Chevrolet - Vintage Air - Owners Manual - 1973 - 1980

an ISO 9001:2008 Registered Company 1973-80 CHEVROLET PICKUP with FACTORY AIR 754175 904184 REV C 1/19/15, INST 73-80 CHEV P-UP w/ AC EVAP KIT PG 1 OF 27 Table of Contents PAGES 1. 2. 3. 4. 5. 6. COVER TABLE OF CONTENTS PACKING LIST/PARTS DISCLAIMER INFORMATION PAGE WIRING NOTICE ENGINE COMPARTMENT, CONDENSER ASSEMBLY, COMPRESSOR & BRACKET FIGURE 1 7. PASSENGER COMPARTMENT FIGURES 2, 2a, 2b & 2c 8. DEFROST DUCT INSTALLATION & FRESH AIR CAP INSTALLATION AND FIREWALL MODIFICATION FIGURES 3 & 4 9. FIREWALL MODIFICATION CONT. & FIREWALL COVER INSTALLATION FIGURES 5 & 6 10. BRACKET & EVAPORATOR HARDLINE INSTALLATION FIGURE 7 11. BRACKET & EVAPORATOR HARDLINE INSTALLATION CONT. FIGURE 8 12. EVAPORATOR INSTALLATION FIGURES 9 & 9a 9b 13. DRAIN HOSE INSTALLATION, LUBRICATING O-RINGS, A/C HOSE INSTALLATION & MODIFIED A/C HOSE KIT FIGURES 10 & 11 14. HEATER HOSE & HEATER CONTROL VALVE INSTALLATION FIGURE 12 15. A/C & HEATER HOSE ROUTING FIGURE 13 16. DRIVER AND PASSENGER SIDE CENTER LOUVER HOSE ADAPTER INSTALLATION & DRIVER AND PASSENGER SIDE LOUVER HOSE ADAPTER INSTALLATION FIGURES 14, 14a, 15 & 15a 17. FINAL STEPS FIGURE 16 18. GLOVE BOX MODIFICATION FIGURES 17 & 17a 19. CONTROL PANEL & DUCT HOSE ROUTING FIGURE 18 20. WIRING DIAGRAM 21. GEN IV WIRING CONNECTION INSTRUCTIONS 22. OPERATION OF CONTROLS 23. TROUBLESHOOTING INFORMATION 24. TROUBLESHOOTING INFORMATION CONT. 25. GLOVE BOX MODIFICATION TEMPLATE 26. POWER STEERING BRACKET MODIFICATION 27. EVAPORATOR KIT PACKING LIST 2 904184 REV C 1/19/15, INST 73-80 CHEV P-UP w/ AC EVAP KIT PG 2 OF 27 EVAPORATOR KIT PACKING LIST No. QTY. 1. 2. 1 1 PART No. EVAPORATOR KIT 754175 DESCRIPTION 744004-VUE 794175 GEN IV 4-VENT EVAPORATOR SUB CASE with 204 ECU ACCESSORY KIT 1973-80 CHEVROLET PICKUP with A/C ** 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. 1 GEN IV 4-VENT EVAPORATOR SUB CASE with 204 ECU 744004-VUE 2 HI OFF DASH HOT 3 ACCESSORY KIT 794175 FLR DEF COLD A/C NOTE: IMAGES MAY NOT DEPICT ACTUAL PARTS AND QUANTITIES. REFER TO PACKING LIST FOR ACTUAL PARTS AND QUANTITIES. 904184 REV C 1/19/15, INST 73-80 CHEV P-UP w/ AC EVAP KIT PG 3 OF 27 Important Notice—Please Read For Maximum System Performance, Vintage Air Recommends the Following: 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. (1 lb., 12 oz.) 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: 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). Safety Switches 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. 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. 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. 4 904184 REV C 1/19/15, INST 73-80 CHEV P-UP w/ AC EVAP KIT PG 4 OF 27 Important Wiring Notice—Please Read Some Vehicles May Have Had Some or All of Their Radio Interference Capacitors Removed. There Should Be a Capacitor Found At Each of the Following Locations: 1. On the positive terminal of the ignition coil. 2. If there is a generator, on the armature terminal of the generator. 3. If there is a generator, on the battery terminal of the voltage regulator. Most alternators have a capacitor installed internally to eliminate what is called “whining” as the engine is revved. If whining is heard in the radio, or just to be extra cautious, a radio interference capacitor can be added to the battery terminal of the alternator. It is also important that the battery lead is in good shape and that the ground leads are not compromised. There should be a heavy ground from the battery to the engine block, and additional grounds to the body and chassis. If these precautions are not observed, it is possible for voltage spikes to be present on the battery leads. These spikes come from ignition systems, 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. 