1968-69 CHEVELLE
Contents
1. LIAAS 18 335 TOd1NOO SIHLNO 40 5501 COAJA NONS OL HOLVHOdVA2 JH NOIX SIHL NO TIIM INNOHD SISSVHO OL G3LHOHS SI AO ACIS ANNOYS 4 38 SAVMIV TIM Y3M018 JHL OL SALLISOd JHL DNIHOLIMS JHL OS8 GNNOH4D OL GILHOHS SI DNIHIM 9S8 ON IVHL JYNSNI OL SI 1504 JHL OL Q31O3NNOO SI ALIHM VD0Z TIVWS 3475 SINIOd 5 4HIM TOHLNOO SLIHM HLIM SISSVHO OL A4IHJA YO L1N38 ON OLNI 31 95 119 GHOVAVQ HHL SI 3HL DNINNIH SAVIS dl NODA YOLOANNOO TOHLNOD OSE GHHIM ATHAHOHANWI 1093 AAOS LNHS HAMO 8 dl NDA YOLOANNOO TOHINOD 2589 SYM ONIH M 1Od UMS 4 MO14 MO4HO GV H TOH1INOO MOSHO2. 0002 L INSTRUMENT PANEL PASSENGER SIDE KICK PANEL ETD OEM A C HEATER ASM 904471 REV A 11 5 08 1968 69 CHEVELLE w AC EVAP INSTR 7 OF 25 4 3 1968 69 CHEVELLE v AC DEFROST DUCT INSTALLATION INSTALL DEFROST DUCTS UNDER DASH AND ALIGN WITH OEM OPENING SECURE USING 10 X 1 2 SHEETMETAL SCREWS AND ATTACH COWL SEE FIGURE 4 OEM DEFROST DUCT OPENING PASS SIDE DEFROST DUCT 626674 DR SIDE DEFROST 10 x 1 2 DUCT ASM SHEET METAL Ww 626673 SCREW DR SIDE PASS SIDE DEF DUCT DEF DUCT ASM ASM 626673 626674 HOSE ADAPTER INSTALLATION INSTALL S CLIPS ON HOSE ADAPTERS AS SHOWN IN FIGURE 5 BELOW INSTALL DRIVER amp PASSENGER SIDE HOSE ADAPTERS OUTSIDE OEM LOUVERS SEE FIGURE 5 BELOW HOSE OEM ADAPTER LOUVER 49870 VCI INSTALL 3 S CLIPS 49870 904471 REV 11 5 08 1968 69 CHEVELLE w EVAP INSTR PG 8 OF 25 1968 69 CHEVELLE w AC FRESH AIR COVER INSTALLATION INSTALL 4 GROMMETS IN FRESH AIR CAP SEE FIGURE BELOW APPLY 1 4 BEAD OF SILICONE AROUND THE BACK SIDE OF THE FRESH AIR CAP AS SHOWN IN FIGURE BELOW ATTACH FRESH AIR CAP TO FIREWALL USING 1 4 20 x 1 1 2 BOLT AND WASHER SEE FIGURE BELOW NOTE FRESH AIR CAP INSTALLS ON ENGINE SIDE OF FIREWALL INSTALL 5 8 PLUG AND IN F
3. 1SV31 IV MOSHO NEL NVHL 55 SI JOVLIOA ACL 19981 SI JOVLIOA 330 NO SNHNL 9 NOLLISOd OLNI 939303 38 OL SAVH ANY dN ANIT SNOLIVOOTONILNNOW TIV NI GITIVLSNI SNISNOH 4 GASNVO ONIHIM YOLOW Y3dd3LS 5 MOSH ONIGNIG YO Ga LONYLSEO GALVIOOSSV LOd YO HOLIMS 0 NOLLONA4 TIV ON NOILONNA HOOG 3001 dO 8801 5 NOLLONNA OL YOLVINOAY HOLVNHILIV GOOD NI LSNW NOLLIGNOQ SIHLNILINSSY OSTV LNO NHOM HOIVNHALIV ANV N3131108 NOLLVTIVLSNI OldVY 395 109 40 1504 AAILISOd JHL LV HOLIDVAVO OIGV4 V TIVLSNI LN KS TIM 9 NVHL 53945 AdOOSIMOSO GALOAdSNS SI SIHL JOVLIOA HDIH OL 3NA LAHS OL AH1SAS dH1 ASNVO SSION NOLLINDI JOVLIOA S AHLIVg 0009 SND1O3HO NOLO YALIN AIYA MOSHO d3AAO 18
4. 431V3H HIMOd dAILISOd HO4 MOSHO JSOOT GINUNA 303 MOSHO TONIHIM N93 DNIHIM G2IVIDOSSV ANY 100 SINIOd TM LY QOOD NDINO SHOLIOVdV O TIVISNI 9 8831 GNVSLIOA OLNVHLHILV449 SI JOVLIQA LIVE AIHA HLO8 HIMOd NO SNOLLO3NNOO HOLVNHILIV ANY HANN NO LON TIM SNOISUSA TIY 118 N39 ATNOIdA 1 GILAVIS 3NION3 44O S1 HS ONINNNY NOLLINDI HIHLIJNOH4 SONSYSSYALNIASION LON SI NSHM SAYOM TIM 1845 904471 REV A 11 5 08 1968 69 w EVAP INSTR PG 23 OF 25 INOD NOILVW4OHNI ONILOOHS 319 JUU 2 3T1I3A3H2 69 8961 1968 69 w AC FIREWALL ENLARGE OEM HOLE FIREWALL 2 OPENING DRILL 5 16 68 69 CHEVELLE w AC EVAP REAR BRKT TEMPLATE 904471 REV A 11 5 08 1968 69 CHEVELLE w AC EVAP INSTR PG 24 OF 25 1968 69 CHEVELLE w AC EVAPORATOR KIT EVAPORATOR KIT PACKING LIST 564471 QTY PART No DESCRIPTION 1 762169 GEN IV 4 VENT w 2 amp 2 1 2 EVAP SUB CASE 1 784166 1968 69 CHEVELLE w AC ACC KIT BEFORE BEGINNING INSTALLATION OPEN ALL
