CORVETTE. GEN IV w/o FACTORY AIR PCZ GOLL ST. - SAN ANTONIO, TX ph fax

Transcription

1 CORVETTE GEN IV w/o FACTORY AIR 5674-PCZ 8865 GOLL ST. - SAN ANTONIO, TX ph fax PCZ REV A 8/3/05, GEN IV CORVETTE w/o AC INSTRUCTIONS PG OF 29

2 Table of Contents PAGES COVER TABLE OF CONTENTS PACKING LIST/PART DISCLAIMER INFORMATION PAGE WIRING NOTICE ENGINE COMPARTMENT FIGURES. PASSENGER COMPARTMENT, FIGURES 2& 3. ASTRO AIR VENTILATION REMOVAL & FRESH AIR COVER FIGURES 4, 4a, & 4b. CONDENSER, COMPRESSOR BRACKET & PULLEY S, FIGURES 5& 6 O.E.M. DEFROST DUCT MODIFICATION, FIGURES 7, 7a & 8 DEFROST DUCT INSTALLATION, PASSENGER & DRIVER SIDE A/C DUCT HOSE ADAPTER INSTALLATION, FIGURES 9& 0. CENTER LOUVER DUCT HOSE ADAPTER INSTALLATION, FIGURE -b. FIREWALL MODIFICATION & EVAPORATOR INSTALLATION, FIGURE c & d. EVAPORATOR INSTALLATION CONT., FIGURE 2, 3 & 3a. DRAIN HOSE INSTALLATION FIGURE 4. FIREWALL COVER INSTALLATION FIGURE 5. A/C & HEATER HOSE, & HEATER CONTROL VALVE INSTALLATION FIGURES 6 & 7 SMALL BLOCK A/C HOSE ROUTING, FIGURES 8 BIG BLOCK A/C HOSE ROUTING, FIGURES 9. HEATER CONTROL VALVE INSTALLATION FIGURE 20. CONTROL PANEL WIRING & DUCT HOSE ROUTING, FIGURE 2. EVAPORATOR HARDLINE AND BRACKET INSTALLATION, FIGURE 22. WIRING DIAGRAM OPERATION OF CONTROLS. THERMOSTAT ADJUSTMENT TROUBLE SHOOTING DEFROST DUCT TEMPLATE FIREWALL MODIFICATION TEMPLATE EVAPORATOR KIT PACKING LIST 9074-PCZ REV A 8/3/05, GEN IV CORVETTE w/o AC INSTRUCTIONS PG 2 OF 29 2

3 EVAPORATOR KIT PACKING LIST No. QTY. PART No. DESCRIPTION VCE CORVETTE w/o AC EVAP. SUBCASE PCN CORVETTE w/o AC ACC. KIT EVAPORATOR KIT 5674-PCZ ** BEFORE BEGINNING INSTALLATION OPEN ALL PACKAGES AND CHECK CONTENTS OF SHIPMENT. PLEASE REPORT ANY SHORTAGES DIRECTLY TO VINTAGE AIR WITHIN 5 DAYS. AFTER 5 DAYS, VINTAGE AIR WILL NOT BE RESPONSIBLE FOR MISSING OR DAMAGED ITEMS CORVETTE w/o AC EVAP. SUB CASE 7674-VCE 2 3 ACCESSORY KIT 7874-PCN 9074-PCZ REV A 8/3/05, GEN IV CORVETTE w/o AC INSTRUCTIONS PG 3 OF 29

4 CORVETTE GEN IV IMPORTANT NOTICE-PLEASE READ FOR MAXIMUM SYSTEM PERFORMANCE VINTAGE AIR RECOMMENDS THE FOLLOWING: *8 HEAVY DUTY FAN * FAN SHROUD *6 SPAL AUXILIARY CONDENSER FAN PACKAGE (PART # CCA) THIS KIT DOES NOT CONTAIN HEATER HOSE. YOU MUST PURCHASE 8 FEET OF 5/8 DIA. HEATER HOSE FROM VINTAGE AIR(3800-VUD) OR FROM YOU LOCAL PARTS RETAILER SAFETY SWITCHES: YOUR VINTAGE AIR SYSTEM IS EQUIPPED WITH A BINARY PRESSURE SAFETY SWITCH. A BINARY SWITCH (078-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 (076-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: EVACUATE THE SYSTEM FOR 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. THE PROPER AMOUNT OF REFRIGERANT IS CRITICAL TO PROPER SYSTEM OPERATION. VINTAGE AIR RECOMMENDS OUR SYSTEMS BE CHARGED BY WEIGHT WITH A QUALITY CHARGING STATION OR SCALE. REFRIGERANT CAPACITIES 34a SYSTEM CHARGE WITH.8 lb. (lb. 2oz) OF REFRIGERANT R-2 SYSTEM CHARGE WITH 2.0 lb. OF REFRIGERANT LUBRICANT CAPACITIES NEW COMPRESSOR - NO ADDITIONAL OIL NEEDED USED COMPRESSOR - CONSULT VINTAGE AIR 9074-PCZ REV A 8/3/05, GEN IV CORVETTE w/o AC INSTRUCTIONS PG 4 OF 29 4

5 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 ON THE POSITIVE TERMINAL OF THE IGNITION COIL. 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 TO THE 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 TURNING SOME OF THE VEHICLE'S OTHER SYSTEMS ON AND OFF. MODERN COMPUTER OPERATED EQUIPMENT CAN BE SENSITIVE TO VOLTAGE 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 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 & TRUCK PARTS SUPPLIERS. THEY TYPICALLY ARE CYLINDRICAL IN SHAPE, A LITTLE OVER AN INCH LONG, A LITTLE OVER A 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. 5 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 ANY OTHER AUXILIARY DEVICE. SHORTING TO GROUND OR CONNECTING TO A CONDENSER FAN OR ANY OTHER AUXILIARY DEVICE WILL CAUSE SEVERE DAMAGE TO THE ECU. WHEN INSTALLING GROUND LEADS ON GEN IV SYSTEMS, THE BLOWER CONTROL GROUND AND ECU GROUND MUST BE CONNECTED DIREECTLY TO THE NEGATIVE BATTERY POST. THE HEATER CONTROL VALVE IS A NORMALLY OPEN VALVE. IT MUST BE CONNECTED TO THE ECU TO BLOCK WATER FLOW IN AC MODE PCZ REV A 8/3/05, GEN IV CORVETTE w/o AC INSTRUCTIONS PG 5 OF 29