5 904184 REV C 1/19/15, INST 73-80 CHEV P-UP w/ AC EVAP KIT PG 5 OF 27 ENGINE COMPARTMENT BEFORE STARTING THE INSTALLATION, CHECK THE FUNCTION OF THE VEHICLE (HORN, LIGHTS,ETC.) FOR PROPER OPERATIONS. STUDY THE INSTRUCTIONS, ILLUSTRATIONS & DIAGRAMS. REMOVE THE FOLLOWING: DISCONNECT BATTERY. DRAIN RADIATOR, REMOVE RADIATOR (RETAIN). EVACUATE THE A/C SYSTEM IF NECESSARY. OEM CONDENSER AND DRIER (DISCARD). SEE FIGURE 1. OEM A/C LINES FROM COMPRESSOR TO EVAPORATOR (DISCARD). OEM COMPRESSOR AND BRACKET (DISCARD). EVAPORATOR BLOWER ASSEMBLY (DISCARD). NOTE: TO REMOVE THE EVAPORATOR AND BLOWER ASSEMBLY (UNDER HOOD) AND THE AIR DISTRIBUTION SYSTEM (UNDER DASH), THE FACTORY MANUAL RECOMMENDS THAT YOU REMOVE RIGHT INNER FENDER FOR ACCESSIBILITY. OEM HEATER HOSES, A/C HOSES AND HARDLINES (DISCARD). SEE FIGURE 1. EVAPORATOR BLOWER HOUSING COMPRESSOR FIGURE 1 CONDENSER ASSEMBLY & INSTALLATION DRIER & CONDENSER REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH THE CONDENSER KIT TO INSTALL THE CONDENSER. BINARY SWITCH INSTALLATION (REFER TO CONDENSER INSTRUCTIONS). COMPRESSOR & BRACKETS REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH THE BRACKET KIT TO INSTALL THE COMPRESSOR AND BRACKET. 904184 REV C 1/19/15, INST 73-80 CHEV P-UP w/ AC EVAP KIT PG 6 OF 27 6 PASSENGER COMPARTMENT REMOVE THE FOLLOWING: GLOVE BOX DOOR AND GLOVE BOX ASSEMBLY (RETAIN) (SEE FIGURE 2, BELOW). UNDER DASH STEERING COLUMN COVER (RETAIN) (SEE FIGURE 2). INSTRUMENT PANEL BEZEL (RETAIN). DASH PAD (RETAIN) (SEE FIGURE 2). DISCONNECT ALL WIRES AND CABLES FROM CONTROL PANEL. REMOVE CONTROL PANEL (DISCARD). REFER TO CONTROL PANEL CONVERSION KIT INSTRUCTIONS. ASH TRAY (RETAIN). ALL HOSE AND DUCTING FROM OEM LOUVERS (SEE FIGURE 2a BELOW). A/C & HEATER ASSEMBLY (DISCARD) (SEE FIGURE 2a). DEFROST DUCT ASSEMBLY (DISCARD) (SEE FIGURE 2a, BELOW). PASSENGER SIDE KICK PANEL ASSEMBLY (RETAIN KICK PANEL COVER & FRESH AIR KICK PANEL CAP, BUT DISCARD DOOR & ACTUATOR). SEE FIGURE 2b. DOOR ASSEMBLY APPLY 1/4” BEAD OF SILICONE ON BACK SIDE OF KICK PANEL BLOCK OFF PLATE. INSTALL KICK PANEL BLOCK OFF PLATE USING (2) #8 x 1/2” PH PAN HEAD SCREWS (SEE FIGURE 2c). NOTE: FOR EASE OF INSTALLING EVAPORATOR UNDER DASH, IT MAY BE HELPFUL TO REMOVE THE (2) OEM BOLTS UNDER THE DASH ON THE PASSENGER SIDE DOOR PILLAR AND PULL BACK DASH. NOTE: SOME MODELS MAY BE EQUIPPED WITH DASH BRACE (REMOVE KICK AND RETAIN) (SEE FIGURE 2a). PANEL CAP DASH PAD KICK PANEL COVER FIGURE 2b INSTRUMENT PANEL BEZEL UNDER DASH COVER CONTROL PANEL GLOVE BOX DOOR & GLOVE BOX ASH TRAY KICK PANEL BLOCK OFF PLATE 62438-LCE (2) OEM BOLTS FIGURE 2 DEFROST DUCT ASSEMBLY (2) #8 x 1/2” PH PAN HEAD SCREWS A/C & HEATER ASSEMBLY DASH BRACE 7 SILICONE BACK SIDE ALL HOSE AND RELATED DUCTING FROM LOUVERS FIGURE 2a 904184 REV C 1/19/15, INST 73-80 CHEV P-UP w/ AC EVAP KIT PG 7 OF 27 KICK PANEL COVER FIGURE 2c DEFROST DUCT INSTALLATION INSTALL DRIVER AND PASSENGER SIDE DEFROST DUCTS AS SHOWN BELOW. (2) DEFROST DUCTS 623224 THINNER SIDE OF FLANGE GOES TOWARD WINDSHIELD DEFROST DUCT OEM OPENING FIGURE 3 FRESH AIR CAP AND FIREWALL MODIFICATION APPLY A 1/4” BEAD OF SILICONE AROUND THE BACK SIDE OF THE FRESH AIR CAP AS SHOWN IN FIGURE 4, BELOW. ATTACH FRESH AIR CAP TO FIREWALL USING A 1/4-20 x 1” BOLT AND WASHER. SEE FIGURE 