1969 CAMARO VCZ-A

Transcription

1 969 CAMARO w/o FACTORY AIR VCZ-A 8865 GOLL ST. - SAN ANTONIO, TX ph fax VCZ-A /22/05, 69 CAMARO w/o FAC. AIR INSTRUCTIONS PG OF 20

2 969 CAMARO w/o FACTORY AIR Table of Contents PAGES COVER TABLE OF CONTENTS PACKING LIST INFORMATION PAGE PASSENGER COMPARTMENT FIGURE CONTROL CABLE INSTALLATION FIGURES 2-4 FIREWALL COVER INSTALLATION FIGURES 5 & 5A EVAPORATOR INSTALLATION FIGURES 6-7B EVAPORATOR INSTALLATION CONT. FIGURES 8-8C DUCT HOSE INSTALLATION FIGURE 9 ENGINE COMPARTMENT FIGURE 0 CONDENSER ASSEMBLY/COMP. BRKT/ PULLEYS FIGURES -B CONDENSER INSTALLATION FIGURES 2-2B CONDENSER INSTALLATION CONT. FIGURES 3 & 3A A/C HOSE INSTALLATION FIGURES 4 HEATER HOSE HEATER CONTROL VALVE INSTALLATION FIGURES 4A &4B FRESH AIR CAP/DUCT HOSE ADAPTER/GLOVE BOX INSTALLATION FIGURES 5-7 CENTER LOUVER/FINAL STEPS FIGURES 8 AIR CONDITIONING ADJUSTMENTS WIRING DIAGRAM & CENTER LOUVER TEMPLATE EVAPORATOR KIT PACKING LIST VCZ-A /22/05, 69 CAMARO w/o FAC. AIR INSTRUCTIONS PG 2 OF 20

3 969 CAMARO w/o FACTORY AIR CAMARO w/o FACTORY AIR EVAPORATOR KIT PACKING LIST No. QTY. PART No. DESCRIPTION 7669-VCE FCN EVAPORATOR SUBCASE 969 CAMARO w/o AC ACCESSORY KIT EVAPORATOR KIT VCZ-A ** 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. EVAPORATOR 7669-VCE VCZ-A /22/05, 69 CAMARO w/o FAC. AIR INSTRUCTIONS PG 3 OF 20 ACCESSORY KIT FCN 3

4 969 CAMARO w/o FACTORY AIR IMPORTANT NOTICE-PLEASE READ FOR MAXIMUM SYSTEM PERFORMANCE VINTAGE AIR RECOMMENDS THE FOLLOWING: * VCR 69 CAMARO RADIATOR * VCF FAN SHROUD 969 CAMARO w/o FACTORY AIR * 3298-VUF 8 FAN * 3258-VUF OEM FAN CLUTCH 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: 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 TO INSTALLATION. REMOVING CAPS PRIOR TO INSTALLATION WILL CAUSE COMPONENTS TO COLLECT MOISTURE AND LEAD TO PREMATURE FAILURE AND REDUCED PERFORMANCE. EVACUATE THE SYSTEM FOR MINUTES WITH SYSTEM COMPONENTS (DRIER, COMPRESSOR, EVAPORATOR AND CONDENSER) AT A TEMPERATURE OF AT LEAST 85 F. ON A COOL DAY THE COMPONENTS CAN BE HEATED WITH A HEAT GUN OR BY RUNNING THE ENGINE WITH THE HEATER ON BEFORE EVACUATING. LEAK CHECK AND CHARGE TO SPECIFICATIONS. VINTAGE AIR SYSTEMS ARE DESIGNED TO OPERATE WITH R34a or R-2 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 COMPONE NTS. USE OF THE PROPER TYPE AND 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. 4 REFRIGERANT CAPACITIES FOR VINTAGE AIR SYSTEMS (FOR OTHER SYSTEMS, CONSULT MANUFACTURER GUIDELINES) 34a SYSTEM CHARGE WITH.8 lbs. (lbs. 2ozs) OF REFRIGERANT LUBRICANT CAPACITIES: R-2 SYSTEM CHARGE WITH 2.0 lbs. OF REFRIGERANT NEW COMPRESSOR - NO ADDITIONAL OIL NEEDED USED COMPRESSOR - CONSULT VINTAGE AIR VCZ-A /22/05, 69 CAMARO w/o FAC. AIR INSTRUCTIONS PG 4 OF 20

