Upload
others
View
5
Download
0
Embed Size (px)
Citation preview
1964-66 CHEVROLET PICKUP WITHOUT FACTORY AIR
WITH DELUXE CONTROLS751164
901139 REV B 7/29/14, INST 64-66 CHEV P-UP wo AC w/ DELX EVAP KIT PG 1 OF 24
an ISO 9001:2008 Registered Company
2901139 REV B 7/29/14, INST 64-66 CHEV P-UP wo AC w/ DELX 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, PASSENGER COMPARTMENT FIGURES 2, 2a & 2b 8. FIREWALL MODIFICATION, BRACKET & EVAPORATOR HARDLINE INSTALLATION FIGURES 3 & 4 9. BRACKET & EVAPORATOR HARDLINE INSTALLATION CONT. FIGURE 510. EVAPORATOR INSTALLATION FIGURES 6 & 6a11. DRAIN HOSE INSTALLATION, LUBRICATING O-RINGS, A/C HOSE INSTALLATION & MODIFIED A/C HOSE KIT FIGURES 7 & 812. FIREWALL & OEM HEATER COVER INSTALLATION FIGURE 913. HEATER HOSE & HEATER CONTROL VALVE INSTALLATION FIGURE 1014. A/C & HEATER HOSE ROUTING FIGURE 1115. DRIVER SIDE UNDER DASH LOUVER & CENTER/PASSENGER SIDE UNDER DASH LOUVER INSTALLATION FIGURES 12, 12a, 13, & 13a16. FINAL STEPS FIGURES 14 & 14a17. CONTROL PANEL & DUCT HOSE ROUTING FIGURE 1518. WIRING DIAGRAM19. GEN IV WIRING CONNECTION INSTRUCTIONS20. OPERATION OF CONTROLS21. TROUBLESHOOTING INFORMATION22. TROUBLESHOOTING INFORMATION CONT.23. 64-66 CHEVROLET PICKUP FIREWALL TEMPLATE24. EVAPORATOR KIT PACKING LIST
3901139 REV B 7/29/14, INST 64-66 CHEV P-UP wo AC w/ DELX 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 KIT751164
1.2.
11
744004-VUE791164
1
ACCESSORY KIT791164
2
GEN IV 4 VENT EVAP ORATOR SUB CASE ACCESSORY KIT 64-66 CHEV P-UP wo AC w/ DELUXE
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.
GEN IV 4 VENT EVAP. SUB CASE
744004-VUE
4901139 REV B 7/29/14, INST 64-66 CHEV P-UP wo AC w/ DELX EVAP KIT PG 4 OF 24
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. VintageAir 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 SystemCharge 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 circulate lubricant.
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:
5901139 REV B 7/29/14, INST 64-66 CHEV P-UP wo AC w/ DELX EVAP KIT PG 5 OF 24
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 may damage wiring, 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.
•
•
•
6901139 REV B 7/29/14, INST 64-66 CHEV P-UP wo AC w/ DELX EVAP KIT PG 6 OF 24
DISCONNECT BATTERY.DRAIN RADIATOR, REMOVE RADIATOR (RETAIN). HEATER BLOWER ASSEMBLY AND OEM HEATER HOSES (DISCARD).
ENGINE COMPARTMENTREMOVE THE FOLLOWING
FIGURE 1
BEFORE STARTING THE INSTALLATION, CHECK THE FUNCTIONOF THE VEHICLE (HORN, LIGHTS,ETC.) FOR PROPER OPERATIONS.
STUDY THE INSTRUCTIONS, ILLUSTRATIONS, & DIAGRAMS.
OEM HEATER BLOWER ASSEMBLY
OEM HEATER HOSES
7901139 REV B 7/29/14, INST 64-66 CHEV P-UP wo AC w/ DELX EVAP KIT PG 7 OF 24
REMOVE GLOVE BOX DOOR (RETAIN) AND GLOVE BOX (DISCARD).DISCONNECT ALL WIRES AND CABLES FROM CONTROL PANEL .REMOVE CONTROL PANEL (RETAIN). REMOVE OEM DUCT HOSE FROM DEFROST DUCTS (SEE FIGURE 2, BELOW).OEM HEATER ASSEMBLY.REMOVE PASSENGER SIDE FRESH AIR DOOR ASM (DISCARD) (RETAIN SCREWS) (SEE FIGURE 2a).INSTALL PASSENGER SIDE FRESH AIR COVER USING OEM SCREWS AS SHOWN IN FIGURE 2b, BELOW.INSTALL HOSE ADAPTERS ON OEM DEFROST DUCTS USING (2) S-CLIPS AS SHOWN IN FIGURE 2, BELOW.
