Chevelle

an ISO 9001: 2000 Registered Company

1968-69 CHEVELLE

w/o FACTORY AIR

561068

901166 REV A 1/20/08 , 1968-69 CHEVELLE w/o AC EVAP INSTR PG 1 OF 26

1968-69 CHEVELLE

w/o AC

PAGES
1. 2. 3. 4. 5. 6.

Table of Contents

COVER TABLE OF CONTENTS PACKING LIST / PARTS DISCLAIMER INFORMATION PAGE WIRING NOTICE ENGINE COMPARTMENT, CONDENSER ASSEMBLY, COMPRESSOR & BRACKET, PULLEYSFIGURE 1 7. PASSENGER COMPARTMENT FIGURES 2 & 3 8. KICK PANEL MODIFICATION FIGURES 4, 5 & 5a 9. DEFROST DUCT INSTALLATION & (OPTIONAL) HOSE ADAPTER INSTALLATION- IF EQUIPPED FIGURES 6 & 7 10. FRESH AIR COVER INSTALLATION & KICK PANEL FRESH AIR CAP INSTALLATION FIGURES 8, 9, 9a & 9b 11. FIREWALL COVER INSTALLATION & EVAPORATOR INSTALLATION FIGURES 10 & 11 12. BRACKET INSTALLATION FIGURE 12 13.EVAPORATOR INSTALLTION CONT. FIGURES 13,14 & 14a 14. 68-69CHEVELLE w/o AC w/o ASTRO VENTS & 69 CHEVELLE w/o AC w/ ASTRO VENTS FIGURES 15 & 16 15. DRAIN HOSE INSTALLATION, LUBRICATING O-RINGS, A/C HOSE INSTALLATION, & MODIFIED A/C HOSE KIT FIGURES 17 & 18 16. AC & HEATER HOSE ROUTING 68 CHEVELLE FIGURE 19 17. AC & HEATER HOSE ROUTING 69 CHEVELLE FIGURE 20 18. FINAL STEPS FIGURES 21 & 22 19. CONTROLPANEL & DUCT HOSE ROUTING FIGURE 23 20. WIRING DIAGRAM 21. GEN IV WIRING CONNECTION INSTRUCTIONS 22. OPERATION OF CONTROLS 23. TROUBLE SHOOTING INFORMATION 24. TROUBLE SHOOTING INFORMATION CONT. 25. KICK PANEL MODIFICATION TEMPLATE 26. EVAPORATOR KIT PACKING LIST
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1968-69 CHEVELLE

w/o AC

EVAPORATOR KIT 561068
1. 2. 11 762169 784165 GEN IV 4 VENT w/ 2 & 2 1/2 EVAP SUB CASE . 1968-69 CHEVELLE w/o 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.

1

GEN IV 4 VENT w/ 2 & 2 1/2 EVAP SUB CASE 762169

2

HI

OFFDASH
HOT

DEF

AC

FLR

COLD

3

ACCESSORY KIT 784165

NOTE: IMA GES MA Y NOT DEPICT ACTUAL PARTS AND QUANTITIES. REFER TO PACKING LIST FOR ACTUAL PARTS AND QUANTITIES.
901166 REV A 1/20/09 , 1968-69 CHEVELLE w/o AC EVAP INSTR PG 3 OF 26

1968-69 CHEVELLE

w/o AC

1968-69 CHEVELLE w/o AC GEN IV
FOR MAXIMUM SYSTEM PERFORMANCE VINTAGE AIR RECOMMENDS THE FOLLOWING:

SAFETYSWITCHES:

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 EXCESSIVELY 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 OPERATIONSIGNAL AT 254 PSI., AND MAY BE SUBSTITUTED FOR USE WITH ELECTRIC CONDENSER FANS. COMPRESSOR SAFETY SWITCHES ARE EXTRE MELY IMPORTANT SINCE AN A/C SYSTEM RELIES ON REFRIGERANT TO CARRY LUBRICATION THROUGH THE SYSTEM. ATTENTION: SYSTEM COMPONENTS: THE COMPRESSOR, EVAPORATOR, CONDENSER & DRIER ARE CAPPED. CAPS MAY BE UNDER PRESSURE WITH DRY NITROGEN ; BE CAREFUL REMOVING CAPS. DO NOT REMOVE CAPS PRIOR TOINSTALLATION. 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 BEFOREEVACUATING. LEAK CHECK AND CHARGE TO SPECIFICATIONS.

SERVICE INFO:

VINTAGE AIR SYSTEMS ARE DESIGNED TO OPERATE WITH R134a 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...