an ISO 9001:2015 Registered Company

1968-76 Chevrolet Corvette without Factory Air

Evaporator Kit(561174-PCZ)

901174-PCZ REV K 08/26/20, PG 1 OF 29

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

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

www.vintageair.com

2

www.vintageair.com

901174-PCZ REV K 08/26/20, PG 2 OF 29

Cover..................................................................................................................................Table of Contents.................................................................................................................Packing List/Parts Disclaimer..................................................................................................Information Page..................................................................................................................Wiring Notice.......................................................................................................................Engine Compartment Disassembly..........................................................................................Passenger Compartment Disassembly..................................................................................... Astro Air Ventilation Duct Removal, Fresh Air Cap Installation....................................................Condenser Assembly and Installation, Compressor and Brackets, Pulleys.....................................Defrost Duct Replacement...................................................................................................Passenger and Driver Side A/C Duct Hose Adapter Installation................................................. Passenger Side Dash Modification......................................................................................... Center Louver Assembly Installation.....................................................................................Firewall Modification, Evaporator Installation.......................................................................... Evaporator Installation (Cont.).............................................................................................Drain Hose Installation........................................................................................................ Firewall Cover....................................................................................................................A/C Hose Installation, Heater Hose & Heater Control Valve Installation, Lubricating O-rings......... Hose Routing.................................................................................................................... Final Steps........................................................................................................................ Control Panel & Duct Hose Routing....................................................................................... Evaporator Hardline Installation...........................................................................................Wiring Diagram..................................................................................................................Gen IV Wiring Connection Instruction...................................................................................Operation of Controls..........................................................................................................Troubleshooting Guide........................................................................................................Troubleshooting Guide (Cont.).............................................................................................Firewall Modification Template, Passenger Compartment Modification Template..........................Packing List.......................................................................................................................

1 2 3 4 5 6 7 8 91011121314 151617181920212223242526272829

Table of Contents

3

www.vintageair.com

901174-PCZ REV K 08/26/20, PG 3 OF 29

Packing List: Evaporator Kit (561174-PCZ)

No. 1.2.

Qty.11

Part No.764172781174-PCN

DescriptionGen IV Evaporator Sub CaseAccessory 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 Evaporator Sub Case764172

Accessory Kit781174-PCN

WIPER OFFHI

COLD

DASH

HOT

DEF

HI

OFF

A/C

4

www.vintageair.com

901174-PCZ REV K 08/26/20, PG 4 OF 29

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 remain 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.

5

www.vintageair.com

901174-PCZ REV K 08/26/20, PG 5 OF 29

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 and 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 and 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 or 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.

•

•

•

6

www.vintageair.com

901174-PCZ REV K 08/26/20, PG 6 OF 29

Engine Compartment Disassembly

1.2.3.4.5.

Disconnect battery.Remove hood to ease installation (retain).Drain radiator.Remove OEM blower assembly and cover (discard).Remove OEM heater core and cover (discard).

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:

Figure 1

Heater Hoses

7

www.vintageair.com

901174-PCZ REV K 08/26/20, PG 7 OF 29

Passenger Compartment Disassembly

1.2.3.4.

5.6.7.8.

Remove the passenger side dash (retain).Disconnect the center dash (retain) and pull forward to remove the OEM center dash bezel (discard).Remove the OEM radio (retain).Remove the OEM control panel (discard panel, retain mounting support bracket). Refer to control panel kitinstruction for installation of new control panel.Drop the steering column from the console.Disconnect the driver side dash and pull forward.Remove the defrost duct and floor heater duct (discard) (See Figure 3, below) .Remove the heater (discard).

Perform the Following:

Figure 2

Figure 3

CORVETTE

Driver SideDash

CenterDashSteering

Column

Center DashBezel

ControlPanel

Radio

Passenger SideDash

HeaterFloor Heater

Duct

DefrostDuct

8

www.vintageair.com

901174-PCZ REV K 08/26/20, PG 8 OF 29

Astro Air Ventilation Duct Removal 1.2.