PASSENGER COMPARTMENT
CONDENSER ASSEMBLY & INSTALLATIONREFER 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 ASSEMBLYCONTROL
PANEL
BACK SIDE OF PASSENGER SIDEFRESH AIR COVER
OEM DUCTHOSE
HOSEADAPTER
49168-VCI
(2) S-CLIPS65980-VUE
GLOVE BOX&
DOOR
FIGURE 2aFIGURE 2b
PASSENGER SIDE FRESH AIRDOOR ASM PASSENGER SIDE
FRESH AIR COVER644095
(6) OEMSCREWS
SILICONE
HOSEADAPTER
49168-VCI
(2) S-CLIPS65980-VUE
8901139 REV B 7/29/14, INST 64-66 CHEV P-UP wo AC w/ DELX EVAP KIT PG 8 OF 24
BRACKET & EVAPORATOR HARDLINE INSTALLATIONON A WORKBENCH, INSTALL EVAPORATOR REAR BRACKET USING (4) 1/4-20 x 1/2” HEX BOLTS.INSTALL HARDLINES WITH PROPERLY LUBRICATED O-RINGS (SEE FIGURE 5, PAGE 9, AND FIGURE 8, PAGE 11). NOTE: WRAP THE #10 FITTING CONNECTIONS WITH PRESS TAPE. SEE FIGURE 5, PAGE 9.INSTALL EVAPORATOR FRONT BRACKET ON EVAPORATOR USING (2)1/4-20 x 1/2” HEX BOLTS AND TIGHTEN AS SHOWN IN FIGURE 4, BELOW.
FIREWALL MODIFICATIONUSING TEMPLATE PROVIDED ON PAGE 23, ALIGN TEMPLATE ON ENGINE SIDE OF FIREWALL WITH OEM HOLES AND MARK AND DRILL 9/32” HOLE IN FIREWALL (SEE FIGURE 3, BELOW).
(2)1/4-20 x 1/2”HEX BOLT
DRILL 9/32”
FRONTEVAPORATOR
BRACKET644094
FIGURE 4
FIGURE 3
60 -66 CHEV. P/UP
FIREWALL DRILL TEMPLATE
FOR REAR EVAP BRKT
OEM HOLE
OEM HOLE
DRILL 9/32”
HOLE
9901139 REV B 7/29/14, INST 64-66 CHEV P-UP wo AC w/ DELX EVAP KIT PG 9 OF 24
REAREVAPORATORBRACKET ASM
644073
BRACKET & EVAPORATOR HARDLINE INSTALLATION CONT.
FIGURE 5
(2) 1/4-20 x 1/2”HEX BOLT
#6 LIQUID LINE095008
TWIST WITHTHIS
WRENCHLUBRICATE O-RING
(SEE FIGURE 8,PAGE 11)
HOLD WITH THIS WRENCH
HEATER LINE(EVAP TO WATER PUMP)
095010
ECU MODULE
#10 O-RING33859-VUF
NOTE: AFTER INSTALLING#10 SUCTION LINE
WRAP ALL EXPOSED METAL(FITTINGS & TUBE)WITH SUPPLIED
PRESS TAPE
#6 LIQUID LINE095008
PRESS TAPE
HEATER LINE(EVAP TO INTAKE)
095011
#6 O-RING
33857-VUF
(2) 1/4-20 x 1/2”HEX BOLT
#10 O-RING(33859-VUF)
#10 SUCTIONLINE
095009
10901139 REV B 7/29/14, INST 64-66 CHEV P-UP wo AC w/ DELX EVAP KIT PG 10 OF 24
INNER COWL
MOUNT EVAPORATORTO FIREWALL
USING THESE HOLES
DRILL (2)3/16” HOLES
(2)#14 x ¾”SHEET METAL
SCREWS
(2) 1/4-20 x 1 ¼”HEX BOLT182899
(2) 1/4”FLAT WASHER18125-VUB
VIEW FROMPASSENGER SIDEINSIDE OF CAB
FIGURE 6
FIGURE 6a
.750 OD x .312 ID x .625 LNYLN SPACER
180391
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. SEE FIGURE 6.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 6a, 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.
11901139 REV B 7/29/14, INST 64-66 CHEV P-UP wo AC w/ DELX EVAP KIT PG 11 OF 24
LOCATE EVAPORATOR DRAIN ON BOTTOM OF EVAPORATOR CASE.IN LINE WITH DRAIN, LIGHTLY MAKE A MARKON THE FIREWALL. MEASURE 1” DOWN ANDDRILL A 5/8” HOLE THROUGH THE FIREWALL. INSTALL DRAIN HOSE TO BOTTOM OFEVAPORATOR UNIT AND ROUTE THROUGHFIREWALL. INSTALL 1/2” 90° DRAIN ELBOW ON DRAIN HOSE.
