an ISO 9001:2015 Registered Company

1969-74 Chevrolet Nova with Factory AirEvaporator Kit

(565072)

18865 Goll St. San Antonio, TX 78266 Phone: 800-862-6658

Sales: sales@vintageair.comTech Support: tech@vintageair.com

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905073 REV E 04/09/19, PG 1 OF 31

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905073 REV E 04/09/19, PG 2 OF 31

Cover..................................................................................................................................Table of Contents.................................................................................................................Packing List/Parts Disclaimer..................................................................................................Information Page..................................................................................................................Wiring Notice.......................................................................................................................Engine Compartment Disassembly, Condenser Assembly and Installation, Compressor and Brackets.............................................................................................................................Passenger Compartment Disassembly...................................................................................... Kick Panel Modification.........................................................................................................Defrost Duct Installation, Hose Adapter Installation..................................................................Fresh Air & Kick Panel Cover Preparation................................................................................Fresh Air & Kick Panel Cover Preparation (Cont.), Wiring Installation..........................................Wiring Installation (Cont.)....................................................................................................Kick Panel Cover Installation, Fresh Air Cap Installation...........................................................Firewall Modification, Firewall Cover Insulation.......................................................................Firewall Cover Installation, Evaporator Bracket Installation.......................................................Evaporator Bracket Installation (Cont.)..................................................................................Evaporator Installation........................................................................................................Center Louver Installation....................................................................................................Drain Hose Installation, Lubricating O-rings, Modified A/C Hose Installation................................A/C and Heater Hose Installation (1969-72 Vehicles Only), A/C and Heater Hose Installation (1973-74 Vehicles Only).....................................................................................A/C and Heater Hose Routing (1969-72 Vehicles Only)............................................................A/C and Heater Hose Routing (1973-74 Vehicles Only)............................................................Heater Control Valve Installation........................................................................................... Control Panel & Duct Hose Routing.......................................................................................Final Steps........................................................................................................................ Wiring Diagram..................................................................................................................Gen IV Wiring Connection Instruction...................................................................................Operation of Controls..........................................................................................................Troubleshooting Guide.........................................................................................................Troubleshooting Guide (Cont.)..............................................................................................Packing List.......................................................................................................................

1 2 3 4 5

6 7 8 910111213141516171819 202122232425262728293031

Table of Contents

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905073 REV E 04/09/19, PG 3 OF 31

Packing List: Evaporator Kit (565072)

No. 1.2.

Qty.11

Part No.744004-VUE784177

DescriptionGen IV 4-Vent Evaporator Accessory Kit

** 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.

NOTE: Images may not depict actual parts and quantities. Refer to packing list for actual parts and quantities.

1

2

Gen IV 4-VentEvaporator Sub Case

744004-VUE

Accessory Kit784177

4

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905073 REV E 04/09/19, PG 4 OF 31

Important Notice—Please ReadFor 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 remained 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.

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905073 REV E 04/09/19, PG 5 OF 31

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.

•

•

•

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905073 REV E 04/09/19, PG 6 OF 31

Engine Compartment Disassembly

Figure 1

Condenser Assembly and Installation1.2.

Refer to separate instructions included with the condenser kit to install the condenser.Binary switch installation (Refer to condenser instructions).

Compressor and Brackets1. Refer to separate instructions included with the bracket kit to install the compressor bracket.

1.2.3.4.5.6.7.

8.9.

10.

Disconnect battery.Remove battery and battery tray (retain).Drain and remove the radiator (retain).Evacuate the A/C system if necessary.Remove OEM condenser and drier (discard). Remove OEM compressor and bracket (discard).Remove OEM evaporator/blower motor assembly (discard) (See Figure 1, below). NOTE: To remove the evaporator and blower assembly (under hood) and the air distribution system (under dash), the factory manual recommends doing the following: Remove right lower rocker molding. Remove fender attaching bolts. Remove skirt to fender and skirt to reinforcement screws. Pull out on lower portion of fender, moving the skirt away from the fender flange and firewall. Block the skirt with a 2” x 4” block of wood. To avoid damage to paint and sheet metal, and for ease of removal and replacement of components, Vintage Air recommends that the right fender be removed, and the inner panel lowered (See Figure 1, below).Remove OEM heater hoses, A/C hoses and hardlines (discard).Remove OEM A/C & firewall grommet (discard).Install a 1 ¾” plastic plug into the firewall (A/C cars only) (See Figure 1a, below).

NOTE: Before starting the installation, check the function of the vehicle (horn, lights, etc.) for proper operation, and study the instructions, illustrations, & diagrams.Perform the Following:

Inner Fender PanelHeater Hoses

Drier

GrommetA/C

Hoses

Compressor and

Bracket

1 ¾” Plastic Plug 317102

7

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905073 REV E 04/09/19, PG 7 OF 31

Figure 1

Passenger Compartment Disassembly

1.2.3.4.5.6.7.8.9.

10.11.

Remove glove box door. (See Figure 1, below)Remove glove box.Remove OEM control panel assembly.Remove OEM heater control knobs.Disconnect all wires and cables from OEM control panel.Disconnect all wires and cables from OEM heater control knobs.Remove OEM heater assembly.Remove OEM duct hoses from defrost ducts.Remove OEM defrost ducts.Remove passenger side kick panel fresh air cap.Remove passenger side kick panel fresh air grille.