5 969 CAMARO w/o FACTORY AIR INSTALLATION INSTRUCTIONS 969 CAMARO w/o FACTORY AIR BEFORE STARTING THE INSTALLATION, CHECK THE FUNCTION OF THE VEHICLE (HORN, LIGHTS, ETC.) FOR PROPER OPERATIONS. STUDY THE INSTRUCTIONS, ILLUSTRATIONS, & DIAGRAMS. PASSENGER COMPARTMENT DISCONNECT BATTERY REMOVE AND DISCARD THE OEM HEATER ASSEMBLY (#). REMOVE AND DISCARD THE OEM DEFROSTER DUCT (#2). REMOVE AND DISCARD THE OEM HEATER COVER (#3) (INSTALLED ON ENGINE SIDE) THE INNER FENDER MUST BE LOOSENED AND LOWERED. REMOVE (4) BOLTS FROM THE FENDER AT THE WINDSHIELD AND DOOR AREA AND RAISE THE FENDER TO REMOVE THE BLOWER MOTOR. REMOVE THE OEM DASH-BOARD (#4). REMOVE THE STEERING COLUMN BOTTOM COVER (#5). REMOVE AND DISCARD VENT DUCTS ON DRIVER & PASSENGER SIDE (#6 & #7). REMOVE AND DISCARD OEM DUCT HOSE (#8). REMOVE THE GLOVE BOX DOOR (#) AND RETAIN. REMOVE AND DISCARD THE OEM GLOVE BOX (# 9). REMOVE INSTRUMENT PANEL (# 0). DROP THE STEERING COLUMN DOWN VCZ-A /22/05, 69 CAMARO w/o FAC. AIR INSTRUCTIONS PG 5 OF 20 FIGURE 5

6 969 CAMARO w/o FACTORY AIR CONTROL CABLE INSTALLATION REMOVE AND DISCARD (3) OEM CONTROL CABLES FROM CONTROL PANEL. SEE FIGURE 2. FIGURE 2 REMOVE & DISCARD ATTACH NEW CABLES (PROVIDED) TO CONTROL PANEL LEVERS AS SHOWN IN FIGURE 3 BELOW. CONTROL PANEL BACK POSITION LEVERS AS SHOWN IN FIGURE 4 BELOW. REMOVE & DISCARD CONTROL PANEL TEMPERATURE CABLE 27 /8 FIGURE 3 DEFROST CABLE 9 /2 BLOWER SWITCH TEMPERATURE DEFROST 6 CONTROL PANEL FRONT VCZ-A /22/05, 69 CAMARO w/o FAC. AIR INSTRUCTIONS PG 6 OF 20 FIGURE 4

7 969 CAMARO w/o FACTORY AIR FIREWALL COVER INSTALLATION USE THE OEM HEATER MOUNTING HOLE IN FIREWALL TO MOUNT THE FIREWALL COVER. APPLY A /4 BEAD OF SILICONE AROUND THE PERIMETER OF THE FIREWALL COVER AND INSTALL. SECURE USING (4) /4 x HEX BOLTS WITH FLAT WASHERS, SEE FIGURE 5 BELOW. USE OEM HOLES IN THE FIREWALL TO MOUNT FIREWALL COVER OEM HEATER MOUNT HOLES DO NOT INSTALL THIS BOLT UNTIL MOUNTING EVAPORATOR (4) THREADED INSERT HOLES (4) FLAT WASHER HOLES FIGURE 5 FIREWALL FIREWALL COVER COVER INSULATION FIREWALL FIREWALL COVER CAP FIGURE 5A VCZ-A /22/05, 69 CAMARO w/o FAC. AIR INSTRUCTIONS PG 7 OF 20 7