5. lt 0 ri 16 904471 REV A 11 5 08 1968 69 CHEVELLE w AC EVAP INSTR PG 16 OF 25 1968 69 CHEVELLE w Ac FINAL STEPS INSTALL DUCT HOSES AS SHOWN IN FIGURE 20 PAGE 18 ROUTE A C WIRES THROUGH 5 8 GROMMENT AS SHOWN ON FIGURE 17 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 20 PAGE 18 WIRE ACCORDING TO WIRING DIAGRAM ON PAGE 19 AND 20 INSTALL NEW GLOVE BOX MODIFY PASSENGER SIDE KICK PANEL AS SHOWN IN FIGURE 19 BELOW REINSTALL ALL PREVIOUSLY REMOVED ITEMS BATTERY TRAY BATTERY amp INNER FENDER FILL RADIATOR WITH AT LEAST A 50 50 MIXTURE OF APPROVED ANTIFREEZE AND DISTILLED WATER IT IS THE OWNER S RESPONSIBILITY TO KEEP THE FREEZE PROTECTION AT THE PROPER LEVEL FOR THE CLIMATE IN WHICH THE VEHICLE IS OPERATED FAILURE TO FOLLOW ANTIFREEZE RECOMMENDATIONS WILL CAUSE HEATER CORE TO CORRODE PREMATURELY AND POSSIBLY BURST IN AC 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 CAPACITIES STATED ON THE INFORMATION PAGE PAGE 4 OF THIS INSTRUCTION MANUAL SEE OPERATION OF CONTROLS PROCEDURES PAGE 21
6. 904471 REV A 11 5 08 1968 69 w AC EVAP INSTR PG 15 OF 25 HEATER HOSE amp HEATER CONTROL VALVE INSTALLATION ROUTE PIECE OF HEATER HOSE FROM THE WATER PUMP TO THE TOP HEATER FITTING OF HEATER CORE AS SHOWN IN FIGURE 11 PAGE 12 AND FIGURE 16a BELOW SECURE USING HOSE CLAMPS ROUTE PIECE OF HEATER HOSE FROM THE INTAKE TO THE BOTTOM HEATER FITTING OF HEATER CORE AS SHOWN IN FIGURE 11 PAGE 12 AND FIGURE 16a BELOW NOTE INSTALL HEATER CONTROL VALVE IN LINE WITH INTAKE MANIFOLD PRESSURE SIDE HEATER HOSE SECURE USING HOSE CLAMPS AS SHOWN IN FIGURE 16a BELOW NOTE PROPER FLOW DIRECTION 1968 69 CHEVELLE w AC 4 XV IBEN 10 SUCTION 096062 HOSE 096073 2 5 8 HOSE NIPPLES NOT SUPPLIED 6 HARDLINE DRIER CONDENSER SAFETV SWITCH 35368 VCG az 1 Z Q 52 lt 2 555 m co 642 kO x n 24 2 2526020 A Z x lt i G LA x gounag lt l 2T ZG 058 02 LLI gt N 2 x T Q 9 lt AIR SYSTEMS REQUIRE 6 DRIER CORE HARDLINE 091175 10 ADEL CLAMP w 10 32 x 1 2 PAN HEATER HOSE HEATE CNTR VALVE INTAKE HOSE FROM HTR CNTRL VLV CLAMPS TO EVAPORATOR 04
7. 1968 69 w AC FIREWALL COVER INSTALLATION APPLY 1 4 BEAD OF SILICONE AROUND THE BACK SIDE OF THE FIREWALL COVER AS SHOWN IN FIGURE 8 BELOW FROM INSIDE THE CAR INSTALL FIREWALL COVER ON FIREWALL USING 3 1 4 20 x 1 HEX BOLTS FLAT WASHERS AND 1 4 20 NUT WITH STAR WASHER SEE FIGURE 8 BELOW FIREWALL COVER 648170 3 1 4 20 NUTS WITH STAR WASHER Co 3 1 4 x P SILICONE FLAT WASHER 3 1 4 20 x 1 8 BACK SIDE OF FIREWALL COVER EVAPORATOR INSTALLATION ON WORK BENCH INSTALL 2 HEATER FITTINGS WITH PROPERLY LUBRICATED O RINGS SEE FIGURE 15 PAGE 14 AND FIGURE 10 PAGE 11 INSTALL 1 4 20 x 1 HEX BOLT AND 1 4 20 x 1 1 2 HEX BOLT w 1 2 ALUM SPACER AND 2 1 4 PUSH NUT BOLT RETAINER ON EVAP REAR BRKT AS SHOWN IN FIGURE 10 PAGE 11 FRONT INSTALL EVAPORATOR FRONT amp REAR MOUNTING BRACKETS 2 EVAPORATOR ON EVAPORATOR USING 5 1 4 20 x 1 2 HEX BOLTS AND I BRACKET TIGHTEN AS SHOWN IN FIGURE 9 BELOW amp FIGURE 10 647065 PAGE 11 Al LAV EVAPORATOR SUBCASE ON PASSENGER SIDE FLOOR BOARD INSTALL A C amp HEATER HOSE ON EVAPORATOR AS SHOWN IN FIGURE 11 1 4 20 x PAGE 12 AND HOSE INSTALLATION HEX BOLT PAGE 14 NOTE WRAP THE 10 FITTING CONNECTIONS WITH PRESS TAPE SEE FIGURE 11 PAGE 12 10 904471 REV
