Chevrolet - Pickup - Parts Catalogue - 1981 - 1987

an ISO 9001:2015 Registered Company 1981-87 CHEVROLET PICKUP WITHOUT FACTORY AIR 751181 18865 Goll St. San Antonio, TX 78266 Phone: 800-862-6658 Sales: [email protected] Tech Support: [email protected] www.vintageair.com 901182 REV D 4/30/21, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 1 OF 29 Table of Contents PAGES 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 7. PASSENGER COMPARTMENT 8. DEFROST DUCT INSTALLATION & FRESH AIR CAP INSTALLATION AND FIREWALL MODIFICATION 9. FIREWALL MODIFICATION CONT. & FIREWALL COVER INSTALLATION 10. BRACKET & EVAPORATOR HARDLINE INSTALLATION 11. BRACKET & EVAPORATOR HARDLINE INSTALLATION CONT. 12. EVAPORATOR INSTALLATION 13. DRAIN HOSE INSTALLATION, LUBRICATING O-RINGS, A/C HOSE INSTALLATION, & MODIFIED A/C HOSE KIT 14. HEATER HOSE & HEATER CONTROL VALVE INSTALLATION 15. A/C & HEATER HOSE ROUTING 16. PASSENGER SIDE LOUVER DASH PANEL MODIFICATION & INSTALLATION 17. DRIVER SIDE/CENTER LOUVER DASH PANEL MODIFICATION & INSTALLATION 18. DRIVER SIDE/CENTER LOUVER DASH PANEL MODIFICATION & INSTALLATION (CONT.) 19. FINAL STEPS 20. GLOVE BOX MODIFICATION 21. CONTROL PANEL & DUCT HOSE ROUTING 22. WIRING DIAGRAM 23. GEN IV WIRING CONNECTION INSTRUCTIONS 24. OPERATION OF CONTROLS 25. TROUBLESHOOTING INFORMATION 26. TROUBLESHOOTING INFORMATION CONT. 27. DRIVER SIDE LOUVER TEMPLATE 28. GLOVE BOX MODIFICATION TEMPLATE 29. EVAPORATOR KIT PACKING LIST YouTube Screenshot A detailed tech video outlining the passenger and driver side louver dash installation process is available on Vintage Air’s YouTube channel at http://bit.ly/3xKRlqv. Viewing the tech video along with the written instructions will provide the installer the most detailed installation procedure. 2 901182 REV D 4/30/21, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 2 OF 29 EVAPORATOR KIT PACKING LIST NO. 1. 2. QTY. PART NO. 1 1 EVAPORATOR KIT 751181 DESCRIPTION 744004-VUE 791181 GEN IV 4 VENT EVAP. SUB CASE w/ 204 ECU ACCESSORY KIT 81-87 CHEV P-UP wo AC ** BEFORE BEGINNING INSTALLATION OPEN ALL PACKAGES AND CHECK CONTENTS OF SHIPMENT. PLEASE REPORT ANY SHORTAGES DIRECTLY TO VINTAGE AIR WITHIN 15 DAYS. AFTER 15 DAYS, VINTAGE AIR WILL NOT BE RESPONSIBLE FOR MISSING OR DAMAGED ITEMS. 1 GEN IV 4 VENT EVAP SUB CASE w/204 ECU 744004-VUE 2 HI OFF DASH HOT ACCESSORY KIT 791181 FLR DEF COLD A/C NOTE: IMA GES MA Y NOT DEPICT ACTUAL PARTS AND QUANTITIES. REFER TO PACKING LIST FOR ACTUAL PARTS AND QUANTITIES. 3 901182 REV D 4/30/21, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 3 OF 29 Important Notice—Please Read For Maximum System Performance, Vintage Air Recommends the Following: NOTE: Vintage Air systems are designed to operate with R134a refrigerant only. Use of any other refrigerant could damage your A/C system and/or vehicle, and possibly cause a fire, in addition to potentially voiding the warranties of the A/C system and its components. Refrigerant Capacities: Vintage Air System: 1.8 lbs. (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: New Vintage Air-Supplied Sanden Compressor: No additional oil needed (Compressor is shipped with proper oil charge). All Other Compressors: Consult manufacturer (Some compressors are shipped dry and will need oil added). Safety Switches Your Vintage Air system is equipped with a binary pressure safety switch. A binary switch disengages the compressor clutch in cases of extreme low pressure conditions (refrigerant loss) or excessively high head pressure (406 PSI) to prevent compressor damage or hose rupture. A trinary switch combines Hi/Lo pressure protection