1969-72 Chevrolet Nova - Vintage Air

901179 REV D 1/10/19 1969-72 NOVA wo AC EVAP INSTR PG 1 OF 24

an ISO 9001: 2015 Registered Company

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

Sales: [email protected] Support: [email protected]

www.vintageair.com

1969-72 Chevrolet Novawithout Factory Air

Evaporator Kit(561072)


PAGES

Table of Contents

1. COVER 2. TABLE OF CONTENTS 3. PACKING LIST / PARTS DISCLAIMER 4. INFORMATION PAGE 5. WIRING NOTICE 6. ENGINE COMPARTMENT, CONDENSER ASSEMBLY, COMPRESSOR & BRACKETS FIGURE 1 7. PASSENGER COMPARTMENT FIGURE 2 8. KICK PANEL MODIFICATION FIGURES 3 & 4 9. DEFROST DUCT INSTALLATION FIGURE 5 10. FRESH AIR COVER & KICK PANEL FRESH AIR CAP INSTALLATION FIGURES 6, 7, 7a & 7b 11. FIREWALL COVER, EVAPORATOR BRACKET INSTALLATION FIGURES 8 & 912. EVAPORATOR BRACKET INSTALLATION CONT. FIGURE 1013. EVAPORATOR INSTALLATION FIGURES 11, 12 & 12a14. DRAIN HOSE INSTALLATION, LUBRICATING O-RINGS, A/C HOSE INSTALLATION, & MODIFIED A/C HOSE KIT FIGURES 13 & 1415. A/C, HEATER HOSE & HEATER CONTROL VALVE INSTALLATION FIGURE 1516. FINAL STEPS FIGURES 16 & 1717. UNDER DASH LOUVER INSTALLATION FIGURES 18 & 18a18. CONTROL PANEL & DUCT HOSE ROUTING FIGURE 1919. WIRING DIAGRAM20. GEN IV WIRING CONNECTION INSTRUCTIONS21. OPERATION OF CONTROLS22. TROUBLESHOOTING INFORMATION23. TROUBLESHOOTING INFORMATION CONT.24. EVAPORATOR KIT PACKING LIST


** BEFORE BEGINNING INSTALLATION OPEN ALL PACKAGES AND CHECK CONTENTS OF SHIPMENT. PLEASE REPORT ANY SHORTAGES DIRECTLY TO VINTAGE AIR WITHIN 15 DAYS. AFTER 15 DAYS, VINTAGE AIR WILL NOT BE RESPONSIBLE FOR MISSING OR DAMAGED ITEMS.

EVAPORATOR KIT 561072

EVAPORATOR KIT PACKING LIST

No. QTY. PART No. DESCRIPTION

1.2.

11

744004-VUE784176

GEN IV 4-VENT EVAPORATOR SUB CASEACCESSORY KIT

1

ACCESSORY KIT784176 NOTE: IMAGES MAY NOT DEPICT ACTUAL PARTS AND QUANTITIES.

REFER TO PACKING LIST FOR ACTUAL PARTS AND QUANTITIES.

2

GEN IV 4-VENT EVAPORATOR SUB CASE

744004-VUE

COLD

HOTOFF

HI DASH

DEF

FLR


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.


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.

•

•

•


BEFORE STARTING THE INSTALLATION, CHECK THE FUNCTION OF THE VEHICLE (HORN, LIGHTS,ETC.) FOR PROPER OPERATIONS.

STUDY THE INSTRUCTIONS, ILLUSTRATIONS, & DIAGRAMS.

ENGINE COMPARTMENT

CONDENSER ASSEMBLY & INSTALLATIONREFER TO SEPARATE INSTRUCTIONS INCLUDED WITH THE CONDENSER KIT TO INSTALL THE CONDENSER. BINARY SWITCH INSTALLATION ( REFER TO CONDENSER INSTRUCTIONS)

REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH THE BRACKET KIT TO INSTALL THE COMPRESSOR BRACKET.