6 ENGINE COMPARTMENT INSTALLATION INSTRUCTIONS FOR CORVETTE BEFORE STARTING THE AIR CONDITIONER INSTALLATION, CHECK FOR PROPER OPERATION OF ALL COMPONENTS (RADIO, LIGHTS, WIPERS, ETC.). STUDY THE INSTRUCTIONS, ILLUSTRATIONS AND DIAGRAMS. FOR EASE OF INSTALLATION CHECK OFF ( ) EACH PROCEDURE PRIOR TO MOVING ON TO THE NEXT STEP. DISCONNECT BATTERY REMOVE HOOD TO EASE INSTALLATION DRAIN RADIATOR REMOVE OEM BLOWER ASSEMBLY AND COVER REMOVE OEM HEATER CORE AND COVER HEATER HOSES FIGURE 9074-PCZ REV A 8/3/05, GEN IV CORVETTE w/o AC INSTRUCTIONS PG 6 OF 29 6

7 PASSENGER COMPARTMENT REMOVE PASSENGER SIDE DASH DISCONNECT CENTER DASH AND PULL FORWARD TO REMOVE OEM CENTER DASH BEZEL REMOVE OEM RADIO REMOVE CONTROL PANEL (RETAIN), REFER TO CONTROL PANEL CONVERSION KIT TO ASSEMBLE CONTROL PANEL. DROP STEERING COLUMN DISCONNECT DRIVER SIDE DASH AND PULL FORWARD CENTER DASH BEZEL CORVETTE DRIVER SIDE DASH STEERING COLUMN CENTER DASH CONTROL PANEL FIGURE 2 RADIO PASSENGER SIDE DASH REMOVE THE DEFROST DUCT (RETAIN), FLOOR HEATER DUCT AS SHOWN IN FIGURE 3 BELOW. REMOVE THE HEATER AS SHOWN. DEFROST DUCT 7 FIGURE 3 FLOOR HEATER DUCT 9074-PCZ REV A 8/3/05, GEN IV CORVETTE w/o AC INSTRUCTIONS PG 7 OF 29 HEATER

8 ASTRO AIR VENTILATION DUCTS REMOVAL REMOVE DRIVER SIDE & PASSENGER SIDE ASTRO AIR VENTILATION DUCTS AND DISCARD. SEE FIGURE 4 BELOW. REMOVE PASSENGER SIDE DASH SUPPORT BRACE (DISCARD) AND CUT OFF MOUNTING TAB ON THE KICK PANEL AS SHOWN IN FIGURE 4. REMOVE THE DRIVER SIDE & PASSENGER SIDE ASTRO AIR VENTILATION DUCT MOUNTING BRACKETS AS SHOWN IN FIGURE 4. INSTALL INSIDE FRESH AIR CAPS ON DRIVER & PASSENGER SIDE AS SHOW IN FIGURE 4a BELOW FIGURE 4 CUT CUT ASTRO AIR VENTILATION DUCT REMOVE DASH SUPPORT BRACE ASTRO AIR VENTILATION DUCT CUT DRIVER SIDE KICK PANEL INSIDE FRESH AIR CAP FIGURE 4a PASSENGER SIDE KICK PANEL FRESH AIR COVER INSTALLATION APPLY A /4 BEAD OF SILICONE AROUND THEBACKSIDEOFTHEFRESHAIRCAP AS SHOWN IN FIGURE 4b BELOW. ATTACH FRESH AIR CAP TO FIREWALL USINGA/4-20x"BOLTAND WASHER, SEE FIGURE 4b. SILICONE BACKSIDE OF FRESH AIR CAP FIGURE 4b FRESH AIR CAP 9074-PCZ REV A 8/3/05, GEN IV CORVETTE w/o AC INSTRUCTIONS PG 8 OF 29 /4-20 x BOLT w/ WASHER 8

9 CONDENSER ASSEMBLY & INSTALLATION REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH THE CONDENSER KIT TO INSTALL THE CONDENSER. REFER TO FIGURE 5 BELOW FOR CONDENSER LOCATION. O.E.M. RADIATOR CORE SUPPORT FIGURE CCL #6 DRIER-CORE SUPPORT HARDLINE OUT IN FLOW 0907-CCD #8 COND-CORE SUPPORT HARDLINE BINARY SWITCH DRIER 9 COMPRESSOR & BRACKETS REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH THE BRACKET KIT TO INSTALL THE COMPRESSOR BRACKET. REFER TO FIGURE 6 BELOW FOR COMPRESSOR MOUNTING POSITION. PULLEYS IN MOST INSTANCES EXISTING BELT LENGTHS WILL REMAIN THE SAME. SEE FIGURE 6 BELOW. PULLEYS (VINTAGE AIR) SHORT PUMP SMALL BLOCK CHEVY (STEEL PULLEY) VCA - WATER PUMP PULLEY (DOUBLE GROOVE) VCA - CRANKSHAFT PULLEY (DOUBLE GROOVE) (WITH POWER STEERING A 3 GROOVE CRANK PULLEY IS REQUIRED) VCA - CRANKSHAFT PULLEY (TRIPLE GROOVE) NOTE: BELT ROUTING MAY VARY WITH DIFFERENT BRACKET SETS. ALWAYS REFER TO INSTRUCTIONS INCLUDED WITH BRACKETS. COMPRESSOR TAB "G" MOUNT THE COMPRESSOR USING TABS "G" & "C" TAB "E" TAB "C" TAB "A" FIGURE PCZ REV A 8/3/05, GEN IV CORVETTE w/o AC INSTRUCTIONS PG 9 OF 29 GENERATOR OR ALTERNATOR WATER PUMP PULLEY CRANKSHAFT PULLEY

