Vintage 1967-72 CHEV PICK-UP User manual

1967-72 CHEV PICK-UP
WITHOUT FACTORY AIR
751170
901149 REV A 12/23/10, INST 67-72 CHEV P-UP wo AC EVAP KIT PG 1 OF 24
an ISO 9001:2008 Registered Company

2
901149 REV A 12/23/10, INST 67-72 CHEV P-UP wo AC EVAP KIT PG 2 OF 24
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
FIGURE 2
8. DEFROST DUCT AND LOUVER INSTALLATION
FIGURES 3, 3a & 3b
9. FRESH AIR CAP AND FIREWALL COVER INSTALLATION/ BRACKET & EVAPORATOR
HARDLINE INSTALLATION
FIGURES 4 & 5
10. BRACKET & EVAPORATOR HARDLINE INSTALLATION CONT.
FIGURE 6
11. EVAPORATOR INSTALLATION
FIGURES 7 & 7a
12. DRAIN HOSE INSTALLATION, LUBRICATING O-RINGS, A/C HOSE INSTALLATION, &
MODIFIED A/C HOSE KIT
FIGURES 8 & 9
13. HEATER HOSE & HEATER CONTROL VALVE INSTALLATION
FIGURE 10
14. AC & HEATER HOSE ROUTING
FIGURE 11
15. FINAL STEPS
FIGURES 12 & 12a
16. CONTROL PANEL & DUCT HOSE ROUTING
FIGURE 13
17. WIRING DIAGRAM
18. GEN IV WIRING CONNECTION INSTRUCTIONS
19. OPERATION OF CONTROLS
20. TROUBLE SHOOTING INFORMATION
21. TROUBLE SHOOTING INFORMATION CONT.
22. DRIVER/PASSENGER SIDE LOUVER TEMPLATE
23. CENTER LOUVER TEMPLATE
24. EVAPORATOR KIT PACKING LIST

3
901149 REV A 12/23/10, INST 67-72 CHEV P-UP wo AC EVAP KIT PG 3 OF 24
** 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
751170
1.
2.
1
1
744005
791170
1
ACCESSORY KIT
791170
2
GEN IV 3 VENT
EVAP SUB CASE
w/204 ECU
744005
GEN IV 3 VENT EVAP. SUB CASE w/204 ECU
ACCESSORY KIT 67-72 CHEV P-UP wo AC
NO. QTY. PART NO. DESCRIPTION
EVAPORATOR KIT PACKING LIST
NOTE: IMAGES MA Y NOT DE PICT ACTUAL PARTS AND QUANTITIES.
REFER TO PACKING LIST FOR ACTUAL PARTS AND QUANTITIES.

4
901149 REV A 12/23/10, INST 67-72 CHEV P-UP wo AC EVAP KIT PG 4 OF 24
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 GUIDELINES)
IMPORTANT NOTICE-PLEASE READ

5
901149 REV A 12/23/10, INST 67-72 CHEV P-UP wo AC EVAP KIT PG 5 OF 24
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
901149 REV A 12/23/10, INST 67-72 CHEV P-UP wo AC EVAP KIT PG 6 OF 24
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

7
901149 REV A 12/23/10, INST 67-72 CHEV P-UP wo AC EVAP KIT PG 7 OF 24
REMOVE GLOVE BOX DOOR (RETAIN) AND GLOVE BOX (DISCARD).
DISCONNECT ALL WIRE AND CABLES FROM CONTROL PANEL AND RADIO.
ALL HOSE AND DUCTING FROM DEFROST DUCTS (SEE FIGURE 2 BELOW.)
OEM HEATER ASSEMBLY.
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
AND BRACKET.
COMPRESSOR & BRACKETS
REMOVE THE FOLLOWING:
FIGURE 2
OEM HEATER ASSEMBLY
& RELATED DUCTING
OEM DEFROST
DUCT ASM
CONTROL
PANEL
RADIO
GLOVE BOX
DOOR

8
901149 REV A 12/23/10, INST 67-72 CHEV P-UP wo AC EVAP KIT PG 8 OF 24
DEFROST DUCT AND LOUVER INSTALLATION
INSTALL S-CLIPS ON DEFROST DUCT HOSE ADAPTERS AND ATTACH TO OEM DEFROSTER DUCTS AS
SHOWN IN FIGURE 3 BELOW.
INSTALL CENTER LOUVER IN DASH AS SHOWN IN FIGURE 3b BELOW. USE TEMPLATE PROVIDED ON
PAGE 23.
INSTALL DRIVER/ PASSENGER SIDE LOUVER IN DASH AS SHOWN IN FIGURE 3a BELOW. USE
TEMPLATE PROVIDED ON PAGE 22.
HOSE
ADAPTER
BALL
LOUVER
49053-VUL
DASH
PASSENGER SIDE
OVAL DEFROST
ADAPTER
49167-VCI
(2) “S”-CLIPS
(2) “S”-CLIPS
DRIVER SIDE
ROUND DEFROST
ADAPTER
49168-VCI
(2) 1/4-20 NUT
w/ STAR WASHER
(2)1/4” FLAT
WASHER
DASH
OEM DEFROST
DUCTS
FIGURE 3
FIGURE 3b
FIGURE 3a