COMPRESSOR & BRACKETS

REMOVE THE FOLLOWING:

BATTERY, BATTERY TRAY (RETAIN). DRAIN RADIATOR, REMOVE RADIATOR (RETAIN).TO REMOVE THE BLOWER ASSEMBLY (UNDER HOOD) AND THE AIR DISTRIBUTION SYSTEM (UNDER DASH), THE FACTORY MANUAL INDICATES:REMOVE RIGHT INNER FENDER PANEL. OEM HEATER HOSES (DISCARD). SEE FIGURE 1.OEM HEATER WIRING (DISCARD). SEE FIGURE 1.

FIGURE 1

HEATERHOSES

BATTERYTRAY

OEMBLOWER MOTOR

ASSEMBLY

INNERFENDER PANEL


NOTE: REMOVAL OF INSTRUMENT PANEL IS REQUIRED TO INSTALL THE EVAPORATOR. VINTAGE AIR RECOMMENDS THAT YOU UTILIZE THE FACTORY SERVICE MANUAL WHEN YOU DISASSEMBLE AND REASSEMBLE THE INSTRUMENT PANEL.GLOVE BOX DOOR (RETAIN). SEE FIGURE 2. GLOVE BOX (DISCARD).HEATER ASSEMBLY (DISCARD). RETAIN SCREWS. SEE FIGURE 2.OEM DEFROST DUCT ASM (DISCARD).LOWER STEERING COLUMN. PROTECT STEERING COLUMN WITH CLOTH.DISCONNECT ALL WIRE AND CABLES FROM INSTRUMENT PANEL, SPEEDOMETER, CONTROL PANEL,AND RADIO.CONTROL PANEL ASSEMBLY (RETAIN).REFER TO CONTROL PANEL CONVERSION KIT INSTRUCTIONS FOR INSTALLATION OF CONTROLS.PASSENGER SIDE KICK PANEL (RETAIN).

CONTROLPANEL

GLOVE BOXDOOR

HEATER ASSEMBLY

FIGURE 2

PASSENGER COMPARTMENTREMOVE THE FOLLOWING

DEFROST DUCTASM

PASSENGER SIDE KICK PANEL


KICK PANEL MODIFICATION

FIGURE 3

FIGURE 4

REMOVE KICK PANEL. DISCONNECT PULL CABLE ASSEMBLY FROM KICK PANEL (DISCARD).CUT FRESH AIR DOOR FLUSH ON THE BACK SIDE OF KICK PANEL (DISCARD). SEE FIGURE 3, BELOW.

CUT OUT GRILLE AS SHOWN IN FIGURE 4, BELOW.INSTALL 1/2” PLASTIC PLUG TO FILL THE HOLE LEFT FROM THE REMOVAL OF THE PULL CABLE ASSEMBLY.

CUT KICK PANEL

1/2” PLUG

PULL CABLE ASSEMBLY

CUT SHADED

AREAOF GRILLE

1/2” PLASTIC PLUG

31102-GUR


INSTALL DEFROST DUCTS UNDER DASH AS SHOWN IN FIGURE 5, BELOW. ALIGN DEFROST DUCTS WITHDEFROST OPENING IN DASH. HOLD IN PLACE. USE BRACKET AS TEMPLATE AND DRILL 7/64” HOLE. SECUREUSING #10 x ½” SHEET METAL SCREW.

DRIVER SIDEDEFROST DUCT

(2) #10 x ½”SHEET METAL

SCREWS

PASSENGER SIDEDEFROST DUCT

DEFROST DUCT INSTALLATION

FIGURE 5


1/4-20 x 1 ½”BOLT w/ WASHER

FRESH AIR COVER INSTALLATION

SILICONE

FRESH AIRCAP

(4) GROMMETS33137-VUI

FIGURE 6BACK SIDEOF FRESH AIR

CAP

ENGINE COMPARTMENT

SIDE OF FIREWALL

INSTALL (4) GROMMETS IN FRESH AIR CAP. SEE FIGURE 6, BELOW.APPLY A 1/4” BEAD OF SILICONE AROUND THE BACK SIDE OF THE FRESH AIR CAP AS SHOWN BELOW.ATTACH FRESH AIR CAP TO FIREWALL USING A 1/4-20 x 1 ½" BOLT AND WASHER, SEE BELOW. NOTE: FRESH AIR CAP INSTALLS ON ENGINE SIDE OF FIREWALL.