8 969 CAMARO w/o FACTORY AIR EVAPORATOR INSTALLATION INSTALL THE (2) DEFROSTER VENTS UNDER DASH AS SHOWN IN FIGURE 6 BELOW. SECURE USING (2) #8 x ½ PH PAN HEAD SCREWS. INSTALL THE NEW DRIVER & PASSENGER SIDE FRESH AIR COVERS, SECURE USING OEM HARDWARE. SEE FIGURE 6 BELOW. LAY THE EVAPORATOR UNIT ON THE FLOOR UNDER DASH, AT THIS TIME LUBRICATE A #6 O-RING (SEE FIGURE & a, PAGE ) AND INSTALL THE #6 HARDLINE ON TO EVAPORATOR. SEE FIGURE 4, PAGE 4. ATTACH CONTROL CABLES TO EVAPORATOR. SEE FIGURES 7A & 7B BELOW. INSTALL THE DRIVER SIDE MOUNTING BRACKET AND THE BLOWER HOUSING MOUNTING BRACKET, SEE FIGURE 7 BELOW. SECURE BRACKETS USING (2) #8 x ½ PH PAN HEAD SCREWS. DRIVER SIDE DEFROSTER PASSENGER SIDE DEFROSTER PASSENGER SIDE FRESH AIR COVER DRIVER SIDE FRESH AIR COVER FIGURE 6 ANGLE ROTATE THE UNIT 90 WILE LIFTING INTO POSITION EVAPORATOR HEAT/DEFROST DOOR CABLE FIGURE 7 DEFROST CABLE 9 /2 EVAPORATOR BLOWER HOUSING BRACKET 8 EVAPORATOR BRACKET FIGURE 7B PUSH ON RING TEMPERATURE CABLE 27 /8 DRIVER SIDE MOUNTING BRACKET BRACKET VCZ-A /22/05, 69 CAMARO w/o FAC. AIR INSTRUCTIONS PG 8 OF 20 PUSH ON RING FIGURE 7A

9 969 CAMARO w/o FACTORY AIR EVAPORATOR INSTALLATION CONT. FIRST ATTACH DRIVER SIDE MOUNTING BRACKET IN OEM HOLE IN RADIO BRACKET USING OEM SCREW AS SHOWN IN FIGURE 8A BELOW. RAISE THE EVAPORATOR UNIT UP UNDER THE DASH AND ALIGN THE JACK-NUT IN THE EVAPORATOR UNIT WITH THE OEM HOLE IN FIREWALL (SEE FIGURE 5, PAGE 7). SECURE USING A /4 x HEX BOLT FROM THE ENGINE COMPARTMENT SIDE. SEE FIGURE 8B BELOW. ATTACH THE BLOWER HOUSING MOUNT BRACKET IN FRONT OF THE VENT DUCT COVER ON THE PASSENGER SIDE OF THE DASH, SECURE USING OEM BOLT. SEE FIGURE 8C BELOW. FIGURE 8B OEM FIREWALL HOLE FLAT WASHER #6 HARDLINE (09692-FCL /4 x HEX BOLT RADIO BRACKET EVAPORATOR EVAPORATOR FIGURE 8 DRIVER SIDE MOUNTING BRACKET FIGURE 8A OEM SCREW FRESH AIR COVER BLOWER HOUSING BRACKET VCZ-A /22/05, 69 CAMARO w/o FAC. AIR INSTRUCTIONS PG 9 OF 20 FIGURE 8C 9