8. 11 5 08 1968 69 CHEVELLE w AC EVAP INSTR PG 10 OF 25 a BRACKET INSTALLATION CONT REAR EVAPORATOR BRACKET 655000 VUB 72 11 O 2 HEATER FITTINGS e 0 7 2 1 4 20 x 1 2 BOLT 1968 69 CHEVELLE w AC 18289 VUB 1 4 20 1 1 2 BOLT 68 69 MOUNTING HOLES 904471 REV 11 5 08 1968 69 CHEVELLE w AC EVAP INSTR PG 11 OF 25 18290 VUB 1 4 20 x 1 HEX BOLT 18035 VUB 1 2 ALUM SPCR 5 189125 1 4 5 BOLT 2 1 4 20 x 1 2 HEX BOLT 189125 MUR 1 4 PUSH BOLT RETAINER 1968 69 w AC EVAPORATOR INSTALLATION 1 LIFT EVAPORATOR UNIT UP UNDER THE DASHBOARD SECURE LOOSELY TO THE FIREWALL FROM THE ENGINE COMPARTMENT SIDE USING 2 1 4 20 AND FLAT WASHER SEE FIGURE 12 SECURE THE FRONT EVAPORATOR MOUNTING BRACKET BETWEEN THE DASH BRACKET AND COWL BRACKET USING OEM SCREW SEE FIGURE 12 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 OEM BOLT ONCE EVAPORATOR IS IN PLACE ROUTE 8 HEATER HOSE OUT KICK PANEL FRESH AIR AND THROUGH FRESH AIR CAP FRONT EVAPORAT
9. AAO YO NO SI NOLLINDI NIHM NO SAVLS 1 SNOILONN 1TOHLNOQ NISHIM SNId HO4MO3HO AYOM YSHLO NO SI NOLLINDI dS SAVLS L SALON SNOLLOV SMOJHO NOLLIGNOD WOLdUNAS 2 69 NOI1VW4 78961 SNILOOHS 318 NOl 904471 REV A 11 5 08 1968 69 w AC EVAP INSTR PG 22 OF 25 OL HMOd GANNY 14534 TIM WALSAS JHL M HTINd SIWALSAS 3HL dl OSIY 5 CAHOLIMS V NO JON ANY LSOd A43L1va JHL NO SI 8905 38 18534 SVHWALSAS 1 YOLV SI SIHL 330 SHL NI HOLIMS HLM SI SIHL SLNHS 53 00 ATRVIN3IWOIN 2HMO 8 NO NYNL SINOLLINDI 8 GILVIDOSSV ONY 1Od HOLIMS HO4 7013 dWAL SGOW SNOLLONNA L OL IV ASNVO NVO AA LIVE MVIM SNOILOANNOO HOOd LV 19 440 SINHS WALSAS NV3 IO SNOLLOANNOOD WALSAS GNNOHD SISSVHO ANY HIM JAVA
10. 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 GEN IV 4 VENT w 2 amp 2 1 2 EVAP SUB CASE O SOO ACCESSORY KIT NOTE IMAGES MAY NOT DEPICT ACTUAL PARTS AND QUANTITIES 784166 REFER TO PACKING LIST FOR ACTUAL PARTS AND QUANTITIES 904471 REVA 11 5 08 1970 72 CHEVELLE w AC GEN IV EVAP INSTR PG 25 OF 25
11. AHM AS ANY N33MNU AYVA 5 32188 INNO D SISSVHO 3AVH TIM HIM ALIHM HUM NS 10 Gay OHY 1NOO 1Od 31 1d34 HIVd44 ALINY 303 MOAHO DOSSV LOd HHOM SNOLLONA4 43HLO TW 440 NHALLON HOSSIHHWOD GIIHSIG 38 OL HOSSIHAWNOD JSNVO TIM HOLSINHAHIL ALINVA YO GALOSNNOOSIG NOLLISOd Y34371 A VA TIIM AS lt JOVLIOA ANTE ALIHM LV ADVLIOA MOAHO LOd OL 11054 SNORAS 5 A133VS SSVdA8 HAIN 5 IV IO1O3NNOONId OML 1OHLNOD NO AS 303 MO3HO ALIHM NO OL HOLIMS SAYNSSAYd SSVdA8 WALSAS JDHVHO HOLSIWYSHL ALINVA YO GALOANNOOS IG LOd OL 318VOlT1ddV LON DOSSV LOd ALINVA O1 HO4 38 LSNW WILSAS YOM SNOLLONA4 YSHLO 719 NO LON SIWALSAS NYNLLON TIM YOSSSYdNOO 2 A VSS4OAN GINOHS SINJNJOVIH3H 1 YSHLO ON