9
901149 REV A 12/23/10, INST 67-72 CHEV P-UP wo AC EVAP KIT PG 9 OF 24
BRACKET & EVAPORATOR HARDLINE INSTALLATION
ON A WORK BENCH INSTALL EVAPORATOR REAR BRACKET USING
(4) 1/4-20 x 1/2” HEX BOLTS.
INSTALL HARDLINES WITH PROPERLY LUBRICATED
O-RINGS. (SEE FIGURE 9, PAGE 12, AND
FIGURE 6, PAGE 10.)
NOTE: WRAP THE #10 FITTING CONNECTIONS
WITH PRESS TAPE. SEE FIGURE 6, PAGE 10.
INSTALL EVAPORATOR FRONT BRACKET
ON EVAPORATOR USING (2)1/4-20 x 1/2”
HEX BOLTS AND TIGHTEN AS SHOWN IN
FIGURE 5 BELOW.
(2)1/4-20 x 1/2”
HEX BOLT
FRONT
EVAPORATOR
BRACKET
644080
FIGURE 5
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 BELOW.
APPLY A 1/4” BEAD OF SILICONE AROUND THE BACK SIDE OF THE FIREWALL COVER AS SHOWN BELOW.
INSTALL FIREWALL COVER TO FIREWALL USING (2) 1/4-20 x 1” HEX BOLTS, (2) FLAT WASHERS AND 1/4” NUT
w/ STARWASHERS IN THE OEM HOLES AS SHOWN BELOW.
USE FIREWALL COVER AS TEMPLATE TO DRILL (6) 3/16” HOLES IN FIREWALL AND THEN SECURE USING
#14 x 3/4” SHEET METAL SCREWS AS SHOWN BELOW.
USING FIREWALL COVER AS TEMPLATE DRILL (2) 9/32” HOLES IN FIREWALL AS SHOWN BELOW.
INSTALL GROMMETS AS SHOWN BELOW.
FRESH AIR CAP AND FIREWALL COVER INSTALLATION
SILICONE
BACK SIDE
OF FRESH AIR
CAP
BACK SIDE
OF FIREWALL
COVER
648218
1/4-20 x 1”
BOLT
SILICONE
1/4” FLAT
WASHER 1/4-20 x 1”
BOLT
1/4-20 x 1”
BOLT
DRILL
9/32” HOLE
DRILL
9/32” HOLE
1/4” FLAT
WASHER 1/4” NUT w/
STAR WASHER
1/4” NUT w/
STAR WASHER
OEM
HOLE
(6) #14 x 3/4”
SHEET METAL
SCREW
LARGE
GROMMET
33137-VUI
GROMMET
33135-VUI
3/8”
GROMMET
33144-VUI
1/4” FLAT
WASHER
FRESH AIR
CAP
OEM
HOLE

10
901149 REV A 12/23/10, INST 67-72 CHEV P-UP wo AC EVAP KIT PG 10 OF 24
REAR
EVAPORATOR
BRACKET ASM
644073
BRACKET & EVAPORATOR HARDLINE INSTALLATION CONT.
FIGURE 6
(2) 1/4-20 x 1/2”
HEX BOLT
(2) 1/4-20 x 1/2”
HEX BOLT
#6 LIQUID LINE
095002
TWIST WITH
THIS
WRENCH
LUBRICATE O-RING
(SEE FIGURE 9,
PAGE 12.)
HOLD WITH
THIS WRENCH
HEATER LINE
(EVAP TO WATER PUMP)
095004
ECU MODULE
#10 O-RING
33859-VUF
NOTE: AFTER INSTALLING
#10 SUCTION LINE
WRAP ALL EXPOSED METAL
(FITTINGS & TUBE)
WITH SUPPLIED
PRESS TAPE
#10 O-RING
(33859-VUF)
#10 SUCTION
LINE
095003
#6 LIQUID LINE
095002
PRESS TAPE
HEATER LINE
(EVAP TO INTAKE)
095005
#6
O-RING
33857-VUF