NOTE: Removal of the instrumental panel is required to install the evaporator. Vintage Air recommends that you utilize the factory service manual when you disassemble and reassemble the instrumental panel. Retain all items removed from vehicle, as some parts and hardware will be reused.Perform the Following:

Defrost Duct Assembly

1972-74 Nova

1969-71 Nova

Defrost Duct Assembly

Passenger Side Kick Panel

Passenger Side Kick Panel

Passenger Side Kick Panel

Fresh Air Cover

Passenger Side Kick Panel

Fresh Air Cover

A/C Heater Assembly &

Related Ducting

A/C Heater Assembly &

Related Ducting

Control Panel

Control Panel

Glove Box

Glove Box

8

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905073 REV E 04/09/19, PG 8 OF 31

Kick Panel Modification1.2.3.4.

5.

Remove (2) OEM screws from the fresh air door assembly. Disconnect and discard the pull cable assemblies from the kick panel (See Figure 1, below).Remove the kick panel by removing the (2) OEM screws (See Figure 1, below).Remove the fresh air door assembly from the OEM kick panel by lifting up on the door toward the spring and sliding it out of the hinge housing (See Photo 1, below).Trim the fresh air door housing to make it flush with the back of the kick panel (See Photos 2 & 3, below).

Figure 1

Passenger Compartment View

Lift Door Toward Spring to Remove Trim Housing

Temporarily Install Firewall Cover with (2) 1/4-20 x 3/4” Bolts & (2) 1/4-20 Nuts with

Star Washers Trace Firewall

OpeningFirewall Cover

640684Apply Insulationto Traced Area

Fresh Air Door Housing

Photo 1 Photo 2 Photo 3

Photo 1 Photo 2 Photo 3

Firewall Cover 640684

Engine Compartment View

Trim Flush with Kick Panel Housing

Fresh Air Door Assembly

Fresh Air Door Assembly

OEM Screws

OEM Screws

9

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905073 REV E 04/09/19, PG 9 OF 31

Defrost Duct Installation

Hose Adapter Installation

1.

1.2.

Install the defrost ducts under the dash as shown in Figure 1, below. Align the defrost ducts with the defrost opening in the dash, hold in place and use the bracket as a template to drill a 7/64” hole. Secure using a #10 x 1/2” sheet metal screw.

Install S-clips onto the hose adapters as shown in Figures 1 & 2, below.Install the driver and passenger side hose adapters onto the OEM louvers (See Figures 1 & 2, below).

Figure 1

Figure 1 Figure 2

FIGURE 5

Driver Side Defrost Duct

Passenger Side Defrost Duct

(2) #10 x 1/2” Sheet Metal

Screws

Driver Side Hose Adapter

629967 Passenger Side Hose Adapter

498824

Install (2) S-Clips

Install (3) S-Clips

Passenger SideDriver Side

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905073 REV E 04/09/19, PG 10 OF 31

Photo 1 Photo 2

Photo 3

Photo 4Photo 5

Fresh Air Cap &Kick Panel Cover Preparation

1.2.

3.

Install (4) large grommets and a 7/8” grommet into the fresh air cap (See Photos 1 & 2, below).On the inside of the fresh air cap, the letter “T” indicates the top mounting hole for the firewall (See Photo 3, below).From the center of the bottom left hole in the kick panel cover, measure 1 ½” down. Mark and drill a 5/8” hole for the 7/8” grommet (See Photos 4 & 5, below).

Photo 1

7/8” Grommet 33144-VUI

(4) Large Grommets 33137-VUI

Fresh Air Cap 622230

“T” Indicates Top Mounting Hole

Kick Panel Cover 626667

Drill 5/8” Hole

1 ½”

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905073 REV E 04/09/19, PG 11 OF 31

Photo 6

Photo 7

Fresh Air Cap &Kick Panel Cover Preparation (Cont.)

4. Install (4) large grommets and a 7/8” grommet into the kick panel cover (See Photos 6 & 7, below).

(4) Large Grommets 33137-VUI

7/8” Grommet 33144-VUI

Wiring Installation1.

2.

From the passenger compartment, route the heater control valve connector and wiring (red, white and green) through the 7/8” grommet in the kick panel cover (See Figure 1, below). NOTE: Leave approximately 1” of wiring between the kick panel cover and the harness connector. This allows enough wiring to reach the harness.Disconnect the circuit breaker from the main wiring harness (See Photo 1, below).

Photo 1Figure 1

Circuit Breaker

7/8” Grommet 33144-VUI

Kick Panel Cover 626667

Approximately 1”

Heater Control Valve Connector and

Wiring (Red, White and Green)

12

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905073 REV E 04/09/19, PG 12 OF 31

Wiring Installation (Cont.)3.

4.

5.

Route the red, white and blue wires from the main wiring harness through the 7/8” grommet in the kick panel cover (See Photo 2, below). NOTE: Leave approximately 5” of wiring between the relay and the kick panel cover. This allows enough wiring to secure the relay to the mounting position.Route the heater control valve wiring (red, white and green) through the 7/8” grommet in the fresh air cap (See Photo 3, below).Route the main harness wiring (red, white and blue) through the 7/8” grommet in the fresh air cap (See Photo 4, below).