with an electric fan operation signal at 254 PSI, and should be substituted for use with electric fans. Compressor safety switches are extremely important since an A/C system relies on refrigerant to circulate lubricant. Service Info: Protect Your Investment: Prior to assembly, it is critical that the compressor, evaporator, A/C hoses and fittings, hardlines, condenser and receiver/drier 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. Bolts Passing Through Cowl and/or Firewall: To ensure a watertight seal between the passenger compartment and the vehicle exterior, for all bolts passing through the cowl and/or firewall, Vintage Air recommends coating the threads with silicone prior to installation. Heater Hose (not included with this kit): Heater hose may be purchased from Vintage Air (Part#31800-VUD) or your local parts retailer. Routing and required length will vary based on installer preference. 4 901182 REV D 4/30/21, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 4 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. 5 • For proper system operation, the heater control valve must be connected to the ECU. 901182 REV D 4/30/21, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 5 OF 29 ENGINE COMPARTMENT BEFORE STARTING THE INSTALLATION, CHECK THE FUNCTION OF THE VEHICLE (HORN, LIGHTS,ETC.) FOR PROPER OPERATIONS. STUDY THE INSTRUCTIONS, ILLUSTRATIONS, & DIAGRAMS. REMOVE THE FOLLOWING DISCONNECT BATTERY. DRAIN RADIATOR, REMOVE RADIATOR (RETAIN). 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. FIGURE 1 OEM HEATER BLOWER ASSEMBLY CONDENSER ASSEMBLY & INSTALLATION REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH THE CONDENSER KIT TO INSTALL THE CONDENSER. BINARY SWITCH INSTALLATION (REFER TO CONDENSER INSTRUCTIONS). COMPRESSOR & BRACKETS REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH THE BRACKET KIT TO INSTALL THE COMPRESSOR AND BRACKET. 901182 REV D 4/30/21, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 6 OF 29 6 PASSENGER COMPARTMENT REMOVE THE FOLLOWING: GLOVE BOX DOOR AND GLOVE BOX ASSEMBLY (RETAIN) (SEE FIGURE 2, BELOW). UNDER DASH STEERING COLUMN COVER (RETAIN) (SEE FIGURE 2). INSTRUMENT PANEL BEZEL (RETAIN). DASH PAD (RETAIN) (SEE FIGURE 2). DISCONNECT ALL WIRES AND CABLES FROM CONTROL PANEL. REMOVE CONTROL PANEL (DISCARD). REFER TO CONTROL PANEL CONVERSION KIT INSTRUCTIONS. ASH TRAY (RETAIN). 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. DASH PAD INSTRUMENT PANEL BEZEL UNDER DASH COVER CONTROL PANEL ASH TRAY GLOVE BOX DOOR & GLOVE BOX FIGURE 2 DEFROST DUCT ASSEMBLY (2) OEM BOLTS OEM HEATER ASSEMBLY DASH BRACE FIGURE 2a 7 901182 REV D 4/30/21, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 7 OF 29 DEFROST DUCT INSTALLATION INSTALL (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. (4) #8 x 1/2” (2) DEFROST PH PAN HEAD DUCT SCREWS 623219 (4) #8 U-NUT 189801 FIGURE 3 FRESH AIR CAP AND FIREWALL MODIFICATION APPLY A 1/4” BEAD OF SILICONE AROUND THE BACK SIDE OF THE FRESH AIR CAP AS SHOWN IN FIGURE 4, BELOW. ATTACH FRESH AIR CAP TO FIREWALL USING A 1/4-20 x 1” BOLT AND WASHER. SEE FIGURE 4, BELOW. PLACE FIREWALL COVER ON FIREWALL AND SECURE USING #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. SILICONE FRESH AIR CAP BACK SIDE OF FRESH AIR CAP 1/4-20 x 1” BOLT 1/4” FLAT WASHER MARK HOLE MARK 1/4-20 x 3/4” 1/4” NUT w/ BOLT HOLE STAR WASHER OEM HOLE OEM MARK HOLE HOLES MARK HOLES 1/4-20 x 3/4” 1/4” NUT w/ STAR WASHER BOLT FIGURE 4 #14 x 3/4” SHEET METAL SCREW MARK HOLE MARK HOLE 8 901182 REV D 4/30/21, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 8 OF 29 FIREWALL MODIFICATION CONT. DRILL HOLES AS SHOWN BELOW IN FIGURE 5. DRILL 3/16” HOLE OEM HOLE DRILL 9/32” HOLE OEM HOLE DRILL 3/8” HOLE DRILL 3/16” HOLE DRILL 3/16” HOLE FIGURE 5 OEM HOLE DRILL 3/16” HOLE FIREWALL COVER INSTALLATION APPLY A 1/4” BEAD OF SILICONE AROUND THE BACK SIDE OF THE FIREWALL COVER AS SHOWN BELOW. INSTALL FIREWALL COVER TO FIREWALL USING 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. 