10 969 CAMARO w/o FACTORY AIR DUCT HOSE INSTALLATION STRETCH THE DUCT HOSE OUT TO ITS MAXIMUM LENGTH AND CUT TO SIZES SHOWN. ROUTE DUCT HOSES TO CORRESPONDING LOUVERS AS SHOWN IN FIGURE 9 BELOW. NOTE: FOR MAXIMUM AIR FLOW MAKE SURE DUCT HOSES ARE PULLED TIGHT AND HAVE NO KINKS OR SHARP BENDS. 2 /2 x 36 A/C DUCT HOSE 2 x 3 DEFROST DUCT HOSE NOTE: SEE PAGE 5 FOR HOSE ADAPTER INSTALLATION INSTRUCTIONS FOR DRIVER & PASSENGER SIDE LOUVERS. SEE PAGE 6 FOR THE CENTER LOUVER INSTALLATION INSTRUCTIONS. (2) 2 x 5 A/C DUCT HOSE 2 x 5 DEFROST DUCT HOSE EVAPORATOR 2 /2 x 26 A/C DUCT HOSE DRIVER SIDE OEM LOUVER DRIVER SIDE: A/C DUCT 2 ½ x 36 DEFROST DUCT 2 x 3 PASSENGER SIDE: A/C DUCT 2 ½ x 26 DEFROST DUCT 2 x 5 CENTER LOUVER: A/C DUCT (2) 2 x 5 CENTER LOUVER FIGURE 9 PASSENGER SIDE OEM LOUVER 0 USING THE CENTER LOUVER TEMPLATE ON PAGE 9 TO CUT HOLE IN DASH FOR THE CENTER LOUVER ASSEMBLY. ROUTE THE BLUE COMPRESSOR LEAD AND THE 7/32 VACUUM HOSE THROUGH THE GROMMET IN THE FIREWALL COVER. DRILL A 5/8 HOLE THROUGH THE FIREWALL BELOW THE FIREWALL COVER AND 2 TOWARDS THE DRIVER SIDE FROM THE CENTER FIREWALL COVER MOUNTING BOLT. ROUTE THE DRAIN HOSE FROM EVAPORATOR DRAIN THROUGH THE 5/8 HOLE IN FIREWALL. SEE FIGURE 0. ENGINE COMPARTMENT REMOVE THE HOOD LATCH ASSEMBLY REMOVE (2) OEM 5/6 U-NUT FROM RADIATOR CORE SUPPORT. FOR CONDENSER INSTALLATION. SEE FIGURE 2. FIGURE 0 HOOD LATCH ASSEMBLY VCZ-A /22/05, 69 CAMARO w/o FAC. AIR INSTRUCTIONS PG 0 OF 20 OEM U-NUT DRAIN HOSE