FIGURE 7b

FIGURE 7a

FIGURE 7

KICK PANEL FRESH AIR CAP INSTALLATIONINSTALL (4) GROMMETS IN KICK PANEL FRESH AIR CAP. SEE FIGURE 7a, BELOW.ROUTE A/C AND HEATER HOSE THROUGH FRESH AIR CAP AND KICKPANEL FRESH AIR CAP AS SHOWN IN FIGURE 7 AND 7b, BELOW.APPLY A 1/4” BEAD OF SILICONE AROUND THE BACK SIDE OF KICK PANEL FRESH AIR CAP AS SHOWN IN FIGURE 7a, BELOW.SECURE KICK PANEL FRESH AIR CAP USING OEM SCREWS, AS SHOWN IN FIGURE 7b, BELOW.REINSTALL KICK PANEL WITH OEM SCREWS.

(5) OEMSCREWS

SILICONE

BACK SIDE OF KICK PANEL

FRESH AIR CAP

#10 A/CHOSE

#6 A/CHOSE(2) HEATER

HOSES

#10 A/C HOSE

#6 A/C HOSE(2) HEATER

HOSE

(4) GROMMETS33137-VUI


INSTALL GROMMET IN FIREWALL COVER AS SHOWN IN FIGURE 8, BELOW APPLY A 1/4“ BEAD OF SILICONE AROUND THE BACK SIDE OF THE FIREWALL COVER AS SHOWN BELOW.SECURE FIREWALL COVER TO FIREWALL USING (3) 1/4-20 x 1” HEX BOLTS w/ FLAT WASHERS. NOTE: FIREWALL COVER INSTALLS INSIDE PASSENGER SIDE COMPARTMENT.

FIREWALL COVER INSTALLATION

NOTE:ENLARGE EXISTING HOLES IN FIREWALL TO 5/16”

FIGURE 8

FIREWALLCOVER648229

VIEW SHOWN FROMINSIDE CAR, THROUGH

DASH

SILICONE

GROMMET33144-VUI

BACK SIDEOF FIREWALL

COVER

(4) 1/4-20 x 1”HEX BOLTS

w/ WASHERS

EVAPORATOR BRACKET INSTALLATION

(2) 1/4-20 x ½”HEX BOLT

FIGURE 9

ON A WORKBENCH, INSTALL EVAPORATOR FRONT & REAR MOUNTING BRACKETS ON EVAPORATOR USING (4)1/4-20 x 1/2” HEX BOLTS, AND TIGHTEN AS SHOWN IN FIGURE 9, BELOW, & FIGURE 10, PAGE 12.LAY EVAPORATOR SUB CASE ON PASSENGER SIDE FLOOR BOARD. INSTALL A/C & HEATER HOSE ON EVAPORATOR AS SHOWN IN FIGURE 11, PAGE 13, AND HOSE INSTALLATION ON PAGE 15.NOTE: WRAP THE #10 FITTING CONNECTIONS WITH PRESS TAPE. SEE FIGURE 11, PAGE 13.


REAREVAPORATOR

BRACKET643170-FCB

(2) 1/4-20 x 1/2”HEX BOLTS

(2) HEATERFITTINGS

EVAPORATOR BRACKET INSTALLATION CONT.

FIGURE 10

18040-VUB3/4” NYLON

SPACER

189125-MUR1/4” PUSH NUTBOLT RETAINER

BRACKET18289-VUB

1/4-20 x 1 ½”HEX BOLT

w/ 18125-VUBFLAT WASHER


LIFT EVAPORATOR UNIT UP UNDER THE DASHBOARD. SECURE LOOSELY TO THE FIREWALL FROM THE ENGINE COMPARTMENT SIDE USING 1/4-20 NUT w/ STAR WASHER AND FLAT WASHER. SEE FIGURE 12 BELOW. 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 UNITUP, THEN DRILL FOR FRONT BRACKET SCREWS.USING (2) #14 x ¾ SHEET METAL SCREWS, SECURE THE FRONT EVAPORATOR MOUNTING BRACKET TO THE INNER COWL. SEE FIGURE 12a BELOW.VERIFY THAT EVAPORATOR UNIT IS LEVEL AND SQUARE TO THE DASH, THEN TIGHTEN ALL MOUNTING BOLTS.NOTE: TIGHTEN THE BOLT ON FIREWALL FIRST, THEN THE FRONT MOUNTING BRACKET SCREWS.