DRAIN HOSE INSTALLATION
FIGURE 7
EVAPORATORCASE1”
LOCATE THE #8 COMPRESSOR A/C HOSE. LUBRICATE (2) #8 O-RINGS (SEE FIGURE 8, ABOVE) AND CONNECTTHE 135° 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 11, PAGE 14. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN FIGURE 8, ABOVE. LOCATE THE #10 COMPRESSOR A/C HOSE. LUBRICATE (2) #10 O-RINGS (SEE FIGURE 8, ABOVE) AND CONNECT THE #10 135° FEMALE FITTING w/134a SERVICE PORT TO THE #10 SUCTION PORT ON THE COMPRESSOR. ROUTE THE 45° FEMALE FITTING TO THE #10 EVAPORATOR. SEE FIGURE 10, PAGE 13 AND FIGURE 11, PAGE 14. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN FIGURE 8, ABOVE. LOCATE THE #6 EVAPORATOR/ DRIER HARDLINE. LUBRICATE (2) #6 O-RINGS (SEE FIGURE 8, ABOVE) AND CONNECT THE HARDLINE TO THE #6 DRIER HARDLINE COMING THROUGH CORE SUPPORT. ATTACH THE OTHER END OF THE HARDLINE TO THE #6 EVAPORATOR. HARDLINE COMING THROUGH THE FIREWALL.SEE FIGURE 10, PAGE 13, AND FIGURE 11, PAGE 14. TIGHTEN EACH FITTING CONNECTION AS SHOWN INFIGURE 8, ABOVE.
A/C HOSE INSTALLATIONSTANDARD HOSE KIT
LUBRICATING O-RINGS
#6 O-RING
#8 O-RING #10 O-RING
HOLD WITHTHIS W RENCH
FOR A PROPER SEAL OF FITTINGS:INSTALL SUPPLIED O-RINGS AS SHOWNAND LUBRICATE WITH SUPPLIED OIL.
O-RING
SUPPLIED OIL FOR O-RINGS O-RING, INSTALLS
OVER MALE INSERTTO SWAGED LIP
MALEINSERT
FEMALENUT
O-RING
TWIST WITHTHIS WRENCH
FIGURE 8
REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH MODIFIED HOSE KIT. MODIFIED A/C HOSE KIT
DRAINHOSE
1”
(OIL SUPPLIED WITH HOSE KIT)
12901139 REV B 7/29/14, INST 64-66 CHEV P-UP wo AC w/ DELX EVAP KIT PG 12 OF 24
APPLY A 1/4” BEAD OF SILICONE ON THE BACK SIDE OF OEM HEATER COVER AS SHOWN BELOW.INSTALL OEM HEATER COVER USING (5) OEM SCREWS AS SHOWN IN FIGURE 9, BELOW.INSTALL GROMMETS IN FIREWALL COVER AS SHOWN BELOW.APPLY A 1/4” BEAD OF SILICONE ON THE BACK SIDE OF FIREWALL COVER AS SHOWN BELOW.INSTALL FIREWALL COVER USING (3) #10 x 1/2” SHEET METAL SCREWS AS SHOWN IN FIGURE 9, BELOW.
FIREWALL COVER644093
OEM HEATER COVER644092
FIREWALL & OEM HEATER COVER INSTALLATION
FIGURE 9
(3) #10 x 1/2”SHEET METAL
SCREWS18247-VUB
(5) OEM SCREWS
SILICONESILICONE
LARGE GROMMET33137-VUI
GROMMET33135-VUIBACK SIDE
OF FIREWALLCOVER
BACK SIDEOF OEM HEATER
COVER
13901139 REV B 7/29/14, INST 64-66 CHEV P-UP wo AC w/ DELX 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 SILICONESPRAY 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.
HEATER HOSE & HEATER CONTROL VALVE INSTALLATION
#10 SUCTIONLINE
HEATERHOSE
NOTE: FLOW DIRECTION FOLLOWSMOLDED ARROW ON VALVE.
LIQUIDLINE FIGURE 10HEATER
HOSE
FROM HTR CNTRL VLVTO EVAPORATOR
FROM EVAPORATOR TO WATER PUMP
FROM INTAKEMANIFOLD
14901139 REV B 7/29/14, INST 64-66 CHEV P-UP wo AC w/ DELX EVAP KIT PG 14 OF 24
FIG
UR
E 11
TIE
WRA
P
#8 D
ISC
HA
RGE
HO
SE095100
NO
TE:
VIN
TAG
E A
IR S
YSTE
MS
REQ
UIR
E(2
) 5/8
” H
OSE
NIP
PLE
S (N
OT
SUP
PLI
ED).