Photo 3

Photo 2

Photo 4

Kick Panel Cover 626667

Heater Control Valve Connector and Wiring (Red, White and Green)

Fresh Air Cap 6222307/8” Grommet

33144-VUI

Main Wiring Harness

(Red, White and Blue)

Approximately 5”

Main Wiring Harness

(Red, White and Blue)

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905073 REV E 04/09/19, PG 13 OF 31

Kick Panel Cover Installation1.2.3.

Route the A/C and heater hoses through the kick panel cover as shown in Figure 1, below.Apply 1/4” bead of silicone around the back side of the kick panel cover as shown in Figure 1, below.Secure the kick panel cover and kick panel using OEM screws as shown in Figure 1, below.

Figure 1

Figure 1#10 A/C Hose

#6 A/C Hose

(2) HeaterHoses

Silicone

(5) OEM Screws

Photo 1

Fresh Air Cap Installation

1.2.3.

4.

Route the A/C and heater hoses through the fresh air cap as shown in Figure 1, below.Gently pull the slack from the hoses in the passenger compartment, making sure the hoses are not kinked.Slide the fresh air cap into position, and secure it to the firewall using (2) #14 x 3/4” sheet metal screws (See Photo 1, below).Apply silicone around the outer edge of the fresh air cap (See Photo 1, below).

NOTE: The fresh air cap installs on the engine side of the firewall.

Kick Panel Cover 626667

Kick Panel

#10 A/C Hose(2) Heater Hose

#6 A/C Hose

Apply Silicone Around Fresh

Air Cap

Secure Fresh Air Capwith (2) #14 x 3/4” Sheet Metal Screws

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905073 REV E 04/09/19, PG 14 OF 31

Firewall Modification

1.2.3.

Flatten the edges of the firewall opening (See Photo 1, below).Enlarge (6) holes on the firewall to 19/64” as shown in Photo 2, below.From inside the passenger compartment, directly below the lowest OEM hole under the firewall opening, mark and drill a 5/8” hole for the drain hose (See Photo 3, below). NOTE: To ensure a tight fit, do not enlarge the hole to more than 5/8”.

NOTE: Firewall modification is required for firewall cover and drain hose installation.

Firewall Cover Insulation

1.

2.3.

To apply insulation to the firewall cover, temporarily install the firewall cover onto the firewall using (2) 1/4-20 x 3/4” bolts and (2) 1/4-20 nuts with star washers (See Photo 1, below).From the passenger compartment, trace the firewall opening onto the firewall cover (See Photo 2, below).Remove the firewall cover, and apply insulation to the traced area (See Photo 3, below).

NOTE: For proper system operation, Vintage Air recommends using heat blocking insulation in the area around the evaporator unit (firewall, kick panel, inner cowl, firewall covers). Due to tight clearance for the evaporator unit between the firewall and dash, Vintage Air recommends an insulation thickness of no more than 1/4”.

Photo 1

Photo 1 Photo 2Photo 3

Photo 2Photo 3

Flatten Firewall Opening Edges

Enlarge (6) Holes to 19/64” Use This Hole for Reference

Drill 5/8” Hole

Temporarily Install Firewall Cover with (2) 1/4-20 x 3/4” Bolts & (2) 1/4-20 Nuts with

Star WashersFirewall Cover

640684

Trace Firewall Opening

Firewall Cover 640684

Apply Insulation to Traced Area

15

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905073 REV E 04/09/19, PG 15 OF 31

Firewall Cover Installation

1.

2.3.

Install (5) 1/4-20 x 3/4” bolts and (5) 1/4” pushnut retainers onto the firewall cover (See Photos 1 & 2, below).Apply a bead of silicone around the mating surface of the firewall cover as shown in Photo 2, below.From the engine side, install the firewall cover onto the firewall from the passenger compartment, secure the firewall cover using (5) 1/4” flat washers and (5) 1/4-20 nuts with star washers.

NOTE: To ensure a watertight seal between the passenger compartment and the exterior, for all bolts passing through the firewall, Vintage Air recommends coating the threads with silicone prior to installation.

Evaporator Bracket Installation1.

2.

On a work bench, install the evaporator front and rear mounting brackets onto the evaporator using (4) 1/4-20 x 1/2” hex bolts and tighten as shown in Figure 1, below and Figure 2, Page 16.Install the (2) heater fittings onto the evaporator with properly lubricated O-rings as shown in Lubricating O-rings, Page 19 and Figure 3, Page 16.

(2) 1/4-20 x ½” Hex Bolt

Figure 1

Firewall Cover 640684 Silicone

Install (5) 1/4-20 x 3/4” Bolts

Install (5) 1/4” Pushnut Bolt Retainers

Passenger Compartment

View

Engine Compartment

View

16

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905073 REV E 04/09/19, PG 16 OF 31

Evaporator Bracket Installation (Cont.)