10 O.E.M. DEFROST DUCT MODIFICATION MEASURE 6 FROM THE TOP OF THE DEFROST DUCT AND MARK AS SHOWN IN FIGURE 7 BELOW. CUT OFF THE BOTTOM PORTION OF THE DEFROST DUCT AS SHOWN. MARK AND CUT ALONG DOTTED LINE 6 6 REMOVE SHADED PORTION FIGURE 7 LOCATE THE DEFROST DUCT TEMPLATE ON PAGE 27, PLACE THE TEMPLATE OVER THE DEFROST DUCT AS SHOWN IN FIGURE 7a BELOW. USING A PENCIL OR SCRIBE MARK ALONG THE EDGE OF THE TEMPLATE AS SHOWN. REMOVE THE TEMPLATE AND CUT ALONG THE DOTTED LINE AND REMOVE THE TOP PORTION OF THE DEFROST DUCT AS SHOWN IN FIGURE 7a. NOTE: DO NOT CUT COMPLETELY THROUGH THE DEFROST DUCT, ONLY REMOVE THE SHADE PORTION AS SHOWN. MARK AND CUT ALONG DOTTED LINE MARK OR SCRIBE ALONG THIS EDGE OF TEMPLATE MARK OR SCRIBE ALONG THIS EDGE OF TEMPLATE MARK OR SCRIBE ALONG THIS EDGE OF TEMPLATE TEMPLATE REMOVE SHADED PORTION DO NOT CUT OFF BOTTOM PORTION OF THE DEFROST DUCT MARK AND CUT ALONG DOTTED LINE FIGURE 7a INSTALL THE DEFROST DUCT HOSE ADAPTER AS SHOWN IN FIGURE 8 BELOW. DUCT HOSE ADAPTER FIGURE PCZ REV A 8/3/05, GEN IV CORVETTE w/o AC INSTRUCTIONS PG 0 OF 29 0

11 DEFROST DUCT & PS AND DS SIDE A/C DUCT HOSE ADAPTER INSTALLATION USING THE O.E.M. DEFROST DUCT MOUNTING SCREWS INSTALL THE DEFROST DUCT WITH HOSE ADAPTER AS SHOWN IN FIGURE 9 BELOW. REMOVE VENT KNOBS AND RETAIN FIGURE 9 O.E.M. DEFROST DUCT MNTG SCREWS REMOVE VENT KNOB DEFROST DUCT w/ HOSE ADAPTER REMOVE VENT KNOB REMOVE THE PASSENGER AND DRIVER SIDE VENT ADAPTERS (DISCARD) AS SHOWN IN FIGURE 0 BELOW. NOTE: RETAIN MOUNTING HARDWARE. INSTALL THE INNER AND OUTER A/C DUCT HOSE ADAPTERS AS SHOWN IN FIGURE 0 BELOW. USE O.E.M. SCREWS TO SECURE ADAPTERS TO DASH. INSTALL THE VENT KNOB AS SHOWN USING A 0-24 x /4 PH PAN HEAD SCREW AND 3/6 FLAT WASHER. NOTE: THE PASSENGER SIDE INSTALLATION IS SHOWN BELOW IN FIGURE 0, REPEAT THE SAME STEPS FOR THE DRIVER SIDE INSTALLATION. VENT ADAPTER OUTER A/C DUCT HOSE ADAPTER INNER A/C DUCT HOSE ADAPTER (3) O.E.M. SCREWS VENT KNOB 8254-VUB 0-24 x /4 PH PAN HEAD SCREW 823-VUB 3/6 FLT WASHER FIGURE PCZ REV A 8/3/05, GEN IV CORVETTE w/o AC INSTRUCTIONS PG OF 29

12 CENTER LOUVER ADAPTER INSTALLATION REMOVE THE O.E.M. CENTER DASH BEZEL & O.E.M. WIPER SWITCH AS SHOWN IN FIGURE BELOW. REMOVE O.E.M. WIPER SWITCH CORVETTE FIGURE REMOVE O.E.M. SCREWS & REMOVE BEZEL INSTALL THE WIPER SWITCH BRACKET & GROUND WIRE USING (2)0-32 x½phpanheadscrews& (2) NUTS w/ STAR WASHER AS SHOWN IN FIGURE a BELOW. INSTALL THE O.EM WIPER SWITCH ON THE CENTER LOUVER BEZEL USING (2) 6-32 x 3/8 PH FLAT HEAD SCREWS w/ NYLOCK NUTS AS SHOW IN FIGURE a BELOW VUB (2) 0-32 x /2 PH FLAT HEAD SCREW & NUT w/ STARWASHER REMOVE O.E.M. WIPER SWITCH O.E.M. WIPER SWITCH GROUND WIRE FIGURE a WIPER SWITCH BRKT INSTALL RECTANGLE LOUVER AS SHOW IN FIGURE b TO CENTER LOUVER BEZEL. USING (2) 8-5 x 3/4 PH FLAT HEAD TAP SCREWS INSTALL THE CENTER LOUVER BEZEL IN THE CENTER DASH BEZEL AS SHOW IN FIGURE b. NOTE: SECURE THE GROUND WIRE BETWEEN THE CENTER LOUVER BEZEL AND THE DASH. RECTANGLE LOUVER 826-FSR 8-5 x 3/4 PH FLAT HEAD TAP SCREW 827-FSR (2) 6-32 x 3/8 PH FLAT HEAD MACH. SCREW w/ NYLOCK NUT O.E.M. SCREW CENTER LOUVER BEZEL FIGURE b CENTER LOUVER BEZEL EDGE OF DASH 826-FSR 8-5 x 3/4 PH FLAT HEAD TAP SCREW 9074-PCZ REV A 8/3/05, GEN IV CORVETTE w/o AC INSTRUCTIONS PG 2 OF 29 GROUND WIRE CENTER DSAH BEZEL 2