12. AIR RECOMMENDS OUR SYSTEMS BE CHARGED BY WEIGHT WITH A QUALITY CHARGING STATION OR SCALE REFRIGERANT CAPACITIES FOR VINTAGE AIR SYSTEMS FOR OTHER SYSTEMS CONSULT MANUFACTURER GUIDELINES 134a SYSTEM R 12 SYSTEM CHARGE WITH 1 8 Ibs CHARGE WITH 2 0 Ibs OF REFRIGERANT 116 12025 OF REFRIGERANT LUBRICANT CAPACITIES NEW COMPRESSOR NO ADDITIONAL OIL NEEDED 904471 REV A 11 5 08 1968 69 CHEVELLE w AC EVAP INSTR PG 4 OF 25 1968 69 CHEVELLE w AC 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 CAPACITOR INSTALLED INTERNALLY TO ELIMINATE WHAT IS CALLED WHINING AS THE ENGINE IS REVVED IF WHINING IS HEARD IN THE RADIO OR JUST 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 A HEAVY GROUND FROM THE BATTERV THE ENGINE BLOCK AND ADDITIONAL GROUNDS TO THE BODY AND TO THE CHASSIS IF THESE PRECAUTIONS ARE NOT OBSERVED IT IS POSSIBLE FOR VOLTAGE SPIKES TO BE PRESE
13. BLY amp INSTALLATION REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH THE CONDENSER KIT TO INSTALL THE CONDENSER BINARY SWITCH INSTALLATION REFER TO CONDENSER INSTRUCTIONS COMPRESSOR amp BRACKETS REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH THE BRACKET KIT TO INSTALL THE COMPRESSOR BRACKET PULLEYS IN MOST INSTANCES THE BELT LENGTHS WILL REMAIN THE SAME PASSENGER COMPARTMENT NOTE REMOVAL OF DASHBOARD REQUIRED TO INSTALL THE EVAPORATOR VINTAGE AIR RECOMMENDS THAT YOU UTILIZE THE FACTORY SERVICE MANUAL WHEN YOU DISASSEMBLE AND REASSEMBLE THE DASHBOARD REMOVE THE FOLLOWING REMOVE THE DASH PAD BY REMOVING 6 SCREWS RETAIN SEE FIGURE 2 BELOW LOWER STEERING COLUMN PROTECT STEERING COLUMN WITH A CLOTH DISCONNECT ALL WIRE AND CABLES FROM INSTRUMENT PANEL SPEEDOMETER CONTROL PANEL AND RADIO REMOVE INSTRUMENT PANEL RETAINING SCREWS AT TOP BOTTOM AND SIDE OF PANEL ALL HOSE AND DUCTING FROM O E M LOUVERS SEE FIGURE 2 BELOW THE 2 O E M UNDER DASH LOUVER ASM DISCARD SEE FIGURE 2 BELOW O E M DEFROST DUCT ASSEMBLY BY REMOVING THE 4 SCREWS SEE FIGURE 3 BELOW O E M AC HEATER ASM SEE FIGURE 3 BELOW PASSENGER SIDE KICK PANEL FRESH AIR DOOR ASM AS SHOWN IN FIGURE 2a 72 lt Te p b 2577 4 CONTROL PANEL DOOR ASM AC HEATER ASSEMBLY amp RELATED DUCTING DEFROST DUCT
14. CESSIVELY HIGH HEAD PRESSURE 406 PSI TO PREVENT COMPRESSOR DAMAGE OR HOSE RUPTURE A TRINARY SWITCH 11076 VUS COMBINES HI LO PRESSURE PROTECTION WITH AN ELECTRIC FAN OPERATION SIGNAL AT 254 PSI AND MAY BE SUBSTITUTED FOR USE WITH ELECTRIC CONDENSER FANS COMPRESSOR SAFETY SWITCHES ARE EXTREMELY IMPORTANT SINCE AN A C SYSTEM RELIES ON REFRIGERANT TO CARRY LUBRICATION THROUGH THE SYSTEM SERVICE INFO ATTENTION SYSTEM COMPONENTS THE COMPRESSOR EVAPORATOR CONDENSER amp DRIER ARE CAPPED 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 VINTAGE AIR SYSTEMS ARE DESIGNED TO OPERATE WITH 34a or R 12 REFRIGERANT ONLY USE OF ANY OTHER REFRIGERANTS RISKS A DANGER OF FIRE AND COULD DAMAGE EITHER YOUR AIR CONDITIONING SYSTEM OR YOUR VEHICLE USE OF ANY OTHER REFRIGERANTS WILL VOID ALL WARRANTIES OF THE AIR CONDITIONING SYSTEM AND COMPONENTS USE OF THE PROPER TYPE AND AMOUNT OF REFRIGERANT IS CRITICAL TO PROPER SYSTEM OPERATION VINTAGE
