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1964-67 PONTIAC GTOWITHOUT FACTORY AIR
561067
901056 REV G 12/20/17, 1964-67 GTO wo AC EVAP INSTR PG 1 OF 23
an ISO 9001: 2015 Registered Company
G T O
18865 Goll St. San Antonio, TX 78266 Phone: 800-862-6658
Sales: [email protected] Support: [email protected]
www.vintageair.com
2901056 REV G 12/20/17, 1964-67 GTO wo AC EVAP INSTR PG 2 OF 23
PAGES
Table of Contents
1. COVER 2. TABLE OF CONTENTS 3. PACKING LIST / PARTS DISCLAIMER 4. INFORMATION PAGE 5. WIRING NOTICE 6. ENGINE COMPARTMENT FIGURE 1 7. CONDENSER ASSEMBLY, COMPRESSOR & BRACKET, PASSENGER COMPARTMENT FIGURE 2 8. KICK PANEL MODIFICATION & DEFROST DUCT INSTALLATION FIGURES 3, 3a & 4 9. FIREWALL COVER INSTALLATION & EVAPORATOR INSTALLATION FIGURES 5 & 610. BRACKET INSTALLATION FIGURE 711. FRESH AIR COVER INSTALLATION & KICK PANEL FRESH AIR CAP INSTALLATION FIGURES 8, 9, 9a & 9b12. EVAPORATOR INSTALLATION CONT. FIGURES 10 & 1113. DRAIN HOSE INSTALLATION, LUBRICATING O-RINGS, A/C HOSE INSTALLATION, & MODIFIED A/C HOSE KIT FIGURES 12 & 1314. AC & HEATER HOSE ROUTING FIGURE 1415. FINAL STEPS FIGURES 15 & 1616. CONTROL PANEL & DUCT HOSE ROUTING FIGURE 1717. DRIVER SIDE UNDER DASH LOUVER & CENTER & PASSENGER SIDE LOUVER INSTALLATION FIGURES 18, 18a, 19 & 19a18. WIRING DIAGRAM19. GEN IV WIRING CONNECTION INSTRUCTIONS20. OPERATION OF CONTROLS21. TROUBLE SHOOTING INFORMATION22. TROUBLE SHOOTING INFORMATION CONT.23. EVAPORATOR KIT PACKING LIST
3901056 REV G 12/20/17, 1964-67 GTO wo AC EVAP INSTR PG 3 OF 23
** 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 KIT561067
EVAPORATOR KIT PACKING LIST
1.2.
11
744004-VUE784157
1
ACCESSORY KIT784157
2
GEN IV 4-VENTEVAPORATOR SUB CASE
with 204 ECU744004-VUE
GEN IV 4-VENT EVAPORATOR SUB CASE with 204 ECU1964-67 GTO without A/C ACCESSORY KIT
No. QTY. PART No. DESCRIPTION
NOTE: IMAGES MAY NOT DEPICT ACTUAL PARTS AND QUANTITIES. REFER TO PACKING LIST FOR ACTUAL PARTS AND QUANTITIES.
4901056 REV G 12/20/17, 1964-67 GTO wo AC EVAP INSTR PG 4 OF 23
Important Notice—Please ReadFor Maximum System Performance, Vintage Air Recommends the Following:
New Vintage Air-supplied Sanden Compressor: No additional oil needed (Compressor is shipped with proper oil charge).All Other Compressors: Consult manufacturer (Some compressors are shipped dry and will need oil added).
NOTE: Vintage Air systems are designed to operate with R134a refrigerant only. Use of any other refrigerant could damage your A/C system and/or vehicle, and possibly cause a fire, in addition to potentially voiding the warranties of the A/C system and its components.
Refrigerant Capacities:Vintage Air System: 1.8 lbs. (1 lb., 12 oz.) of R134a, charged by weight with a quality charging station or scale. NOTE: Use of the proper type and amount of refrigerant is critical to system operation and performance.Other Systems: Consult manufacturer’s guidelines.
Lubricant Capacities:
Safety Switches
Service Info:Protect Your Investment: Prior to assembly, it is critical that the compressor, evaporator, A/C hoses and fittings, hardlines, condenser and receiver/drier remained capped. Removing caps prior to assembly will allow moisture, insects and debris into the components, possibly leading to reduced performance and/or premature failure of your A/C system. This is especially important with the receiver/drier. Additionally, when caps are removed for assembly, BE CAREFUL! Some components are shipped under pressure with dry nitrogen.Evacuate the System for 35-45 Minutes: Ensure that system components (Drier, compressor, evaporator and condenser) are at a temperature of at least 85° F. On a cool day, the components can be heated with a heat gun or by running the engine with the heater on before evacuating. Leak check and charge to specifications.