13 FIREWALL MODIFICATION CUT OUT FIREWALL MODIFICATION TEMPLATE ON PAGE 28. ALIGN AND TAPE INTO PLACE AS SHOWN AS SHOWN IN FIGURE c AND MARK AROUND THE DOTTED LINE. REMOVE THE TEMPLATE CUT ALONG THE DOTTED LINE TO REMOVE THE SHADED PORTION OF THE FIREWALL AS SHOWN IN FIGURE d. ALIGN DO NOT CUT MARK ALONG DOTTED LINE 69 CORVETTE w/o FACTORY AIR FIREWALL TEMPLATE DO NOT CUT ALIGN TEMPLATE FIGURE c CUT ALONG DOTTED LINE FIGURE d EVAPORATOR INSTALLATION ON A WORK BENCH, INSTALL EVAPORATOR REAR BRACKET, AND INSTALL EVAPORATOR HARDLINES WITH PROPERLY LUBRICATED O-RINGS. (SEE FIGURE 7, PAGE 8, AND FIGURES 22, PAGE 22.) INSTALL FRONT MOUNTING BRACKET ON EVAPORATOR USING (2) /4-20 x /2 HEX BOLTS AND TIGHTEN AS SHOWN IN FIGURE 2, PAGE 4. PLACE 4mil POLYETHYLENE SHEET OVER THE STEPPER MOTORS. SEE FIGURE 3, PAGE 4. LIFT EVAPORATOR UNIT UP UNDER THE DASHBOARD SEE FIGURE 3, PAGE 4. SECURE LOOSELY TO THE FIREWALL FROM THE ENGINE COMPARTMENT SIDE USING A /4-20 x BOLT AND WASHER, SEE FIGURE 3, PAGE 4. USING A #4 x 3/4 SHEETMETAL SCREW SECURE THE FRONT EVAPORATOR MOUNTING BRACKET TO THE INNER COWL BY ALIGNING THE RIGHT HOLE IN FRONT EVAPORATOR MOUNTING BRACKET WITH THE O.E.M. HOLE IN INNER COWL. SEE FIGURE 3, PAGE 4 TO SECURE THE LEFT SIDE OF THE FRONT MOUNTING BRACKET, WITH EVAPORATOR MOUNTING BRACKET IN PLACE DRILL A 3/6 HOLE IN INNER COWL USING THE LEFT MOUNTING BRACKET HOLE AS A GUIDE. SECURE THE BRACKET TO THE INNER COWL USING A #4 x 3/4 SHEETMETAL SCREW SEE FIGURE 3, PAGE 4. 3 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 SCREWS.) 9074-PCZ REV A 8/3/05, GEN IV CORVETTE w/o AC INSTRUCTIONS PG 3 OF 29

14 FIGURE 2 FRONT MNTG BRACKET (2)/4-20 x ½ HEX BOLT O.E.M. HOLE INNER COWL /4-20 x BOLT & WASHER LEFT MOUNTING HOLE RIGHT MOUNTING HOLE FIGURE 7 ONCE BRACKET IS IN PLACE, DRILL 3/6 MOUNTING HOLE 4ml9x5 POLYETHYLENE SHEET FIGURE 3 (2) #4 x 3/4 SHEETMETAL SCREW * NOTE: INSTALL THIS BOLT FIRST 9074-PCZ REV A 8/3/05, GEN IV CORVETTE w/o AC INSTRUCTIONS PG 4 OF 29 4

15 DRAIN HOSE INSTALLATION IN-LINE WITH THE DRAIN, LIGHTLY MAKE A MARK ON THE FIREWALL. MEASURE ONE INCH DOWN AND DRILL A 5/8 HOLE THROUGH THE FIREWALL. SEE FIGURE 4 BELOW. INSTALL DRAIN HOSE TO BOTTOM OF EVAPORATOR UNIT AND ROUTE THROUGH FIREWALL. SEE FIGURE FIGURE 4, BELOW. DRAIN HOSE DRAIN FIGURE PCZ REV A 8/3/05, GEN IV CORVETTE w/o AC INSTRUCTIONS PG 5 OF 29

16 FIREWALL COVER LOCATE THE DIMPLE IN THE BACK SIDE OF THE FIREWALL COVER. USE A ½ DRILL BIT AND DRILL ½ HOLE IN FIREWALL COVER AS SHOWN IN FIGURE 5 BELOW APPLY A /4 BEAD OF SILICONE AROUND THE BACK SIDE OF THE FIREWALL COVER AS SHOWN IN FIGURE 5 BELOW. PASS LINES THROUGH FIREWALL COVER, AND SECURE WITH (2) 7/6 PANEL RETAINERS. SEE FIGURE 5 BELOW. ONCE THE FIREWALL COVER IS IN PLACE LOCATE THE HOLE ON THE LEFT SIDE OF THE FIREWALL COVER AND DRILL A 3/8 HOLE THROUGH THE FIREWALL AND INSTALL A 7/6 PANEL RETAINER TO SECURE THE LEFT SIDE OF THE FIREWALL COVER TO FIREWALL. SEE FIGURE 5 BELOW. APPLY A /4 BEAD OF SILICONE AROUND THE BACK SIDE OF THE FIREWALL COVER CAP AS SHOWN IN FIGURE 5 BELOW. USING (2) #8 x ½ PH PAN HEAD SCREWS INSTALL FIREWALL COVER CAP AS SHOWN IN FIGURE 5 BELOW. BACKSIDE OF DRILL FIREWALL COVER DIMPLE SILICONE S B Y FIGURE 5 DRILL 3/8 HOLE #0 SUCTION LINE (3) 7/6 PANEL RETAINER SILICONE 9074-PCZ REV A 8/3/05, GEN IV CORVETTE w/o AC INSTRUCTIONS PG 6 OF 29 #6 LIQUID LINE (2)8x½ PH PAN HEAD SCREWS 6