4, BELOW. PLACE FIREWALL COVER ON FIREWALL AND SECURE USING (2) #14 x 3/4“ SHEET METAL SCREWS AS SHOWN BELOW. USING FIREWALL COVER AS TEMPLATE, MARK THE HOLES ON THE FIREWALL AS SHOWN BELOW. REMOVE FIREWALL COVER. SILICONE FRESH AIR CAP MARK HOLE BACK SIDE OF FRESH AIR CAP 1/4-20 x 1” BOLT 1/4” FLAT WASHER MARK HOLE OEM HOLES MARK HOLES #14 x 3/4” SHEET METAL SCREW #14 x 3/4” SHEET METAL SCREW OEM HOLE MARK HOLES MARK HOLES FIGURE 4 MARK HOLE OEM HOLE 904184 REV C 1/19/15, INST 73-80 CHEV P-UP w/ AC EVAP KIT PG 8 OF 27 8 FIREWALL MODIFICATION CONT. DRILL HOLES AS SHOWN BELOW IN FIGURE 5. DRILL 3/16” HOLE OEM HOLE OEM HEATER HOLES (3) DRILL 1 ⅛” HOLES (2) DRILL 2” HOLES DRILL 3/16” HOLE DRILL 3/16” HOLE FIGURE 5 OEM HOLE FIREWALL COVER INSTALLATION APPLY A 1/4” BEAD OF SILICONE AROUND THE BACK SIDE OF THE FIREWALL COVER AS SHOWN BELOW. INSTALL FIREWALL COVER TO FIREWALL USING A 1/4-20 x 3/4” HEX BOLT, 1/4“ FLAT WASHER, 1/4” NUT w/ STAR WASHER AND (8) #14 x 3/4“ SHEET METAL SCREWS AS SHOWN BELOW. INSTALL GROMMETS AS SHOWN BELOW. SILICONE LARGE GROMMET 33137-VUI (8) #14 x 3/4” SHEET METAL SCREWS GROMMET 33135-VUI BACK SIDE OF FIREWALL COVER 644086 9 GROMMET 33144-VUI 1/4” NUT w/ STAR WASHER FIGURE 6 1/4-20 x 3/4” BOLT 1/4” FLAT WASHER 904184 REV C 1/19/15, INST 73-80 CHEV P-UP w/ AC EVAP KIT PG 9 OF 27 BRACKET & EVAPORATOR HARDLINE INSTALLATION ON A WORKBENCH, INSTALL EVAPORATOR REAR BRACKET USING (4) 1/4-20 x 1/2” HEX BOLTS (SEE FIGURE 8, PAGE 11). INSTALL #6 EVAPORATOR HARDLINE AND (2) HEATER HARDLINES WITH PROPERLY LUBRICATED O-RINGS (SEE FIGURE 8, PAGE 11, AND FIGURE 11, PAGE 13). INSTALL EVAPORATOR FRONT BRACKET ON EVAPORATOR USING (2) 1/4-20 x 1/2” HEX BOLTS, AND TIGHTEN AS SHOWN IN FIGURE 7, BELOW. (2) 1/4-20 x 1/2” HEX BOLTS EVAPORATOR FRONT BRACKET 644087 FIGURE 7 10 904184 REV C 1/19/15, INST 73-80 CHEV P-UP w/ AC EVAP KIT PG 10 OF 27 BRACKET & EVAPORATOR HARDLINE INSTALLATION CONT. ECU MODULE (2) 1/4-20 x 1/2” HEX BOLTS HOLD WITH THIS WRENCH (2) 1/4-20 x 1/2” HEX BOLTS REAR EVAPORATOR BRACKET 644083 TWIST WITH THIS WRENCH LUBRICATE O-RING (SEE FIGURE 11, PAGE 13.) FIGURE 8 #6 O-RING (33857-VUF) #10 O-RING (33859-VUF) #6 LIQUID LINE 091153 11 HEATER LINE (EVAPORATOR TO WATER PUMP) 091151 HEATER LINE (EVAPORATOR TO INTAKE) 091151 904184 REV C 1/19/15, INST 73-80 CHEV P-UP w/ AC EVAP KIT PG 11 OF 27 EVAPORATOR INSTALLATION LIFT EVAPORATOR UNIT UP UNDER THE DASHBOARD. SECURE LOOSELY TO THE FIREWALL USING (2) 1/4-20 x 1 ¼” HEX BOLTS, (2) FLAT WASHERS AND (2) .563 L SPACERS (SEE FIGURE 9). NOTE: TO ENSURE PROPER DRAINAGE, IT IS VERY IMPORTANT THAT THE EVAPORATOR IS LEVEL, BOTH LEFT-RIGHT AND FORE-AFT. CHECK FOR LEVEL ON THE FLAT PORTIONS OF THE CASE AROUND THE DRAIN, BLOCK THE UNIT UP, THEN DRILL FOR FRONT BRACKET SCREWS. SECURE THE FRONT EVAPORATOR MOUNTING BRACKET TO COWL USING (2) #14 x 3/4” HEX SHEET METAL SCREWS. SEE FIGURE 9a, BELOW. VERIFY THAT EVAPORATOR UNIT IS LEVEL AND SQUARE TO THE DASH. THEN DRILL (2) TIGHTEN ALL MOUNTING BOLTS. 3/16” HOLES (2) #14 x 3/4” NOTE: TIGHTEN THE BOLT ON FIREWALL FIRST, THEN THE FRONT SHEET METAL MOUNTING BRACKET. SCREWS INSTALL #10 SUCTION LINE AS SHOWN IN FIGURE 9b, BELOW. NOTE: WRAP THE #10 FITTING CONNECTIONS WITH PRESS TAPE. SEE FIGURE 9b, BELOW. REINSTALL (2) OEM BOLTS UNDER DASH ON PASSENGER SIDE DOOR PILLAR. REINSTALL DASH BRACE INNER (IF EQUIPPED). COWL FIGURE 9a (2) 1/4-20 x 1 ¼” HEX BOLTS VIEW FROM PASSENGER SIDE INSIDE OF CAB (2) 1/4” FLAT WASHERS (2) .563 L SPACERS NOTE: AFTER INSTALLING #10 SUCTION LINE, WRAP ALL EXPOSED METAL (FITTINGS & TUBE) WITH SUPPLIED PRESS TAPE. FIGURE 9 #10 O-RING 33859-VUF PRESS TAPE #10 SUCTION LINE 091152 FIGURE 9b 12 904184 REV C 1/19/15, INST 73-80 CHEV P-UP w/ AC EVAP KIT PG 12 OF 27 DRAIN HOSE INSTALLATION 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. 