A/C
& H
EATE
R H
OSE
RO
UTI
NG
#6
DRI
ER/C
ORE
H
ARD
LIN
E0
95
01
3#
6 C
ON
D/D
RIER
HA
RDLI
NE
095015
#6 L
IQU
IDH
ARD
LIN
E095012
CO
MPR
ESSO
RSA
FETY
SW
ITC
H (
BIN
ARY
TYP
E)SC
REW
ON
DRI
ER (
REFE
R TO
CO
ND
ENSE
R IN
STRU
CTI
ON
S)
#10 S
UC
TIO
NH
OSE
095101
HEA
TER
HO
SE(H
EATE
R C
NTR
LV
ALV
E/ IN
TAK
E
#8
CO
ND
/CO
MP
HA
RDLI
NE
09
50
14
HEA
TER
HO
SE
FRO
M H
TR C
NTR
L V
LVTO
EVA
PORA
TOR
FRO
M E
VA
PORA
TOR
TO W
ATE
R PU
MP
NO
TE:
FLO
W D
IREC
TIO
N F
OLL
OW
SM
OLD
ED A
RR
OW
ON
VA
LVE.
FRO
M IN
TAKE
MA
NIF
OLD
15901139 REV B 7/29/14, INST 64-66 CHEV P-UP wo AC w/ DELX EVAP KIT PG 15 OF 24
(2) #10 X 1/2”HEX SHEET
METAL SCREWS18247-VUB
(3)#10 x 1/2” HEX SHEET
METAL SCREWS
LOCATE DRIVER SIDE LOUVER HOUSING UNDER DASH AND DRILL (2) 1/8” HOLES. SECURE LOUVER HOUSING TO DASH USING (2) #10 x 1/2” HEX SHEET METAL SCREWS AS SHOWN IN FIGURE 12, BELOW.INSTALL LOUVER IN UNDER DASH HOUSING AS SHOWN IN FIGURE 12a.
DRIVER SIDE UNDER DASH LOUVER INSTALLATION
LOCATE CENTER/PASSENGER SIDE LOUVER ASM UNDER DASH AND DRILL (3) 1/8” HOLES.SECURE LOUVER ASM UNDER DASH USING (3) #10 x 1/2“ HEX SHEET METAL SCREWS AS SHOWN IN FIGURE 13, BELOW.INSTALL LOUVERS IN CENTER/PASSENGER SIDE UNDER DASH LOUVER ASM AS SHOWN IN FIGURE 13a.INSTALL (3) 1/2” PLASTIC PLUG AS SHOWN BELOW.
CENTER/PASSENGER SIDE UNDER DASH LOUVER INSTALLATION
DR SIDEUNDER DASH
LOUVER HOUSING494052
CENTER/PASSENGER SIDE UNDER DASH
LOUVER ASM496069
FIGURE 12
FIGURE 13
FIGURE 13a
(3) LOUVERS490570
LOUVER49057-VUL
FIGURE 12a
(3) 1/2” PLASTIC PLUGS
31102-GUR
16901139 REV B 7/29/14, INST 64-66 CHEV P-UP wo AC w/ DELX EVAP KIT PG 16 OF 24
INSTALL DUCT HOSES AS SHOWN IN FIGURE 15, PAGE 17.ROUTE A/C WIRES THROUGH 3/8” GROMMET AS SHOWN IN FIGURE 14(12 VOLT/GROUND/BINARY SWITCH/HEATER VALVE).INSTALL CONTROL PANEL ASM.PLUG THE WIRING HARNESS INTO THE ECU MODULE ON SUB CASE AS SHOWN IN FIGURE 15, PAGE 17(WIRE ACCORDING TO WIRING DIAGRAM ON PAGE 18 AND 19).INSTALL NEW GLOVE BOX USING OEM SCREWS (SEE FIGURE 14a).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 THEOWNER'S RESPONSIBILITY TO KEEP THE FREEZE PROTECTION AT THE PROPER LEVEL FOR THE CLIMATE INWHICH THE VEHICLE IS OPERATED. FAILURE TO FOLLOW ANTIFREEZE RECOMMENDATIONS WILL CAUSEHEATER 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 A/C SYSTEMS BE SERVICED BY A CERTIFIED AUTOMOTIVE AIRCONDITIONING TECHNICIAN. EVACUATE THE SYSTEM FOR A MINIMUM OF 45 MINUTES PRIOR TO CHARGING AND LEAK CHECK PRIORTO SERVICING. CHARGE THE SYSTEM TO THE CAPACITIES STATED ON THE INFORMATION PAGE (PAGE 4) OF THISINSTRUCTION MANUAL. SEE OPERATION OF CONTROLS PROCEDURES PAGE 20.