3.

4.5.

Remove driver and passenger side astro air ventilation ducts (discard) (See Figure 4, below).Remove passenger side dash support brace (discard) and cut off the mounting tab on the kick panel as shown in Figure 4, below.Remove the driver and passenger side astro air ventilation duct mounting brackets as shown in Figure 4, below.Install (2) S-clips on inside fresh air caps as shown in Figure 4a, below.Install inside fresh air caps onto the driver and passenger side as shown in Figure 4a, below.

Figure 4b

Fresh Air Cover Installation1.2.

Apply a 1/4” bead of silicone around the back side of the fresh air cap as shown in Figure 4b, below.Attach the fresh air cap to the firewall using a 1/4-20 x 1” bolt and washer (See Figure 4b, below).

Figure 4a

Figure 4

RemoveDash

SupportBrace

Cut

Astro AirVentilation

Duct

Driver SideKick Panel

Passenger SideKick Panel

Astro AirVentilation

Duct

Cut

S-clipS-clip

Inside Fresh Air Cap

Cut

Silicone Back Sideof Fresh Air

Cap

Fresh AirCap

1/4-20 x 1”Bolt withWasher

9

www.vintageair.com

901174-PCZ REV K 08/26/20, PG 9 OF 29

Figure 5

Figure 6

Condenser Assembly and Installation1.

2.

Refer to separate instructions included with the condenser kit to install the condenser (See Figure 5, below, for condenser location).Binary switch installation (Refer to condenser instructions).

FLOW

FLOW

Compressor and Brackets1. Refer to separate instructions included with the bracket kit to install the compressor bracket (See Figure 6,

below, for compressor mounting location).

Pulleys1. In most instances, the belt lengths will remain the same (See Figure 6, below).

Tab“C”

Tab“G”

Tab“A”

Tab“E”

Compressor

Water PumpPulley

CrankshaftPulley

Generatoror

Alternator

Mount theCompressorUsing Tabs“G” & “C”

NOTE: Belt routing may varywith different bracket sets.Always refer to instructions included with brackets.

#6 Drier/CoreSupport Hardline

Drier

OEMRadiator

CoreSupport

#8 Condenser/CoreSupport Hardline

Out In

BinarySwitch

22503-VCA - Water Pump Pulley (2-Groove)22506-VCA - Crankshaft Pulley (2-Groove) (with Power Steering, a 3-Groove Crank Pulley is Required)22507-VCA - Crankshaft Pulley (3-Groove)

735002 - Water Pump Pulley (3-Groove)Fits 1966-70 (5/8” Shaft)735003 - Water Pump Pulley (3-Groove)Fits 1971-74 (3/4” Shaft)

Pulleys available through Vintage Air:

Short Pump Small Block Chevy

Short Pump Big Block Chevy

10

www.vintageair.com

901174-PCZ REV K 08/26/20, PG 10 OF 29

Defrost Duct Replacement 1.

2.

3.4.

Remove screws attaching the OEM defrost duct (retain (2) screws attaching the duct to the dash pad) (See Photo 1, below).Remove remaining screws attaching the dash pad to the dash, and remove the dash pad from the vehicle (retain) (See Photo 1, below).Place new defrost duct on the dash pad, in place of the OEM defrost duct (See Photo 2, below).Attach using (2) screws removed in Step #1. Tighten and reinstall the dash pad using the OEM screws previously removed (See Photo 3, below).

Photo 1 Photo 2

Photo 3

DashPad

DashPad

OEM ScrewLocation

OEM ScrewLocation Defrost Duct

625090

OEMScrew

OEMScrew

11

www.vintageair.com

901174-PCZ REV K 08/26/20, PG 11 OF 29

Passenger and Driver SideA/C Duct Hose Adapter Installation

1.2.

3.

4.

5.