1” 1” EVAPORATOR CASE DRAIN HOSE LUBRICATING O-RINGS O-RING MALE INSERT FEMALE NUT FOR A PROPER SEAL OF FITTINGS: INSTALL SUPPLIED O-RINGS AS SHOWN AND LUBRICATE WITH SUPPLIED OIL. O-RING #6 O-RING SUPPLIED OIL FOR O-RINGS #8 O-RING FIGURE 10 O-RINGS, INSTALLS OVER MALE INSERT TO SWAGED LIP #10 O-RING FIGURE 11 A/C HOSE INSTALLATION HOLD WITH THIS WRENCH TWIST WITH THIS WRENCH STANDARD HOSE KIT LOCATE THE #8 COMPRESSOR A/C HOSE. LUBRICATE (2) #8 O-RINGS (SEE FIGURE 11, ABOVE) AND CONNECT THE 90° FEMALE FITTING TO THE #8 DISCHARGE PORT ON THE COMPRESSOR. ROUTE THE STRAIGHT FEMALE FITTING w/ 134a SERVICE PORT TO THE #8 CONDENSER HARDLINE COMING THROUGH CORE SUPPORT. SEE FIGURE 13, PAGE 15. TIGHTEN EACH FITTING CONNECTION AS SHOWN. LOCATE THE #10 COMPRESSOR A/C HOSE. LUBRICATE (2) #10 O-RINGS (SEE FIGURE 11, ABOVE) AND CONNECT THE #10 135° FEMALE FITTING w/134a SERVICE PORT TO THE #10 SUCTION PORT ON THE COMPRESSOR. ROUTE THE STRAIGHT FEMALE FITTING TO THE #10 EVAPORATOR. SEE FIGURE 12, PAGE 14, AND FIGURE 13, PAGE 15. TIGHTEN EACH FITTING CONNECTION AS SHOWN. INSTALL #6 A/C LIQUID LINE AS SHOWN IN FIGURE 13, PAGE 15. MODIFIED A/C HOSE KIT 13 REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH MODIFIED HOSE KIT. 904184 REV C 1/19/15, INST 73-80 CHEV P-UP w/ AC EVAP KIT PG 13 OF 27 HEATER HOSE & HEATER CONTROL VALVE INSTALLATION ROUTE HEATER HOSE FROM WATER PUMP TO THE HEATER LINE COMING THROUGH THE FIREWALL AS SHOWN IN FIGURE 12, BELOW. SECURE USING HOSE CLAMPS. NOTE: A SMALL AMOUNT OF SILICONE SPRAY WILL EASE HEATER HOSE INSTALLATION. ROUTE HEATER HOSE FROM THE INTAKE TO THE HEATER LINE COMING THROUGH THE FIREWALL AS SHOWN BELOW. NOTE: INSTALL HEATER CONTROL VALVE IN LINE WITH INTAKE MANIFOLD (PRESSURE SIDE) HEATER HOSE. SECURE USING HOSE CLAMPS AS SHOWN. NOTE PROPER FLOW DIRECTION. HOSE SHOULD PROTRUDE THROUGH THE FIREWALL COVER SLIGHTLY TO CLOSE THE GAP BETWEEN THE ALUMINUM LINE AND THE FIREWALL COVER. SEAL ANY REMAINING GAP WITH RTV SILICONE. FROM HE TO W ATER CORE ATER PUMP HEATER HOSE #10 SUCTION LINE O-RINGS FROM H TO H TR CNTR L EATE R CO VLV RE FRO M MAN INTAK E IFO LD #6 LIQUID LINE HEATER HOSE NOTE: FLOW DIRECTION FOLLOWS MOLDED ARROW ON VALVE. FIGURE 12 14 904184 REV C 1/19/15, INST 73-80 CHEV P-UP w/ AC EVAP KIT PG 14 OF 27 FRO M MA INTA NIF K OL E D NOTE: FLOW DIRECTION FOLLOWS MOLDED ARROW ON VALVE. HEATER HOSE 904184 REV C 1/19/15, INST 73-80 CHEV P-UP w/ AC EVAP KIT PG 15 OF 27 FIGURE 13 HEATER HOSE (HEATER CONTROL VALVE/INTAKE) #10 SUCTION HOSE 096005 SAFETY SWITCH (BINARY TYPE) SCREW-ON DRIER (REFER TO CONDENSER INSTRUCTIONS) #6 CONDENSER/DRIER HARDLINE 091145 COMPRESSOR OUT #6 DRIER/ CORE SUPPORT HARDLINE 091146 IN #8 DISCHARGE HOSE 096004 NOTE: VINTAGE AIR SYSTEMS REQUIRE (2) 5/8” HOSE NIPPLES (NOT SUPPLIED). #8 CONDENSER HARDLINE 091148 #6 CORE/ EVAPORATOR LIQUID HARDLINE 091147 #2 ADEL CLAMP 31600-VUD #6 LIQUID HARDLINE 091150 #10 ADEL CLAMP 31601-VUD TIE WRAP A/C & HEATER HOSE ROUTING FROM HEATER CONTROL VALVE TO HEATER CORE 15 DRIVER AND PASSENGER SIDE CENTER LOUVER HOSE ADAPTER INSTALLATION INSTALL (4) S-CLIPS ON DRIVER SIDE CENTER LOUVER HOSE ADAPTER (SEE FIGURE 14, BELOW). INSTALL DRIVER SIDE CENTER LOUVER HOSE ADAPTER IN CENTER LOUVER AS SHOWN BELOW IN FIGURE 14. INSTALL (4) S-CLIPS