FINAL STEPS
FIGURE 14a
GLOVE BOX496066
FIGURE 14
GROMMET33144-VUI
PLUG317098
WIRING HARNESS(12 VOLT/GROUNDS/BINARY SWITCH)
WIRING HARNESS(HEATER CONTROL VALVE)
17901139 REV B 7/29/14, INST 64-66 CHEV P-UP wo AC w/ DELX EVAP KIT PG 17 OF 24
CONTROL PANEL & DUCT HOSE ROUTING
FIGURE 15
PLUGFROM
CONTROLWIRING
HARNESS232002-VUA
PLUGFROM
WIRINGHARNESS
232001-VUR
PASS. SIDEDEF. DUCT2” x 13”
DRIVER SIDEDEF DUCT2” x 26”
PASSENGER SIDELOUVER
2 ½” x 13”
DR SIDE CENTER LOUVER
2 ½” x 18”
DRIVER SIDELOUVER
2 ½” x 42”PASS SIDE
CENTER LOUVER2 ½” x 16”
18901139 REV B 7/29/14, INST 64-66 CHEV P-UP wo AC w/ DELX EVAP KIT PG 18 OF 24
WHT/GRN
WHT/YELWHT/RED
RED
WHTBACKLIGHT NEG
FAN WIPER
MODE WIPER
TEMP WIPER
5V-SW
GND
BACKLIGHT POS
AC ANNUNCIATOR
PRE-WIRED
GEN IV WIRING DIAGRAMREV D, 5/6/2014
GEN IV ECU
PROGRAM
Wiring Diagram
TEMP
MODE
FAN
A/C(IF USED)
232007-VUR
232002-VUA
** CIRCUITBREAKER30 AMP
*** WIDE OPENTHROTTLESWITCH
(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 BetweenBattery and Circuit Breaker Is Unprotected and Should Be Carefully Routed to Avoid a ShortCircuit).Wide Open Throttle Switch Contacts Close Only at Full Throttle, Which Disables A/C Compressor.
JF8
BLK
ORA
TAN
VIEWED FROM WIRE SIDE
••
•
HEATERCONTROL VALVE
19901139 REV B 7/29/14, INST 64-66 CHEV P-UP wo AC w/ DELX EVAP KIT PG 19 OF 24
RED
CIRCUIT BREAKER30 AMP
+
+
-
BLACK
REDWHITE
RED
CHASSIS GROUND
A/CCOMPRESSOR
RELAY
Ignition Switch:
Dash Light:
NOTE: MOUNT RELAYIN DESIRED LOCATION
UNDER DASH
GREEN
FIREWALL
BLUE
BLUE
RED &
WHITE
VIOLET
(IGNITION HOTTERMINAL)
IGNITION SWITCH
DASH BACK LIGHT+0-12vTAN
GRAY
BLUE
WHITE
WHITE
REDRED
WHITE
COMPRESSOR
BATTERY
NOTE: CONNECT WHITEWIRES DIRECTLY TO
(-) BATTERY TERMINAL
BATRUN
12V
RED GREEN
RED
RED
BLUE
LATCH
BLACK
BINARYSAFETYSWITCH
YELLOW
ORANGE
WIRING HARNESS
Violet 12V Ign Switch Source (Key On Accessory) Position Must Be Switched.
Tan Wire Used Only With Vintage Air Supplied Control Panel With LED Back Light.
Binary: Connect As Shown (Typical Compressor Wiring). Be Sure Compressor Body Is Grounded.
Trinary Switch: Connect According To Trinary Switch Wiring Diagram.
Install With Servo Motor Facing Down, As Shown. Note Flow Direction Arrow Molded Into Valve Body, And Install Accordingly.
White Must Run To (-) Battery. Red May Run To (+) Battery Or Starter. Mount Circuit Breaker As Close to Battery As Possible.
Heater Control Valve:
Binary/Trinary & Compressor:
Circuit Breaker/Battery:
CONTROL WIRING HARNESS
NOTE: YELLOW & ORANGE
COMING FROM HARNESS ARE NOT
USED.