11
901149 REV A 12/23/10, INST 67-72 CHEV P-UP wo AC EVAP KIT PG 11 OF 24
INNER COWL
DRILL (2)
⁄” HOLES
(2)#14 x ¾”
SHEET METAL
SCREWS
1/4-20 x 1”
HEX BOLT
1/4-20 x 1”
HEX BOLT
FLAT
WASHER
1/4”
FLAT
WASHER
1/4” NUT w/
STAR WASHER
VIEW FROM
PASSENGER SIDE
INSIDE OF CAB
FIGURE 7
FIGURE 7a
EVAPORATOR INSTALLATION
LIFT EVAPORATOR UNIT UP UNDER THE DASHBOARD. SECURE LOOSELY TO THE FIREWALL USING
(2) 1/4-20 x 1” HEX BOLTS, (2) FLAT WASHERS AND 1/4” NUT w/ STAR WASHER. SEE FIGURE 7.
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 7a 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.)

12
901149 REV A 12/23/10, INST 67-72 CHEV P-UP wo AC EVAP KIT PG 12 OF 24
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 8
EVAPORATOR
CASE
1”
LOCATE THE #8 COMPRESSOR A/C HOSE. LUBRICATE (2) #8 O-RINGS (SEE FIGURE 9, ABOVE) AND CONNECT
THE 135° FEMALE FITTING w/134a SERVICE PORT TO THE #8 DISCHARGE PORT ON THE COMPRESSOR. ROUTE
THE STRAIGHT FEMALE FITTING TO THE #8 CONDENSER HARDLINE COMING THROUGH CORE SUPPORT. SEE
FIGURE 11, PAGE 14. TIGHTEN EACH FITTING CONNECTION AS SHOWN.
LOCATE THE #10 COMPRESSOR A/C HOSE. LUBRICATE (2) #10 O-RINGS (SEE FIGURE 9, ABOVE) AND
CONNECT 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 10, PAGE 13 AND
FIGURE 11, PAGE 14. TIGHTEN EACH FITTING CONNECTION AS SHOWN.
LOCATE THE #6 EVAPORATOR A/C HOSE. LUBRICATE (2) #6 O-RINGS (SEE FIGURE 9, ABOVE) AND CONNECT
THE STRAIGHT FEMALE FITTING TO THE #6 CONDENSER HARDLINE COMING THROUGH CORE SUPPORT.
ROUTE THE 90° FEMALE FITTING TO THE #6 EVAPORATOR. SEE FIGURE 10, PAGE 13 AND FIGURE 11, PAGE 14.
TIGHTEN EACH FITTING CONNECTION AS SHOWN.
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 9
REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH MODIFIED HOSE KIT.
MODIFIED A/C HOSE KIT
DRAIN
HOSE
1”

13
901149 REV A 12/23/10, INST 67-72 CHEV P-UP wo AC EVAP KIT PG 13 OF 24
ROUTE HEATER HOSE FROM WATER PUMP TO THE HEATER LINE COMING THROUGH THE FIREWALL AS
SHOWN IN FIGURE 10, 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.
#10 SUCTION
LINE
FIGURE 10
O-RINGS
HEATER
HOSE
NOTE: FLOW ARROW DECAL
ON HEATER CONTROL VALVE.
HEATER HOSE & HEATER CONTROL VALVE INSTALLATION
LIQUID
LINE
FROM HTR CNTRL VLV
TO EVAPORATOR
FROM INTAKE
MANIFOLD
FROM EVAPORATOR
TO WATER PUMP

14
901149 REV A 12/23/10, INST 67-72 CHEV P-UP wo AC EVAP KIT PG 14 OF 24
FIGURE 11
#6 HOSE
096002
TIE WRAP
#8 DISCHARGE
HOSE
096001
#6 COND/DRIER
HARDLINE
35056-LCG
HEATERHOSE
(HEA
TECNTRL
VALVE/INTAKE)
R
NOTE: VINTAGE AIR SYSTEMS REQUIRE
(2) 5/8” HOSE NIPPLES (NOT SUPPLIED)
HEATER
HOSE
FROM EVAPORATOR
TO WATER PUMP
FROMINT
AKE
MANIFOLD
FROM HTR CNTRL VLV
TO EVAPORATOR
COMPRESSOR
SAFETY SWITCH (BINARY TYPE)
SCREW ON DRIER (REFER TO
CONDENSER INSTRUCTIONS)
AC & HEATER HOSE ROUTING
#10 SUCTION
HOSE
096003
#8 CONDENSER/
COMP HARDLINE
095007
#6 DRIER/CORE
SUPPORT
HARDLINE
095006
NOTE: DIRECTION OF WATER FLOW.
INSTALL HEATER CONTROL VALVE AS SHOWN.