Your Vintage Air system is equipped with a binary pressure safety switch. A binary switch disengages the compressor clutch in cases of extreme low pressure conditions (Refrigerant Loss) or excessively high head pressure (406 PSI) to prevent compressor damage or hose rupture. A trinary switch combines Hi/Lo pressure protection with an electric fan operation signal at 254 PSI, and should be substituted for use with electric fans. Compressor safety switches are extremely important since an A/C system relies on refrigerant to circulate lubricant.
Bolts Passing Through Cowl and/or Firewall:To ensure a watertight seal between the passenger compartment and the vehicle exterior, for all bolts passing through the cowl and/or firewall, Vintage Air recommends coating the threads with silicone prior to installation.
Heater Hose (Not Included With This Kit):Heater hose may be purchased from Vintage Air (Part# 31800-VUD) or your local parts retailer. Routing and required length will vary based on installer preference.
5901056 REV G 12/20/17, 1964-67 GTO wo AC EVAP INSTR PG 5 OF 23
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.
•
•
•
6901056 REV G 12/20/17, 1964-67 GTO wo AC EVAP INSTR PG 6 OF 23
BEFORE STARTING THE INSTALLATION, CHECK THE FUNCTION OF THE VEHICLE (HORN, LIGHTS,ETC.) FOR PROPER OPERATIONS.
STUDY THE INSTRUCTIONS, ILLUSTRATIONS, & DIAGRAMS.
ENGINE COMPARTMENTREMOVE THE FOLLOWING
FIGURE 1
INNERFENDER
OEMBLOWER MOTOR
ASSEMBLY
HEATERHOSES
DRAIN RADIATOR, REMOVE RADIATOR (RETAIN).
TO REMOVE THE OEM BLOWER MOTOR ASSEMBLY (UNDER HOOD) AND THE AIR DISTRIBUTION SYSTEM (UNDER DASH) THE FACTORY MANUAL INDICATES DOING THE FOLLOWING, REMOVE RIGHT INNER FENDER.
OEM HEATER HOSES (DISCARD). SEE FIGURE 1.
OEM HEATER WIRING HARNESS MOLDED GROMMET (DISCARD) SEE FIGURE 1.
INSTALL 1 ⅛” PLASTIC PLUG SEE FIGURE 1.
1⅛PLASTIC PLUG
317098
OEM HEATERWIRING HARNESS
MOLDED GROMMET
7901056 REV G 12/20/17, 1964-67 GTO wo AC EVAP INSTR PG 7 OF 23
REMOVE GLOVE BOX DOOR (RETAIN) AND GLOVE BOX (DISCARD).DISCONNECT ALL WIRE AND CABLES FROM CONTROL PANEL AND RADIO. O.E.M DEFROST DUCT ASSEMBLY, SEE FIGURE 2 BELOW. O.E.M HEATER ASSEMBLY SEE BELOW.
PASSENGER COMPARTMENT
CONDENSER ASSEMBLY & INSTALLATIONREFER TO SEPARATE INSTRUCTIONS INCLUDED WITH THE CONDENSER KIT TO INSTALL THE CONDENSER.BINARY SWITCH INSTALLATION (REFER TO CONDENSER INSTRUCTIONS).
REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH THE BRACKET KIT TO INSTALL THE COMPRESSOR BRACKET.
COMPRESSOR & BRACKETS
REMOVE THE FOLLOWING:
FIGURE 2
GLOVE BOXDOOR
CONTROL PANEL
A/C HEATER ASSEMBLY
OEM DEFROST DUCT ASM
8901056 REV G 12/20/17, 1964-67 GTO wo AC EVAP INSTR PG 8 OF 23
FIGURE 4
KICK PANEL MODIFICATIONREMOVE KICK PANEL.REMOVE KICK PANEL FRESH AIR DOOR ASM BY REMOVING (5) OEM SCREWS.DISCONNECT PULL CABLE ASSEMBLY FROM UNDER DASH (DISCARD). SEE FIGURE 3 BELOW.MODIFY PASSENGER SIDE KICK PANEL AS SHOWN IN FIGURE 3a BELOW.
FIGURE 3 FIGURE 3a
FRESH AIRDOOR ASM
CUT
DEFROST DUCT INSTALLATIONINSTALL DEFROST DUCTS UNDER DASH AND ALIGN WITH OEM OPENING. INSTALL THE DRIVER AND PASSENGER SIDE DEFROST DUCT ASM TO COWL USING (2) #10 x 1/2 HEX SHEET METAL SCREWS. NOTE: APPLY SILICONE ON SCREWS TO ENSURE LEAK FREE INSTALLATION. SEE FIGURE 4 BELOW.