15. D DIRECTLY TO THE NEGATIVE BATTERY POST e THE HEATER CONTROL VALVE IS A NORMALLY OPEN VALVE IT MUST BE CONNECTED TO THE ECU TO BLOCK WATER FLOW IN AC MODE 904471 REV A 11 5 08 1968 69 CHEVELLE w AC EVAP INSTR PG 5 OF 25 1968 69 v AC BEFORE STARTING THE INSTALLATION CHECK THE FUNCTION OF THE VEHICLE HORN LIGHTS ETC FOR PROPER OPERATIONS STUDY THE INSTRUCTIONS ILLUSTRATIONS amp DIAGRAMS ENGINE COMPARTMENT REMOVE THE FOLLOWING BATTERV BATTERV TRAY RETAIN DRAIN RADIATOR EVACUATE THE A C SVSTEM IF NECESSARV O E M CONDENSER AND DRIER DISCARD SEE FIGURE 1 O E M A C LINES FROM COMPRESSOR TO EVAPORATOR DISCARD SEE FIGURE 1 O E M COMPRESSOR AND BRACKET DISCARD SEE FIGURE 1 EVAPORATOR BLOWER ASSEMBLY DISCARD TO REMOVE THE EVAPORATOR AND BLOWER ASSEMBLV UNDER HOOD AND THE AIR DISTRIBUTION SVSTEM UNDER DASH THE FACTORV MANUAL INDICATES DOING THE FOLLOWING REMOVE RIGHT INNER FENDER OEM HEATER HOSES A C HOSES HARDLINES AND DRIER DISCARD SEE FIGURE 1 OEM A C 8 HEATER WIRING VACUUM HARNESS MOLDED GROMMET SEE FIGURE 1 INSTALL 1 3 4 PLUG IN FIREWALL SEE FIGURE 1 OEM A C amp HEATER WIRING VACUUM HARNESS MOLDED GROMMET 1 3 4 PLUG 69 CHEVELLE SHOWN FIGURE 1 904471 REV A 11 5 08 1968 69 CHEVELLE w AC EVAP INSTR PG 6 OF 25 1968 69 CHEVELLE w Ac CONDENSER ASSEM
16. F 25 1968 69 CHEVELLE w AC EVAPORATOR KIT KIT PACKING LIST 564471 QTY PART No DESCRIPTION 1 762169 GEN IV 4 VENT w 2 amp 2 1 2 EVAP SUB CASE 1 784166 1968 69 CHEVELLE w AC ACC 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 GEN IV 4 VENT 2 8 2 1 2 EVAP SUB CASE 762169 572 Bo moO 850 5 ACCESSORY NOTE IMAGES MAY NOT DEPICT ACTUAL PARTS AND QUANTITIES 784166 REFER TO PACKING LIST FOR ACTUAL PARTS AND QUANTITIES 904471 REV 11 5 08 1968 69 CHEVELLE w AC EVAP INSTR PG 3 OF 25 3 1968 69 CHEVELLE v AC 1968 69 CHEVELLE w AC GEN IV IMPORTANT NOTICE PLEASE READ FOR MAXIMUM SVSTEM PERFORMANCE VINTAGE AIR RECOMMENDS THE FOLLOWING THIS KIT DOES NOT CONTAIN HEATER HOSE YOU MUST PURCHASE 8 FEET OF 5 8 DIA HEATER HOSE FROM VINTAGE AIR 31800 VUD OR FROM YOU LOCAL PARTS RETAILER SAFETY SWITCHES YOUR VINTAGE AIR SYSTEM IS EQUIPPED WITH A BINARY PRESSURE SAFETY SWITCH A BINARY SWITCH 11078 VUS DISENGAGES THE COMPRESSOR CLUTCH IN CASE OF EXTREME LOW PRESSURE CONDITION REFRIGERANT LOSS OR EX
17. GLOVE BOX 62567 VCE GROMMET J 33144 VUI GLOVE BOX FIGURE 17 DOOR CUT amp REMOVE 11 2 PASSENGER SIDE KICK PANEL 17 904471 REV 11 5 08 1968 69 CHEVELLE w AC EVAP INSTR PG 17 OF 25 DEFROST DUCT DR SIDE x 18 DRIVER SIDE LOUVER 212 x 32 AT 26 _ i 4 WELLE be WOW EU 100 NG ESS 232001 VUR WIRING DIAGRAM 1968 69 CHEVELLE w AC RED NA VIEWED FROM BOARD TOP SIDE RED O STEPPER c in YEL DASH FLOOR BLU HOT OPTIONAL 5 WIDE OPEN THROTTLE SWITCH CONTACTS z s l ew STEPPER l DEF WHICH DISABLES DEFRO
18. IAL gt dWV APV NI3 ONISN OL SAAM ALIHM 1D3NNOO 31ON 123 0 gt 4 5 gt LIINNOD SSINIVH Livd 5155 ION 93119405 HOLIMS 13 5 ANNIE OSSIHWOD HOLIMS 123 YNIWJIL LOH JAYA 123 A I 41 SIOULNOD GASAN SI AVAD SSINAVH dATVA O1V4OdVA3 10 NYL 1091405 JONVJO MOTTHA JAIS 1 31ON SSaNAVH 2 a v SAV13q INNOW ON k 123 qad JOLVJOdVA1 10 3qIS 553 1041405 SNOILONULSNI ATONIGYO DOV SNOLLONILSNI HNVd ONKIM AI N39 TOALNOD OL 3432 2 69 8961 904471 REV 11 5 08 1968 69 CHEVELLE w AC EVAP INSTR PG 20 OF 25 1968 69 CHEVELLE w AC OPERATION OF CONTROLS Pee NOTE WHEN BATTERY POWER IS FIRST CONNECTED TO THE ECU THE COMPUTER 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 DISCONNEC