15
901149 REV A 12/23/10, INST 67-72 CHEV P-UP wo AC EVAP KIT PG 15 OF 24
INSTALL DUCT HOSES AS SHOWN IN FIGURE 13, PAGE 16.
ROUTE A/C WIRES THROUGH 3/8” GROMMET AS SHOWN ON FIGURE 12
(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 13, PAGE 16
(WIRE ACCORDING TO WIRING DIAGRAM ON PAGE 17 AND 18.)
INSTALL NEW GLOVE BOX USING OEM SCREWS, (SEE FIGURE 12a.)
INSTALL GLOVE BOX DOOR
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 19.
FINAL STEPS
FIGURE 12a
FIGURE 12
GLOVE BOX
496067
GROMMET
33144-VUI

16
901149 REV A 12/23/10, INST 67-72 CHEV P-UP wo AC EVAP KIT PG 16 OF 24
CONTROL PANEL & DUCT HOSE ROUTING
FIGURE 13
PLUG
FROM
CONTROL
WIRING
HARNESS
232006-VU
R
PLUG
FROM
WIRING
HARNESS
232001-VUR
PASSENGER SIDE
LOUVER
2 ½” x 36”
DRIVER SIDE
LOUVER
2 ½” x 48”
CENTER
LOUVER
2 ½” x 18”
PASS. SIDE
DEF. DUCT
2” x 12”
DRIVER SIDE
DEF DUCT
2” x 24”

17
901149 REV A 12/23/10, INST 67-72 CHEV P-UP wo AC EVAP KIT PG 17 OF 24
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
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 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

18
901149 REV A 12/23/10, INST 67-72 CHEV P-UP wo AC EVAP KIT PG 18 OF 24
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 :
CON NECT WHITE
WIRES DIRECTLY TO
( ) BATTERY TERMINAL
CONNECT
CONNECT
BA CK 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
HARNESS 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.

19
901149 REV A 12/23/10, INST 67-72 CHEV P-UP wo AC EVAP KIT PG 19 OF 24
BLOWER SPEED
ADJUST TO DESIRED
SPEED
TEMPERATURE LEVER
SLIDE THE TEMPERATURE
LEVER ALL THE WAY RIGHT
TO THE HOT POSITION.
(SLIDE LEVER LEFT OR RIGHT
TO DESIRED TEMPERATURE)
SLIDE THE LEVER TO
THE CENTER POSITION
MODE LEVER
BLOWER SPEED
ADJUST TO DESIRED
SPEED
SLIDE THE LEVER TO
THE LEFT POSITION
MODE LEVER
TEMPERATURE LEVER
ADJUST TO DESIRED
SPEED
BLOWER SPEED
SLIDE THE LEVER TO
THE RIGHT POSITION
MODE LEVER
HEAT MODE
AC MODE
MODE
LEVER
OPERATION OF CONTROLS
NOTE: CONTROLS MUST BE CALIBRATED FOR PROPER OPERATION.
THE TEMPERATURE LEVER TOGGLES BETWEEN A/C AND HEAT MODES. FOR A/C MODE SLIDE THE
TEMPERATURE LEVER ALL THE WAY LEFT TO ENGAGE THE COMPRESSOR, THEN MOVE THE LEVER
TO SELECT THE DESIRED TEMPERATURE. FOR HEAT MODE SLIDE THE LEVER RIGHT TO DISENGAGE
THE COMPRESSOR, THEN MOVE THE LEVER TO SELECT DESIRED TEMPERATURE.
NOTE: EACH TIME THE SYSTEM TOGGLES BETWEEN MODES, THE BLOWER WILL MOMENTARILY
CHANGE SPEEDS.
ALL SWITCHES ARE VARIABLE BETWEEN POSITIONS, SYSTEM WILL PERFORM A BLEND BETWEEN
THE FUNCTIONS.
ADJUST LEVER TO
DESIRED TEMPERATURE.
(COMPRESSOR IS
AUTOMATICALLY
ENGAGED)
TEMPERATURE LEVER
IN A/C MODE SLIDE THE
TEMPERATURE LEVER ALL
THE WAY TO THE LEFT
TO ENGAGE COMPRESSOR.
(SLIDE LEVER LEFT OR RIGHT
TO ADJUST DESIRED
TEMPERATURE)
BLOWER
SPEED
TEMPERATURE
LEVER
HEAT
DEF
AIR FAN
HEAT
DEF
AIR FAN
DEFROST/ DE-FOG MODE
HEAT
DEF
AIR FAN