WIRING HARNESS
GRAY WIRE IS USED FOR PROGRAMING CONTROLS
IF APPLICABLE
WIRING HARNESS
Gen IV Wiring Connection Instruction
HEATERCONTROL VALVE
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).
NOTE: HEATER CONTROL VALVE CONNECTION AND CHASSIS GROUND MAY BE LOCATED ON EITHER SIDE OF THE FIREWALL. ENSURECONNECTOR IS LATCHED
FIRMLY.
20901139 REV B 7/29/14, INST 64-66 CHEV P-UP wo AC w/ DELX EVAP KIT PG 20 OF 24
BLOWER SPEEDADJUST TO DESIRED
SPEEDTEMPERATURE LEVER
SLIDE THE TEMPERATURE LEVER ALL THE WAY UPTO THE HOT POSITION.
(SLIDE LEVER UP OR DOWN TO DESIRED TEMPERATURE)
SLIDE THE LEVER TOTHE CENTER POSITION
FOR FLOOR MODE
MODE LEVER
BLOWER SPEEDADJUST TO DESIRED
SPEED
SLIDE THE LEVER ALLTHE WAY DOWNFOR DASH MODE
MODE LEVER
TEMPERATURE LEVER
ADJUST TO DESIREDSPEED
BLOWER SPEED
SLIDE THE LEVER ALLTHE WAY UP
FOR DEF MODE
MODE LEVER
HEAT MODE
MODELEVER
OPERATION OF CONTROLSNOTE: 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 DOWN TO ENGAGE THE COMPRESSOR, THEN MOVE THE LEVER TO SELECT THE DESIRED TEMPERATURE. FOR HEAT MODE SLIDE THE LEVER UP 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 TODESIRED TEMPERATURE.
(COMPRESSOR IS AUTOMATICALLY
ENGAGED)
TEMPERATURE LEVERIN A/C MODE SLIDE THE TEMPERATURE LEVER ALL
THE WAY DOWN TO ENGAGE COMPRESSOR.
(SLIDE LEVER UP OR DOWNTO ADJUST DESIRED
TEMPERATURE)
DEFROST/ DE-FOG MODE
AC MODE
DEF HEATFANAIR
TEMPERATURELEVER
BLOWERSPEED
DEF HEATFANAIR
DEF HEATFANAIR
21901139 REV B 7/29/14, INST 64-66 CHEV P-UP wo AC w/ DELX EVAP KIT PG 21 OF 24
Sym
pto
m
C
on
dit
ion
Ch
eck
s
Act
ion
s
N
ote
s
Blo
wer
sta
ys o
n
hig
h s
pee
d w
hen
ig
nitio
n is
on.
1a.
No o
ther
funct
ions
work
.
Chec
k fo
r dam
aged
pin
s or
wires
in c
ontr
ol hea
d p
lug.
Ver
ify
that
all
pin
s ar
e in
sert
ed into
plu
g.
Ensu
re t
hat
no
pin
s ar
e ben
t or
dam
aged
in E
CU
.
Chec
k fo
r dam
aged
gro
und
wire
(white)
in c
ontr
ol hea
d
har
nes
s.
Ver
ify
continuity
to c
has
sis
gro
und w
ith w
hite
contr
ol
hea
d w
ire
at v
ario
us
poin
ts.
Loss
of gro
und o
n t
his
wire
render
s co
ntr
ol hea
d
inoper
able
.
All
oth
er f
unct
ions
work
.Chec
k fo
r dam
aged
blo
wer
sw
itch
or
pote
ntiom
eter
and
asso
ciat
ed w
irin
g.
Blo
wer
sta
ys o
n
hig
h s
pee
d w
hen
ig
nitio
n is
on o
r off.
Unplu
g 3
-wire
BSC c
ontr
ol
connec
tor
from
ECU
. If
blo
wer
sh
uts
off,
ECU
is
eith
er
impro
per
ly w
ired
or
dam
aged
.
Be
sure
the
smal
l, 2
0 G
A w
hite
gro
und w
ire
is c
onnec
ted
to t
he
bat
tery
gro
und p
ost
. If
it
is,
repla
ce t
he
ECU
.
Unplu
g 3
-wire
BSC c
ontr
ol
connec
tor
from
ECU
. If
blo
wer
st
ays
runnin
g,
BSC is
eith
er
impro
per
ly w
ired
or
dam
aged
.
Chec
k to
ensu
re t
hat
no B
SC w
irin
g is
dam
aged
or
short
ed t
o v
ehic
le g
round.
The
BSC o
per
ates
the
blo
wer
by
gro
und s
ide
puls
e w
idth
modula
tion s
witch
ing.
The
posi
tive
wire
to t
he
blo
wer
will
alw
ays
be
hot.