OEMDEFROST DUCT
OPENING
(2) #10 x 1/2 HEX SHEET
METAL SCREW18247-VUB
DEFROSTDUCT
626658
9901056 REV G 12/20/17, 1964-67 GTO wo AC EVAP INSTR PG 9 OF 23
(2)1/4-20 x 1/2”HEX BOLT
FRONTEVAPORATOR
BRACKET643060
FIGURE 6
FIREWALL COVER INSTALLATIONAPPLY A 1/4” BEAD OF SILICONE AROUND THE BACK SIDE OF THE FIREWALL COVER AS SHOWN IN FIGURE 5, 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 5, BELOW.
FIGURE 5
(3) 1/4-20 x 1HEX BOLTS
HOLE NOT USED
(3) 1/4 x 3/4FLAT WASHER
(3) 1/4-20 NUTS WITH
STAR WASHER BACK SIDE
OF FIREWALLCOVER
SILICONE FIREWALLCOVER648169
EVAPORATOR INSTALLATIONON A WORK BENCH INSTALL (2) HEATER FITTINGS WITH PROPERLY LUBRICATED O-RINGS. (SEE FIGURE 13, PAGE 13, AND FIGURE 7 PAGE 10.)INSTALL (2) HEX BOLTS, (2) NYLON SPACERS AND (2) 1/4 PUSH NUT BOLT RETAINERS ON EVAP REAR BRKT AS SHOWN IN FIGURE 7, PAGE 10.INSTALL EVAPORATOR FRONT & REAR MOUNTING BRACKETS ON EVAPORATOR USING (6)1/4-20 x 1/2 HEX BOLTS AND TIGHTEN AS SHOWN IN FIGURE 6 BELOW & FIGURE 7,PAGE 10.LAY EVAPORATOR SUBCASE ON PASSENGER SIDEFLOOR BOARD. INSTALL A/C & HEATER HOSEON EVAPORATOR AS SHOWN IN FIGURE 10, PAGE 12 AND HOSE INSTALLATION ON PAGE 14.(NOTE: WRAP THE #10 FITTING CONNECTIONS WITH PRESS TAPE. SEE FIGURE 10, PAGE 12.)
10901056 REV G 12/20/17, 1964-67 GTO wo AC EVAP INSTR PG 10 OF 23
BRACKET INSTALLATION
REAREVAPORATOR
BRACKET643059
(2) HEATERFITTINGS
(2) 1/4-20 x 1/2HEX BOLT
FIGURE 7
(2) 1/4-20 x 1/218290-VUB 1/4-20 x 1HEX BOLT
189125-MUR1/4 PUSH NUTBOLT RETAINER
1/4-20 x 1½ HEX BOLT
18289-VUB
1/4 PUSH NUTBOLT RETAINER189125-MUR
NYLON SPACER.750 OD x .313 ID x .563 L
180389
NYLON SPACER.750 OD x .257 ID x .062 L
180388
HEX BOLT
11901056 REV G 12/20/17, 1964-67 GTO wo AC EVAP INSTR PG 11 OF 23
FRESH AIR COVER INSTALLATION
FIGURE 9bFIGURE 9
KICK PANEL FRESH AIR CAP INSTALLATION
INSTALL (4) GROMMETS IN KICK PANEL FRESH AIR CAP, SEE FIGURE 9a BELOW.ROUTE A/C AND HEATER HOSE THROUGH FRESH AIR CAP AND KICKPANEL FRESH AIR CAP AS SHOWN IN FIGURE 9 AND 9b, BELOW.APPLY A 1/4” BEAD OF SILICONE AROUND THE BACK SIDE OF KICK PANEL FRESH AIR CAP AS SHOWN IN FIGURE 9a, BELOW.SECURE KICK PANEL FRESH AIR CAP USING OEM SCREWS, AS SHOWN IN FIGURE 9b BELOW. (5) OEM
SCREWS
SILICONE
BACK SIDE OF KICK PANEL
FRESH AIR CAP
#10 A/CHOSE
#6 A/CHOSE(2)HEATER
HOSES
#10 A/C HOSE
#6 A/C HOSE(2) HEATER
HOSE
(4)GROMMETS33137-VUI
1/4-20 x 1 1/2BOLT w/ WASHER
SILICONE
FRESH AIRCAP
(4) GROMMETS33137-VUI
FIGURE 8BACK SIDEOF FRESH AIR
CAP
ENGINE COMPARTMENT
SIDE OF FIREWALL
INSTALL (4) GROMMETS IN FRESH AIR CAP. SEE FIGURE 8 BELOWAPPLY A 1/4” BEAD OF SILICONE AROUND THE BACK SIDE OF THE FRESH AIR CAP AS SHOWN INFIGURE 8 BELOW.ATTACH FRESH AIR CAP TO FIREWALL USING A 1/4-20 x 1 1/2 BOLT AND WASHER, SEE FIGURE 8BELOW. NOTE: FRESH AIR CAP INSTALLS ON ENGINE SIDEOF FIREWALL.