1/4-20 x 1 ½” Hex Bolt

3/4” Nylon Spacer

Rear Evaporator Bracket

1/4” Push Nut Bolt Retainer

(2) 1/4-20 x 1/2” Hex Bolts

Rear Evaporator Bracket

643170-FCB

(2) Heater Fittings

Figure 2

Figure 3

5/16” Flat Washer

17

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905073 REV E 04/09/19, PG 17 OF 31

Evaporator Installation

1.2.

3.

4.

5.

6.

7.

8.

Place the evaporator unit under the dash.Install the 90° fitting from the #6 drier/evaporator A/C hose onto the expansion valve on the evaporator unit using a properly lubricated #6 O-ring (See Lubricating O-rings, Page 19 and Figure 1, below).Install the heater hose and a hose clamp onto the upper heater hardline on the evaporator unit (See Figure 1, below).Install the lower heater hose and a hose clamp onto the lower heater hardline on the evaporator unit (See Figure 1, below).Lift the evaporator unit up under the dashboard, and secure it loosely to the firewall from the engine compartment side using a 1/4-20 nut with star washer (See Figure 2, below). NOTE: To ensure proper drainage, it is very important that the evaporator level, both left-right and fore-aft. Check leveling on the flat portions of the sub case around the drain.Using (2) #14 x 3/4 sheet metal screws, secure the front evaporator mounting bracket to the inner cowl (See Figure 2a, below).Verify that the evaporator unit is leveled and square to the dash, then tighten all mounting bolts. NOTE: Tighten the bolt on the firewall first, then the front mounting bracket screws.Install the 90° female fitting from the #10 compressor/evaporator A/C hose onto the evaporator unit using a properly lubricated #10 O-ring (See Lubricating O-rings, Page 19 and Figure 1, below). NOTE: After installing the #10 compressor/evaporator A/C hose, wrap all exposed metal with the supplied press tape. (See Figure 1, below).

NOTE: To ensure a watertight seal between the passenger compartment and the vehicle exterior, for all bolts passing through the firewall, Vintage Air recommends coating the threads with silicone prior to installation.

Figure 1

Figure 2a

Figure 2

Press Tape

#6 A/C Hose

(2) Heater Hoses #10 A/C Hose

(2) Hose Clamps

Drill (2) 3/16” Holes (2) #14 x 3/4”

Sheet Metal Screws

Inner Cowl

Kick Panel Fresh Air Cap

1/4-20 Nut with Star Washer

18

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905073 REV E 04/09/19, PG 18 OF 31

Figure 1

Figure 2

Center Louver Installation1.2.3.

Install (4) S-clips onto the center louver hose adapter as shown in Figure 1, below.Install the center louver hose adapter onto the center louver assembly (See Figure 1, below).Install the center louver assembly into the dash using (2) OEM screws (See Figure 2, below).

(4) S-Clips

OEM Center Louver Assembly

Center Louver Hose Adapter

629968

OEM Screws

19

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905073 REV E 04/09/19, PG 19 OF 31

Drain Hose Installation

Modified A/C Hose Kit

1.

1.

Install the drain hose through the previously drilled 5/8” hole in the firewall. Attach the drain hose onto the drain outlet on the bottom of the evaporator unit (See Photo 1, below).

Refer to separate instructions included with modified hose kit.

Figure ##

O-ring Installs Over Male Insert to Swaged Lip

O-ring#6 O-ring

#8 O-ring #10 O-ring

O-ring

Supplied Oil for O-rings

Male Insert

Female Nut

Hold With This Wrench

Twist With This Wrench

Lubricating O-rings For a proper seal of fittings: Install supplied O-rings as shown, and lubricate with supplied oil.

NOTE: Standard torque specifications:#6: 11 to 13 ft-lb.#8: 15 to 20 ft-lb.

#10: 21 to 27 ft-lb.

Photo 1

Photo 1

Attach Drain hose to Drain Outlet

Evaporator Drain Outlet

Install Drain Hose into 5/8” Hole

20

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905073 REV E 04/09/19, PG 20 OF 31

Photo 1

Photo 1

Photo 2 Photo 3

A/C and Heater Hose Installation(1969-72 Vehicles Only)

A/C and Heater Hose Installation(1973-74 Vehicles Only)

1.

2.

3.

4.

1.

2.

3.

4.

Locate the #6 evaporator/drier A/C hose and install a properly lubricated #6 O-ring (See Lubricating O-rings, Page 19). Connect the 90° fitting to the #6 condenser hardline coming through the core support and tighten the fitting (See Photo 1, below and Lubricating O-rings, Page 19).Locate the #8 condenser/compressor A/C hose and install (2) properly lubricated #8 O-rings (See Lubricating O-rings, Page 19). Connect the 90° fitting with service port to the #8 discharge port on the compressor (See Photo 3, below). Install the 45° fitting to the #8 condenser hardline coming through the core support (See Photo 2, below). Tighten fitting connection as shown in Lubricating O-rings, Page 19.Locate the #10 evaporator/compressor A/C hose and install a properly lubricated #10 O-ring (See Lubricating O-rings, Page 19). Connect the #10 135° fitting with service port to the #10 suction port on the compressor (See Photo 3, below).Install a #10 Adel clamp onto the #10 A/C hose. Secure the Adel clamp to the alternator bracket using a 10-32 x 1/2” pan head screw and 10-32 nut with star washer (See Figure 1, Page 22).