ON PASSENGER SIDE CENTER LOUVER HOSE ADAPTER (SEE FIGURE 14a, BELOW). INSTALL PASSENGER SIDE CENTER LOUVER HOSE ADAPTER IN OEM PASSENGER SIDE CENTER LOUVER AS SHOWN BELOW IN FIGURE 14a. DASH PAD DRIVER SIDE INSTRUMENT CENTER LOUVER PANEL BEZEL HOSE ADAPTER PASSENGER SIDE 623216 CENTER LOUVER HOSE ADAPTER 623221 (4) S-CLIPS (4) S-CLIPS FIGURE 14 OEM PASSENGER SIDE CENTER LOUVER FIGURE 14a DRIVER AND PASSENGER SIDE LOUVER HOSE ADAPTER INSTALLATION INSTALL (3) S-CLIPS ON PASSENGER SIDE LOUVER HOSE ADAPTER (SEE FIGURE 15). INSTALL PASSENGER SIDE LOUVER HOSE ADAPTER TO PASSENGER SIDE LOUVER AS SHOWN BELOW IN FIGURE 15. CUT & REMOVE DRIVER SIDE LOUVER DUCT AS SHOWN IN FIGURE 15a. INSTALL (4) S-CLIPS ON DRIVER SIDE LOUVER HOSE ADAPTER AS SHOWN IN FIGURE 15a. CUT & INSTALL DRIVER SIDE LOUVER HOSE ADAPTER IN DRIVER SIDE REMOVE DRIVER SIDE LOUVER DUCT AS SHOWN BELOW. LOUVER DUCT (3) S-CLIPS 1/2” DRIVER SIDE LOUVER DUCT FIGURE 15 DRIVER SIDE LOUVER HOSE ADAPTER 623215 PASSENGER SIDE LOUVER HOSE ADAPTER 623220 FIGURE 15a 904184 REV C 1/19/15, INST 73-80 CHEV P-UP w/ AC EVAP KIT PG 16 OF 27 (4) S-CLIPS 16 FINAL STEPS INSTALL DUCT HOSES AS SHOWN IN FIGURE 18, PAGE 19. ROUTE A/C WIRES THROUGH 3/8” GROMMET AS SHOWN IN FIGURE 16 (12 VOLT/GROUND/BINARY SWITCH/HEATER VALVE). INSTALL CONTROL PANEL ASSEMBLY. PLUG THE WIRING HARNESS IN THE ECU MODULE ON SUB CASE AS SHOWN IN FIGURE 18, PAGE 19 (WIRE ACCORDING TO WIRING DIAGRAM ON PAGE 20 AND 21). MODIFY GLOVE BOX AS SHOWN ON PAGE 18. REINSTALL GLOVE BOX. REINSTALL ALL PREVIOUSLY REMOVED ITEMS, INNER FENDER. FILL RADIATOR WITH AT LEAST A 50/50 MIXTURE OF APPROVED ANTIFREEZE AND DISTILLED WATER. IT IS THE OWNER'S RESPONSIBILITY TO KEEP THE FREEZE PROTECTION AT THE PROPER LEVEL FOR THE CLIMATE IN WHICH THE VEHICLE IS OPERATED. FAILURE TO FOLLOW ANTIFREEZE RECOMMENDATIONS WILL CAUSE HEATER CORE TO CORRODE PREMATURELY AND POSSIBLY BURST IN A/C MODE AND/OR FREEZING 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 CAPACITIES STATED ON THE INFORMATION PAGE (PAGE 4) OF THIS INSTRUCTION MANUAL. SEE OPERATION OF CONTROLS PROCEDURES PAGE 22. 3/8” GROMMET 33144-VUI WIRING HARNESS (HEATER CONTROL VALVE) WIRING HARNESS (12 VOLT/GROUNDS/BINARY SWITCH) FIGURE 16 17 904184 REV C 1/19/15, INST 73-80 CHEV P-UP w/ AC EVAP KIT PG 17 OF 27 GLOVE BOX MODIFICATION USE GLOVE BOX MODIFICATION TEMPLATE PROVIDED ON PAGE 25. PLACE THE TEMPLATE ON THE OUTSIDE OF THE GLOVE BOX ON THE PASSENGER SIDE. MARK THE OUTSIDE OF THE GLOVE BOX ALONG THE FRONT OF THE TEMPLATE AS SHOWN IN FIGURE 17, BELOW. PLACE THE SAME TEMPLATE ON THE INSIDE OF THE GLOVE BOX ON THE DRIVER SIDE. MARK THE INSIDE OF THE GLOVE BOX ALONG THE FRONT OF THE TEMPLATE AS SHOWN BELOW. CUT SIDES OF GLOVE BOX. MARK THE BOTTOM CONNECTING EACH SIDE OF GLOVE BOX THAT WAS JUST CUT, AND DISCARD THE FRONT PORTION OF THE BOX. INSTALL THE NEW SUPPLIED GLOVE BOX BY PRESSING THE S-CLIPS ONTO THE OEM PORTION OF THE BOX AS SHOWN IN FIGURE 17a, BELOW. OEM with A/C GLOVE BOX DRIVER SIDE OF GLOVE BOX MODIFIED GLOVE BOX DISCARD FRONT PORTION OF BOX. S-CLIP FACTORY AIR GLOVE BOX TEMPLATE S-CLIP FACTORY AIR GLOVE BOX TEMPLATE S-CLIP CUT BOX WITH A HACK SAW BLADE ON THESE (3) FRONT LINES ONLY. PASSENGER SIDE OF GLOVE BOX FIGURE 17 S-CLIP FIGURE 17a 18 904184 REV C 1/19/15, INST 73-80 CHEV P-UP w/ AC EVAP KIT PG 18 OF 27 CONTROL PANEL & DUCT HOSE ROUTING HI DEF OFF FLR COLD A/C DASH HOT PASSENGER SIDE DEFROST DUCT 2” x 12” PLUG FROM CONTROL WIRING HARNESS 232007-VUR DRIVER SIDE DEFROST DUCT 2” x 28” PLUG FROM WIRING HARNESS 232001-VUR