FIGURE 9a
12901056 REV G 12/20/17, 1964-67 GTO wo AC EVAP INSTR PG 12 OF 23
#10 A/C HOSE
(2) 1/4-20 NUTw/ FLAT WASHER
FIGURE 11
EVAPORATOR INSTALLATION CONT.
KICK PANELFRESH AIR
CAP
LIFT EVAPORATOR UNIT UP UNDER THE DASHBOARD. SECURE LOOSELY TO THE FIREWALL FROM THE ENGINE COMPARTMENT SIDE USING (2) 1/4-20 NUT AND FLAT WASHER, SEE FIGURE 11.SECURE THE FRONT EVAPORATOR MOUNTING BRACKET TO COWL USING (2) #14 x 3/4 HEX SHEET METAL SCREWS SEE FIGURE 11 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.
FIGURE 10
HEATER HOSE
#6 A/C HOSE
PRESSTAPE
(2) #14 x 3/4HEX SHEET
METAL SCREW
13901056 REV G 12/20/17, 1964-67 GTO wo AC EVAP INSTR PG 13 OF 23
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. SEE FIGURE 12 BELOW.INSTALL DRAIN HOSE TO BOTTOM OFEVAPORATOR UNIT AND ROUTE THROUGHFIREWALL. INSTALL 1/2” 90° DRAIN ELBOW ON DRAIN HOSE SEE FIGURE 12.
DRAIN HOSE INSTALLATION
EVAPORATORCASE1”
LOCATE THE #8 COMPRESSOR A/C HOSE. LUBRICATE (2) #8 O-RINGS (SEE FIGURE 13, ABOVE) AND CONNECTTHE 90° FEMALE FITTING TO THE #8 DISCHARGE PORT ON THE COMPRESSOR. ROUTE THE STR FEMALE FITTING w/ 134a SERVICE PORT TO THE #8 CONDENSER HARDLINE COMING THROUGH CORE SUPPORT. SEE FIGURE 14 PAGE 14. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN FIGURE 13 ABOVE. LOCATE THE #10 COMPRESSOR A/C HOSE. LUBRICATE (2) #10 O-RINGS (SEE FIGURE 13, ABOVE) AND CONNECT THE #10 135° FEMALE FITTING w/134a SERVICE PORT TO THE #10 SUCTION PORT ON THE COMPRESSOR. ROUTE THE 90° FEMALE FITTING TO THE #10 EVAPORATOR. SEE FIGURE 10 PAGE 12 AND FIGURE 14 PAGE 14. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN 13 ABOVE. LOCATE THE #6 EVAPORATOR A/C HOSE. LUBRICATE (2) #6 O-RINGS (SEE FIGURE 13, ABOVE) AND CONNECT THE STR FEMALE FITTING TO THE DRIER. ROUTE THE 90° FEMALE FITTING TO THE #6 EVAPORATOR. SEE FIGURE 10, PAGE 12 AND FIGURE 14 PAGE 14. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN FIGURE 13, ABOVE.
A/C HOSE INSTALLATIONSTANDARD HOSE KIT
LUBRICATING O-RINGS
#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 O-RING, INSTALLS
OVER MALE INSERTTO SWAGED LIP
MALEINSERT
FEMALENUT
O-RING
TWIST WITHTHIS WRENCH
FIGURE 13
REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH MODIFIED HOSE KIT.
MODIFIED A/C HOSE KIT
FIGURE 12
DRAINHOSE
1”
14901056 REV G 12/20/17, 1964-67 GTO wo AC EVAP INSTR PG 14 OF 23
CO
MPR
ESSO
RSA
FETY
SW
ITC
H(B
INA
RY T
YPE)
SCRE
W O
N D
RIER
(REF
ER T
OC
ON
DEN
SER
INST
RUC
TIO
NS)
A/C
& H
EATE
R H
OSE
RO
UTI
NG
FIG
UR
E 14
(4)
TIE
WRA
PS
#1
0 S
UC
TIO
NH
OSE
09
60
76
64-6
7 G
TO S
HO
WN
#6
HA
RDLI
NE
CO
ND
ENSE
R/D
RIER
09
11
60
#6
HA
RDLI
NE
CO
ND
ENSE
R0
91
16
1
#8
CO
ND
ENSE
R/C
OM
P H
ARD
LIN
E0
91
16
2
#8
DIS
CH
ARG
EH
OSE
09
60
77
NO
TE:
OEM
WA
TER
PUM
P O
UTL
ET IS
3/4
”. A
3/4
” x
5/8
” RE
DU
CER
FIT
TIN
G IS
REQ
UIR
ED (
NO
T SU
PPLI
ED)
HEA
TER
HO
SE(H
EATE
R C
NTR
LV
ALV
E/IN
TAK
E)
HEATER HOSE & HEATER CONTROL VALVE INSTALLATIONROUTE A PIECE OF HEATER HOSE FROM THE WATER PUMP TO THE TOP HEATER FITTING OF HEATER CORE AS SHOWN IN FIGURE 10 PAGE 12 AND FIGURE 14 BELOW. SECURE USING HOSE CLAMPS.NOTE: OEM WATER PUMP OUTLET IS 3/4”. A 3/4” x 5/8” REDUCER FITTING IS REQUIRED(NOT SUPPLIED).
