYPE)
SCREW-ON DRIER
(REFER TO
CONDENSER
INSTRUCTIONS)
#6 CORE/EVAPORATOR
LIQUID
HARDLINE
091149
#8 CONDENSER
HARDLINE
091156
IN
#6 DRIER/
CORE SUPPORT
HARD LINE
091155
FROM INTAKE
MANIFOLD

16
904185 REV D 11/29/22, INST 81-87 CHEV P-UP w/ AC EVAP KIT PG 16 OF 27
DRIVER AND PASSENGER SIDE
CENTER L
OUVER HOSE ADAPTER INSTALLATION
INSTALL (4) S-CLIPS ON DRIVER SIDE CENTER LOUVER HOSE ADAPTER (SEE FIGURE 14, BELOW).
INSTALL DRIVER SIDE CENTER LOUVER HOSE ADAPTER IN CENTER LOUVER AS SHOWN BEL
OW IN FIGURE 14.
INSTALL (4) S-CLIPS ON PASSENGER SIDE CENTER LOUVER HOSE ADAPTER (SEE FIGURE 14a, BELOW).
INSTALL PASSENGER SIDE CENTER LOUVER HOSE ADAPTER IN OEM PASSENGER SIDE CENTER LOUVER
AS SHOWN BELOW IN FIGURE 14a.
DRIVER AND P
ASSENGER SIDE LOUVER HOSE ADAPTER INSTALLATION
REMOVE OEM PASSENGER SIDE HOSE ADAPTER FROM DASH PAD (DISCARD) (RETAIN 3 OEM NUTS).
INSTALL PASSENGER SIDE LOUVER HOSE ADAPTER TO DASH PAD USING (3) OEM NUTS
(SEE FIGURE 15, BELOW).
CUT & REMOVE DRIVER SIDE LOUVER DUCT AS SHOWN IN FIGURE 15a.
INSTALL (4) S-CLIPS ON DRIVER SIDE LOUVER HOSE ADAPTER AS SHOWN IN FIGURE 15a.
INSTALL DRIVER SIDE LOUVER HOSE ADAPTER IN
DRIVER SIDE LOUVER DUCT AS SHOWN BELOW.
(3) OEM
NUTS
PASSENGER SIDE
LOUVER HOSE
ADAPTER
623214
1/2”
DRIVER SIDE
LOUVER DUCT
CUT &
REMOVE
DASH
PAD
DASH
PAD
INSTRUMENT
PANEL BEZEL
DRIVER SIDE
CENTER LOUVER
HOSE ADAPTER
623216
PASSENGER SIDE
CENTER LOUVER
HOSE ADAPTER
623216
OEM
PASSENGER SIDE
CENTER LOUVER
(4) S-CLIPS
(4) S-CLIPS
FIGURE 14 FIGURE 14a
FIGURE 15
FIGURE 15a
DRIVER SIDE
LOUVER DUCT DRIVER SIDE
LOUVER HOSE
ADAPTER
623215
(4) S-CLIPS

17
904185 REV D 11/29/22, INST 81-87 CHEV P-UP w/ 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 IN FIGURE 16
(12 VOLT/GROUND/BINARY SWITCH/HEATER VALVE).
INSTALL CONTROL PANEL ASSEMBLY.
PLUG THE WIRING HARNESS INTO THE ECU MODULE ON SUB CASE AS SHOWN IN FIGURE 18, PAGE 19
(WIRE ACCORDING TO WIRING DIAGRAM ON PAGES 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 A/C MODE AND/OR FREEZING WEA
THER,
VOIDING YOUR WARRANTY.
DOUBLE CHECK ALL FITTINGS, BRACKETS AND BELTS FOR TIGHTNESS.
VINTAGE AIR RECOMMENDS THAT ALL A/C 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
WIRING HARNESS
(HEATER CONTROL VALVE)
WIRING HARNESS
(12 VOLT/GROUNDS/BINARY SWITCH)

18
904185 REV D 11/29/22, INST 81-87 CHEV P-UP w/ AC EVAP KIT PG 18 OF 27
GLOVE BOX MODIFICATION
USE GLOVE BOX MODIFICATION TEMPLATE PROVIDED ON PAGE 25.
PLACE THE TEMPLATE ON THE OUTSIDE OF THE GLOVE BOX ON THE PASSENGER SIDE
. 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 INSIDE OF THE GLOVE BOX ON THE DRIVER SIDE. MARK THE
INSIDE OF THE GLOVE BOX ALONG THE FRONT OF THE TEMPLATE AS SHOWN BELOW.
CUT SIDES OF GLOVE BOX.
MARK THE BOTTOM CONNECTING EACH SIDE OF GLOVE BOX THAT WAS JUST CUT AND 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 with A/C
GLOVE BOX
DRIVER SIDE
OF GLOVE BOX
CUT BOX WITH A
HACK SAW BLADE
ON THESE (3) FRONT
LINES ONLY
S-CLIP
DISCARD FRONT
PORTION OF
BOX
S-CLIP
S-CLIP
S-CLIP
MODIFIED GLOVE
BOX
FACTORY AIR
GLOVE BOX
TEMPLATE
FACTORY AIR
GLOVE BOX
TEMPLATE
FIGURE 17 FIGURE 17a
PASSENGER SIDE
OF GLOVE BOX

19
904185 REV D 11/29/22, INST 81-87 CHEV P-UP w/ AC EVAP KIT PG 19 OF 27
CONTROL PANEL & DUCT HOSE ROUTING
FIGURE 18
PLUG
FROM
CONTROL
WIRING
HARNESS
232007-
VUR
PLUG
FROM
WIRING
HARNESS
232001-VUR
PASSENGER SIDE
DEFROST DUCT
2” x 12”
DRIVER SIDE
DEFROST DUCT
2” x 28”
OFF
DASH
HOT
FLR
A/C
HI
DEF
COLD
PASSENGER SIDE
LOUVER
2 ½” x 45”
CENTER DRIVER
SIDE LOUVER
2 ½” x 28”
DRIVER SIDE
LOUVER
2 ½” x 26”
CENTER PASSENGER
SIDE LOUVER
2 ½” x 15”

20
904185 REV D 11/29/22, INST 81-87 CHEV P-UP w/ AC EVAP KIT PG 20 OF 27
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 E, 10/6/2017
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 as close to the battery as possible. (NOTE: Wire between
battery and circuit breaker is unprotected and should be carefully routed to avoid a short
circuit).
Wide open throttle switch contacts close only at full throttle, which disables A/C
compressor.
JF8
BLK
ORA
TAN
VIEWED FROM WIRE SIDE
*
**
***
HEATER
CONTROL VALVE