PASSENGER SIDE LOUVER 2 ½” x 45” CENTER DRIVER SIDE LOUVER 2 ½” x 28” FIGURE 18 DRIVER SIDE LOUVER 2 ½” x 26” CENTER PASSENGER SIDE LOUVER 2 ½” x 15” 19 904184 REV C 1/19/15, INST 73-80 CHEV P-UP w/ AC EVAP KIT PG 19 OF 27 Wiring Diagram 232007-VUR TAN ORA BLK AC ANNUNCIATOR BACKLIGHT POS BACKLIGHT NEG GND 5V-SW WHT RED WHT/RED WHT/YEL JF8 TEMP WIPER MODE WIPER WHT/GRN FAN WIPER PRE-WIRED VIEWED FROM WIRE SIDE 232002-VUA A/C (IF USED) GEN IV ECU GEN IV WIRING DIAGRAM REV D, 5/6/2014 TEMP MODE FAN PROGRAM * DASH LAMP (IF USED) *** WIDE OPEN THROTTLE SWITCH (OPTIONAL) ** CIRCUIT BREAKER 30 AMP HEATER CONTROL VALVE • Dash Lamp Is Used Only With Type 232007-VUR Harness. • Warning: Always Mount Circuit Breaker As Close to the Battery As Possible. (NOTE: Wire Between Battery and Circuit Breaker Is Unprotected and Should Be Carefully Routed to Avoid a Short Circuit). • Wide Open Throttle Switch Contacts Close Only at Full Throttle, Which Disables A/C Compressor. 904184 REV C 1/19/15, INST 73-80 CHEV P-UP w/ AC EVAP KIT PG 20 OF 27 20 Gen IV Wiring Connection Instruction WIRING HARNESS CONTROL WIRING HARNESS RED & WHITE A/C COMPRESSOR RELAY RED BLUE NOTE: MOUNT RELAY IN DESIRED LOCATION UNDER DASH RED WH IT E Ignition Switch: VIOLET Violet 12V Ign Switch Source (Key On Accessory) Position Must Be Switched. +12V NOTE: WIRING YELLOW & ORANGE (IGNITION HOT HARNESS COMING FROM TERMINAL) HARNESS ARE NOT USED. YELLOW RUN BAT IGNITION SWITCH ORANGE TAN DASH BACK LIGHT+0-12v GRAY GRAY WIRE IS USED FOR PROGRAMING CONTROLS IF APPLICABLE RED GREEN RED GREEN FIREWALL BLACK BLUE Heater Control Valve: RED LATCH WIRING HARNESS WHITE CHASSIS GROUND NOTE: HEATER CONTROL VALVE CONNECTION AND CHASSIS GROUND MAY BE LOCATED ON EITHER SIDE OF THE FIREWALL. ENSURE CONNECTOR IS LATCHED FIRMLY. HEATER CONTROL VALVE K BLAC BLUE COMPRESSOR WHITE NOTE: CONNECT WHITE WIRES DIRECTLY TO (-) BATTERY TERMINAL WHITE RED RED CIRCUIT BREAKER 30 AMP RED 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). 21 Install With Servo Motor Facing Down, As Shown. Note Flow Direction Arrow Molded Into Valve Body, And Install Accordingly. Binary/Trinary & Compressor: Binary: Connect As Shown (Typical Compressor Wiring). Be Sure Compressor Body Is Grounded. BINARY SAFETY SWITCH BLUE Dash Light: Tan Wire Used Only With Vintage Air Supplied Control Panel With LED Back Light. + - Trinary Switch: Connect According To Trinary Switch Wiring Diagram. Circuit Breaker/Battery: White Must Run To (-) Battery. Red May Run To (+) Battery Or Starter. Mount Circuit Breaker As Close to Battery As Possible. BATTERY 904184 REV C 1/19/15, INST 73-80 CHEV P-UP w/ AC EVAP KIT PG 21 OF 27 OPERATION OF CONTROLS NOTE: WHEN BATTERY POWER IS FIRST CONNECTED TO THE ECU, THE MICROPROCESSOR GOES THROUGH AN INITIALIZATION SEQUENCE. THIS INITIALIZATION MAY TAKE UP TO 30 SECONDS. DURING INITIALIZATION, THE BLOWER WILL NOT OPERATE, BUT THE DOORS INSIDE THE UNIT WILL BE OPERATING. A LOW BATTERY OR DISCONNECTING THE BATTERY MAY ALSO TRIGGER A REINITIALIZATION. DURING START UP, A LOW BATTERY MAY DROP BELOW 7 VOLTS, TRIGGERING REINITIALIZATION. A/C MODE OFF MODE LEVER DASH HI FLR BLOWER SPEED DEF HOT COLD A/C TEMPERATURE LEVER IN A/C MODE SLIDE THE TEMPERATURE LEVER ALL THE WAY TO THE RIGHT MODE LEVER TO ENGAGE COMPRESSOR. SLIDE THE LEVER TO (SLIDE LEVER LEFT OR RIGHT THE LEFT POSITION TO ADJUST DESIRED TEMPERATURE) HEAT MODE BLOWER SPEED ADJUST TO DESIRED SPEED OFF DASH TEMPERATURE LEVER HI FLR DEF HOT COLD BLOWER SPEED ADJUST TO DESIRED SPEED A/C TEMPERATURE LEVER