ROUTE A PIECE OF HEATER HOSE FROM THE INTAKE TO THE BOTTOM HEATER FITTING OF HEATER COREAS SHOWN IN FIGURE 10 PAGE 12 AND FIGURE 14, BELOW. INSTALL HEATER CONTROL VALVE IN-LINE WITH INTAKE MANIFOLD (PRESSURE SIDE) HEATER HOSE, SECURE USING HOSE CLAMPS AS SHOWN IN FIGURE 14, BELOW. NOTE PROPER FLOW DIRECTION.
FRO
M IN
TAKE
MAN
IFO
LD
FRO
M E
VAPO
RATO
R
TO W
ATER
PU
MP HO
SEC
LAM
PS
FRO
M H
EATE
R C
ON
TRO
L VA
LVE
TO E
VA
PORA
TOR
HEA
TER
HO
SE
15901056 REV G 12/20/17, 1964-67 GTO wo AC EVAP INSTR PG 15 OF 23
INSTALL DUCT HOSES AS SHOWN IN FIGURE 17, PAGE 16.ROUTE A/C WIRES THROUGH 3/8” GROMMET AS SHOWN IN FIGURE 15(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 17, PAGE 16(WIRE ACCORDING TO WIRING DIAGRAM ON PAGE 18 AND 19.)INSTALL GLOVE BOX DOOR.INSTALL NEW GLOVE BOX USING OEM SCREWS, SEE FIGURE 16. REINSTALL KICK PANEL.INSTALL LOUVERS AS SHOWN ON PAGE 17.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 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 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 20.
FINAL STEPS
FIGURE 15
GROMMET33144-VUI
GLOVE BOX626659
FIGURE 16
16901056 REV G 12/20/17, 1964-67 GTO wo AC EVAP INSTR PG 16 OF 23
PASS. SIDEUNDER DASH
LOUVER2 ½” x 20”
DRIVER SIDEUNDER DASH
LOUVER2 ½” x 36”
UNDER DASH DRIVER SIDE
CENTER LOUVER2 ½” x 18”
UNDER DASH PASS SIDE
CENTER LOUVER2 ½” x 18”
CONTROL PANEL & DUCT HOSE ROUTING
CONTROL PANELHARNESSFROM ECU
232002-VUA
PLUGFROM
WIRINGHARNESS
232600-VUA
DEFROST DUCTDR. SIDE2” x 20”
DEFROST DUCTPASS. SIDE2” x 12”
FIGURE 17
17901056 REV G 12/20/17, 1964-67 GTO wo AC EVAP INSTR PG 17 OF 23
(2) #10 X 1/2”HEX SHEET
METAL SCREWS
(3) #10 x 1/2” HEX SHEET
METAL SCREWS
LOCATE DRIVER SIDE LOUVER HOUSING UNDER DASH AND DRILL (2) 1/8” HOLES. SECURE LOUVER HOUSING TO DASH USING (2) #10 x 1/2” HEX SHEET METAL SCREWS AS SHOWN IN FIGURE 18 BELOW.INSTALL LOUVER IN UNDER DASH HOUSING AS SHOWN IN FIGURE 18a.INSTALL (2) 1/2” PLASTIC PLUGS AS SHOWN IN FIGURE 18a, BELOW.
DRIVER SIDE UNDER DASH LOUVER INSTALLATION
LOCATE CENTER/PASSENGER SIDE LOUVER BEZEL UNDER DASH AND DRILL (3) 1/8” HOLES.SECURE LOUVER BEZEL UNDER DASH USING (3) #10 x 1/2” HEX SHEET METAL SCREWS AS SHOWN IN FIGURE 19 BELOW.INSTALL LOUVERS IN CENTER/PASSENGER SIDE UNDER DASH LOUVER BEZEL AS SHOWN IN FIGURE 19a.INSTALL (3) 1/2” PLASTIC PLUGS AS SHOWN IN FIGURE 19a, BELOW.