Remove (2) vent knobs as shown in Figure 7, below (retain).Remove the passenger and driver side vent adapters (discard) as shown in Figure 8, below. NOTE: Retain mounting hardware.Install the inner and outer A/C duct hose adapters as shown in Figure 8, below. Use OEM screws to secure the adapters to the dash.Install the vent knob as shown using a 10-24 x 1 ¼” pan head screw and 3/16” flat washer. NOTE: Thepassenger side installation is shown below in Figure 8. Repeat the same steps for the driver sideinstallation.See Figure 8a, below, for a completely assembled view of the A/C duct hose adapter.

Figure 7

Figure 8

Figure 8a

RemoveVent Knob

RemoveVent Knob

10-24 x 1 ¼”Pan Head Screw 3/16” Flat

Washer

(3) OEMScrews

Vent Knob

Outer A/C DuctHose Adapter

Inner A/C DuctHose Adapter

Vent Adapter

OEMAssembly

AssembledView of

A/C DuctHose Adapter

12

www.vintageair.com

901174-PCZ REV K 08/26/20, PG 12 OF 29

Passenger Side Dash Modification1.

2.3.

Align the template (provided on Page 28) on the back side of the passenger side dash as shown in Figure 9, below.Using a pencil or scribe, mark along the edge of the template as shown.Remove the template and cut along the dotted line. Remove the plastic portion of the dash. NOTE: Do not cut through the foam dash pad on the back side of the plastic (See Figure 9a, below).

PASSENGER SIDE DASH

MODIFICATION TEMPLATE

Figure 9Figure 9a

Back Side ofPassenger Side

Dash

Template

RemoveShaded Portion

Foam Pad

13

www.vintageair.com

901174-PCZ REV K 08/26/20, PG 13 OF 29

Center Louver Assembly Installation1.

2.

3.

4.5.

Remove the OEM center dash bezel, OEM wiper switch knob and OEM wiper switch as shown in Figure 10, below.Secure the wiper switch and ground wire to the wiper switch bracket using (2) 10-32 x 1/2” pan head screws and (2) nuts with star washers as shown in Photo 4, below.Install the OEM wiper switch assembly onto the supplied center louver bezel using (2) #6 x 3/8” pan head screws as shown in Photo 5, below.Reinstall the wiper knob onto the wiper switch.Install the center louver bezel assembly into the dash using the OEM mounting scews. As shown in Photo 5, below, secure the ground wire between the louver bezel assembly and the dash.

Figure 10

Photo 4

Photo 5

CORVETTE

Remove OEMWiper Switch

Remove OEMScrews and Bezel

Ground Wire(If Equipped)

(2) 10-32 x 1/2” Pan Head Screws

(2) 10-32 Nutswith Star Washer

(2) #6 x 3/8”Pan Head Screws

MountingHole

MountingHole

MountingHole

Secure Ground WireBetween Bezel Assembly

and Dash

14

www.vintageair.com

901174-PCZ REV K 08/26/20, PG 14 OF 29

Figure 12 Figure 12a

Firewall Modification1.

2.

3.

Cut out the firewall modification template provided on Page 28. Working in the engine compartment, place the template on the firewall as shown in Figure 12, below.Once the template is aligned correctly and taped into place, mark around the dotted line (See Figure 12, below). Once you have marked around the dotted line, remove the template. Cut along the dotted line to remove the shaded portion of the firewall as shown in Figure 12a, below.

Cut AlongDotted LineTemplate

Mark AlongDotted Line

Evaporator Installation

1.

2.

3.4.

5.

6.

7.