1/4-20 x 3/4” 1/4” FLAT WASHER 1/4” NUT w/ BOLT STAR WASHER SILICONE LARGE GROMMET 33137-VUI GROMMET 33135-VUI BACK SIDE OF FIREWALL COVER 644086 9 1/4-20 x 3/4” BOLT 1/4” FLAT WASHER FIGURE 6 (7) #14 x 3/4” SHEET METAL SCREW 1/4” NUT w/ STAR WASHER 901182 REV D 4/30/21, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 9 OF 29 BRACKET & EVAPORATOR HARDLINE INSTALLATION ON A WORKBENCH, INSTALL EVAPORATOR REAR BRACKET USING (4) 1/4-20 x 1/2” HEX BOLTS (SEE FIGURE 8, PAGE 11). INSTALL #6 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. EVAP FRONT BRKT 644087 (2)1/4-20 x ½” HEX BOLT FIGURE 7 10 901182 REV D 4/30/21, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 10 OF 29 BRACKET & EVAPORATOR HARDLINE INSTALLATION CONT. ECU MODULE (2) 1/4-20 x ½” HEX BOLT HOLD WITH THIS WRENCH (2) 1/4-20 x ½” HEX BOLT REAR EVAPORATOR BRACKET 644083 TWIST WITH THIS WRENCH LUBRICATE O-RING (SEE FIGURE 11, PAGE 13) FIGURE 8 #6 O-RING (33857-VUF) #10 O-RING (33859-VUF) #6 LIQUID LINE 091153 11 HEATER LINE (EVAP TO WATER PUMP) 091151 HEATER LINE (EVAP TO INTAKE) 091151 901182 REV D 4/30/21, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 11 OF 29 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. DRILL (2) VERIFY THAT EVAPORATOR UNIT IS LEVEL AND SQUARE TO THE DASH, THEN 3/ 1 6” HOLES TIGHTEN ALL MOUNTING BOLTS. NOTE: TIGHTEN THE BOLT ON FIREWALL FIRST, THEN THE FRONT (2)#14 x ¾” MOUNTING BRACKET. SHEET METAL INSTALL #10 SUCTION LINE AS SHOWN IN FIGURE 9b, BELOW. SCREWS NOTE: WRAP THE #10 FITTING CONNECTIONS WITH PRESS TAPE. SEE FIGURE 9b, BELOW. REINSTALL (2) OEM BOLTS UNDER DASH ON PASSENGER SIDE DOOR PILLAR. INNER COWL FIGURE 9a (2)1/4-20 x 1¼” HEX BOLT VIEW FROM PASSENGER SIDE INSIDE OF CAB (2) 1/4” FLAT WASHER (2) .563 L SPACERS NOTE: AFTER INSTALLING #10 SUCTION LINE WRAP ALL EXPOSED METAL (FITTINGS & TUBE) WITH SUPPLIED PRESS TAPE FIGURE 9 #10 O-RING 33859-VUF PRESS TAPE #10 SUCTION LINE 091152 FIGURE 9b 12 901182 REV D 4/30/21, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 12 OF 29 DRAIN HOSE INSTALLATION LOCATE EVAPORATOR DRAIN ON BOTTOM OF EVAPORATOR CASE. IN LINE WITH DRAIN, LIGHTLY MAKE A MARK ON THE FIREWALL, MEASURE 1” DOWN AND DRILL A 5/8” HOLE THROUGH THE FIREWALL. INSTALL DRAIN HOSE TO BOTTOM OF EVAPORATOR UNIT AND ROUTE THROUGH FIREWALL. INSTALL 1/2” 90° DRAIN ELBOW ON DRAIN HOSE. 1” EVAPORATOR CASE 1” DRAIN HOSE FIGURE 10 LUBRICATING O-RINGS O-RING MALE INSERT FEMALE NUT FOR A PROPER SEAL OF FITTINGS: INSTALL SUPPLIED O-RINGS AS SHOWN AND LUBRICATE WITH SUPPLIED OIL. O -RING #6 O-RING SUPPLIED OIL FOR O -RINGS # 8 O -RING O-RING, INSTALLS OVER MALE INSERT TO SWAGED LIP TWIST WITH THIS WREN CH #10 O -RING FIGURE 11 HOLD WITH THIS W RE NC H A/C HOSE INSTALLATION STANDARD HOSE KIT LOCATE THE #8 COMPRESSOR A/C HOSE. LUBRICATE (2) #8 O-RINGS (SEE FIGURE 11, ABOVE) AND CONNECT THE 90° FEMALE FITTING TO THE #8 DISCHARGE PORT ON THE COMPRESSOR. ROUTE THE STRAIGHT FEMALE FITTING w/ 134a SERVICE PORT TO THE #8 CONDENSER HARDLINE COMING THROUGH CORE SUPPORT. SEE FIGURE 13, PAGE 15. TIGHTEN EACH FITTING CONNECTION AS SHOWN. LOCATE THE #10 COMPRESSOR A/C HOSE. LUBRICATE (2) #10 O-RINGS (SEE FIGURE 11, ABOVE) AND CONNECT THE #10 135° FEMALE FITTING w/134a