Vintage 1967-72 CHEV PICK-UP Instructions Manual

an ISO 9001:2008 Registered Company

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

PAGES

Table of Contents

1. COVER

2. TABLE OF CONTENTS

3. PACKING LIST / PARTS DISCLAIMER

4. INFORMAT ION 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 & HEAT ER 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 INFORMAT ION

21. TROUBLE SHOOTING INFORMAT ION CONT.

22. DRIVER/PASSENGER SIDE LOUVER TEMPLATE

23. CENTER LOUVER TEMPLATE

24. EVAPORATOR KIT PACKING LIST

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** 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 MISS ING 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 MAY NOT DE PICT ACTUAL PARTS AND QUANTITIES.

REFER TO PACKING LIST FOR ACTUAL PARTS AND QUANTITIES .

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FOR MAXIMUM SYSTEM PERFORMANCE VINTAGE AI R 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 MANUFA CTURER GUIDELINES)

IMPORTANT NOTICE-PLEASE READ

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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 AR

E 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 WI

RE, 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.

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

DISCONNECT BATTERY.
DRAIN RADIAT OR, REMOVE RADIAT OR (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.) FO R PROPER OPERATIONS.

STUDY THE INSTRUCTIONS, ILLUST RATIONS, & DIAGRA MS.

OEM HEATER

BLOWER

ASSEMBLY

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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

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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

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