On a workbench, install the evaporator rear bracket, and install the evaporator hardlines with properly lubricated O-rings (See Figure 22, Page 22, and Figure 17, Page 18).Install the front mounting bracket onto the evaporator using (2) 1/4-20 x 1/2” hex bolts, and tighten as shown in Figure 13, Page 15.Place the polyethylene sheet over the stepper motors (See Figure 14, Page 15).Lift the evaporator unit up under the dashboard (See Figure 14, Page 15). Secure loosely to the firewall using a 1/4-20 x 1” bolt and washer (See Figure 14, Page 15). 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 flatportions of the case around the drain.Using a #14 x 3/4” sheet metal screw, secure the front evaporator mounting bracket to the inner cowl by aligning the right hole in the front evaporator mounting bracket with the OEM hole in the inner cowl (See Figure 14, Page 15).To secure the left side of the front mounting bracket, with the evaporator mounting bracket in place, drill a 3/16” hole in the inner cowl using the left mounting bracket hole as a guide. Secure the bracket to the inner cowl using a #14 x 3/4” sheet metal screw (See Figure 14, Page 15).Verify that the evaporator unit is level and square to the dash; then tighten all mounting bolts. NOTE: Tighten the bolt on the firewall first. Then tighten the front mounting bracket screws.

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.

15

www.vintageair.com

901174-PCZ REV K 08/26/20, PG 15 OF 29

Figure 14

Figure 13

Evaporator Installation (Cont.)

FIGURE 7

10-32 x 1/2”Screw

LeftMounting

HoleRight

MountingHole

Evaporator FrontBracket

643071-PCA

(2) 1/4-20 x 1/2”Hex Bolts

4-VentA/C Plenum

1/4-20 x 1”Bolt & Washer

(Install Bolt & WasherFrom Engine

Compartment Side)

Place PolyethyleneSheet Over theStepper Motors

Once Bracket isin Place, Drill a 3/16”

Mounting Hole

(2) #14 x 3/4”Sheet Metal Screws

NOTE: InstallThis Screw First

OEMHole

InnerCowl

16

www.vintageair.com

901174-PCZ REV K 08/26/20, PG 16 OF 29

Figure 15

Drain Hose Installation1.

2.

In line with the drain, lightly make a mark on the firewall. Measure 1” down and drill a 5/8” hole through the firewall (See Figure 15, below).Install the drain hose to the bottom of the evaporator unit, and route through the firewall (See Figure 15, below).

DrainHose

Drain

1”

17

www.vintageair.com

901174-PCZ REV K 08/26/20, PG 17 OF 29

Firewall Cover1.2.3.

4.5.

Apply a 1/4” bead of silicone around the back side of the firewall cover as shown in Figure 16, below.Pass the lines through the firewall cover, and secure with (2) 7/16” panel retainers (See Figure 16, below).Once the firewall cover is in place, locate the hole on the left side of the firewall cover. Drill a 3/8” hole through the firewall. Install a 7/16” panel retainer to secure the left side of the firewall cover to the firewall (See Figure 16, below).Install (2) grommets in the firewall cover cap as shown in Figure 16, below.Apply a 1/4” bead of silicone around the back side of the firewall cover cap as shown in Figure 16, below.Using (2) #8 x 1/2” pan head screws, install the firewall cover cap as shown.

S B

Y

Figure 16

Back Sideof FirewallCover Cap

Drill 3/8”Hole

FirewallCap

Silicone

Back Sideof Firewall

Cover

Silicone

(3) 7/16”Panel

Retainers

LargeGrommet #10 Suction

Line

#6 LiquidLine

1 ¼” x 1” with 3/8” Hole

Grommet

(2) #8 x 1/2”Pan Head Screws

18

www.vintageair.com

901174-PCZ REV K 08/26/20, PG 18 OF 29

A/C Hose Installation

Heater Hose & Heater Control Valve Installation

1.

2.

3.

1.

2.