17 A/C HOSE INSTALLATION STANDARD HOSE KIT LOCATE THE #8 COMPRESSOR A/C HOSE. LUBRICATE (2) #8 O-RINGS (SEE FIGUR E 6, PAGE 8) AND CONNECT THE 90 FITTING TO THE #8 DISCHARGE PORT ON THE COMPRESSOR AND ROUTE THE STRAIGHT FITTING TO THE #8 CONDENSER HARDLINE COMING THROUGH THE CORE SUPPORT SEE FIGURE 8, PAGE8. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN FIGURE7,PAGE8. LOCATE THE #0 COMPRESSOR A/C HOSE. LUBRICATE (2) #0 O-RINGS (SEE FIGURE 6,PAGE8) AND CONNECT THE 35 FITTING TO THE #0 SUCTION PORT ON THE COMPRESSOR AND ROUTE THE STRAIGHT FITTING TO THE #0 EVAPORATOR HARDLINE COMING THROUGH THE FIREWALL SEE FIGURE 8, PAGE 8. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN FIGURE 7, PAGE 8. ( NOTE: WRAP THE #0 FITTING CONNECTIONS ATFIREWALL WITH PRESS TAPE. SEE FIGURE 8, PAGE 8. LOCATE THE #6 EVAP/COR HARDLINE AND LUBRICATE (2) #6 O-RINGS (SEE FIGURE 6,PAGE8) AND CONNECT THE HARDLINE TO THE #6 HARDLINE COMING THROUGH THE CORE SUPPORT FROM DRIER. ATTACH THE OTHER END OF THE HARDLINE WITH LUBRICATED ORING TO THE #6 EVAPORATOR HARDLINE COMING THROUGH THE FIREWALL. SEE FIGURE 8, PAGE8. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN FIGURE 7,PAGE8. USE A #2 ADEL CLAMP TOSECURE THE #6 EVAP/CORE HARDLINE TO THE INNER FENDERWELL AS SHOWN IN FIGURES 8 & 9 PAGES 8 & 9. SECURE THE ADEL CLAMP TO THE INNER FENFER USING A 0-32 x ½ MACHINE SCREW AND NUT. MODIFIED A/C HOSE KIT REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH MODIFIED HOSE KIT. BIG BLOCK MODIFIED HOSE KIT LOCATE THE #8 COMPRESSOR A/C HOSE. LUBRICATE (2) #8 O-RINGS (SEE FIGURE 6,PAGE8) AND CONNECT THE 90 FITTING TO THE #8 DISCHARGE PORT ON THE COMPRESSOR AND ROUTE THE STRAIGHT FITTING TO THE #8 CONDENSER HARDLINE COMING THROUGH THE CORE SUPPORT SEE FIGURE 9, PAGE 9. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN FIGURE7,PAGE8. LOCATE THE #0 COMPRESSOR A/C HOSE. LUBRICATE (2) #0 O-RINGS (SEE FIGURE 6,PAGE8) AND CONNECT THE 90 FITTING TO THE #0 SUCTION PORT ON THE COMPRESSOR AND ROUTE THE STRAIGHT FITTING TO THE #0 EVAPORATOR HARDLINE COMING THROUGH THE FIREWALL SEE FIGURE 9, PAGE 9. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN FIGURE 7,PAGE8. ( NOTE: WRAP THE #0 FITTING CONNECTIONS ATFIREWALL WITH PRESS TAPE. SEE FIGURE 8, PAGE 8. LOCATE THE #6 EVAP/COR HARDLINE AND LUBRICATE (2) #6 O-RINGS (SEE FIGURE 6,PAGE8) AND CONNECT THE HARDLINE TO THE #6 HARDLINE COMING THROUGH THE CORE SUPPORT FROM DRIER. ATTACH THE OTHER END OF THE HARDLINE WITH LUBRICATED ORING TO THE #6 EVAPORATOR HARDLINE COMING THROUGH THE FIREWALL. SEE FIGURE 8, PAGE8. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN FIGURE 7, PAGE 8. USE A #2 ADEL CLAMP TO SECURE THE #6 EVAP/CORE HARDLINE TO THE INNER FENDERWELL AS SHOWN IN FIGURES 8 & 9 PAGES 8 & 9. SECURE THE ADEL CLAMP TO THE INNER FENFER USING A 0-32 x ½ MACHINE SCREW AND NUT. HEATER HOSE & HEATER CONTROL VALVE INSTALLATION ROUTE A PIECE OF HEATER HOSE FROM THE WATER PUMP TO THE HEATER LINE COMING THROUGH THE FIREWALL AS SHOWN IN FIGURES 20, PAGE 20. SECURE USING HOSE CLAMPS. ROUTE A PIECE OF HEATER HOSE FROM THE INTAKE TO THE HEATER LINE COMING THROUGH THE FIREWALL AS SHOWN IN FIGURES 20, PAGE 20. NOTE: INSTALL HEATER CONTROL VALVE IN-LINE WITH INTAKE MANIFOLD (PRESSURE SIDE) HEATER HOSE, SECURE USING HOSE CLAMPS AS SHOWN IN FIGURE 20 ON PAGE 20. NOTE PROPER FLOW DIRECTION PCZ REV A 8/3/05, GEN IV CORVETTE w/o AC INSTRUCTIONS PG 7 OF 29