19. IREWALL SEE FIGURE USE TEMPLATE ON PAGE 24 AND DRILL 5 1 HOLE IN FIREWALL AS SHOWN IN FIGURE OEM HEATER HOLE FRESH AIR IN FIREWALL 4 GROMMETS 222 S 0 ENLARGE EXSTING N HOLE IN FIREWALL 1 4 20 1 1 2 9 9 5 16 BOLT w BV ENGINE WASHER OP wa ae COMPARTMENT S I SIDE OF 9 SILICONE 5 8 PLUG 5 16 lt 33142 VUI HOLE S 5 33145 VUI NOTE FIREWALL COVER MOUNTING HOLES MUST BE ENLARGED BACK SIDE OF FRESH AIR GOIH ENLARGE EXSTING HOLE IN FIREWALL TO 5 1 KICK PANEL FRESH AIR CAP INSTALLATION INSTALL 4 GROMMETS KICK PANEL FRESH AIR SEE FIGURE 7 BELOW ROUTE AND HOSE THROUGH FRESH AIR AND KICK PANEL FRESH AIR CAP AS SHOWN IN FIGURE 7 AND 7b BELOW APPLY 1 4 BEAD OF SILICONE AROUND THE BACK SIDE OF KICK PANEL FRESH AIR CAP AS SHOWN IN FIGURE 7 BELOW SECURE KICK PANEL FRESH AIR CAP USING OEM SCREWS AS SHOWN IN FIGURE 7b BELOW 4 33137 VUI BACKSIDE OF KICK PANEL FRESH AIR CAP 5 SCREWS 10 A C HOSE 0 10 9 HOSE 6 2 HEATER HOSE HOSE 2 HEATER HOSE 9 HOSES 904471 REVA 11 5 08 1968 69 CHEVELLE w AC EVAP INSTR PG 9 OF 25
20. L SUPPLIED O RINGS AS SHOWN O AND LUBRICATE WITH SUPPLIED OIL O RING 6 O RING lt SUPPLIED OIL FOR O RINGS O RING INSTALES gt s OVER MALE INSERT TO SWAGED LIP 8 O RING 10 O RING a a S RTN Vy WITH THIS WRENCH A C HOSE INSTALLATION STANDARD HOSE KIT LOCATE THE 8 COMPRESSOR A C HOSE LUBRICATE 2 8 O RINGS SEE FIGURE 15 ABOVE AND CONNECT THE 135 FEMALE FITTING w 134 SERVICE PORT TO THE 8 DISCHARGE PORT ON THE COMPRESSOR ROUTE THE STRAIGHT FEMALE FITTING TO THE 8 CONDENSER HARDLINE COMING THROUGH CORE SUPPORT SEE FIGURE 16 PAGE 15 AND FIGURE 16a PAGE 16 TIGHTEN EACH FITTING CONNECTION AS SHOWN IN FIGURE 15 ABOVE LOCATE THE 10 COMPRESSOR HOSE LUBRICATE 2 10 O RINGS SEE FIGURE 15 ABOVE AND CONNECT THE 10 135 FEMALE FITTING w 134a SERVICE PORT TO THE 10 SUCTION PORT ON THE COMPRESSOR ROUTE THE 907 FEMALE FITTING TO THE 10 EVAPORATOR SEE FIGURE 11 PAGE 12 AND FIGURE 1 PAGE 15 AND FIGURE 1 q PAGE 16 TIGHTEN EACH FITTING CONNECTION AS SHOWN IN 15 ABOVE LOCATE THE EVAPORATOR A C HOSE LUBRICATE 2 O RINGS SEE FIGURE 15 ABOVE AND CONNECT THE STRAIGHT FEMALE FITTING TO THE HARDLINE COMING THROUGH THE CORE SUPPORT FROM DRIER ROUTE THE 90 FEMALE FITTING TO THE EVAPORATOR SEE FIGURE 11 PAGE 12 AND FIGURE 16 PAGE 15 AND FIGURE 16a PAGE 16 TIGHTEN EACH FITTING CONNECTION AS SHOWN IN FIGURE 15 ABOVE MODIFIED 5 SEPARATE INST
21. NT ON THE BATTERY LEADS THESE SPIKES COME FROM IGNITION SYSTEMS CHARGING SYSTEMS AND FROM TURNING SOME OF THE VEHICLE S OTHER SYSTEMS ON AND OFF MODERN COMPUTER OPERATED EQUIPMENT CAN BE SENSITIVE TO SPIKES ON THEIR POWER LEADS WHICH CAN CAUSE UNEXPECTED RESETS STRANGE BEHAVIOR AND MAY ALSO CAUSE PERMANENT DAMAGE VINTAGE AIR STRIVES TO HARDEN THEIR PRODUCTS AGAINST THESE TYPES OF ELECTRICAL NOISE BUT THERE IS POINT WHERE VEHICLE S ELECTRICAL SYSTEM CAN BE DEGRADED SO MUCH THAT NOTHING CAN HELP RADIO INTERFERENCE CAPACITORS SHOULD BE AVAILABLE AT MOST AUTO amp TRUCK PARTS SUPPLIERS THEV TVPICALLV ARE CVLINDRICAL IN SHAPE A LITTLE OVER AN INCH LONG A LITTLE OVERA HALF INCH IN DIAMETER THEY HAVE A SINGLE