SLIDE THE TEMPERATURE LEVER ALL THE WAY LEFT TO THE HOT POSITION. (SLIDE LEVER LEFT OR RIGHT TO DESIRED TEMPERATURE) MODE LEVER SLIDE THE LEVER TO THE CENTER POSITION DEFROST/ DE-FOG MODE OFF DASH HOT BLOWER SPEED ADJUST TO DESIRED SPEED MODE LEVER SLIDE THE LEVER TO THE RIGHT POSITION HI FLR DEF COLD A/C TEMPERATURE LEVER ADJUST LEVER TO DESIRED TEMPERATURE. (COMPRESSOR IS AUTOMATICALLY ENGAGED) 904184 REV C 1/19/15, INST 73-80 CHEV P-UP w/ AC EVAP KIT PG 22 OF 27 22 Symptom 904184 REV C 1/19/15, INST 73-80 CHEV P-UP w/ AC EVAP KIT PG 23 OF 27 Compressor will not turn off (All other functions work). 3. Compressor will not turn on (All other functions work). 2. Blower stays on high speed when ignition is on or off. 1b. Blower stays on high speed when ignition is on. 1a. 23 System is charged. System is not charged. All other functions work. No other functions work. Condition Repair or replace pot/control wiring. Replace relay. Check for faulty A/C relay. Check 2-pin connector at ECU housing. Check continuity to ground on white control head wire. Check for 5V on red control head wire. Charge system or bypass pressure switch. Replace BSC (This will require removal of evaporator from vehicle). Check to ensure that no BSC wiring is damaged or shorted to vehicle ground. The BSC operates the blower by ground side pulse width modulation 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. Be sure the small, 20 GA white ground wire is connected to the battery ground post. If it is, replace the ECU. Verify continuity to chassis ground with white control head wire at various points. Verify that all pins are inserted into plug. Ensure that no pins are bent or damaged in ECU. Actions Check for faulty A/C potentiometer or associated wiring. Check for disconnected or faulty thermistor. Check for faulty A/C potentiometer or associated wiring (Not applicable to 3-pot controls). System must be charged for compressor to engage. Unplug 3-wire BSC control connector from ECU. If blower stays running, BSC is either improperly wired or damaged. Unplug 3-wire BSC control connector from ECU. If blower shuts off, ECU is either improperly wired or damaged. Check for damaged ground wire (white) in control head harness. Check for damaged blower switch or potentiometer and associated wiring. Check for damaged pins or wires in control head plug. Checks Red wire at A/C pot should have approximately 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 or down. Disconnected or faulty thermistor will cause compressor to be disabled. To check for proper pot function, check voltage at white/blue wire. Voltage should be between 0V and 5V, and will vary with pot lever position. Danger: Never bypass safety switch with engine running. Serious injury can result. No other part replacements should be necessary. See blower switch check procedure. Loss of ground on this wire renders control head inoperable. Notes Troubleshooting Guide 904184 REV C 1/19/15, INST 73-80 CHEV P-UP w/ AC EVAP KIT PG 24 OF 27 Symptom 8. When ignition is turned on, blower momentarily comes on, then shuts off. This occurs with the blower switch in the OFF position. Erratic functions of blower, mode, temp, etc. 7. Blower turns on and off rapidly. 6. Loss of mode door function. 5. System will not turn on, or runs intermittently. 4. 