Locate the #8 condenser/compressor A/C hose and install (2) properly lubricated #8 O-rings (See Lubricating O-rings, Page 19). Connect the 90° fitting with service port to the #8 discharge port on the compressor (See Figure 1, Page 21). Install the 45° fitting onto the #8 condenser hardline coming through the core support (See Photo 1, below). Tighten each fitting connection as shown in Lubricating O-rings, Page 19.Locate the #10 evaporator/compressor A/C hose and install a properly lubricated #10 O-ring (See Lubricating O-rings, Page 19). Connect the #10 135° fitting with service port to the #10 suction port on the compressor (See Figure 1, Page 21).Locate the #6 evaporator/drier A/C hose and install a properly lubricated #6 O-ring (See Lubricating O-rings, Page 19). Connect the 90° fitting to the drier and tighten the fitting (See Figure 1, Page 21 and Lubricating O-rings, Page 19).Install a #10 Adel clamp onto the #10 A/C hose. Secure the Adel clamp to the alternator bracket using a 10-32 x 1/2” pan head screw and 10-32 nut with star washer (See Figure 1, Page 21).

#8 Condenser/Compressor A/C Hose

45° Fitting#8 Condenser

Hardline

#6 Evaporator/Drier A/C Hose

#6 Condenser Hardline

#8 Condenser Hardline

#10 135° Fitting with Service Port

#10 Compressor Suction Port

Compressor

90° Fitting 90° Fitting

#8 Condenser/Compressor A/C Hose

#8 90°Fitting with Service Port

#8 Compressor Discharge Port

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21 905073 REV E 04/09/19, PG 21 OF 31

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tag

e A

ir S

yste

ms

use

5/

8”

hea

ter

con

nec

tion

s. O

n e

ng

ines

eq

uip

ped

wit

h 3

/4

” h

ose

nip

ple

s, t

hes

e w

ill n

eed

to

be

rem

oved

an

d r

epla

ced

wit

h 5

/8

” n

ipp

les

(not

su

pp

lied

). F

or w

ater

p

um

ps

wit

h a

cas

t-in

3/

4”

hea

ter

outl

et,

a 3

/4

” x

5/

8”

red

uce

r fi

ttin

g in

th

e h

eate

r h

ose

(not

su

pp

lied

) or

mol

ded

hos

e (V

inta

ge

Air

Par

t #

09

90

10

) w

ill n

eed

to

be

inst

alle

d.

Fig

ure

1

NO

TE:

Flow

Dir

ecti

on F

ollo

ws

Mol

ded

Arr

ow o

n V

alve

.

ww

w.v

inta

gea

ir.c

om

22 905073 REV E 04/09/19, PG 22 OF 31

Fig

ure

1

R

From

Eva

pora

tor

To W

ater

Pum

pH

eate

r H

ose

Tie

Wra

p

Hos

e Cla

mps

From

Hea

ter

Con

trol

Val

ve

To E

vapo

rato

r

Hea

ter

Hos

e (H

eate

r Con

trol

Va

lve/

Inta

ke)

#6

Drier

/ Con

dens

er

Har

dlin

e 35

368-

VCG

#8

Con

dens

er/

Com

pres

sor

Har

dlin

e 09

1690

#6

Drier

/ Ev

apor

ator

H

ardl

ine

0916

91

From

Int

ake

Man

ifol

d

NO

TE:

Vin

tag

e A

ir S

yste

ms

use

5/

8”

hea

ter

con

nec

tion

s. O

n e

ng

ines

eq

uip

ped

wit

h 3

/4

” h

ose

nip

ple

s, t

hes

e w

ill n

eed

to

be

rem

oved

an

d r

epla

ced

wit

h 5

/8

” n

ipp

les

(not

su

pp

lied

). F

or w

ater

p

um

ps

wit

h a

cas

t-in

3/

4”

hea

ter

outl

et,

a 3

/4

” x

5/

8”

red

uce

r fi

ttin

g in

th

e h

eate

r h

ose

(not

su

pp

lied

) or

mol

ded

hos

e (V

inta

ge

Air

Par

t #

09

90

10

) w

ill n

eed

to

be

inst

alle

d.

A/

C a

nd

Hea

ter

Hos

e R

outi

ng

(19

73

-74

Veh

icle

s O

nly

)

#8

Com

pres

sor/

Con

dens

er

A/C

Hos

e 09

0166

#10

Eva

pora

tor/

Com

pres

sor

A/C

Hos

e 09

6073

#10

Ade

l Cla

mp

with

10-

32 x

1/

2” P

an H

ead

Scr

ew w

ith a

nd

10-3

2 N

ut W

ith

Sta

r W

ashe

r

#6

Evap

orat

or/

Drier

A/C

Hos

e

NO

TE:

Flow

Dir

ecti

on F

ollo

ws

Mol

ded

Arr

ow o

n V

alve

.

23

www.vintageair.com

905073 REV E 04/09/19, PG 23 OF 31

Heater Control Valve Installation1.

2.

3.