If th
e “g
round”
side
of
the
blo
wer
is
short
ed t
o c
has
sis
gro
und,
the
blo
wer
will
run o
n H
I.
Rep
lace
BSC (
This
will
req
uire
rem
oval
of
evap
ora
tor
from
veh
icle
).N
o o
ther
par
t re
pla
cem
ents
sh
ould
be
nec
essa
ry.
Com
pre
ssor
will
not
turn
on
(All
oth
er funct
ions
work
).
2.
Sys
tem
is
not
char
ged
.Sys
tem
must
be
char
ged
for
com
pre
ssor
to e
ngag
e.Char
ge
syst
em o
r byp
ass
pre
ssure
sw
itch
.
Dan
ger:
Never
byp
ass
sa
fety
sw
itch
wit
h
en
gin
e r
un
nin
g.
Seri
ou
s in
jury
can
resu
lt.
Sys
tem
is
char
ged
.
1b
.
Tro
ub
lesh
oo
tin
g G
uid
e
Chec
k fo
r fa
ulty
A/C
pote
ntiom
eter
or
asso
ciat
ed
wirin
g (
Not
applic
able
to 3
-pot
contr
ols
).
Chec
k fo
r dis
connec
ted o
r fa
ulty
ther
mis
tor.
Chec
k co
ntinuity
to g
round o
n w
hite
contr
ol hea
d w
ire.
Chec
k fo
r 5V o
n r
ed c
ontr
ol hea
d w
ire.
Chec
k 2-p
in c
onnec
tor
at E
CU
housi
ng.
To c
hec
k fo
r pro
per
pot
funct
ion,
chec
k vo
ltag
e at
w
hite/
blu
e w
ire.
Voltag
e sh
ould
be
bet
wee
n 0
V a
nd
5V,
and w
ill v
ary
with p
ot
leve
r posi
tion.
Dis
connec
ted o
r fa
ulty
ther
mis
tor
will
cau
se
com
pre
ssor
to b
e dis
able
d.
Red
wire
at A
/C p
ot
should
hav
e ap
pro
xim
atel
y 5V
with ignitio
n o
n.
White
wire
will
hav
e co
ntinuity
to
chas
sis
gro
und.
White/
Blu
e w
ire
should
var
y bet
wee
n 0
V a
nd 5
V w
hen
le
ver
is m
oved
up o
r dow
n.
3. Com
pre
ssor
will
not
turn
off
(A
ll oth
er funct
ions
work
).
Chec
k fo
r fa
ulty
A/C
pote
ntiom
eter
or
asso
ciat
ed
wirin
g.
Chec
k fo
r fa
ulty
A/C
rel
ay.
Rep
air
or
repla
ce p
ot/
contr
ol w
irin
g.
Rep
lace
rel
ay.
See
blo
wer
sw
itch
chec
k pro
cedure
.
22901139 REV B 7/29/14, INST 64-66 CHEV P-UP wo AC w/ DELX EVAP KIT PG 22 OF 24
Sym
pto
m
C
on
dit
ion
Ch
eck
s
Act
ion
s
N
ote
s
Sys
tem
will
not
turn
on,
or
runs
inte
rmitte
ntly.
4.
Work
s w
hen
engin
e is
not
runnin
g;
shuts
off w
hen
en
gin
e is
sta
rted
(T
ypic
ally
ear
ly G
en I
V,
but
poss
ible
on a
ll ve
rsio
ns)
.
Nois
e in
terf
eren
ce f
rom
either
ig
nitio
n o
r al
tern
ator.
Inst
all ca
pac
itors
on ignitio
n c
oil
and a
lter
nat
or. E
nsu
re
good g
round a
t al
l poin
ts.
Rel
oca
te c
oil
and a
ssoci
ated
w
irin
g a
way
fro
m E
CU
and E
CU
wirin
g.
Chec
k fo
r burn
edor
loose
plu
g w
ires
.
Ver
ify
connec
tions
on p
ow
er
lead
, ig
nitio
n lea
d,
and b
oth
white
gro
und w
ires
.
Ver
ify
pro
per
met
er f
unct
ion b
y ch
ecki
ng t
he
conditio
n o
f a
know
n g
ood b
atte
ry.
Ignitio
n n
ois
e (r
adia
ted o
rco
nduct
ed)
will
cau
se t
he
syst
em t
o s
hut
dow
n d
ue
tohig
h v
oltag
e sp
ikes
. If
this
is s
usp
ecte
d,
chec
k w
ith a
qual
ity
osc
illosc
ope.