18 ECU MODULE EVAPORATOR SUB CASE PRESS TAPE PRESS TAPE #2 ADEL CLAMP 0-32 x ½ SCREW w/ NUT #0 A/C SUCTION HOSE (COMP-EVAP) #6 LIQUID LINE FROM EXPANSION VALVE TO DRIER (09070-CFL) #8 A/C DISCHARGE HOSE (COMP-COND HARDLINE) OUT IN BINARY SWITCH FIGURE 8 GEN IV CORVETTE w/o AC SMALL BLOCK HOSE ROUTING HOLD WITH THIS WRENCH FIGURE 8 LUBRICATE O-RING (SEE FIGURE 6) FIGURE 6 #6 O-RING #8 O-RING #0 O-RING O-RING MALE INSERT FEMALE NUT SUPPLIED OIL FOR O-RINGS O-RING, SLIDE OVER MALE INSERT TO SWAGED LIP FOR A PROPER SEAL OF FITTINGS: INSTALL SUPPLIED O-RINGS AS SHOWN AND LUBRICATE WITH SUPPLIED OIL. FLOW FIREWALL COVER 9074-PCZ REV A 8/3/05, GEN IV CORVETTE w/o AC INSTRUCTIONS PG 8 OF 29 HEATER CONTROL VALVE TWIST WITH THIS WRENCH FIGURE 7 8

19 PRESS TAPE #2 ADEL CLAMP 0-32 x ½ SCREW w/ NUT OUT IN BINARY SWITCH GEN IV CORVETTE w/o AC BIG BLOCK MODIFIED HOSE ROUTING #0 A/C SUCTION HOSE (COMP-EVAP) #6 LIQUID LINE FROM EXPANSION VALVE TO DRIER (09070-CFL) #8 A/C DISCHARGE HOSE (COMP-COND HARDLINE) FLOW FIGURE 9 EVAPORATOR SUB CASE 9 ECU MODULE PRESS TAPE FIREWALL COVER 9074-PCZ REV A 8/3/05, GEN IV CORVETTE w/o AC INSTRUCTIONS PG 9 OF 29 HEATER CONTROL VALVE

20 HEATER CONTROL VALVE INSTALLATION ECU MODULE PRESS TAPE #0 SUCTION LINE (INSULATED) FIREWALL COVER EXPANSION VALVE O-RING #0 SUCTION HOSE FLOW FIREWALL COVER CAP HEATER HOSE #6 LIQUID LINE TO WATER PUMP FROM HTR CNTRL VLV FROM INTAKE FIGURE 20 FINAL STEPS - DUCT HOSE ROUTING & CONTROL PANEL HARNESS INSTALL DUCT HOSES AS SHOWN IN FIGURE 2, PAGE 2. REINSTALL THE CENTER DASH ASSEMBLY. PLUG THE CONTROL PANEL HARNESS INTO THE ECU MODULE ON SUB CASE AS SHOWN. SEE FIGURE 2, PAGE 2. ROUTE THE CONTROL PANEL HARNESS UNDER THE CENTER DASH ASSEMBLY AND CONNECT THE CONTROL HARNESS TO THE CONTROL POTS AS SHOWN IN FIGURE 2, PAGE 2. PLUG THE WIRING HARNESS INTO THE ECU MODULE ON SUB CASE AS SHOWN. (WIRE ACCORDING TO WIRING DIAGRAM ON PAGE 23.) REINSTALL CONTROL PANEL. REINSTALL ALL PREVIOUSLY REMOVED ITEMS (BATTERY BOX & BATTERY). 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 PCZ REV A 8/3/05, GEN IV CORVETTE w/o AC INSTRUCTIONS PG 20 OF 29 20

21 CONTROL PANEL & DUCT HOSE ROUTING SECURE BLOWER SPEED SWITCH WIRE TO BRACKET USING TYE WRAP AS SHOWN WHT WHT WHT/ YEL RED WHT RED WHT/ BLU NOTE: THIS PLUG WILL NOT BE USED ON THIS APPLICATION RED WHT WHT/ GRN RED WHT/ RED CONTROL WIRING HARNESS VUA PLUG-IN AS SHOWN PASSENGER SIDE LOUVER 2 /2 x 36 NOTE: PLUG-IN CONNECTOR BEFORE INSTALLING PC BOARD ON SWITCH ECU MODULE PASSENGER SIDE LOUVER 2 /2 x 48 PLUG FROM WIRING HARNESS VUR PASSENGER SIDE DEF. DUCT 2 x 0 2 DRIVER SIDE LOUVER 2 /2 x 36 FIGURE PCZ REV A 8/3/05, GEN IV CORVETTE w/o AC INSTRUCTIONS PG 2 OF 29 DRIVER SIDE DEF. DUCT 2 x 2 CENTER LOUVER 2 /2 x 24

22 EVAPORATOR HARD LINE INSTALLATION ECU MODULE #0 O-RING (33859-VUF) PASS. SIDE (EVAP. BRKT) PCB NOTE: AFTER INSTALLING # 0 SUCTION LINE WRAP ALL EXPOSED METAL (FITTINGS & TUBE) WITH SUPPLIED PRESS TAPE. #0 SUCTION LINE (095-PCS) #0 O-RING (33589-VUF) #6 O-RING (33857-VUF) PRESS TAPE /4-20 x /2 BOLT (LOCATED ON SUB CASE) HOLD WITH THIS WRENCH HEATER LINE (EVAP TO WATER PUMP) 0953-PCH #6 LIQUID LINE (0950-PCL) FIGURE 23 FIGURE 8 HEATER LINE (EVAP TO INTAKE) 0952-PCH LUBRICATE O-RING (SEE FIGURES 0 &, PAGE 2) TWIST WITH THIS WRENCH 9074-PCZ REV A 8/3/05, GEN IV CORVETTE w/o AC INSTRUCTIONS PG 22 OF 29 22