LEAD COMING FROM ONE END OF THE CYLINDER WITH A TERMINAL ON THE END OF THE WIRE AND THEY WILL HAVE A MOUNTING CLIP WHICH IS SCREWED INTO A GOOD GROUND ON THE VEHICLE THE SPECIFIC VALUE OF THE CAPACITANCE IS NOT TOO SIGNIFICANT IN COMPARISON TO IGNITION CAPACITORS THAT ARE MATCHED WITH THE COIL TO REDUCE PITTING OF THE POINTS e CARE MUST BE TAKEN WHEN INSTALLING THE COMPRESSOR LEAD NOT TO SHORT IT GROUND THE COMPRESSOR LEAD MUST NOT BE CONNECTED A CONDENSER FAN OR ANY OTHER AUXILIARY DEVICE SHORTING TO GROUND OR CONNECTING T A FAN OR ANY OTHER AUXILIARY DEVICE WILL CAUSE SEVERE DAMAGE WHEN INSTALLING GROUND LEADS IV SYSTEMS THE BLOWER CONTROL GROUND AND ECU GROUND MUST BE CONNECTE
22. OR BRKT 647065 10 A C HEATER HOSE KICK PANEL FRESH AIR 2 1 4 20 NUT w FLAT WASHER cam 904471 REV A 11 5 08 1968 69 CHEVELLE w AC EVAP INSTR PG 12 OF 25 12 Si 1968 69 CHEVELLE w Ac 68 CENTER LOUVER INSTALLATION INSTALL 4 S CLIPS ON HOSE ADAPTER SEE FIGURE 13 INSTALL CENTER LOUVER HOSE ADAPTER OUTSIDE OEM CENTER LOUVER ASSEMBLY AS SHOWN IN FIGURE 13 BELOW 4 S CLIPS 65980 VUE 69 CENTER LOUVER INSTALLATION REMOVE THE CENTER LOUVER DOOR FLAP SEE FIGURE 13a INSTALL 4 S CLIPS ON HOSE ADAPTER SEE FIGURE 13 INSTALL CENTER LOUVER HOSE ADAPTER OUTSIDE OEM CENTER LOUVER ASSEMBLY AS SHOWN IN FIGURE 13a BELOW DOOR FLAP 904471 REV 11 5 08 1968 69 CHEVELLE w EVAP INSTR PG 13 OF 25 1968 69 CHEVELLE v AC DRAIN HOSE INSTALLATION LOCATE EVAPORATOR DRAIN ON OF EVAPORATOR CASE IN LINE WITH DRAIN LIGHTLY A MARK ON THE FIREWALL MEASURE 1 DOWN AND Y DRILL 5 8 HOLE THROUGH THE FIREWALL SEE FIGURE 14 BELOW INSTALL DRAIN HOSE TO BOTTOM OF 23 EVAPORATOR UNIT AND ROUTE THROUGH PAT FIREWALL SEE FIGURE 14 lt 1 n NL es EVAPORATOR DRAIN CASE HOSE LUBRICATING O RINGS MALE FEMALE FOR A PROPER SEAL OF FITTINGS O RING INSERT NUT INSTAL
23. RUCTIONS INCLUDED WITH MODIFIED HOSE KIT 14 904471 REV 11 5 08 1968 69 CHEVELLE w AC EVAP INSTR PG 14 OF 25 HEATER HOSE amp HEATER CONTROL VALVE INSTALLATION ROUTE PIECE OF HEATER HOSE FROM THE WATER PUMP TO THE TOP HEATER FITTING OF HEATER CORE AS SHOWN IN FIGURE 11 PAGE 12 AND FIGURE 16 BELOW SECURE USING HOSE CLAMPS ROUTE PIECE OF HEATER HOSE FROM THE INTAKE TO THE BOTTOM HEATER FITTING OF HEATER CORE AS SHOWN IN FIGURE 11 PAGE 12 AND FIGURE 16 BELOW NOTE INSTALL HEATER CONTROL VALVE IN LINE WITH INTAKE MANIFOLD PRESSURE SIDE HEATER HOSE SECURE USING HOSE CLAMPS AS SHOWN IN FIGURE 16 BELOW NOTE PROPER FLOW DIRECTION 1968 69 CHEVELLE w AC lt SUER 2 gt 15 gt Z O ui p 5 T 9839 z O A al E ku gt a 260 a 58 lt GE gt IN A H LEA a w T lt O nn na 2 L c a 25 289 ta 22 IL lt 47 952 ge 5 5 28 85 NM 88 188 VALVE INTAKE 10 SUCTION HOSE e 096076 lt e 8 DISCHARGE HOSE 096075 AS 75 7 FROM CNTRL VLV 3 TIE WRAPS TO EVAPORATOR 6 HOSE 096072 Ma di u lt
24. ST PLENUM AC COMPRESSOR BLU VIEWED FROM FAN WIRE SIDE gt RED GRY we STEPPER HH oY O O O VEL TEMPERTURE BLEND RED 1M5 BLU PRGM ____ off N A TACH YEL BLK LT BLU fel BLK DASH LAMP U NOT USED NOT USED WIDE THROTTLE 9 SWITCH OPTIONAL JF8 JM8 ele gt l ole ele M BLK EVAPORATOR TEMPERATURE GENIV WIRING DIAGRAM SENSOR REVISION B 2006 05 04 IGNITION SWITCH 12 O GEN IV ECU WHT RED WHT WHT RED RED RED RED RED 5 ee 30 BLOWER MOTOR 30 AMP HEATER YEL 85 86 85 87 86 CONTROL BLK VALVE COMPRESSOR RELAV RELAV DK BLU ici DK BLU WHT BINARY 4 OR TRINARY SAFETY WARNING ALWAYS MOUNT CIRCUIT SWITCH zs BREAKER UNDER THE HOOD IN THE ENGINE COMPARTMENT AND AS CLOSE THE BATTERY AS POSSIBLE DRIER u BATTERY CHASSIS NOTE GROUND 19 904471 REV 11 5 08 1968 69 CHEVELLE w AC EVAP INSTR PG 19 OF 25 318ISSOd SV 3 1 OL 35012 SV INIWLIVAWOD JNIDNI AMVINS SNOILONMILSNI dONAAOA 1102812 LNNOW SAVMIV HOLIMS A134VS AYNIAL 5 ONINUVM 2 ONIM OL 3439 HOLIMS A134VS TVNIW
25. TING THE BATTERY MAY ALSO TRIGGER ARE INITIALIZATION DURING START UP A LOW BATTERY MAY DROP BELOW 7 VOLTS TRIGGERING RE INITIALIZATIC BLOWER SPEED SYSTEM OFF MODE 7 LEVER THERMOSTAT BLUE AC INDICATOR wn LIGHT 0 OLD BLOWER SPEED A C THERMOSTAT LEVER MODE LEVER THIS LEVER CONTROLS IN A C MODE SLIDE THE THERMOSTAT LEVER SLIDE THE LEVER TO a ALL THE WAY RIGHT TO THE COLD POSITION THE DASH POSITION FOR MAXIMUM COOLING BLUE AC INDICATOR LIGHT WILL COME ON ONLY WHEN AC COMPRESSOR IS ENGAGED SLIDE LEVER LEFT OR RIGHT HEAT MODE TO ADJUST DESIRED TEMPERATURE yu 0 010 A C THERMOSTAT LEVER MODE LEVER IN HEAT MODE SLIDE THE SLIDE THE LEVER TO THERMOSTAT LEVER ALL THE THE FLR POSITION WAY TO THE LEFT TO THE SLIDE THE LEVER TO THE HOT POSITION FOR MAXIMUM HEATING LEFT OR RIGHT SLIDE LEVER LEFTORRIGHTTO ADJUST DESIRED DASH ADJUST DESIRED TEMPERATURE FLR DEF LOCATION DEFROST MODE 0 OLD A C THERMOSTAT LEVER MODE LEVER IN DEF MODE SLIDE THE SLIDE THE LEVER THERMOSTAT LEVER ALL THE THE DEF POSITION WAY TO THE LEFT 10 THE HOT POSITION FOR MAXIMUM HEATING SLIDE LEVER LEFT OR RIGHT TO ADJUST DESIRED TEMPERATURE 21 904471 REVA 11 5 08 1968 69 CHEVELLE w AC EVAP INSTR PG 21 OF 25 SI d3A31 N
26. sa 1968 69 CHEVELLE w FACTORY AIR 564471 1968 69 CHEVELLE w AC Table of Contents PAGES Or P o S COVER TABLE OF CONTENTS PACKING LIST PARTS DISCLAIMER INFORMATION PAGE WIRING NOTICE ENGINE COMPARTMENT FIGURE 1 CONDENSER ASSEMBLY COMPRESSOR amp BRACKET PULLEYS amp PASSENGER COMPARTMENT FIGURES 2 2a amp 3 DEFROST DUCT INSTALLATION amp HOSE ADAPTER INSTALLATION FIGURES 4 amp 5 FRESH AIR COVER INSTALLATION amp KICK PANEL FRESH AIR CAP INSTALLATION FIGURES 6 7 7a amp 7b FIREWALL COVER INSTALLATION amp EVAPORATOR INSTALLATION FIGURES 8 amp 9 BRACKET INSTALLATION FIGURE 10 EVAPORATOR INSTALLATION CONT FIGURES 11 12 amp 12a CENTER LOUVER INSTALLATION FIGURES 13 amp 13a DRAIN HOSE INSTALLATION LUBRICATING O RINGS A C HOSE INSTALLATION 8 FIGURES 14 amp 15 AC amp HEATER HOSE ROUTING 68 CHEVELLE FIGURE 16 amp HEATER HOSE ROUTING 69 CHEVELLE FIGURE 16a FINAL STEPS GLOVE BOX AND KICK PANEL MODIFICATION FIGURES 17 18 amp 19 CONTROL PANEL amp DUCT HOSE ROUTING FIGURE 20 WIRING DIAGRAM GEN IV WIRING CONNECTION INSTRUCTIONS OPERATION OF CONTROLS TROUBLE SHOOTING INFORMATION TROUBLE SHOOTING INFORMATION CONT 68 69 CHEVELLE w AC EVAP REAR BRKT TEMPLATE EVAPORATOR KIT PACKING LIST 904471 REV A 11 5 08 1968 69 CHEVELLE w EVAP INSTR PG 2 O
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