20
901149 REV A 12/23/10, INST 67-72 CHEV P-UP wo AC EVAP KIT PG 20 OF 24
SYMPTOM CONDITION CH ECKS ACTIONS NOTES
TROUBLE SHOOTING INFORMATION
1. BLOWER STAYS ON HIGH SPEED WHEN IGNITION IS ON
BLOWER STAYS ON HIGH SPEED WHEN IGNITION IS ON OR OFF
2. COMPRESSOR WILL NOT TURN ON (ALL OTHER FUNCTIONS WORK)
SYSTEM IS NOT CHARGED SYSTEM MUST BE CHARGED FOR COMP. TO
ENGAGE CHARGE SYSTEM OR BYPASS PRESSURE SWITCH.
CHECK TWO PIN CONNECTOR AT ECU HOUSING
TO CHECK FOR PROPER POT FUNCTION, CHECK VOLTAGE AT WHITE/ BLUE WIRE. VOLTAGE SHOULD BE BETWEEN 0 AND 5V, AND WILL VAR WITH POT LEVER POSTION.
DISCONNECTED OR FAULTY THERMISTOR WILL CAUSE COMPRESSOR TO BE DISABLED.
3. COMPRESS WILL NOT TURN OFF (ALL OTHER FUNCTIONS WORK)
CHECK FOR FAULTY A/C POT OR ASSOC. WIRING REPAIR/REPLACE POT/ CONTROL WIRING
RED WIRE @ A/C POT SHOULD HAVE APPROX. 5V WITH IGNITION ON. WHITE WIRE WILL HAVE CONTINUITY TO CHASSIS GROUND, WHITE/ BLUE WIRE SHOULD VARY BETWEEN 0V AND 5V WHEN LEVER IS MOVED UP AND DOWN.
REPLACE RELAY
CHECK FOR FAULTY A/C RELAY
CHECK CONTINUITY TO GROUND ON WHITE CONTROL HEAD WIRE. CHECK FOR 5V ON RED CONTROL HEAD WIRE.
DANGER- NEVER BYPASS SAFETY SWITCH WITH ENGINE RUNNING, SERIOUS INJURY CAN RESULT.
CHECK FOR FAULTY A/C POT OR ASSOC. WIRING (NOT APPLICABLE TO 3 POT CONTROLS
CHECK FOR DISCONNECTED OR FAULTY THERMISTOR.
NO OTHER FUNCTIONS WORK
ALL OTHER FUNCTIONS WORK
CHECK FOR DAMAGED PINS OR WIRES IN CONTROL HEAD PLUG.
CHECK FOR DAMAGED GROUND WIRE (WHITE) IN CONTROL HEAD HARNESS.
CHECK FOR DAMAGED BLOWER SWITCH OR POT AND ASSOCIATED WIRING.
UNPLUG 3 WIRE BSC CONTROL CONNECTOR FROM ECU. IF BLOWER SHUTS OFF, ECU IS EITHER IMPROPERLY WIRED, OR DAMAGED.
UNPLUG 3 WIRE BSC CONTROL CONNECTOR FROM ECU. IF BLOWER STAYS RUNNING, THE BSC IS EITHER IMPROPERLY WIRED, OR DAMAGED.
VERIFY ALL PINS ARE INSERTED INTO PLUG. INSURE NO PINS ARE BENT OR DAMAGES IN ECU.
LOSS OF GROUND ON THIS WIRE RENDER CONTROL HEAD IN OPERABLE
SEE BLOWER SWITCH CHECK PROCEDURE
NO OTHER PART REPLACEMENTS SHOULD BE NECESSARY
VERIFY CONTINUITY TO CHASSIS GROUND WITH WHITE CONTROL HEAD WIRE AT VARIOUS POINTS
BE SURE SMALL, 20 GA WHITE GROUND WIRE IS CONNECTED TO THE BATTERY GROUND POST. IF IT IS, REPLACE ECU. REPLACE BSC. (THIS WILL REQUIRE EVAPORATOR TO BE REMOVED FROM VEHICLE.)
CHECK TO INSURE THAT NO BSC WIRING IS DAMAGED OR SHORTED TO VEHICLE GROUND. THE BSC OPERATES THE BLOWER BY GROUND. THE BSC OPERATES THE BLOWER BY GROUND SIDE PWM SWITCHING. THE POSITIVE WIRE TO THE BLOWER WILL ALWAYS BE HOT. IF THE “GROUND” SIDE OF THE BLOWER IS SHORTED TO CHASSIS GROUND, THE BLOWER WILL RUN ON HI.