Route a piece of heater hose (not provided) from the lower heater core fitting to the water pump. Secure using hose clamps. (See Figure 1, below).Route a piece of heater hose (not provided) from the intake manifold to the heater control valve. Connect the heater hose from the upper heater core fitting to the heater control valve. Secure using hose clamps (See Figure 1, below). NOTE: Ensure proper flow direction through the heater control valve (the flow direction follows the molded arrow on the valve).Plug the heater control valve connector into the connector on the main wiring harness (See Photo 2, below). Secure the white wire from the heater control valve portion of the main harness to a suitable chassis ground.

Heater Hoses

From Heater Control Valve to Heater Core

From Heater Core to Water Pump

to Heater Control Valve

Figure 1

NOTE: Flow Direction Follows Molded Arrow on Valve.

From Intake Manifold

ClampsHose

Photo 1

Secure White Wire to Chasis Ground

Heater Control Valve Connector

Heater Control Harness Connector

24

www.vintageair.com

905073 REV E 04/09/19, PG 24 OF 31

Control Panel & Duct Hose Routing

Figure 1

Driver Side Defrost Duct

2” x 20”

Driver Side Louver

2 ½ x 36”

Center Louver Driver Side 2 ½” x 18” Center Louver

Passenger Side 2 ½” x 20”

Passenger Side Louver

2 ½” x 40”

Plug From Wiring Harness 232600-VUA

Plug From Control Wiring

Harness 232002-VUA

Passenger Side Defrost Duct

2” x 12”

25

www.vintageair.com

905073 REV E 04/09/19, PG 25 OF 31

Final Steps1.

2.

3.

4.5.6.

7.8.9.

10.11.12.13.14.

Install duct hoses as shown in Figure 1, Page 24. Extend duct hose to a taut condition, then cut to length as noted. There should be little or no slack in hose once installed.Reinstall control panel assembly. NOTE: Controls must be calibrated for proper operation. Refer to control panel instructions.Plug the wiring harness into the ECU module on sub case as shown in Figure 1, Page 24. Wire according to wiring diagram on Pages 25 and 26.Modify the passenger side kick panel fresh air cover as shown in Figure 1, below.Reinstall the passenger side kick panel fresh air cover.Install the glove box behind the dash. Using the mounting holes of the glove box as a template, mark and drill using a 1/16” drill bit. Secure the glove box to the dash using the OEM screws.Reinstall the glove box door.Reinstall all previously removed items (battery, radiator, radio).Fill radiator with at least a 50/50 mixture of approved antifreeze and distilled water or pre mix antifreeze. 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 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 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 capacity stated on the information Page 4 of this instruction manual.See Operation of Controls procedures Page 28.

Figure 1 Figure 1a

3 ⅛”

4 ⅞

”

Glove Box 49069-VCI

26

www.vintageair.com

905073 REV E 04/09/19, PG 26 OF 31

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 E, 10/6/2017

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

27

www.vintageair.com

905073 REV E 04/09/19, PG 27 OF 31

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.

28

www.vintageair.com

905073 REV E 04/09/19, PG 28 OF 31

Operation of Controls

Adjust to desiredspeed.

Blower SpeedAdjust to desired

speed.

Adjust to desiredmode position (DASH position recommended).

Adjust to desiredspeed.

Adjust to DEFROST position for maximum defrost, or between FLOOR and DEFROST positions for a bi-level

blend (Compressor is automatically engaged).

Adjust to desired temperature.

For A/C operation, adjust tocoldest position to engage

compressor (Adjust between HOT and COLD to reachdesired temperature).

A/C Operation

Heat Operation

Defrost/De-fog Operation

Blower Speed

Blower Speed

This lever/knob controlsblower speed, from

OFF to HI.

This lever/knob controls the mode positions,from DASH to FLOORto DEFROST, with a blend in between.

This lever controlsthe temperature,

from HOT to COLD.

Blower Speed

Mode Control

Temperature Control

Temperature Control

Temperature Control

Temperature Control

Mode Control

Mode Control

Mode Control

For maximum heating, adjust to hottest position (Adjust between HOT and COLD to reach desired temperature).Adjust to desired

mode position(FLOOR position recommended).

On Gen IV systems with three lever/knob controls, the temperature control toggles between heat and A/C operations. To activate A/C, move the temperature lever/knob all the way to cold and then back it off to the desired vent temperature. For heat operation, move the temperature lever/knob all the way to hot and then adjust to the desired vent temperature. The blower will momentarily change speed, each time you toggle between operations, to indicate the change. NOTE: For proper control panel function, refer to the control panel instructions.

COLD

HOT

HI

OFF

DASH

DEF

FLR

HOTOFF

DASH

DEF

FLR

COLDHI

HOTOFF

DASH

DEF

FLR

COLDHI

Blower Speed

Temperature Control

Mode ControlCOLD

HOT

HI

OFF

DASH

DEF

FLR

ww

w.v

inta

gea

ir.c

om

29 905073 REV E 04/09/19, PG 29 OF 31

Sym

pto

m

Con

dit

ion

Ch

ecks

A

ctio

ns

Not

es

Blo

wer

sta

ys o

n hi

gh s

peed

whe

n ig

nitio

n is

on.

1a.

No

othe

r fu

nctio

ns w

ork.

Che

ck f

or d

amag

ed p

ins

or

wires

in c

ontr

ol h

ead

plug

.Ve

rify

tha

t al

l pin

s ar

e in

sert

ed in

to p

lug.