CENTER/PASSENGER SIDE UNDER DASH LOUVER INSTALLATION
DR SIDEUNDER DASH
LOUVER HOUSING494050
CENTER/PASSENGER SIDE UNDER DASH
LOUVER ASM626654
NOTE: LOUVERS WITHOUTHOSE ADAPTER
(3) 490560
FIGURE 18FIGURE 18a
FIGURE 19
FIGURE 19a
LOUVER49056-VUL
(3) 1/2” PLASTIC PLUGS
31102-GUR
(2) 1/2” PLASTIC PLUGS
31102-GUR
18901056 REV G 12/20/17, 1964-67 GTO wo AC EVAP INSTR PG 18 OF 23
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
REVISION C 10/06/17
19901056 REV G 12/20/17, 1964-67 GTO wo AC EVAP INSTR PG 19 OF 23
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.
20901056 REV G 12/20/17, 1964-67 GTO wo AC EVAP INSTR PG 20 OF 23
OPERATION OF CONTROLS
DEFROST/ DE-FOG MODEHEAT MODE
TEMPERATURE LEVERSLIDE THE TEMPERATURE LEVER ALL THE WAY RIGHT
TO THE WARMER POSITION.(SLIDE LEVER LEFT OR RIGHTTO DESIRED TEMPERATURE)SLIDE THE LEVER TO
THE CENTER POSITION
MODE LEVER
TEMPERATURE LEVER
SLIDE THE LEVER TOTHE RIGHT POSITION
MODE LEVER
SLIDE THE LEVER TOTHE LEFT POSITION
BLOWER SPEEDADJUST TO DESIRED
SPEED
TEMPERATURE LEVERIN A/C MODE SLIDE THE TEMPERATURE LEVER ALL
THE WAY TO THE LEFT TO ENGAGE COMPRESSOR.(SLIDE LEVER LEFT OR RIGHT
TO ADJUST DESIRED TEMPERATURE)
MODE LEVER
NOTE: CONTROLS MUST BE CALIBRATED FOR PROPER OPERATION-REFER TO CONTROL PANEL INSTRUCTIONS.
THE TEMPERATURE LEVER TOGGLES BETWEEN A/C AND HEAT MODES. FOR A/C MODE SLIDE THE TEMPERATURE LEVER ALL THE WAY LEFT TO ENGAGE THE COMPRESSOR, THEN MOVE THE LEVERTO SELECT THE DESIRED TEMPERATURE. FOR HEAT MODE SLIDE THE LEVER RIGHT TO DISENGAGE THE COMPRESSOR, THEN MOVE THE LEVER TO SELECT DESIRED TEMPRATURE.
NOTE: EACH TIME THE SYSTEM TOGGLES BETWEEN MODES, THE BLOWER WILL MOMENTARILY CHANGE SPEEDS.
ALL SWITCHES ARE VARIABLE BETWEEN POSITIONS, SYSTEM WILL PERFORM A BLEND BETWEEN THE FUNCTIONS.
BLOWER SPEEDADJUST TO DESIRED
SPEED
BLOWER SPEEDADJUST TO DESIRED
SPEED
AC MODE
TEMPERATURELEVER
OFF WARMER
HIMEDLOOFF
AIR
TEMP
BLOWERSPEED
MODELEVER
OFF DE-ICENORMAL
OFF WARMER
HIMEDLOOFF
AIR
TEMP
OFF DE-ICENORMAL
OFF WARMER
HIMEDLOOFF
AIR
TEMP
OFF DE-ICENORMAL
ADJUST LEVER TODESIRED TEMPERATURE.
(COMPRESSOR IS AUTOMATICALLY
ENGAGED)
21901056 REV G 12/20/17, 1964-67 GTO wo AC EVAP INSTR PG 21 OF 23
Sym
pto
m
C
on
dit
ion
C
heck
s
Act
ion
s
N
ote
s
Blo
wer
sta
ys o
n
hig
h s
pee
d w
hen
ig
nitio
n is
on.
1a.
No o
ther
funct
ions
work
.
Chec
k fo
r dam
aged
pin
s or
wires
in c
ontr
ol hea
d p
lug.
Ver
ify
that
all
pin
s ar
e in
sert
ed into
plu
g.
Ensu
re t
hat
no
pin
s ar
e ben
t or
dam
aged
in E
CU
.
Chec
k fo
r dam
aged
gro
und
wire
(white)
in c
ontr
ol hea
d
har
nes
s.
Ver
ify
continuity
to c
has
sis
gro
und w
ith w
hite
contr
ol
hea
d w
ire
at v
ario
us
poin
ts.
Loss
of gro
und o
n t
his
wire
render
s co
ntr
ol hea
d
inoper
able
.
All
oth
er f
unct
ions
work
.Chec
k fo
r dam
aged
blo
wer
sw
itch
or
pote
ntiom
eter
and
asso
ciat
ed w
irin
g.
Blo
wer
sta
ys o
n
hig
h s
pee
d w
hen
ig
nitio
n is
on o
r off.
Unplu
g 3
-wire
BSC c
ontr
ol
connec
tor
from
ECU
. If
blo
wer
sh
uts
off,
ECU
is
eith
er
impro
per
ly w
ired
or
dam
aged
.