24 This is an indicator that the system has been reset. Be sure the red power wire is on the battery post, and not on a switched source. Also, if the system is pulled below 7V for even a split second, the system will reset. Run red power wire directly to battery. Repair or replace. Charge battery. Check for faulty battery or alternator. Battery voltage is less than 12V. Check for damaged switch or pot and associated wiring. Ensure all system grounds and power connections are clean and tight. Verify proper meter function by checking the condition of a known good battery. Check for positive power at heater valve green wire and blower red wire. Check for ground on control head white wire. Install capacitors on ignition coil and alternator. Ensure good ground at all points. Relocate coil and associated wiring away from ECU and ECU wiring. Check for burned or loose plug wires. Actions Check for at least 12V at circuit breaker. Check for damaged stepper motor or wiring. Check for obstructed or binding mode doors. Check for damaged mode switch or potentiometer and associated wiring. Verify battery voltage is greater than 10 volts and less than 16. Verify connections on power lead, ignition lead, and both white ground wires. Noise interference from either ignition or alternator. Checks Battery voltage is at least 12V. Partial function of mode doors. No mode change at all. Will not turn on under any conditions. Works when engine is not running; shuts off when engine is started (Typically early Gen IV, but possible on all versions). Condition System shuts off blower at 10V. Poor connections or weak battery can cause shutdown at up to 11V. Typically caused by evaporator housing installed in a bind in the vehicle. Be sure all mounting locations line up and don’t have to be forced into position. Ignition noise (radiated or conducted) will cause the system to shut down due to high voltage spikes. If this is suspected, check with a quality oscilloscope. Spikes greater than 16V will shut down the ECU. Install a radio capacitor at the positive post of the ignition coil (See radio capacitor installation bulletin). A faulty alternator or worn out battery can also result in this condition. Notes Troubleshooting Guide (Cont.) GLOVE BOX MODIFICATION TEMPLATE 73-87 CHEV P-UP GLOVE BOX MODIFICATION TEMPLATE CUT ALONG DOTTED LINE 25 904184 REV C 1/19/15, INST 73-80 CHEV P-UP w/ AC EVAP KIT PG 25 OF 27 POWER STEERING BRACKET MODIFICATION NOTE: USE ILLUSTRATIONS BELOW TO DETERMINE POWER STEERING BRACKET, VERSION 1 OR 2. CUT ALONG DASHED LINES AND ALIGN THE TEMPLATE HOLE AND ADJUSTMENT SLOT WITH THE HOLE AND ADJUSTMENT SLOT ON THE POWER STEERING BRACKET. MARK THE BRACKET AROUND THE PERIMETER OF THE TEMPLATE. CUT AND REMOVE THE SHADED PORTION OF THE POWER STEERING BRACKET AS SHOWN BELOW. DISCARD THE A/C COMPRESSOR MOUNTING PORTION OF THE BRACKET. REINSTALL THE POWER STEERING BRACKET ON THE POWER STEERING PUMP. VERSION 1 VERSION 2 FOL D FOLD 1973-87 CHEVY P-UP w/ AC POWER STEERING BRACKET TEMPLATE VERSION 2 1973-87 CHEVY P-UP w/ AC POWER STEERING BRACKET TEMPLATE VERSION 1 CUT & REMOVE SHADED PORTION CUT ALONG DOTTED LINE CUT ALONG DOTTED LINE 26 904184 REV C 1/19/15, INST 73-80 CHEV P-UP w/ AC EVAP KIT PG 26 OF 27 EVAPORATOR KIT 754175 EVAPORATOR KIT PACKING LIST No. QTY. 1. 2. 1 1 PART No. DESCRIPTION 744004-VUE 794175 GEN IV 4-VENT EVAPORATOR SUB CASE with 204 ECU ACCESSORY KIT 1973-80 CHEV P-UP with A/C CHECK BY: PACKED BY: DATE: 1 GEN IV 4-VENT EVAPORATOR SUB CASE with 204 ECU 744004-VUE 2 HI OFF DASH HOT ACCESSORY KIT 794175 FLR DEF COLD A/C NOTE: IMAGES MAY NOT DEPICT ACTUAL PARTS AND QUANTITIES. REFER TO PACKING LIST FOR ACTUAL PARTS AND QUANTITIES. 904184 REV C 1/19/15, INST 73-80 CHEV P-UP w/ AC EVAP KIT PG 27 OF 27