Ens

ure

that

no

pins

are

ben

t or

dam

aged

in E

CU

.Che

ck f

or d

amag

ed g

roun

d w

ire

(whi

te)

in c

ontr

ol h

ead

harn

ess.

Verify

con

tinui

ty t

o ch

assi

s gr

ound

with

whi

te c

ontr

ol

head

wire

at v

ario

us p

oint

s.

Loss

of gr

ound

on

this

wire

rend

ers

cont

rol h

ead

inop

erab

le.

All

othe

r fu

nctio

ns w

ork.

Che

ck f

or d

amag

ed b

low

er

switc

h or

pot

entio

met

er a

nd

asso

ciat

ed w

irin

g.

Blo

wer

sta

ys o

n hi

gh s

peed

whe

n ig

nitio

n is

on

or o

ff.

Unp

lug

3-w

ire

BSC c

ontr

ol

conn

ecto

r fr

om E

CU

. If

blo

wer

sh

uts

off,

ECU

is e

ither

im

prop

erly

wired

or

dam

aged

.

Be

sure

the

sm

all,

20 G

A w

hite

gro

und

wire

is c

onne

cted

to

the

bat

tery

gro

und

post

. If

it is

, re

plac

e th

e EC

U.

Unp

lug

3-w

ire

BSC c

ontr

ol

conn

ecto

r fr

om E

CU

. If

blo

wer

st

ays

runn

ing,

BSC is

eith

er

impr

oper

ly w

ired

or

dam

aged

.

Che

ck t

o en

sure

tha

t no

BSC w

irin

g is

dam

aged

or

shor

ted

to v

ehic

le g

roun

d. T

he B

SC o

pera

tes

the

blow

er

by g

roun

d si

de p

ulse

wid

th m

odul

atio

n sw

itchi

ng.

The

posi

tive

wire

to t

he b

low

er w

ill a

lway

s be

hot

. If

the

“g

roun

d” s

ide

of t

he b

low

er is

sho

rted

to

chas

sis

grou

nd,

the

blow

er w

ill r

un o

n H

I.

Repl

ace

BSC (

This

will

req

uire

rem

oval

of ev

apor

ator

fr

om v

ehic

le).

No

othe

r pa

rt r

epla

cem

ents

sh

ould

be

nece

ssar

y.

Com

pres

sor

will

no

t tu

rn o

n (A

ll ot

her

func

tions

w

ork)

.

2.

Syst

em is

not

cha

rged

.Sy

stem

mus

t be

cha

rged

for

co

mpr

esso

r to

eng

age.

Cha

rge

syst

em o

r by

pass

pre

ssur

e sw

itch.

Dan

ger

: N

ever

byp

ass

safe

ty s

wit

ch w

ith

en

gin

e ru

nn

ing

. S

erio

us

inju

ry c

an r

esu

lt.

Syst

em is

cha

rged

.

1b

.

Trou

ble

shoo

tin

g G

uid

e

Che

ck f

or f

aulty

A/C

po

tent

iom

eter

or

asso

ciat

ed

wirin

g (N

ot a

pplic

able

to

3-po

t co

ntro

ls).

Che

ck f

or d

isco

nnec

ted

or

faul

ty t

herm

isto

r.

Che

ck c

ontin

uity

to

grou

nd o

n w

hite

con

trol

hea

d w

ire.

Che

ck f

or 5

V o

n re

d co

ntro

l hea

d w

ire.

Che

ck 2

-pin

con

nect

or a

t EC

U h

ousi

ng.

To c

heck

for

pro

per

pot

func

tion,

che

ck v

olta

ge a

t w

hite

/blu

e w

ire.

Vol

tage

sh

ould

be

betw

een

0V a

nd

5V,

and

will

var

y w

ith p

ot

leve

r po

sitio

n.

Dis

conn

ecte

d or

fau

lty

ther

mis

tor

will

cau

se

com

pres

sor

to b

e di

sabl

ed.

Red

wire

at A

/C p

ot s

houl

d ha

ve a

ppro

xim

atel

y 5V

w

ith ig

nitio

n on

. W

hite

w

ire

will

hav

e co

ntin

uity

to

chas

sis

grou

nd.

Whi

te/

Blu

e w

ire

shou

ld v

ary

betw

een

0V a

nd 5

V w

hen

leve

r is

mov

ed u

p or

dow

n.

3. Com

pres

sor

will

no

t tu

rn o

ff

(All

othe

r fu

nctio

ns

wor

k).

Che

ck f

or f

aulty

A/C

po

tent

iom

eter

or

asso

ciat

ed

wirin

g.

Che

ck f

or f

aulty

A/C

rel

ay.

Repa

ir o

r re

plac

e po

t/co

ntro

l wirin

g.

Repl

ace

rela

y.

See

blo

wer

sw

itch

chec

k pr

oced

ure.

ww

w.v

inta

gea

ir.c

om

30 905073 REV E 04/09/19, PG 30 OF 31

Sym

pto

m

Con

dit

ion

Ch

ecks

A

ctio

ns

Not

es

Syst

em w

ill n

ot

turn

on,

or

runs

in

term

itten

tly.

4.