Locate the #8 compressor A/C hose. Lubricate (2) #8 O-rings (See Figure 17, below) and connect the 135° female fitting to the #8 discharge port on the compressor. Then route the 45° female fitting to the #8 condenser hardline coming through the core support (See Figure 18, Page 19). Tighten each fitting connection as shown in Figure 17, below.Locate the #10 compressor A/C hose. Lubricate (2) #10 O-rings (See Figure 17, below) and connect the 45° female fitting with 134a service port to the #10 suction port on the compressor. Then route the straight fitting to the #10 evaporator hardline coming through the firewall (See Figure 18, Page 19). Tighten each fitting connection as shown in Figure 17, below. NOTE: Wrap the #10 fitting connections at the firewall with press tape (See Figure 18, Page 19).Locate the #6 A/C hose. Lubricate (2) #6 O-rings (See Figure 17, below) and connect the 90° fitting to the #6 hardline coming through the core support from the drier. Attach the straight fitting with 134a service port to the #6 evaporator hardline coming through the firewall (See Figure 18, Page 19). Tighten each fitting connection as shown in Figure 17, below. Use a #6 Adel clamp to secure the #6 A/C hose to the inner fender well as shown in Figure 18, Page 19. Secure the Adel clamp to the inner fender using a 10-32 x 1/2” machine screw and nut.

Route a piece of heater hose from the water pump to the heater line coming through the firewall as shown in Figure 19, Page 20. Secure using hose clamps.Route a piece of heater hose from the intake to the heater line coming through the firewall as shown in Figure 19, Page 20. NOTE: Install heater control valve in line with the intake manifold (pressure side) heater hose, and secure using hose clamps as shown in Figure 19, Page 20. Also note proper flow direction.

Standard Hose Kit:

1. Refer to separate instructions included with modified hose kit.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.

Figure 17

ww

w.v

inta

gea

ir.c

om

19 901174-PCZ REV K 08/26/20, PG 19 OF 29

FLO

W

Fig

ure

18

Ou

t

Hos

e R

outi

ng

Evap

orat

orSub

Cas

e

Fire

wal

lCov

er

ECU

Mod

ule

Pres

sTa

pe

Pres

sTa

pe

Hea

ter

Con

trol

Valv

e

#10

A/C

Suc

tion

Hos

e(C

ompr

esso

r/Ev

apor

ator

)

#6

A/C

Hos

e(D

rier

/Eva

pora

tor)

#8

A/C

Dis

char

ge H

ose

(Com

pres

sor/

Con

dens

er H

ardl

ine)

Bin

ary

Switc

h

In

20

www.vintageair.com

901174-PCZ REV K 08/26/20, PG 20 OF 29

Final Steps1.

2.3.4.

5.6.

7.8.

9.10.11.

12.13.

Using the supplied tie wraps and a #10 x 3/4” sheet metal screw, install the driver side louver adapter assembly as shown in Figure 20, below. NOTE: Use the tie wraps to raise and secure the louver adapter assembly.Install the duct hoses as shown in Figure 21, Page 21.Reinstall the center dash assembly.Reinstall the control panel assembly. Refer to control panel instructions. NOTE: Controls must be calibrated for proper operation. Refer to control panel instructions.Plug the control panel harness into the ECU module on the sub case as shown in Figure 21, Page 21.Plug the wiring harnesses into the ECU module on the sub case. Wire according to wiring diagrams on Pages 23 & 24.Reinstall all previously removed items.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 licensed automotive A/C technician.Evacuate the system for a minimum of 45 minutes prior to charging, and perform a leak check prior to servicing.Charge the system to the capacities stated on Page 4 of this instruction manual.See Operation of Controls procedures on Page 25.

FROM INTAKE

TO WATER PUMP FROM HTR CNTRL VLV

Figure 19

Figure 20

NOTE: Flow Direction FollowsMolded Arrow on Valve.