Spik
esgre
ater
than
16V w
ill s
hut
dow
n t
he
ECU
. In
stal
l a
radio
cap
acitor
at t
he
posi
tive
post
of th
e ig
nitio
nco
il (S
ee r
adio
cap
acitor
inst
alla
tion b
ulle
tin).
A
faulty
alte
rnat
or
or
worn
out
bat
tery
can
als
o r
esult
in t
his
conditio
n.
Will
not
turn
on u
nder
an
y co
nditio
ns.
Ver
ify
bat
tery
voltag
e is
gre
ater
than
10 v
olts
and les
sth
an 1
6.
Loss
of m
ode
door
funct
ion.
No m
ode
chan
ge
at a
ll.Chec
k fo
r dam
aged
mode
switch
or
pote
ntiom
eter
and
asso
ciat
ed w
irin
g.
Part
ial fu
nct
ion o
f m
ode
doors
.
Typic
ally
cau
sed b
y ev
apora
tor
housi
ng
inst
alle
d in a
bin
d in t
he
vehic
le.
Be
sure
all
mounting loca
tions
line
up
and d
on’t h
ave
to b
e fo
rced
in
to p
osi
tion.
Blo
wer
turn
s on
and o
ff r
apid
ly.
6.
Bat
tery
voltag
e is
at
leas
t 12V.
Chec
k fo
r at
lea
st 1
2V a
t ci
rcuit b
reak
er.
Ensu
re a
ll sy
stem
gro
unds
and p
ow
er c
onnec
tions
are
clea
n a
nd t
ight.
Bat
tery
voltag
e is
les
s th
an 1
2V.
5.
Tro
ub
lesh
oo
tin
g G
uid
e (
Co
nt.
)
Chec
k fo
r fa
ulty
bat
tery
or
alte
rnat
or.
Char
ge
bat
tery
.
Sys
tem
shuts
off b
low
er a
t 10V.
Poor
connec
tions
or
wea
k bat
tery
can
cau
se
shutd
ow
n a
t up t
o 1
1V.
7. When
ignitio
n is
turn
ed o
n,
blo
wer
m
om
enta
rily
co
mes
on,
then
sh
uts
off.
This
occ
urs
with t
he
blo
wer
sw
itch
in
the
OFF
posi
tion.
This
is
an indic
ator
that
the
syst
em h
as b
een r
eset
. Be
sure
the
red p
ow
er w
ire
is o
nth
e bat
tery
post
, an
d n
ot
on a
sw
itch
ed s
ourc
e. A
lso,
if
the
syst
em is
pulle
d b
elow
7V f
or
even
a s
plit
sec
ond,
the
syst
em w
ill r
eset
.
Run r
ed p
ow
er w
ire
direc
tly
to b
atte
ry.
Chec
k fo
r posi
tive
pow
er a
t hea
ter
valv
e gre
en w
ire
and
blo
wer
red
wire.
Chec
k fo
r gro
und o
n c
ontr
ol hea
d w
hite
wire.
Chec
k fo
r obst
ruct
ed o
r bin
din
g m
ode
doors
.
Chec
k fo
r dam
aged
ste
pper
m
oto
r or
wirin
g.
Err
atic
funct
ions
of
blo
wer
, m
ode,
te
mp,
etc.
Chec
k fo
r dam
aged
sw
itch
or
pot
and a
ssoci
ated
wirin
g.
Rep
air
or
repla
ce.
8.
23901139 REV A 10/6/11, INST 64-66 CHEV P-UP wo AC w/ DELX EVAP KIT PG 23 OF 24
UPPER OEMHOLE
OEM HOLE
DRILL Ø 9/32
CUT ALONGDOTTED LINE
CUT ALONGDOTTED LINE
64-66 CHEV P-UP FIREWALL TEMPLATEFOR REAR EVAP BRKT
901139 REV B 7/29/14, INST 64-66 CHEV P-UP wo AC w/ DELX EVAP KIT PG 24 OF 24
CHECK BY:PACKED BY:
DATE:
EVAPORATOR KIT751164
1.2.
11
744004-VUE791164
GEN IV 4 VENT EVAPORATOR SUB CASEACCESSORY KIT 64-66 CHEV P-UP wo AC w/ DELUXE
NO. QTY. PART NO. DESCRIPTION
EVAPORATOR KIT PACKING LIST
1
ACCESSORY KIT791164
NOTE: IMAGES MAY NOT DEPICT ACTUAL PARTS AND QUANTITIES.REFER TO PACKING LIST FOR ACTUAL PARTS AND QUANTITIES.
GEN IV 4 VENT EVAP. SUB CASE
744004-VUE
2