23 A/C-HEAT BLEND STEPPER #3 20 ga GRAY 20 ga ORANGE 20 ga YELLOW 20 ga WHITE 20 ga BLUE 20 ga GREEN ga VIOLET N/A N/A M O D E 20 ga RED WHITE N/A TO IGNITION THERMISTOR PROBE T H E R M O S T A T WHITE BLOWER SPEED SWITCH HCV CHASSIS GROUND AC COMP 6 ga BLUE 30 AMP CIRCUIT BREAKER 2 ga RED 2 ga RED BLOWER TO COMPRESSOR COMP SAFETY SWITCH BSC (BLOWER SPEED CONTROL) DEFROST STEPPER #2 A/C-HEAT STEPPER # # A/C-HEAT STEPPER ECU (ELECTRONIC CONTROL UNIT) TOP VIEW #2 DEFROST STEPPER #3 A/C-HEAT BLEND STEPPER N/A BSC BLACK THERMISTOR PROBE N/A WHITE YELLOW BLACK BLACK RED WHT/BLU WHITE/YELLOW BLACK WHT/RED WHITE/GREEN TO BATTERY ( ) (NEGATIVE TERMINAL) TO BATTERY ( ) (NEGATIVE TERMINAL) 6 ga GREEN WHITE HEATER CONTROL VALVE TO BATTERY (POSITIVE TERMINAL) OR BATTERY TERMINAL ON STARTER SOLENOID BLUE (+) GEN IV CORVETTE w/o AC BLACK BLACK ORANGE RED RED RED CONNECT AUXILIARY DEVICES TO THE COMPRESSOR LEAD. THIS WILL RESULT IN SEVERE DAMAGE TO SYSTEM! WARNING: DO NOT 9074-PCZ REV A 8/3/05, GEN IV CORVETTE w/o AC INSTRUCTIONS PG 23 OF 29

24 OPERATION OF CONTROLS NOTE: WHEN EVER BATTERY POWER IS RE CONNECTED TO THE ECU, THE COMPUTER GOES THROUGH AN INITIALIZATION SEQUENCE. THIS INITIALIZATION MAY TAKE UP TO 30 SECONDS. DURING INITIALIZATION THE DOORS INSIDE THE UNIT WILL BE OPERATING. A LOW BATTERY MAY ALSO TRIGGER A RE-INITIALIZATION. WHEN THE ENGINE IS BEING CRANKED A WEAK BATTERY MAY DROP BELOW 7 VOLTS, TRIGGERING RE-INITIALIZATION. SYSTEM OFF A/C MODE BLOWER SPEED OFF A C DEF FLR C HI BLOWER SPEED THIS LEVER CONTROLS THE BLOWER SPEED, FROMOFFTOHI A/C THERMOSTAT DIAL ROLL THE THERMOSTAT DIALALLTHEWAYUP FOR MAXIMUM COOLING, ROLL THE DIAL DOWN TO DECREASE THE AMOUNT OF COOLING OFF A C DEF FLR C HI MODE DIAL E C O N O PNL PNL FLR H THERMOSTAT DIAL MODE DIAL ROLL THE DIAL DOWN TO THE PNL LEGEND IN AC RANGE OF THE MODE DIAL E C O N O PNL PNL FLR H HEAT MODE DEFROST MODE OFF DEF C HI BLOWER SPEED THIS LEVER CONTROLS THE BLOWER SPEED, FROMOFFTOHI BLOWER SPEED THIS LEVER CONTROLS THE BLOWER SPEED, FROMOFFTOHI OFF DEF C HI A C FLR A/C THERMOSTAT DIAL ROLL THE THERMOSTAT DIALALLTHEWAYDOWN FOR MAXIMUM HEATING, ROLL THE DIAL UP TO DECREASE THE AMOUNT OF HEATINGING A/C THERMOSTAT DIAL ROLL THE THERMOSTAT DIALALLTHEWAYDOWN FOR MAXIMUM HEATING, ROLL THE DIAL UP TO DECREASE THE AMOUNT OF HEATINGING A C FLR E C O N O PNL PNL FLR H MODE DIAL ROLL THE DIAL DOWN TO THE FLR LEGEND IN THE ECONO RANGE OF THE MODE DIAL MODE DIAL ROLL THE DIAL DOWN TO THE DEF LEGEND IN THE AC RANGE OF THE MODE DIAL E C O N O PNL PNL FLR H MODE DIAL, AC & ECONO RANGES BOTH RANGES OF THE MODE DIAL OPERATE IDENTICALLY, WITH THE SINGULAR EXPECTATION THAT THE EXTRA COOLING AVAILABLE FROM THE AC COMPRESSOR IS NOT AVAILABLE WHILE THE MODE DIAL IS IN THE ECONO RANGE. WHEN THE MODE DIAL MOVES FROM ONE MODE RANGE TO THE OTHER, THE BLOWER SPEED CHANGES FOR AN INSTANT AND RETURNS TO NORMAL. THIS BEHAVIOR IS USED TO INDICATE THAT THE OPERATOR HAS MOVED INTO THE ALTERNATE MODE RANGE PCZ REV A 8/3/05, GEN IV CORVETTE w/o AC INSTRUCTIONS PG 24 OF 29 24