INNER COWL

DRILL (2)3/16” HOLES (2)#14 x ¾”

SHEET METALSCREWS

FIGURE 11

FIGURE 12

FIGURE 12a

EVAPORATOR INSTALLATION

#10 A/C HOSE

HOSECLAMPSHEATER

HOSE

#6 A/C HOSE

PRESSTAPE

1/4-20 NUTw/ STAR WASHERw/ FLAT WASHER

KICK PANELFRESH AIR

CAP


DRAIN HOSE INSTALLATION

FIGURE 13

O-RINGMALE INSERT

FEMALE NUT

SUPPLIED OILFOR O-RINGS

O-RINGSLIDE OVER

MALE INSERT TOSWAGED LIP

TWIST WITHTHIS

WRENCH

HOLD WITHTHIS

WRENCH

FOR A PROPER SEAL OF FITTINGS:INSTALL SUPPLIED O-RINGS AS SHOWNAND LUBRICATE WITH SUPPLIED OIL.

LOCATE EVAPORATOR DRAIN ON BOTTOM OF EVAPORATOR CASE.IN LINE WITH THE DRAIN, LIGHTLY MAKE A MARK ONTHE FIREWALL. MEASURE ONE INCH DOWN AND DRILLA 5/8” HOLE THROUGH THE FIREWALL. SEE FIGURE 13.INSTALL DRAIN HOSE TO BOTTOM OF EVAPORATORUNIT AND ROUTE THROUGH FIREWALL. INSTALL½” 90° DRAIN ELBOW ON DRAIN HOSE AS SHOWN.

O-RING

#6 O-RING

#8 O-RING #10 O-RING

FIGURE 14

LUBRICATING O-RINGS

DRAINDRAINHOSE

1”

LOCATE THE #8 COMPRESSOR A/C HOSE. LUBRICATE (2) #8 O-RINGS (SEE FIGURE 14, ABOVE) AND CONNECTTHE 135° FEMALE FITTING w/ 134a SERVICE PORT TO THE #8 DISCHARGE PORT ON THE COMPRESSOR.ROUTE THE 45° FEMALE FITTING TO THE #8 CONDENSER HARDLINE COMING THROUGH CORE SUPPORT. SEE FIGURE 15, PAGE 15. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN FIGURE 14 ABOVE.LOCATE THE #10 COMPRESSOR A/C HOSE. LUBRICATE (2) #10 O-RINGS (SEE FIGURE 14, ABOVE) ANDCONNECT THE #10 135° FEMALE FITTING w/134a SERVICE PORT TO THE #10 SUCTION PORT ON THECOMPRESSOR. ROUTE THE 90° FEMALE FITTING TO THE #10 EVAPORATOR. SEE FIGURE 11 PAGE 13 ANDFIGURE 15, PAGE 15. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN 14 ABOVE. LOCATE THE #6 EVAPORATOR A/C HOSE. LUBRICATE (2) #6 O-RINGS (SEE FIGURE 14 , ABOVE) ANDCONNECT THE 90° FEMALE FITTING TO THE DRIER. ROUTE THE 90° FEMALE FITTING TO THE #6 EVAPORATOR. SEE FIGURE 11, PAGE 13 AND FIGURE 15 PAGE 15. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN FIGURE 14, ABOVE.USE A #10 ADEL CLAMP TO SECURE THE #10 A/C HOSE TO ALTERNATOR BRKT AS SHOWN IN FIGURE 15, PAGE 15. SECURE THE ADEL CLAMP TO THE ALTERNATOR BRKT USING 10-32 x ½” PH PAN HEAD SCREWS w/ NUTS.