SERVICE PORT TO THE #10 SUCTION PORT ON THE COMPRESSOR. ROUTE THE STRAIGHT FEMALE FITTING TO THE #10 EVAPORATOR. SEE FIGURE 12, PAGE 14 AND FIGURE 13, PAGE 15. TIGHTEN EACH FITTING CONNECTION AS SHOWN. INSTALL #6 A/C LIQUID LINE AS SHOWN IN FIGURE 13, PAGE 15. MODIFIED A/C HOSE KIT 13 REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH MODIFIED HOSE KIT. 901182 REV D 4/30/21, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 13 OF 29 HEATER HOSE & HEATER CONTROL VALVE INSTALLATION ROUTE HEATER HOSE FROM WATER PUMP TO THE HEATER LINE COMING THROUGH THE FIREWALL AS SHOWN IN FIGURE 12, BELOW. SECURE USING HOSE CLAMPS. NOTE: A SMALL AMOUNT OF SILICONE SPRAY WILL EASE HEATER HOSE INSTALLATION. ROUTE HEATER HOSE FROM THE INTAKE TO THE HEATER LINE COMING THROUGH THE FIREWALL AS SHOWN BELOW. NOTE: INSTALL HEATER CONTROL VALVE IN LINE WITH INTAKE MANIFOLD (PRESSURE SIDE) HEATER HOSE. SECURE USING HOSE CLAMPS AS SHOWN. NOTE PROPER FLOW DIRECTION. HOSE SHOULD PROTRUDE THROUGH THE FIREWALL COVER SLIGHTLY TO CLOSE THE GAP BETWEEN THE ALUMINUM LINE AND THE FIREWALL COVER. SEAL ANY REMAINING GAP WITH RTV SILICONE. FROM HEA TO WA TER CORE TER PU MP HEATER HOSE #10 SUCTION LINE HOSE CLAMPS O-RINGS #6 LIQUID LINE FIGURE 12 FROM I MAN NTAKE IFOL D FROM HEATER CONTROL VALVE TO EVAPORATOR HEATER HOSE NOTE: FLOW DIRECTION FOLLOWS MOLDED ARROW ON VALVE. 14 901182 REV D 4/30/21, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 14 OF 29 15 901182 REV D 4/30/21, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 15 OF 29 HOSE CLAMPS FRO M MA INT NIF AKE OL D FIGURE 13 #6 CORE/EVAP LIQUID HARDLINE 091149 #6 COND/DRIER HARDLINE 091154 COMPRESSOR #10 SUCTION HOSE 096005 SAFETY SWITCH (BINARY TYPE) SCREW ON DRIER (REFER TO CONDENSER INSTRUCTIONS) OUT IN #8 COND HARDLINE 091156 #8 DISCHARGE HOSE 096004 #6 DRIER/ CORE SUPPORT HARD LINE 091155 HEATER HOSE (HEATER CNTRL VALVE/INTAKE) NOTE: VINTAGE AIR SYSTEMS REQUIRE (2) 5/8” HOSE NIPPLES (NOT SUPPLIED) #10 ADEL CLAMP 31601-VUD #6 LIQUID HARDLINE 091150 #2 ADEL CLAMP 31600-VUD NOTE: FLOW DIRECTION FOLLOWS MOLDED ARROW ON VALVE. FROM HEATER CONTROL VALVE TO EVAPORATOR HOSE FRO M TO EVAP WA O TER RATO PUM R P HEATER TIE WRAP AC & HEATER HOSE ROUTING PASSENGER SIDE LOUVER DASH PANEL MODIFICATION & INSTALLATION REMOVE THE PASSENGER SIDE DASH TRIM FROM THE DASH PAD (SEE FIGURE 14, BELOW). PLACE THE SUPPLIED TEMPLATE (ARROWS POINTING UP) ONTO THE BACK SIDE OF THE DASH PANEL TRIM AS SHOWN IN PHOTO 1, BELOW. MARK AND DRILL THE (2) MOUNTING HOLES USING A 5/32” DRILLBIT (SEE PHOTO 1, BELOW), THEN REMOVE THE TEMPLATE . FLIP THE DASH PANEL TRIM OVER, AND PLACE THE TEMPLATE ONTO THE FRONT OF THE TRIM USING THE (2) SUPPLIED #8 x 1” OVAL HEAD SCREWS TO SECURE. TRIM THE AREA INSIDE THE TEMPLATE TO FIT THE NEW LOUVER (SEE PHOTO 2, BELOW). REMOVE THE SCREWS AND TEMPLATE FROM THE DASH PANEL TRIM. REPEAT STEPS 2 AND 3 FOR THE OTHER LOUVER ON THE DASH PANEL TRIM. INSTALL THE NEW LOUVERS INTO THE MODIFIED DASH PANEL TRIM USING (2) #8 x 1” OVAL HEAD SCREWS (SEE PHOTOS 3 AND 4, BELOW). OEM PASSENGER SIDE DASH TRIM 3 ½” LOUVER TEMPLATE 644131 ARROWS POINTING UP FIGURE 14 MARK AND DRILL (2) MOUNTING HOLES USING 5/32” DRILLBIT PHOTO 1 RECTANGLE CHROME LOUVER WITH 2 ½” HOSE ADAPTER AND BEZEL 490549 (2) #8 x 1” OVAL HEAD SCREWS TRIM AREA INSIDE TEMPLATE TO FIT NEW LOUVER PHOTO 2 PHOTO 3 FINAL INSTALLATION PHOTO 4 16 901182 REV D 4/30/21, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 16 OF 29 DRIVER SIDE/CENTER LOUVER DASH PANEL MODIFICATION & INSTALLATION USING THE DRIVER SIDE LOUVER TEMPLATE PROVIDED ON PAGE 27, MARK AND CUT THE INSTRUMENT