25 THERMOSTAT ADJUSTMENT OFF HI THERMISTOR PROBE DEF C EVAP. A C FLR PLASTIC E C O N O PNL PNL FLR H ADJUST THIS DIAL UP OR DOWN TO REGULATE TEMPERATURE TOP VIEW AIR CONDITIONING ADJUSTMENTS: WHEN THE MODE DIAL IS IN THE AC RANGE, THE COMPRESSOR WILL AUTOMATICALLY CYCLE ON AND OFF SO AS TO MAKE THE AIR TEMPERATURE CORRESPOND WITH THE POSITION OF THE THERMOSTAT DIAL. AT THE UPPER-MOST END OF THE THERMOSTAT DIAL, THE COOLING EFFORT CAN BE SO INTENSE THAT UNDER HIGH HUMIDITY CONDITIONS, ICE MAY FORM ON THE EVAPORATOR COIL. THIS CONDITION KNOW AS, ICING UP OR ICE UP, CAN BE RECOGNIZED WHEN THE SYSTEM SEEMS TO BE OPERATING PROPERLY, BUT THE FLOW OF COLD AIR IS GREATLY DIMINISHED. TO COUNTER THISS EFFECT, SIMPLY BACK THE THERMOSTAT DIAL AWAY FROM ITS EXISTING POSITION SLIGHTLY, THEREBY PERMITTING THE ICE FROM THE HIGH HUMIDITY TO MELT AND NOT RE-OCCUR PCZ REV A 8/3/05, GEN IV CORVETTE w/o AC INSTRUCTIONS PG 25 OF 29

26 TROUBLE SHOOTING INFORMATION SYMPTOM SOLUTION BLOWER STAYS ON HIGH, NO MODE FUNCTIONS PARTIAL FUNCTION OF CONTROL HEAD. (SOME FUNCTIONS WORK) BE SURE CONTROL HEAD CONNECTOR IS PROPERLY INSTALLED CHECK FOR DAMAGE TO CONTROL HARNESS COMPRESSOR DOES NOT TURN ON. (ALL OTHER FUNCTIONS WORK) CHECK FOR PROPER CHARGE BE SURE A/C DIAL IS IN A/C RANGE NO FUNCTION AT ALL CHECK MAIN POWER LEAD AFTER CIRCUIT BREAKER CHECK FOR POWER WITH IGNITION ON AT PURPLE WIRE CHECK ALL GROUNDS 9074-PCZ REV A 8/3/05, GEN IV CORVETTE w/o AC INSTRUCTIONS PG 26 OF 29 26

27 MARK OR SCRIBE ALONG THIS EDGE OF TEMPLATE GEN IV CORVETTE w/o AC DEFROST DUCT TEMPLATE CUT OUT TEMPLATE AND TAPE TOGETHER AS SHOWN BELOW. TAPE MARK OR SCRIBE ALONG THIS EDGE OF TEMPLATE MARK OR SCRIBE ALONG THIS EDGE OF TEMPLATE ALIGN TEMPLATE WITH BOTTOM OF THE DEFROST DUCT OVER LAP SHADED PORTIONS AND TAPE TOGETHER MARK OR SCRIBE ALONG THIS EDGE OF TEMPLATE ALIGN TEMPLATE WITH BOTTOM OF THE DEFROST DUCT MARK OR SCRIBE ALONG THIS EDGE OF TEMPLATE OVER LAP SHADED PORTIONS AND TAPE TOGETHER CUT ALONG DOTTED LINE MARK OR SCRIBE ALONG THIS EDGE OF TEMPLATE ALIGN TEMPLATE WITH BOTTOM OF THE DEFROST DUCT MARK OR SCRIBE ALONG THIS EDGE OF TEMPLATE ALIGN TEMPLATE WITH BOTTOM OF THE DEFROST DUCT 27 MARK OR SCRIBE ALONG THIS EDGE OF TEMPLATE CUT ALONG DOTTED LINE 9074-PCZ REV A 8/3/05, GEN IV CORVETTE w/o AC INSTRUCTIONS PG 27 OF 29

28 FIREWALL MODIFICATION TEMPLATE DO NOT CUT ALIGN WITH EDGE OF FIREWALL OPENING 69 CORVETTE w/o FACTORY AIR FIREWALL TEMPLATE REMOVE SHADED PORTION CUT ALONG DOTTED LINE 9074-PCZ REV A 8/3/05, GEN IV CORVETTE w/o AC INSTRUCTIONS PG 28 OF 29 28

29 EVAPORATOR KIT PACKING LIST No. QTY. PART No. DESCRIPTION VCE CORVETTE w/o AC EVAP. SUBCASE PCN CORVETTE w/o AC ACC. KIT EVAPORATOR KIT 5674-PCZ CHECKED BY: PACKED BY: DATE: CORVETTE w/o AC EVAP. SUB CASE 7674-VCE 2 ACCESSORY KIT 7874-PCN 9074-PCZ REV A 8/3/05, GEN IV CORVETTE w/o AC INSTRUCTIONS PG 29 OF 29

30 ACCESSORY KIT PACKING LIST No. QTY. PART No. DESCRIPTION VUE VUE CCE CCA VUE CCE CCE CCE 3337-VUI 3335-VUI CCE PCA 0955-PCA PCA PCA PCA PCA TVR CCE CCE AUR ACCESSORY KIT 7874-PCN 2 DUCT HOSE 2 ½ DUCT HOSE CORVETTE O.E.M. DS/PS INNER HA CORVETTE CENTER LOUVER BEZEL w/o AC ASM S CLIP CORVETTE DEF DUCT HA CORVETTE FIREWALL COVER CORVETTE FIREWALL COVER CAP LARGE GROMMET /4 x w/ 3/8 HOLE GROMMET CORVETTE INSIDE FRESH AIR CAP CORVETTE IK KIT HARDLINE KIT CORVETTE EVAP BRKT KIT FRESH AIR CAP ASM CORVETTE CNTRL PNL CONVERSION KIT GEN IV WIRING KIT VELCRO STRIP CORVETTE O.E.M. PS OUTER HA CORVETTE O.E.M DS OUTER HA 4mil9x5POLYETHYLENE SHEET 8 CHECKED BY: PACKED BY: DATE: PCN REV A 7/20/05, GEN IV CORVETTE ACC. KIT PG OF