Be
sure
the
smal
l, 2
0 G
A w
hite
gro
und w
ire
is c
onnec
ted
to t
he
bat
tery
gro
und p
ost
. If
it
is,
repla
ce t
he
ECU
.
Unplu
g 3
-wire
BSC c
ontr
ol
connec
tor
from
ECU
. If
blo
wer
st
ays
runnin
g,
BSC is
eith
er
impro
per
ly w
ired
or
dam
aged
.
Chec
k to
ensu
re t
hat
no B
SC w
irin
g is
dam
aged
or
short
ed t
o v
ehic
le g
round.
The
BSC o
per
ates
the
blo
wer
by
gro
und s
ide
puls
e w
idth
modula
tion s
witch
ing.
The
posi
tive
wire
to t
he
blo
wer
will
alw
ays
be
hot.
If th
e “g
round”
side
of
the
blo
wer
is
short
ed t
o c
has
sis
gro
und,
the
blo
wer
will
run o
n H
I.
Rep
lace
BSC (
This
will
req
uire
rem
oval
of ev
apora
tor
from
veh
icle
).N
o o
ther
par
t re
pla
cem
ents
sh
ould
be
nec
essa
ry.
Com
pre
ssor
will
not
turn
on
(All
oth
er funct
ions
work
).
2.
Sys
tem
is
not
char
ged
.Sys
tem
must
be
char
ged
for
com
pre
ssor
to e
ngag
e.Char
ge
syst
em o
r byp
ass
pre
ssure
sw
itch
.
Dan
ger:
Never
byp
ass
sa
fety
sw
itch
wit
h
en
gin
e r
un
nin
g.
Seri
ou
s in
jury
can
resu
lt.
Sys
tem
is
char
ged
.
1b
.
Tro
ub
lesh
oo
tin
g G
uid
e
Chec
k fo
r fa
ulty
A/C
pote
ntiom
eter
or
asso
ciat
ed
wirin
g (
Not
applic
able
to 3
-pot
contr
ols
).
Chec
k fo
r dis
connec
ted o
r fa
ulty
ther
mis
tor.
Chec
k co
ntinuity
to g
round o
n w
hite
contr
ol hea
d w
ire.
Chec
k fo
r 5V o
n r
ed c
ontr
ol hea
d w
ire.
Chec
k 2-p
in c
onnec
tor
at E
CU
housi
ng.
To c
hec
k fo
r pro
per
pot
funct
ion,
chec
k vo
ltag
e at
w
hite/
blu
e w
ire.
Voltag
e sh
ould
be
bet
wee
n 0
V a
nd
5V,
and w
ill v
ary
with p
ot
leve
r posi
tion.
Dis
connec
ted o
r fa
ulty
ther
mis
tor
will
cau
se
com
pre
ssor
to b
e dis
able
d.
Red
wire
at A
/C p
ot
should
hav
e ap
pro
xim
atel
y 5V
with ignitio
n o
n.
White
wire
will
hav
e co
ntinuity
to
chas
sis
gro
und.
White/
Blu
e w
ire
should
var
y bet
wee
n 0
V a
nd 5
V w
hen
le
ver
is m
oved
up o
r dow
n.
3. Com
pre
ssor
will
not
turn
off
(A
ll oth
er funct
ions
work
).
Chec
k fo
r fa
ulty
A/C
pote
ntiom
eter
or
asso
ciat
ed
wirin
g.
Chec
k fo
r fa
ulty
A/C
rel
ay.
Rep
air
or
repla
ce p
ot/
contr
ol w
irin
g.
Rep
lace
rel
ay.
See
blo
wer
sw
itch
chec
k pro
cedure
.
22901056 REV G 12/20/17, 1964-67 GTO wo AC EVAP INSTR PG 22 OF 23
Sym
pto
m
C
on
dit
ion
C
heck
s
Act
ion
s
N
ote
s
Sys
tem
will
not
turn
on,
or
runs
inte
rmitte
ntly.
4.
Work
s w
hen
engin
e is
not
runnin
g;
shuts
off w
hen
en
gin
e is
sta
rted
(T
ypic
ally
ear
ly G
en I
V,
but
poss
ible
on a
ll ve
rsio
ns)
.
Nois
e in
terf
eren
ce f
rom
either
ig
nitio
n o
r al
tern
ator.
Inst
all ca
pac
itors
on ignitio
n c
oil
and a
lter
nat
or. E
nsu
re
good g
round a
t al
l poin
ts.
Rel
oca
te c
oil
and a
ssoci
ated
w
irin
g a
way
fro
m E
CU
and E
CU
wirin
g.
Chec
k fo
r burn
edor
loose
plu
g w
ires
.