PANEL BEZEL AS SHOWN IN FIGURE 15, BELOW. MEASURE, MARK, CUT AND REMOVE THE BACK OF THE PACKAGE TRAY (SEE PHOTO 1 AND FIGURE 15A, BELOW). NOTE: BE SURE TO CUT USING THE DIMENSION PROVIDED TO PROPERLY INSTALL THE NEW LOUVER BEZEL. PLACE THE DRIVER SIDE LOUVER INTO THE SQUARE OPENING AND DRILL THE (4) MOUNTING HOLES USING A 3/32” DRILL BIT, THEN SECURE THE LOUVER USING (4) #4 x 1/2” SCREWS (SEE PHOTOS 2 AND 3, BELOW). PACKAGE TRAY 7 -8 CK 73 U 19 Y TR IR NT EV N A VE CHNO DE E SI AT R VE MPL DRI TE 1 ¼” DASH INSTRUMENT BEZEL CUT PLACE DRIVER SIDE LOUVER TEMPLATE LOCATED ON PAGE 27 HERE FIGURE 15 TOP VIEW FIGURE 15a DRILL (4) MOUNTING HOLES USING 3/32” DRILLBIT SQUARE ASSEMBLY LOUVER WITH 2 ½” HOSE ADAPTER 49178-VCL PHOTO 1 CUT PACKAGE TRAY PHOTO 2 17 901182 REV D 4/30/21, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 17 OF 29 (4) #4 x 1/2” SCREWS PHOTO 3 DRIVER SIDE/CENTER LOUVER DASH PANEL MODIFICATION & INSTALLATION (CONT.) PLACE THE LOUVER BEZEL INTO THE PACKAGE TRAY OPENING. NOTE: BE SURE THE BEZEL IS SITTING ON THE TRAY LIP. USING THE LOUVER BEZEL AS A TEMPLATE, DRILL (3) 5/32” MOUNTING HOLES INTO THE TOP AND BOTTOM WALLS OF THE TRAY (SEE PHOTOS 4, 5 AND 6, BELOW) REMOVE THE LOUVER BEZEL FROM THE TRAY AND INSTALL (3) #8 J-NUTS (SEE PHOTO 7, BELOW). REINSTALL THE LOUVER BRACKET INTO THE BEZEL AND SECURE THE BRACKET USING (3) #8 x 1/2” PAN HEAD SCREWS (SEE PHOTOS 8 AND 9, BELOW). INSTALL THE LOUVER INTO THE LOUVER BRACKET (SEE PHOTO 10, BELOW). DRILL (3) 5/32” MOUNTING HOLES PLACE LOUVER BEZEL INTO PACKAGE TRAY OPENING PHOTO 4 PHOTO 5 PHOTO 6 (3) #8 x 1/2” PAN HEAD SCREWS INSTALL (3) #8 J-NUTS PHOTO 7 PHOTO 8 INSTALL LOUVER INTO LOUVER BRACKET PHOTO 9 RECTANGLE CHROME LOUVER WITH 2 ½” HOSE ADAPTER 490548 PHOTO 10 18 901182 REV D 4/30/21, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 18 OF 29 FINAL STEPS INSTALL DUCT HOSES AS SHOWN IN FIGURE 18, PAGE 21. ROUTE A/C WIRES THROUGH 3/8” GROMMET AS SHOWN IN FIGURE 16, BELOW. (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 21 (WIRE ACCORDING TO WIRING DIAGRAM ON PAGE 22 AND 23). MODIFY GLOVE BOX AS SHOWN ON PAGE 20. REINSTALL GLOVE BOX. REINSTALL ALL PREVIOUSLY REMOVED ITEMS, INNER FENDER. FILL RADIATOR WITH AT LEAST A 50/50 MIXTURE OF APPROVED ANTIFREEZE AND DISTILLED WATER. IT IS THE OWNER'S RESPONSIBILITY TO KEEP THE FREEZE PROTECTION AT THE PROPER LEVEL FOR THE CLIMATE IN WHICH THE VEHICLE IS OPERATED. FAILURE TO FOLLOW ANTIFREEZE RECOMMENDATIONS WILL CAUSE HEATER CORE TO CORRODE PREMATURELY AND POSSIBLY BURST IN A/C MODE AND/OR FREEZING WEATHER, VOIDING YOUR WARRANTY. DOUBLE CHECK ALL FITTINGS, BRACKETS AND BELTS FOR TIGHTNESS. VINTAGE AIR RECOMMENDS THAT ALL A/C SYSTEMS BE SERVICED BY A CERTIFIED AUTOMOTIVE AIR CONDITIONING TECHNICIAN. EVACUATE THE SYSTEM FOR A MINIMUM OF 45 MINUTES PRIOR TO CHARGING AND LEAK CHECK PRIOR TO SERVICING. CHARGE THE SYSTEM TO THE CAPACITIES STATED ON THE INFORMATION PAGE (PAGE 4) OF THIS INSTRUCTION MANUAL. SEE OPERATION OF CONTROLS PROCEDURES PAGE 24. 3/8” GROMMET 33144-VUI WIRING HARNESS (HEATER CONTROL VALVE) WIRING HARNESS (12 VOLT/GROUNDS/BINARY SWITCH) FIGURE 16 19 901182 REV D 4/30/21, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 19 OF 29 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 ALONG THE 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 BOX AS SHOWN IN FIGURE 17a, BELOW. OEM wo A/C GLOVE BOX OEM wo A/C GLOVE BOX DISCARD FRONT PORTION OF BOX DISCARD FRONT PORTION OF BOX FACTORY AIR GLOVE BOX TEMPLATE FACTORY AIR GLOVE BOX TEMPLATE CUT BOX WITH A HACK SAW BLADE ON THESE THREE FRONT LINES ONLY CUT BOX WITH A HACK SAW BLADE ON THESE THREE FRONT LINES ONLY FIGURE 17 MODIFIED GLOVE BOX FIGURE 17a 901182 REV D 4/30/21, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 20 OF 29 20 CONTROL PANEL & DUCT HOSE ROUTING HI DEF OFF FLR COLD A/C DASH HOT PASS. SIDE DEF. DUCT 2” x 12” PLUG FROM CONTROL WIRING HARNESS 232007-VUR DRIVER SIDE DEF DUCT 2” x 28” PLUG FROM WIRING HARNESS 232600-VUA PASS SIDE LOUVER 2 ½” x 45” CENTER DRIVER SIDE LOUVER 2 ½” x 28” FIGURE 18 DRIVER SIDE LOUVER 2 ½” x 26” CENTER PASS SIDE LOUVER 2 ½” x 15” 21 901182 REV D 4/30/21, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 21 OF 29 Wiring Diagram 232007-VUR TAN ORA BLK WHT JF8 RED WHT/RED WHT/YEL WHT/GRN AC ANNUNCIATOR BACKLIGHT POS BACKLIGHT NEG GND 5V-SW TEMP WIPER MODE WIPER FAN WIPER PRE-WIRED VIEWED FROM WIRE SIDE 232002-VUA A/C (IF USED) GEN IV ECU GEN IV WIRING DIAGRAM REV E, 10/6/2017 TEMP MODE FAN PROGRAM * DASH LAMP (IF USED) *** WIDE OPEN THROTTLE SWITCH (OPTIONAL) ** CIRCUIT BREAKER 30 AMP HEATER CONTROL VALVE * Dash lamp is used only with type 232007-VUR harness. ** Warning: Always mount circuit breaker as close to the battery as possible. (NOTE: Wire between battery and circuit breaker is unprotected and should be carefully routed to avoid a short circuit). *** Wide open throttle switch contacts close only at full throttle, which disables A/C compressor. 901182 REV D 4/30/21, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 22 OF 29 22 Gen IV Wiring Connection Instruction WIRING HARNESS CONTROL WIRING HARNESS RED & WHITE A/C COMPRESSOR RELAY RED BLUE NOTE: MOUNT RELAY IN DESIRED LOCATION UNDER DASH RED WH IT E Ignition Switch: VIOLET Violet 12V ignition switch source (key on accessory) position must be switched. +12V NOTE: WIRING YELLOW & ORANGE (IGNITION HOT HARNESS COMING FROM TERMINAL) HARNESS ARE NOT USED. YELLOW RUN BAT IGNITION SWITCH ORANGE TAN DASH BACK LIGHT+0-12v GRAY GRAY WIRE IS USED FOR PROGRAMING CONTROLS IF APPLICABLE RED GREEN RED GREEN FIREWALL BLACK BLUE Heater Control Valve: RED LATCH WIRING HARNESS WHITE CHASSIS GROUND NOTE: HEATER CONTROL VALVE CONNECTION AND CHASSIS GROUND MAY BE LOCATED ON EITHER SIDE OF THE FIREWALL. ENSURE CONNECTOR IS LATCHED FIRMLY. HEATER CONTROL VALVE K BLAC BLUE COMPRESSOR WHITE NOTE: CONNECT WHITE WIRES DIRECTLY TO (-) BATTERY TERMINAL WHITE RED RED CIRCUIT BREAKER 30 AMP RED WARNING: ALWAYS MOUNT CIRCUIT BREAKER AS CLOSE TO THE BATTERY AS POSSIBLE. (NOTE: WIRE BETWEEN BATTERY AND CIRCUIT BREAKER IS UNPROTECTED AND SHOULD BE CAREFULLY ROUTED TO AVOID A SHORT CIRCUIT). 23 Install with servo motor facing down, as shown. Note flow direction arrow molded into valve body and install accordingly. Binary/Trinary & Compressor: Binary: Connect as shown (typical compressor wiring). Be sure compressor body is grounded. BINARY SAFETY SWITCH BLUE Dash Light: When using a Vintage Air-supplied control panel, connect the tan wire from the Gen IV evaporator wiring harness to the factory dash lights to enable panel backlighting. + - Trinary Switch: Connect according to trinary switch wiring diagram. Circuit Breaker/Battery: White must run to (-) battery. Red may run to (+) battery or starter. Mount circuit breaker as close to battery as possible. BATTERY 901182 REV D 4/30/21, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 23 OF 29 OPERATION OF CONTROLS 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. AC MODE OFF MODE LEVER DASH HI FLR HOT BLOWER SPEED DEF COLD A/C TEMPERATURE TEMPERATURE LEVER LEVER IN A/C MODE SLIDE THE TEMPERATURE LEVER ALL THE WAY TO THE RIGHT MODE LEVER TO ENGAGE COMPRESSOR. SLIDE THE LEVER TO (SLIDE LEVER LEFT OR RIGHT THE LEFT POSITION TO ADJUST DESIRED TEMPERATURE) HEAT MODE BLOWER SPEED ADJUST TO DESIRED SPEED OFF DASH HI FLR HOT DEF COLD A/C BLOWER SPEED ADJUST TO DESIRED SPEED TEMPERATURE LEVER SLIDE THE TEMPERATURE LEVER ALL THE WAY LEFT MODE LEVER TO THE HOT POSITION. SLIDE THE LEVER TO (SLIDE LEVER LEFT OR RIGHT THE CENTER POSITION TO DESIRED TEMPERATURE) DEFROST/ DE-FOG MODE OFF DASH HI FLR HOT BLOWER SPEED ADJUST TO DESIRED SPEED MODE LEVER SLIDE THE LEVER TO THE RIGHT POSITION DEF COLD A/C TEMPERATURE LEVER ADJUST LEVER TO DESIRED TEMPERATURE. (COMPRESSOR IS AUTOMATICALLY ENGAGED) 901182 REV D 4/30/21, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 24 OF 29 24 Symptom 901182 REV D 4/30/21, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 25 OF 29 Compressor will not turn off (All other functions work). 3. Compressor will not turn on (All other functions work). 2. Blower stays on high speed when ignition is on or off. 1b. Blower stays on high speed when ignition is on. 1a. 25 System is charged. System is not charged. All other functions work. No other functions work. Condition Repair or replace pot/control wiring. Replace relay. Check for faulty A/C relay. Check 2-pin connector at ECU housing. Check continuity to ground on white control head wire. Check for 5V on red control head wire. Charge system or bypass pressure switch. Replace BSC (This will require removal of evaporator from vehicle). Check to ensure that no BSC wiring is damaged or shorted to vehicle ground. The BSC operates the blower by ground side pulse width modulation switching. The positive wire to the blower will always be hot. If the “ground” side of the blower is shorted to chassis ground, the blower will run on HI. Be sure the small, 20 GA white ground wire is connected to the battery ground post. If it is, replace the ECU. Verify continuity to chassis ground with white control head wire at various points. Verify that all pins are inserted into plug. Ensure that no pins are bent or damaged in ECU. Actions Check for faulty A/C potentiometer or associated wiring. Check for disconnected or faulty thermistor. Check for faulty A/C potentiometer or associated wiring (not applicable to 3-pot controls). System must be charged for compressor to engage. Unplug 3-wire BSC control connector from ECU. If blower stays running, BSC is either improperly wired or damaged. Unplug 3-wire BSC control connector from ECU. If blower shuts off, ECU is either improperly wired or damaged. Check for damaged ground wire (white) in control head harness. Check for damaged blower switch or potentiometer and associated wiring. Check for damaged pins or wires in control head plug. Checks Red wire at A/C pot should have approximately 5V with ignition on. White wire will have continuity to chassis ground. White/ Blue wire should vary between 0V and 5V when lever is moved up or down. Disconnected or faulty thermistor will cause compressor to be disabled. To check for proper pot function, check voltage at white/blue wire. Voltage should be between 0V and 5V, and will vary with pot lever position. Danger: Never bypass safety switch with engine running. Serious injury can result. No other part replacements should be necessary. See blower switch check procedure. Loss of ground on this wire renders control head inoperable. Notes Troubleshooting Guide 901182 REV D 4/30/21, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 26 OF 29 Symptom 8. When ignition is turned on, blower momentarily comes on, then shuts off. This occurs with the blower switch in the OFF position. Erratic functions of blower, mode, temp, etc. 7. Blower turns on and off rapidly. 6. Loss of mode door function. 5. System will not turn on, or runs intermittently. 4. 26 This is an indicator that the system has been reset. Be sure the red power wire is on the battery post, and not on a switched source. Also, if the system is pulled below 7V for even a split second, the system will reset. Run red power wire directly to battery. Repair or replace. Charge battery. Check for faulty battery or alternator. Battery voltage is less than 12V. Check for damaged switch or pot and associated wiring. Ensure all system grounds and power connections are clean and tight. Verify proper meter function by checking the condition of a known good battery. Check for positive power at heater valve green wire and blower red wire. Check for ground on control head white wire. Install capacitors on ignition coil and alternator. Ensure good ground at all points. Relocate coil and associated wiring away from ECU and ECU wiring. Check for burned or loose plug wires. Actions Check for at least 12V at circuit breaker. Check for damaged stepper motor or wiring. Check for obstructed or binding mode doors. Check for damaged mode switch or potentiometer and associated wiring. Verify battery voltage is greater than 10 volts and less than 16. Verify connections on power lead, ignition lead, and both white ground wires. Noise interference from either ignition or alternator. Checks Battery voltage is at least 12V. Partial function of mode doors. No mode change at all. Will not turn on under any conditions. Works when engine is not running; shuts off when engine is started (typically early Gen IV, but possible on all versions). Condition System shuts off blower at 10V. Poor connections or weak battery can cause shutdown at up to 11V. Typically caused by evaporator housing installed in a bind in the vehicle. Be sure all mounting locations line up and don’t have to be forced into position. Ignition noise (radiated or conducted) will cause the system to shut down due to high voltage spikes. If this is suspected, check with a quality oscilloscope. Spikes greater than 16V will shut down the ECU. Install a radio capacitor at the positive post of the ignition coil (see radio capacitor installation bulletin). A faulty alternator or worn out battery can also result in this condition. Notes Troubleshooting Guide (Cont.) DRIVER SIDE LOUVER TEMPLATE 3 ⅛” CUT ALONG DOTTED LINE (DO NOT EXCEED DIMENSIONS GIVEN) 2 13/16” 1973-87 CHEVY TRUCK NON-AIR DRIVER SIDE LOUVER TEMPLATE 2 13/16” CUT ALONG DOTTED LINE NOTE: Due to printing variances, measure the line below before using this template. If template is scaled properly, the line should measure 6 inches. 27 901182 REV D 4/30/21, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 27 OF 29 GLOVE BOX MODIFICATION TEMPLATE 73-87 CHEV P-UP GLOVE BOX MODIFICATION TEMPLATE CUT ALONG DOTTED LINE NOTE: Due to printing variances, measure the line below before using this template. If template is scaled properly, the line should measure 6 inches. 28 901182 REV D 4/30/21, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 28 OF 29 EVAPORATOR KIT PACKING LIST NO. 1. 2. QTY. PART NO. 1 1 EVAPORATOR KIT 751181 DESCRIPTION 744004-VUE 791181 GEN IV 4 VENT EVAP. SUB CASE w/ 204 ECU ACCESSORY KIT 81-87 CHEV P-UP wo AC CHECK BY: PACKED BY: DATE: 1 GEN IV 4 VENT EVAP SUB CASE w/204 ECU 744004-VUE 2 HI OFF DASH HOT ACCESSORY KIT 791181 FLR DEF COLD A/C NOTE: IMA GES MA Y NOT DEPICT ACTUAL PARTS AND QUANTITIES. REFER TO PACKING LIST FOR ACTUAL PARTS AND QUANTITIES. 901182 REV D 4/30/21, INST 81-87 CHEV P-UP wo AC EVAP KIT PG 29 OF 29