A/C HOSE INSTALLATIONSTANDARD HOSE KIT

REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH MODIFIED HOSE KIT. MODIFIED A/C HOSE KIT


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A/C, HEATER HOSE & HEATER CONTROL VALVE INSTALLATION

ROUTE HEATER HOSE FROM THE WATER PUMP TO THE TOP HEATER FITTING OF HEATER CORE AS SHOWN IN FIGURE 11, PAGE 13, AND FIGURE 15, BELOW. SECURE USING HOSE CLAMPS.

ROUTE HEATER HOSE FROM THE INTAKE TO THE BOTTOM HEATER FITTING OF HEATER CORE AS SHOWN IN FIGURE 11, PAGE 13, AND FIGURE 15, BELOW. NOTE: INSTALL HEATER CONTROL VALVE IN LINE WITH INTAKE MANIFOLD (PRESSURE SIDE) HEATER HOSE. SECURE USING HOSE CLAMPS AS SHOWN BELOW. NOTE PROPER FLOW DIRECTION.

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TER

HO

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EATE

R C

NTR

LV

ALV

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TAK

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PU

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W D

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S M

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ED A

RR

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ON

VA

LVE.


INSTALL DUCT HOSES AS SHOWN IN FIGURE 19, PAGE 18. EXTEND DUCT HOSE TO A TAUT CONDITION, THEN CUTTO LENGTH AS NOTED. THERE SHOULD BE LITTLE OR NO SLACK IN HOSE ONCE INSTALLED.ROUTE A/C WIRES THROUGH ⅜” GROMMET AS SHOWN IN FIGURE 17, BELOW.(12 VOLT/ GROUND/ BINARY SWITCH/ HEATER VALVE).RE-INSTALL CONTROL PANEL ASSEMBLY.(NOTE: CONTROLS MUST BE CALIBRATED FOR PROPER OPERATION. REFER TO CONTROL PANEL INSTRUCTIONS)PLUG THE WIRING HARNESS IN TO THE ECU MODULE ON SUB CASE AS SHOWN IN FIGURE 19, PAGE 18(WIRE ACCORDING TO WIRING DIAGRAM ON PAGE 19 AND 20)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.INSTALL UNDER DASH LOUVER ASSEMBLY. SEE PAGE 17.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 AC 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 PAGE 4 OF THIS INSTRUCTION MANUAL.SEE OPERATION OF CONTROLS PROCEDURES, PAGE 21.

FINAL STEPS

FIGURE 16

FIGURE 17

GROMMET33144-VUI

GLOVE BOX49069-VCI


PASSENGER SIDEHOUSING629969

DRILL 1/8”HOLE

(2) LOUVERS49056-VUL

FIGURE 18a

FIGURE 18

(2)#10 x ½” SHEET METAL

SCREWS

ASH TRAY

(2)#10 x ½ SHEET METAL

SCREWS

DRIVER SIDE LOUVER BEZEL

494052

LOUVER49057-VUL

LOUVER49057-VUL

REMOVE THE (2)SCREWS FROM BOTTOM OF ASH TRAY.INSTALL THE CENTER/PASSENGER SIDE LOUVER BEZEL UNDER DASH USING THE (2) ASH TRAY MOUNTINGHOLES. SECURE WITH (2) #10 x ½” SHEET METAL SCREWS AS SHOWN IN FIGURE 18a.ALIGN CENTER/PASSENGER SIDE LOUVER BEZEL UNDER DASH AND DRILL A HOLE 1/8“ HOLE. SECURE WITH #10 x ½” SHEET METAL SCREW. SEE FIGURE 18a.USING (2) #10 x ½” SHEET METAL SCREWS, INSTALL THE DRIVER SIDE LOUVER HOUSING UNDER DASH AS SHOWN IN FIGURE 18, BELOW.INSTALL LOUVERS IN DRIVER SIDE HOUSING AND CENTER/PASSENGER SIDE LOUVER BEZEL AS SHOWN INFIGURE 18 & 18a.ONCE THE LOUVER ASSEMBLY IS IN PLACE, ROUTE THE DUCT HOSES AND ATTACH THEM TO THE CORRECT LOCATION ON EVAPORATOR AS SHOWN IN FIGURE 19, PAGE 18.

UNDER DASH LOUVER INSTALLATION

LIGHTS WASHER WIPER LIGHTS WASHER WIPER

#10 x ½” SHEET METAL

SCREWS


FIGURE 19

CONTROL PANEL & DUCT HOSE ROUTING

PLUGFROM

CONTROLWIRING

HARNESS232002-VUA

PLUGFROM

WIRINGHARNESS

232600-VUA

PASS. SIDELOUVER

2 ½” x 40”

DRIVER SIDELOUVER

2 ½” x 36”

CENTER LOUVERDRIVER SIDE2 ½” x 18”

CENTER LOUVERPASS SIDE2 ½” x 20”

PASS. SIDEDEF. DUCT2” x 12”

DRIVER SIDEDEF DUCT2” x 20”


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


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.


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 ControlBlower Speed

Temperature Control

Mode 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 control panel instructions.

COLD

HOT

HI

OFF

DASH

DEF

FLR

COLD

HOT

HI

OFF

DASH

DEF

FLR

HOTOFF

DASH

DEF

FLR

COLDHI

HOTOFF

DASH

DEF

FLR

COLDHI


Sym

pto

m

C

on

dit

ion

C

heck

s

Act

ion

s

N

ote

s

Blo

wer

sta

ys o

n

hig

h s

pee

d w

hen

ig

nitio

n is

on.

1a.

No o

ther

funct

ions

work

.

Chec

k fo

r dam

aged

pin

s or

wires

in c

ontr

ol hea

d p

lug.

Ver

ify

that

all

pin

s ar

e in

sert

ed into

plu

g.

Ensu

re t

hat

no

pin

s ar

e ben

t or

dam

aged

in E

CU

.

Chec

k fo

r dam

aged

gro

und

wire

(white)

in c

ontr

ol hea

d

har

nes

s.

Ver

ify

continuity

to c

has

sis

gro

und w

ith w

hite

contr

ol

hea

d w

ire

at v

ario

us

poin

ts.

Loss

of gro

und o

n t

his

wire

render

s co

ntr

ol hea

d

inoper

able

.

All

oth

er f

unct

ions

work

.Chec

k fo

r dam

aged

blo

wer

sw

itch

or

pote

ntiom

eter

and

asso

ciat

ed w

irin

g.

Blo

wer

sta

ys o

n

hig

h s

pee

d w

hen

ig

nitio

n is

on o

r off.

Unplu

g 3

-wire

BSC c

ontr

ol

connec

tor

from

ECU

. If

blo

wer

sh

uts

off,

ECU

is

eith

er

impro

per

ly w

ired

or

dam

aged

.

Be

sure

the

smal

l, 2

0 G

A w

hite

gro

und w

ire

is c

onnec

ted

to t

he

bat

tery

gro

und p

ost

. If

it

is,

repla

ce t

he

ECU

.

Unplu

g 3

-wire

BSC c

ontr

ol

connec

tor

from

ECU

. If

blo

wer

st

ays

runnin

g,

BSC is

eith

er

impro

per

ly w

ired

or

dam

aged

.

Chec

k to

ensu

re t

hat

no B

SC w

irin

g is

dam

aged

or

short

ed t

o v

ehic

le g

round.

The

BSC o

per

ates

the

blo

wer

by

gro

und s

ide

puls

e w

idth

modula

tion s

witch

ing.

The

posi

tive

wire

to t

he

blo

wer

will

alw

ays

be

hot.

If th

e “g

round”

side

of

the

blo

wer

is

short

ed t

o c

has

sis

gro

und,

the

blo

wer

will

run o

n H

I.

Rep

lace

BSC (

This

will

req

uire

rem

oval

of ev

apora

tor

from

veh

icle

).N

o o

ther

par

t re

pla

cem

ents

sh

ould

be

nec

essa

ry.

Com

pre

ssor

will

not

turn

on

(All

oth

er funct

ions

work

).