Ver
ify
connec
tions
on p
ow
er
lead
, ig
nitio
n lea
d,
and b
oth
white
gro
und w
ires
.
Ver
ify
pro
per
met
er f
unct
ion b
y ch
ecki
ng t
he
conditio
n o
f a
know
n g
ood b
atte
ry.
Ignitio
n n
ois
e (r
adia
ted o
rco
nduct
ed)
will
cau
se t
he
syst
em t
o s
hut
dow
n d
ue
tohig
h v
oltag
e sp
ikes
. If
this
is s
usp
ecte
d,
chec
k w
ith a
qual
ity
osc
illosc
ope.
Spik
esgre
ater
than
16V w
ill s
hut
dow
n t
he
ECU
. In
stal
l a
radio
cap
acitor
at t
he
posi
tive
post
of th
e ig
nitio
nco
il (S
ee r
adio
cap
acitor
inst
alla
tion b
ulle
tin).
A
faulty
alte
rnat
or
or
worn
out
bat
tery
can
als
o r
esult
in t
his
conditio
n.
Will
not
turn
on u
nder
an
y co
nditio
ns.
Ver
ify
bat
tery
voltag
e is
gre
ater
than
10 v
olts
and les
sth
an 1
6.
Loss
of m
ode
door
funct
ion.
No m
ode
chan
ge
at a
ll.Chec
k fo
r dam
aged
mode
switch
or
pote
ntiom
eter
and
asso
ciat
ed w
irin
g.
Part
ial fu
nct
ion o
f m
ode
doors
.
Typic
ally
cau
sed b
y ev
apora
tor
housi
ng
inst
alle
d in a
bin
d in t
he
vehic
le.
Be
sure
all
mounting loca
tions
line
up
and d
on’t h
ave
to b
e fo
rced
in
to p
osi
tion.
Blo
wer
turn
s on
and o
ff r
apid
ly.
6.
Bat
tery
voltag
e is
at
leas
t 12V.
Chec
k fo
r at
lea
st 1
2V a
t ci
rcuit b
reak
er.
Ensu
re a
ll sy
stem
gro
unds
and p
ow
er c
onnec
tions
are
clea
n a
nd t
ight.
Bat
tery
voltag
e is
les
s th
an 1
2V.
5.
Tro
ub
lesh
oo
tin
g G
uid
e (
Co
nt.
)
Chec
k fo
r fa
ulty
bat
tery
or
alte
rnat
or.
Char
ge
bat
tery
.
Sys
tem
shuts
off b
low
er a
t 10V.
Poor
connec
tions
or
wea
k bat
tery
can
cau
se
shutd
ow
n a
t up t
o 1
1V.
7. When
ignitio
n is
turn
ed o
n,
blo
wer
m
om
enta
rily
co
mes
on,
then
sh
uts
off.
This
occ
urs
with t
he
blo
wer
sw
itch
in
the
OFF
posi
tion.
This
is
an indic
ator
that
the
syst
em h
as b
een r
eset
. Be
sure
the
red p
ow
er w
ire
is o
nth
e bat
tery
post
, an
d n
ot
on a
sw
itch
ed s
ourc
e. A
lso,
if
the
syst
em is
pulle
d b
elow
7V f
or
even
a s
plit
sec
ond,
the
syst
em w
ill r
eset
.
Run r
ed p
ow
er w
ire
direc
tly
to b
atte
ry.
Chec
k fo
r posi
tive
pow
er a
t hea
ter
valv
e gre
en w
ire
and
blo
wer
red
wire.
Chec
k fo
r gro
und o
n c
ontr
ol hea
d w
hite
wire.
Chec
k fo
r obst
ruct
ed o
r bin
din
g m
ode
doors
.
Chec
k fo
r dam
aged
ste
pper
m
oto
r or
wirin
g.
Err
atic
funct
ions
of
blo
wer
, m
ode,
te
mp,
etc.
Chec
k fo
r dam
aged
sw
itch
or
pot
and a
ssoci
ated
wirin
g.
Rep
air
or
repla
ce.
8.
901056 REV G 12/20/17, 1964-67 GTO wo AC EVAP INSTR PG 23 OF 23
EVAPORATOR KIT561067
EVAPORATOR KIT PACKING LIST
1.2.
11
744004-VUE784157
1
ACCESSORY KIT784157
2
GEN IV 4-VENT EVAPORATOR SUB CASE with 204 ECU1964-67 GTO without A/C ACCESSORY KIT
CHECKED BY:PACKED BY:
DATE:
No. QTY. PART No. DESCRIPTION
NOTE: IMAGES MAY NOT DEPICT ACTUAL PARTS AND QUANTITIES. REFER TO PACKING LIST FOR ACTUAL PARTS AND QUANTITIES.
GEN IV 4-VENTEVAPORATOR SUB CASE
with 204 ECU744004-VUE