ECUModule

PressTape

#10Suction

Line(Insulated)

ExpansionValve

FirewallCover Cap

FirewallCover

HeaterHose

#6 A/CHose

#10 SuctionHose

O-ring

#10 x 3/4”Sheet Metal

Screw

Driver Side LouverAdapter Assembly

496137

21

www.vintageair.com

901174-PCZ REV K 08/26/20, PG 21 OF 29

COLD

DASH

HOT

DEF

HI

OFF

A/C

Figure 21

Control PanelWiring Harness232007-VUA

PassengerSide Louver2 ½” x 30”

PassengerSide Louver2 ½” x 20”

(Evaporator Side)

Passenger SideDuct Extension

Assembly605173-PCA

Defrost Duct2 ½” x 15”

Driver Side2 ½” x 22”

Driver Side Center Louver

2 ½” x 18”

Passenger Side Center Louver

2 ½” x 18”

Plug FromWiring Harness232600-VUA

Control Panel & Duct Hose Routing

ww

w.v

inta

gea

ir.c

om

22 901174-PCZ REV K 08/26/20, PG 22 OF 29

FIG

UR

E 8

Fig

ure

22

NO

TE:

Aft

er in

stal

ling

th

e#

10

su

ctio

n li

ne,

wra

p a

llex

pos

ed m

etal

(fi

ttin

gs

&tu

be)

wit

h s

up

plie

d p

ress

tap

e.

Evap

orat

or H

ard

line

Inst

alla

tion

#10

O-r

ing

(2)

#10

O-r

ings

ECU

Mod

ule

Pres

s Ta

pe#

6 O

-rin

g

#10

Suc

tion

Line

(091

51-P

CS)

Hea

ter

Line

(Hea

ter

to W

ater

Pum

p)09

152-

PCH

Hea

ter

Line

(Hea

ter

to I

ntak

e)09

153-

PCH

(2)

1/4-

20 x

1/2

” Bol

ts(L

ocat

ed o

n Sub

Cas

e)

Hol

d w

ithTh

is W

renc

h

Twis

t w

ithTh

is W

renc

h

Lubr

icat

e O

-rin

g (S

ee F

igur

e 17

, Pa

ge 1

8

#6

Liqu

id L

ine

(091

50-P

CL)

23

www.vintageair.com

901174-PCZ REV K 08/26/20, PG 23 OF 29

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

24

www.vintageair.com

901174-PCZ REV K 08/26/20, PG 24 OF 29

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 ignition switch source (key on accessory) position must be switched.

When using a Vintage Air suppliedcontrol panel, connect the tan wirefrom the Gen IV evaporator wiringharness to the factory dash lights toenable panel backlighting.

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.

25

www.vintageair.com

901174-PCZ REV K 08/26/20, PG 25 OF 29

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 DEFROST to FLOORto DASH, with a blend in between.

This lever/knob 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 forcalibration procedure.

COLD

DASH

HOT

FLOOR

DEF

HI

OFF

A/C

COLD

DASH

HOT

FLOOR

DEF

HI

OFF

A/C

COLD

DASH

HOT

FLOOR

DEF

HI

OFF

A/C

COLD

DASH

HOT

FLOOR

DEF

HI

OFF

A/C

Blower Speed

Mode Control

Temperature Control

ww

w.v

inta

gea

ir.c

om

26 901174-PCZ REV K 08/26/20, PG 26 OF 29

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

27 901174-PCZ REV K 08/26/20, PG 27 OF 29

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.

28

www.vintageair.com

901174-PCZ REV K 08/26/20, PG 28 OF 29

Firewall Modification Template

Passenger Compartment Modification Template

Do Not CutAlign with Edge

of Firewall Opening

RemoveShaded Portion

Firewall ModificationTemplate

Passenger Side DashModification Template

Cut Along Dotted Line

Cut Along Dotted Line

29

www.vintageair.com

901174-PCZ REV K 08/26/20, PG 29 OF 29

WIPER OFFHI

COLD

DASH

HOT

DEF

HI

OFF

A/C

Packing List: Evaporator Kit (561174-PCZ)

No. 1.2.

Qty.11

Part No.764172781174-PCN

DescriptionGen IV Evaporator Sub CaseAccessory Kit

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

1

2

Gen IV Evaporator Sub Case 764172

Accessory Kit781174-PCN

Checked By:Packed By:

Date: