1981-87 chevrolet pickup - vintage air · 1981-87 chevrolet pickup without factory air 751181...

1981-87 CHEVROLET PICKUP WITHOUT FACTORY AIR

751181

901182 REV B 7/22/14, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 1 OF 27

an ISO 9001:2008 Registered Company


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 & BRACKET, PULLEYS FIGURE 1 7. PASSENGER COMPARTMENT FIGURES 2 & 2a 8. DEFROST DUCT INSTALLATION & FRESH AIR CAP INSTALLATION AND FIREWALL MODIFICATION FIGURES 3 & 4 9. FIREWALL MODIFICATION CONT. & FIREWALL COVER INSTALLATION FIGURES 5 & 610. BRACKET & EVAPORATOR HARDLINE INSTALLATION FIGURE 711. BRACKET & EVAPORATOR HARDLINE INSTALLATION CONT. FIGURE 812. EVAPORATOR INSTALLATION FIGURES 9 & 9a 9b13. DRAIN HOSE INSTALLATION, LUBRICATING O-RINGS, A/C HOSE INSTALLATION, & MODIFIED A/C HOSE KIT FIGURES 10 & 1114. HEATER HOSE & HEATER CONTROL VALVE INSTALLATION FIGURE 1215. A/C & HEATER HOSE ROUTING FIGURE 1316. PASSENGER SIDE LOUVER DASH PANEL INSTALLATION & DRIVER SIDE/CENTER LOUVER INSTALLATION FIGURES 14, 15, 15a, 15b & 15c17. FINAL STEPS FIGURE 1618. GLOVE BOX MODIFICATION FIGURES 17 & 17a19. CONTROL PANEL & DUCT HOSE ROUTING FIGURE 1820. WIRING DIAGRAM21. GEN IV WIRING CONNECTION INSTRUCTIONS22. OPERATION OF CONTROLS23. TROUBLESHOOTING INFORMATION24. TROUBLESHOOTING INFORMATION CONT.25. DRIVER SIDE LOUVER TEMPLATE26. GLOVE BOX MODIFICATION TEMPLATE27. 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 KIT751181

1.2.

11

744004-VUE791181

1

GEN IV 4 VENTEVAP SUB CASE

w/204 ECU744004-VUE

GEN IV 4 VENT EVAP. SUB CASE w/ 204 ECU ACCESSORY KIT 81-87 CHEV P-UP wo AC

NO. QTY. PART NO. DESCRIPTION

EVAPORATOR KIT PACKING LIST

ACCESSORY KIT791181

2

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

OFF

DASH

HOT

FLR

A/C

HI

DEF

COLD


Use of Any Other Refrigerants Will Void All Warranties of the Air Conditioning System and Components. Use of the Proper Type and

Amount of Refrigerant Is Critical to Proper System Operation. VintageAir Recommends Our Systems Be Charged By Weight With a Quality

Charging Station or Scale.

Service Info:

Safety Switches:

Important Notice—Please Read

Attention: The following system components are capped: Compressor, evaporator, condenser & drier. Caps may be under pressure with dry nitrogen. Be careful removing caps. Do not remove caps prior to installation. Removing caps prior to installation will cause components to collect moisture and lead to premature failure and reduced performance.

Evacuate the system for 35-45 minutes with system components (Drier, compressor, evaporator and condenser) at a temperature of at least 85° F. On a cool day, the components can be heated with a heat gun OR by running the engine with the heater on before evacuating. Leak check and charge to specifications.

For Maximum System Performance, Vintage Air Recommends the Following:

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.

Vintage Air Systems Are Designed to Operate With R134a Refrigerant Only! Use of Any Other Refrigerants Is a Fire Hazard and Could Damage Either Your Air Conditioning System or Your Vehicle.

Refrigerant Capacity for Vintage Air Systems:(For other systems, consult manufacturer’s guidelines)

R134a SystemCharge with 1.8 lbs. (1 lb., 12 oz.) of refrigerant.

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).

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.

Heater Hose (Not Included With This Kit):

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.

Bolts Passing Through Cowl and/or Firewall:


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.

•

•

•


DISCONNECT BATTERY.DRAIN RADIATOR, REMOVE RADIATOR (RETAIN). HEATER BLOWER ASSEMBLY AND OEM HEATER HOSES (DISCARD).NOTE: TO REMOVE THE OEM HEATER BLOWER ASSEMBLY (UNDER HOOD) AND THE AIR DISTRIBUTION SYSTEM (UNDER DASH), THE FACTORY MANUAL RECOMMENDS THAT YOU REMOVE RIGHT INNER FENDER FOR ACCESSIBILITY.

ENGINE COMPARTMENTREMOVE THE FOLLOWING

FIGURE 1

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

STUDY THE INSTRUCTIONS, ILLUSTRATIONS, & DIAGRAMS.

OEM HEATER BLOWER ASSEMBLY

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 AND BRACKET.

COMPRESSOR & BRACKETS


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).OEM HEATER ASSEMBLY (DISCARD) (SEE FIGURE 2a).DEFROST DUCT ASSEMBLY (DISCARD) (SEE FIGURE 2a).NOTE: FOR EASE OF INSTALLING EVAPORATOR UNDER DASH, IT MAYBE HELPFUL TO REMOVE THE (2) OEM BOLTS UNDER THE DASH ON THE PASSENGER SIDE DOOR PILLAR, AND PULL BACK DASH.

PASSENGER COMPARTMENTREMOVE THE FOLLOWING:

FIGURE 2

CONTROL PANEL

INSTRUMENTPANELBEZEL

UNDER DASH COVER

GLOVE BOXDOOR &

GLOVE BOX

DASH PAD

ASH TRAY

FIGURE 2a

OEM HEATER ASSEMBLY

DEFROST DUCT ASSEMBLY

(2) OEMBOLTS

DASH BRACE


DEFROST DUCT INSTALLATIONINSTALL (4) #8 U-NUTS IN OEM DEFROST DUCT OPENINGS AS SHOWN BELOW IN FIGURE 3.INSTALL DRIVER AND PASSENGER SIDE DEFROST DUCTS USING (4) #8 x 1/2” PH PAN HEAD SCREWS AS SHOWN BELOW.

(2) DEFROSTDUCT

623219

FIGURE 3

(4) #8 x 1/2”PH PAN HEAD

SCREWS

(4) #8 U-NUT189801

FIGURE 4

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 #14 x 3/4“ SHEET METAL SCREW AND (2) 1/4-20 x 3/4” HEX BOLTS w/ 1/4” NUTS w/ STAR WASHER AS SHOWN BELOW.USING FIREWALL COVER AS TEMPLATE, MARK THE HOLES ON FIREWALL AS SHOWN BELOW.REMOVE FIREWALL COVER.

FRESH AIR CAP AND FIREWALL MODIFICATION

SILICONE

BACK SIDE OF FRESH AIR CAP

1/4-20 x 1”BOLT

1/4” FLATWASHER

FRESH AIR CAP

MARKHOLE

MARKHOLE

MARKHOLE

MARK HOLE

MARKHOLES

#14 x 3/4”SHEET METAL

SCREW

OEM HOLE

MARK HOLES

OEM HOLE

1/4-20 x 3/4”BOLT

1/4” NUT w/ STAR WASHER

1/4-20 x 3/4”BOLT 1/4” NUT w/

STAR WASHER


FIGURE 5

DRILL HOLES AS SHOWN BELOW IN FIGURE 5.FIREWALL MODIFICATION CONT.

FIGURE 6

APPLY A 1/4” BEAD OF SILICONE AROUND THE BACK SIDE OF THE FIREWALL COVER AS SHOWN BELOW.INSTALL FIREWALL COVER TO FIREWALL USING 1/4-20 x 3/4” HEX BOLT, 1/4“ FLAT WASHER, 1/4” NUT w/ STAR WASHER AND (7) #14 x 3/4“ SHEET METAL SCREWS AS SHOWN BELOW.INSTALL GROMMETS AS SHOWN BELOW.

FIREWALL COVER INSTALLATION

LARGE GROMMET33137-VUI

GROMMET33135-VUI

(7) #14 x 3/4”SHEET METAL

SCREW

1/4-20 x 3/4”BOLT

1/4-20 x 3/4”BOLT

1/4” FLAT WASHER

1/4” FLAT WASHER



BACK SIDE OF FIREWALL COVER

644086

SILICONE

DRILL 3/16” HOLE

DRILL 9/32” HOLE

DRILL 3/16” HOLE

DRILL 3/16” HOLE

OEM HOLE

OEM HOLE

OEM HOLE

DRILL 3/16” HOLE

DRILL 3/8” HOLE


BRACKET & EVAPORATOR HARDLINE INSTALLATIONON A WORKBENCH, INSTALL EVAPORATOR REAR BRACKET USING (4) 1/4-20 x 1/2” HEX BOLTS(SEE FIGURE 8, PAGE 11).INSTALL #6 EVAP 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.

FIGURE 7

EVAP FRONTBRKT

644087

(2)1/4-20 x ½”HEX BOLT


BRACKET & EVAPORATOR HARDLINE INSTALLATION CONT.

FIGURE 8

#6 LIQUID LINE091153

TWIST WITHTHIS

WRENCHLUBRICATE O-RING

(SEE FIGURE 11,PAGE 13)

HOLD WITH THIS WRENCH

HEATER LINE(EVAP TO WATER PUMP)

091151

ECU MODULE

#10 O-RING(33859-VUF)

(2) 1/4-20 x ½”HEX BOLT

(2) 1/4-20 x ½”HEX BOLT

REAREVAPORATOR

BRACKET644083

HEATER LINE(EVAP TO INTAKE)

091151

#6 O-RING(33857-VUF)


INNER COWL

DRILL (2)3/16” HOLES

(2)#14 x ¾”SHEET METAL

SCREWS

(2)1/4-20 x 1¼”HEX BOLT

(2) 1/4” FLAT WASHER

(2) .563 LSPACERS

VIEW FROMPASSENGER SIDEINSIDE OF CAB

FIGURE 9

FIGURE 9a

FIGURE 9b

NOTE: AFTER INSTALLING #10 SUCTION LINE

WRAP ALL EXPOSED METAL (FITTINGS & TUBE) WITH

SUPPLIED PRESS TAPE

PRESS TAPE

#10 O-RING33859-VUF

#10 SUCTIONLINE

091152

EVAPORATOR INSTALLATION LIFT EVAPORATOR UNIT UP UNDER THE DASHBOARD. SECURE LOOSELY TO THE FIREWALL USING (2) 1/4-20 x 1¼” 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 TIGHTEN ALL MOUNTING BOLTS. NOTE: TIGHTEN THE BOLT ON FIREWALL FIRST, THEN THE FRONT MOUNTING BRACKET.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.


LOCATE EVAPORATOR DRAIN ON BOTTOM OF EVAPORATOR CASE.IN LINE WITH DRAIN, LIGHTLY MAKE A MARKON THE FIREWALL, MEASURE 1” DOWN ANDDRILL A 5/8” HOLE THROUGH THE FIREWALL. INSTALL DRAIN HOSE TO BOTTOM OFEVAPORATOR UNIT AND ROUTE THROUGHFIREWALL. INSTALL 1/2” 90° DRAIN ELBOW ON DRAIN HOSE.

DRAIN HOSE INSTALLATION

FIGURE 10

EVAPORATORCASE1”

LOCATE THE #8 COMPRESSOR A/C HOSE. LUBRICATE (2) #8 O-RINGS (SEE FIGURE 11, ABOVE) AND CONNECTTHE 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.

A/C HOSE INSTALLATIONSTANDARD HOSE KIT

LUBRICATING O-RINGS

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

DRAINHOSE

1”

#6 O-RING

#8 O-RING #10 O-RING

HOLD WITHTHIS W RENCH

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

O-RING

SUPPLIED OIL FOR O-RINGS

MALEINSERT

FEMALENUT

O-RING

TWIST WITHTHIS WRENCH

FIGURE 11

O-RING, INSTALLSOVER MALE INSERT

TO SWAGED LIP


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 SILICONESPRAY 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.

HEATER HOSE & HEATER CONTROL VALVE INSTALLATION

FIGURE 12

O-RINGS

NOTE: FLOW DIRECTION FOLLOWS MOLDED ARROW ON VALVE.

FROM HEATER CORETO WATER PUMP

HEATERHOSE

#10 SUCTIONLINE

FROM INTAKEMANIFOLD#6 LIQUID

LINE

HOSECLAMPS

HEATERHOSE

FROM HEATER CONTROL VALVETO EVAPORATOR


FIG

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WRA

P #2

AD

ELC

LAM

P3

16

00

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#6 L

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IDH

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LIN

E09115

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NO

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VIN

TAG

E A

IR S

YSTE

MS

REQ

UIR

E(2

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OSE

NIP

PLE

S (N

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SUP

PLI

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AC

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EATE

R H

OSE

RO

UTI

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HEA

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HO

SE(H

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R C

NTR

LVA

LVE/

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#8

DIS

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EH

OSE

09

60

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#10 S

UC

TIO

NH

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096005

#1

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DEL

CLA

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31

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#6 C

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D/D

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HA

RDLI

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091154

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RSA

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SW

ITC

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#6

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FRO

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LVE

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HEA

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PASSENGER SIDE LOUVER DASH PANEL INSTALLATIONREMOVE PASSENGER SIDE DASH TRIM FROM DASH PAD (SEE FIGURE 14).INSTALL PASSENGER SIDE LOUVER DASH PANEL USING (7) NUTS (SEE FIGURE 14).

DRIVER SIDE/ CENTER LOUVER INSTALLATIONUSING DRIVER SIDE LOUVER TEMPLATE PROVIDED ON PAGE 25, MARK AND CUT INSTRUMENT PANEL BEZEL AS SHOWN IN FIGURE 15, BELOW.CUT AND REMOVE PACKAGE TRAY AS SHOWN IN FIGURE 15a.INSTALL DRIVER SIDE LOUVER AND CENTER LOUVER AS SHOWN IN FIGURE 15b.DRILL (4) 3/32” HOLES IN DRIVER SIDE LOUVER AND SECURE USING (4) #4 PH PAN HEAD SCREWS (SEE FIGURE 15C).DRILL (4) 3/32” HOLES IN DRIVER SIDE CENTER LOUVER AND SECURE USING (4) #4 PH PAN HEAD SCREWS (SEE FIGURE 15C).

PACKAGETRAY

DASH INSTRUMENT

BEZEL

DRIVER SIDELOUVER

49178-VCL

PACKAGETRAY

(4) #4 PH PAN HEAD

SCREWSDRILL (4)

3/32” HOLES

DRILL (4) 3/32” HOLES

CUT ALONG EDGE

AS SHOWN

PLACE DRIVER SIDELOUVER TEMPLATE LOCATED

ON PAGE 25 HERE

FIGURE 14

FIGURE 15

FIGURE 15a

FIGURE 15b

FIGURE 15c

(4) #4 PH PAN HEAD

SCREWS

PASSENGER SIDELOUVER DASH PANEL

49176-VCL

OEM PASSENGER SIDEDASH TRIM

1973-87

CHEVY TRUCK

NON AIR

DRIVER SIDE VENT

TEMPLA

TE

CENTERLOUVER

49179-VCL

DRIVER SIDE CENTER LOUVER

49179-VCL

LOUVERPLATE ADAPTER

49180-VCL


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 ASM.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 THEOWNER'S RESPONSIBILITY TO KEEP THE FREEZE PROTECTION AT THE PROPER LEVEL FOR THE CLIMATE INWHICH THE VEHICLE IS OPERATED. FAILURE TO FOLLOW ANTIFREEZE RECOMMENDATIONS WILL CAUSEHEATER 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 AIRCONDITIONING TECHNICIAN. EVACUATE THE SYSTEM FOR A MINIMUM OF 45 MINUTES PRIOR TO CHARGING AND LEAK CHECK PRIORTO SERVICING. CHARGE THE SYSTEM TO THE CAPACITIES STATED ON THE INFORMATION PAGE (PAGE 4) OF THISINSTRUCTION MANUAL. SEE OPERATION OF CONTROLS PROCEDURES PAGE 22.

FINAL STEPS

FIGURE 16

3/8” GROMMET33144-VUI

WIRING HARNESS(HEATER CONTROL VALVE)

WIRING HARNESS(12 VOLT/GROUNDS/BINARY SWITCH)


GLOVE BOX MODIFICATION USE GLOVE BOX MODIFICATION TEMPLATE PROVIDED ON PAGE 26.PLACE TEMPLATE ON THE OUTSIDE OF THE GLOVE BOX. MARK THE OUTSIDE OF THE GLOVE BOX ALONGTHE FRONT OF THE TEMPLATE AS SHOWN IN FIGURE 17 BELOW.PLACE THE SAME TEMPLATE ON THE OUTSIDE OF THE GLOVE BOX ON THE OPPOSITE SIDE. MARK THE OUTSIDE OF THE GLOVE BOX ALONG THE FRONT OF THE TEMPLATE AS SHOWN BELOW.MARK THE BOTTOM OF THE BOX CONNECTING EACH END OF TEMPLATE.CUT THE BOX ON THE LINES YOU HAVE MARKED. DISCARD THE FRONT PORTION OF THE BOX.INSTALL THE NEW SUPPLIED GLOVE BOX BY PRESSING THE S-CLIPS ONTO THE OEM PORTION OF THE BOXAS SHOWN IN FIGURE 17a, BELOW.

OEM wo A/CGLOVE BOX

MODIFIED GLOVEBOX

DISCARD FRONTPORTION OF BOX

FACTORY AIR GLOVE BOX

TEMPLATE

CUT BOX WITH AHACK SAW BLADEON THESE THREE FRONT LINES ONLY

OEM wo A/CGLOVE BOX

DISCARD FRONTPORTION OF BOX

FACTORY AIR GLOVE BOX

TEMPLATE

CUT BOX WITH AHACK SAW BLADEON THESE THREE FRONT LINES ONLY

FIGURE 17

FIGURE 17a


CONTROL PANEL & DUCT HOSE ROUTING

FIGURE 18

PLUGFROM

CONTROLWIRING

HARNESS232007-VUR

PLUGFROM

WIRINGHARNESS

232001-VUR

PASS. SIDEDEF. DUCT2” x 12”

DRIVER SIDEDEF DUCT2” x 28”

OFF

DASH

HOT

FLRA/C

HI

DEF

COLD

PASS SIDELOUVER

2 ½” x 45”

CENTER DRIVER SIDE LOUVER

2 ½” x 28”

DRIVER SIDELOUVER

2 ½” x 26”

CENTER PASSSIDE LOUVER

2 ½” x 15”


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 D, 5/6/2014

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.


BLOWER SPEEDADJUST TO DESIRED

SPEED

TEMPERATURE LEVERSLIDE THE TEMPERATURE LEVER ALL THE WAY LEFTTO THE HOT POSITION.

(SLIDE LEVER LEFT OR RIGHT TO DESIRED TEMPERATURE)

SLIDE THE LEVER TOTHE CENTER POSITION

MODE LEVER

BLOWER SPEEDADJUST TO DESIRED

SPEED

SLIDE THE LEVER TO THE LEFT POSITION

MODE LEVER

TEMPERATURE LEVERADJUST TO DESIRED

SPEED

BLOWER SPEED

SLIDE THE LEVER TOTHE RIGHT POSITION

MODE LEVER

DEFROST/ DE-FOG MODE

HEAT MODE

AC MODE

MODELEVER

OPERATION OF CONTROLS

ADJUST LEVER TODESIRED TEMPERATURE.

(COMPRESSOR IS AUTOMATICALLY

ENGAGED)

TEMPERATURE LEVERIN A/C MODE SLIDE THE TEMPERATURE LEVER ALL THE WAY TO THE RIGHT

TO ENGAGE COMPRESSOR.(SLIDE LEVER LEFT OR RIGHT

TO ADJUST DESIRED TEMPERATURE)

COLDHOTA/C

DASH FLR DEF

OFF HI BLOWERSPEED

TEMPERATURELEVER

COLDHOTA/C

DASH FLR DEF

OFF HI

COLDHOTA/C

DASH FLR DEF

OFF HI

NOTE: WHEN BATTERY POWER IS FIRST CONNECTED TO THE ECU, THE MICRO PROCESSOR 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 RE-INITIALIZATION. DURING START UP, A LOW BATTERY MAY DROP BELOW 7 VOLTS, TRIGGERING RE-INITIALIZATION.


Sym

pto

m

C

on

dit

ion

Ch

eck

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

evap

ora

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

Ch

eck

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.


3 ⅛”

1973-87CHEVY TRUCK

NON-AIRDRIVER SIDE LOUVER

TEMPLATE

(DO NOT EXCEED DIMENSIONS GIVEN)

2 ⁄”

2 ⁄”

DRIVER SIDE LOUVER TEMPLATE

CUT ALONGDOTTED LINE

CU

T A

LON

GD

OTT

ED L

INE


CUT ALONGDOTTED LINE

73-87 CHEV P-UP GLOVE BOX

MODIFICATIONTEMPLATE

GLOVE BOX MODIFICATION TEMPLATE


CHECK BY:PACKED BY:

DATE:

EVAPORATOR KIT751181

1.2.

11

744004-VUE791181

GEN IV 4 VENT EVAP. SUB CASE w/ 204 ECU ACCESSORY KIT 81-87 CHEV P-UP wo AC

NO. QTY. PART NO. DESCRIPTION

EVAPORATOR KIT PACKING LIST

1

ACCESSORY KIT791181

2

GEN IV 4 VENTEVAP SUB CASE

w/204 ECU744004-VUE

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

OFF

DASH

HOT

FLR

A/C

HI

DEF

COLD

1981-87 chevrolet pickup - vintage air · 1981-87 chevrolet pickup without factory air 751181...

Documents