2.

Sys

tem

is

not

char

ged

.Sys

tem

must

be

char

ged

for

com

pre

ssor

to e

ngag

e.Char

ge

syst

em o

r byp

ass

pre

ssure

sw

itch

.

Dan

ger:

Never

byp

ass

sa

fety

sw

itch

wit

h

en

gin

e r

un

nin

g.

Seri

ou

s in

jury

can

resu

lt.

Sys

tem

is

char

ged

.

1b

.

Tro

ub

lesh

oo

tin

g G

uid

e

Chec

k fo

r fa

ulty

A/C

pote

ntiom

eter

or

asso

ciat

ed

wirin

g (

Not

applic

able

to 3

-pot

contr

ols

).

Chec

k fo

r dis

connec

ted o

r fa

ulty

ther

mis

tor.

Chec

k co

ntinuity

to g

round o

n w

hite

contr

ol hea

d w

ire.

Chec

k fo

r 5V o

n r

ed c

ontr

ol hea

d w

ire.

Chec

k 2-p

in c

onnec

tor

at E

CU

housi

ng.

To c

hec

k fo

r pro

per

pot

funct

ion,

chec

k vo

ltag

e at

w

hite/

blu

e w

ire.

Voltag

e sh

ould

be

bet

wee

n 0

V a

nd

5V,

and w

ill v

ary

with p

ot

leve

r posi

tion.

Dis

connec

ted o

r fa

ulty

ther

mis

tor

will

cau

se

com

pre

ssor

to b

e dis

able

d.

Red

wire

at A

/C p

ot

should

hav

e ap

pro

xim

atel

y 5V

with ignitio

n o

n.

White

wire

will

hav

e co

ntinuity

to

chas

sis

gro

und.

White/

Blu

e w

ire

should

var

y bet

wee

n 0

V a

nd 5

V w

hen

le

ver

is m

oved

up o

r dow

n.

3. Com

pre

ssor

will

not

turn

off

(A

ll oth

er funct

ions

work

).

Chec

k fo

r fa

ulty

A/C

pote

ntiom

eter

or

asso

ciat

ed

wirin

g.

Chec

k fo

r fa

ulty

A/C

rel

ay.

Rep

air

or

repla

ce p

ot/

contr

ol w

irin

g.

Rep

lace

rel

ay.

See

blo

wer

sw

itch

chec

k pro

cedure

.


Sym

pto

m

C

on

dit

ion

C

heck

s

Act

ion

s

N

ote

s

Sys

tem

will

not

turn

on,

or

runs

inte

rmitte

ntly.

4.

Work

s w

hen

engin

e is

not

runnin

g;

shuts

off w

hen

en

gin

e is

sta

rted

(T

ypic

ally

ear

ly G

en I

V,

but

poss

ible

on a

ll ve

rsio

ns)

.

Nois

e in

terf

eren

ce f

rom

either

ig

nitio

n o

r al

tern

ator.

Inst

all ca

pac

itors

on ignitio

n c

oil

and a

lter

nat

or. E

nsu

re

good g

round a

t al

l poin

ts.

Rel

oca

te c

oil

and a

ssoci

ated

w

irin

g a

way

fro

m E

CU

and E

CU

wirin

g.

Chec

k fo

r burn

edor

loose

plu

g w

ires

.

Ver

ify

connec

tions

on p

ow

er

lead

, ig

nitio

n lea

d,

and b

oth

white

gro

und w

ires

.

Ver

ify

pro

per

met

er f

unct

ion b

y ch

ecki

ng t

he

conditio

n o

f a

know

n g

ood b

atte

ry.

Ignitio

n n

ois

e (r

adia

ted o

rco

nduct

ed)

will

cau

se t

he

syst

em t

o s

hut

dow

n d

ue

tohig

h v

oltag

e sp

ikes

. If

this

is s

usp

ecte

d,

chec

k w

ith a

qual

ity

osc

illosc

ope.