Wor

ks w

hen

engi

ne is

not

runn

ing;

shu

ts o

ff w

hen

engi

ne is

sta

rted

(T

ypic

ally

ear

ly G

en I

V,

but

poss

ible

on

all

vers

ions

).

Noi

se in

terf

eren

ce f

rom

eith

er

igni

tion

or a

ltern

ator

.

Inst

all c

apac

itors

on

igni

tion

coil

and

alte

rnat

or.

Ensu

re

good

gro

und

at a

ll po

ints

. Re

loca

te c

oil a

nd a

ssoc

iate

d w

irin

g aw

ay f

rom

ECU

and

ECU

wirin

g. C

heck

for

bur

ned

or lo

ose

plug

wires

.

Verify

con

nect

ions

on

pow

er

lead

, ig

nitio

n le

ad,

and

both

whi

te g

roun

d w

ires

.

Verify

pro

per

met

er f

unct

ion

by c

heck

ing

the

cond

ition

of

a kn

own

good

bat

tery

.

Igni

tion

nois

e (r

adia

ted

orco

nduc

ted)

will

cau

se t

he

syst

em t

o sh

ut d

own

due

tohi

gh v

olta

ge s

pike

s. I

f th

isis

sus

pect

ed,

chec

k w

ith a

qu

ality

osc

illos

cope

. Spi

kes

grea

ter

than

16V

will

shu

t do

wn

the

ECU

. In

stal

l a

radi

o ca

paci

tor

at t

he

posi

tive

post

of th

e ig

nitio

nco

il (S

ee r

adio

cap

acito

r in

stal

latio

n bu

lletin

). A

fa

ulty

alte

rnat

or o

r w

orn

out

batt

ery

can

also

res

ult

in t

his

cond

ition

.

Will

not

tur

n on

und

er

any

cond

ition

s.Ve

rify

bat

tery

vol

tage

is

grea

ter

than

10

volts

and

less

than

16.

Loss

of m

ode

door

fu

nctio

n.

No

mod

e ch

ange

at

all.

Che

ck f

or d

amag

ed m

ode

switc

h or

pot

entio

met

er a

nd

asso

ciat

ed w

irin

g.

Part

ial f

unct

ion

of m

ode

door

s.

Typi

cally

cau

sed

by

evap

orat

or h

ousi

ng

inst

alle

d in

a b

ind

in t

he

vehi

cle.

Be

sure

all

mou

ntin

g lo

catio

ns li

ne u

p an

d do

n’t

have

to

be for

ced

into

pos

ition

.

Blo

wer

tur

ns o

n an

d of

f ra

pidl

y.

6.

Bat

tery

vol

tage

is a

t le

ast

12V.

Che

ck f

or a

t le

ast

12V a

t ci

rcui

t br

eake

r.En

sure

all

syst

em g

roun

ds a

nd p

ower

con

nect

ions

are

cl

ean

and

tight

.

Bat

tery

vol

tage

is le

ss

than

12V

.

5.

Trou

ble

shoo

tin

g G

uid

e (C

ont.

)

Che

ck f

or f

aulty

bat

tery

or

alte

rnat

or.

Cha

rge

batt

ery.

Syst

em s

huts

off b

low

er a

t 10

V. P

oor

conn

ectio

ns o

r w

eak

batt

ery

can

caus

e sh

utdo

wn

at u

p to

11V

.

7. Whe

n ig

nitio

n is

tu

rned

on,

blo

wer

m

omen

tarily

co

mes

on,

the

n sh

uts

off.

This

oc

curs

with

the

bl

ower

sw

itch

in

the

OFF

pos

ition

.

This

is a

n in

dica

tor

that

the

sy

stem

has

bee

n re

set.

Be

sure

the

red

pow

er w

ire

is o

nth

e ba

tter

y po

st,

and

not

on a

sw

itche

d so

urce

. Als

o, if

the

sy

stem

is p

ulle

d be

low

7V f

orev

en a

spl

it se

cond

, th

e sy

stem

will

res

et.

Run

red

pow

er w

ire

dire

ctly

to

batt

ery.

Che

ck f

or p

ositi

ve p

ower

at

heat

er v

alve

gre

en w

ire

and

blow

er r

ed w

ire.

Che

ck f

or g

roun

d on

con

trol

hea

d w

hite

w

ire.

Che

ck f

or o

bstr

ucte

d or

bi

ndin

g m

ode

door

s.Che

ck f

or d

amag

ed s

tepp

er

mot

or o

r w

irin

g.

Erra

tic fun

ctio

ns o

fbl

ower

, m

ode,

te

mp,

etc

.

Che

ck f

or d

amag

ed s

witc

h or

po

t an

d as

soci

ated

wirin

g.Re

pair o

r re

plac

e.

8.

31

www.vintageair.com

905073 REV E 04/09/19, PG 31 OF 31

Packing List: Evaporator Kit (565072)

No. 1.2.

Qty.11

Part No.744004-VUE784177

DescriptionGen IV 4-Vent Evaporator Accessory Kit

NOTE: Images may not depict actual parts and quantities. Refer to packing list for actual parts and quantities.

1

2

Accessory Kit784177

Checked By:Packed By:

Date:

Gen IV 4-VentEvaporator Sub Case

744004-VUE