Spik

esgre

ater

than

16V w

ill s

hut

dow

n t

he

ECU

. In

stal

l a

radio

cap

acitor

at t

he

posi

tive

post

of th

e ig

nitio

nco

il (S

ee r

adio

cap

acitor

inst

alla

tion b

ulle

tin).

A

faulty

alte

rnat

or

or

worn

out

bat

tery

can

als

o r

esult

in t

his

conditio

n.

Will

not

turn

on u

nder

an

y co

nditio

ns.

Ver

ify

bat

tery

voltag

e is

gre

ater

than

10 v

olts

and les

sth

an 1

6.

Loss

of m

ode

door

funct

ion.

No m

ode

chan

ge

at a

ll.Chec

k fo

r dam

aged

mode

switch

or

pote

ntiom

eter

and

asso

ciat

ed w

irin

g.

Part

ial fu

nct

ion o

f m

ode

doors

.

Typic

ally

cau

sed b

y ev

apora

tor

housi

ng

inst

alle

d in a

bin

d in t

he

vehic

le.

Be

sure

all

mounting loca

tions

line

up

and d

on’t h

ave

to b

e fo

rced

in

to p

osi

tion.

Blo

wer

turn

s on

and o

ff r

apid

ly.

6.

Bat

tery

voltag

e is

at

leas

t 12V.

Chec

k fo

r at

lea

st 1

2V a

t ci

rcuit b

reak

er.

Ensu

re a

ll sy

stem

gro

unds

and p

ow

er c

onnec

tions

are

clea

n a

nd t

ight.

Bat

tery

voltag

e is

les

s th

an 1

2V.

5.

Tro

ub

lesh

oo

tin

g G

uid

e (

Co

nt.

)

Chec

k fo

r fa

ulty

bat

tery

or

alte

rnat

or.

Char

ge

bat

tery

.

Sys

tem

shuts

off b

low

er a

t 10V.

Poor

connec

tions

or

wea

k bat

tery

can

cau

se

shutd

ow

n a

t up t

o 1

1V.

7. When

ignitio

n is

turn

ed o

n,

blo

wer

m

om

enta

rily

co

mes

on,

then

sh

uts

off.

This

occ

urs

with t

he

blo

wer

sw

itch

in

the

OFF

posi

tion.

This

is

an indic

ator

that

the

syst

em h

as b

een r

eset

. Be

sure

the

red p

ow

er w

ire

is o

nth

e bat

tery

post

, an

d n

ot

on a

sw

itch

ed s

ourc

e. A

lso,

if

the

syst

em is

pulle

d b

elow

7V f

or

even

a s

plit

sec

ond,

the

syst

em w

ill r

eset

.

Run r

ed p

ow

er w

ire

direc

tly

to b

atte

ry.

Chec

k fo

r posi

tive

pow

er a

t hea

ter

valv

e gre

en w

ire

and

blo

wer

red

wire.

Chec

k fo

r gro

und o

n c

ontr

ol hea

d w

hite

wire.

Chec

k fo

r obst

ruct

ed o

r bin

din

g m

ode

doors

.

Chec

k fo

r dam

aged

ste

pper

m

oto

r or

wirin

g.

Err

atic

funct

ions

of

blo

wer

, m

ode,

te

mp,

etc.

Chec

k fo

r dam

aged

sw

itch

or

pot

and a

ssoci

ated

wirin

g.

Rep

air

or

repla

ce.

8.


EVAPORATOR KIT 561072

CHECK BY:PACKED BY:

DATE:

EVAPORATOR KIT PACKING LIST

No. QTY. PART No. DESCRIPTION

1.2.

11

744004-VUE784176

GEN IV 4-VENT EVAPORATOR SUB CASEACCESSORY KIT

GEN IV 4-VENT EVAPORATOR SUB CASE

744004-VUE

1

ACCESSORY KIT784176

NOTE: IMAGES MAY NOT DEPICT ACTUAL PARTS AND QUANTITIES.REFER TO PACKING LIST FOR ACTUAL PARTS AND QUANTITIES

2

COLD

HOTOFF

HI DASH

DEF

FLR

Date post:	23-Mar-2022
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1969-72 Chevrolet Nova - Vintage Air

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