11 969 CAMARO w/o FACTORY AIR CONDENSER ASSEMBLY THE CONDENSER ASSEMBLY MOUNTS TO THE FRONT SIDE OF THE CORE SUPPORT. LOWER CONDENSER ASSEMBLY INTO POSITION. BE SURE THE TOP BRACKET IS BEHIND (FRONT LIP) FLANGE ON TOP OF THE CORE SUPPORT. FASTEN DRIVER SIDE LOWER CONDENSER BRACKET TO CORE SUPPORT USING 5/6" X -/2" BOLT AND NUT. LOWER HOOD LATCH SUPPORT BRACKET INTO PLACE. NOTE THAT THE LOWER MOUNTING TAB OF LATCH SUPPORT BRACKET WILL SLIP BEHIND PASSENGER SIDE LOWER CONDENSER BRACKET AND AGAINST THE CORE SUPPORT. ATTACH HOOD LATCH SUPPORT BRACKET WITH ORIGINAL 5/6" BOLT. NOTE THAT THE LOWER BOLT WILL PASS THROUGH THE PASSENGER SIDE LOWER CONDENSER BRACKET AND SECURE IT TO THE CORE SUPPORT. SEE FIGURE 2, PAGE 2. REPLACE HOOD LATCH ASSEMBLY. THE 2 (TWO) ORIGINAL 5/6" BOLTS CONNECTING IT TO THE CORE SUPPORT WILL NOW PASS THROUGH AND SECURE THE TOP CONDENSER BRACKET. SEE FIGURE 2A, PAGE 2. COMPRESSOR & BRACKETS REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH THE BRACKET KIT TO INSTALL THE COMPRESSOR BRACKET. REFER TO FIGURE FOR COMPRESSOR MOUNTING POSITION. INSTALL COMPRESSOR USING TABS C & G WITH OUTLETS FACING UP. PULLEYS IN MOST INSTANCES THE BELT LENGTHS WILL REMAIN THE SAME. A/C HARDLINES AT THE CONDENSER LOCATE THE O-RING PACKAGE. THERE IS A SPECIFIC SIZE AND THICKNESS O-RING FOR EACH CONNECTION. THE SMALL WHITE TUBE IS A SPECIFIC OIL FOR O'RINGS AND THREADS. SEE FIGURE a. O-RINGS SHOULD NOT BE REUSED ONCE A FITTING IS TIGHTENED (DISCARD AND INSTALL NEW O-RINGS). DO NOT OVER TIGHTEN. ALWAYS USE TWO (2) WRENCHES TO PREVENT TWISTING FITTINGS ON HARDLINES. FIGURE b. FOR A PROPER SEAL OF FITTINGS INSTALL SUPPLIED O-RINGS AS SHOWN AND LUBRICATE WITH SUPPLIED OIL. O'RING, SLIDE OVER MALE INSERT TO SWAGED LIP FIGURE a SUPPLIED OIL FOR O'RINGS AND THREADS TAB "E" TAB "A" A/C COMPRESSOR PULLEY #6 O'RING #8 O'RING #0 O'RING TAB "G" TAB "C" WATER PUMP PULLEY TWIST WITH THIS WRENCH LUBRICATE O'RING (SEE FIGURE 9) HOLD WITH THIS WRENCH ALTERNATOR PULLEY (IF PRESENT) A.I.R. PUMP PULLEY (IF PRESENT) POWER STEERING PULLEY CRANKSHAFT PULLEY FIGURE b VCZ-A /22/05, 69 CAMARO w/o FAC. AIR INSTRUCTIONS PG OF 20 FIGURE

12 969 CAMARO w/o FACTORY AIR CONDENSER INSTALLATION 0/24 STAR-NUT 0/24 x 3/8 BOLT BACK FRONT (2) 5/6 U-NUT MOUNTED TO CONDENSER BRACKET CORE SUPPORT O.E.M BOLT BACK FRONT TOP CONDENSER BRACKET (BEHIND CORE SUPPORT) SIDE VIEW (TOP) 0/24 STAR-NUT SIDE VIEW (BOTTOM) 0/24 x 3/8 BOLT DRIER BRACKET CONDENSER FRONT VIEW 8 HOOD LATCH ASSEMBLY 5 #8 DISCHARGE LINE TO ENGINE COMPARTMENT 0969-FFD FRONT VIEW FIGURE 2a DRIER CLAMPS #6 ALUM. HARDLINE COND./DRIER VCG OUT FLOW IN CORE SUPPORT FIGURE 2B 2 #6 DRIER/EXP. VALVE LIQUID LINE VCG 5 /4 CONDENSER TO DRIER LIQUID LINE LOWER DRIER BRACKET (TIP) BOTTOM PASSENGER SIDE BRACKET BOTTOM DRIVER SIDE BRACKET O-RING VCZ-A /22/05, 69 CAMARO w/o FAC. AIR INSTRUCTIONS PG 2 OF 20 CONDENSER FRONT VIEW LOCK WASHERS FLAT WASHERS FIGURE 2 NUT FLAT WASHERS 5/6 BOLT

13 969 CAMARO w/o FACTORY AIR CONDENSER INSTALLATION CONT. LOCATE THE TWO #8 HARDLINES AND O-RINGS,INSTALL ON CONDENSER AND DISCHARGE HOSE. SEE FIGURE 3 BELOW AND FIGURE 2, PAGE 2. FASTEN THE HARDLINE TO THE FRONT OF THE DRIVER'S INNER FENDER PANEL WITH A #4 ADEL CLAMP AND A #0/32 x /2 MACHINE SCREW AND NUT, DRILL 3/6 HOLE. SEE FIGURE 3A. RECAP END TO KEEP CLEAN. LOCATE THE #6 ALUMINUM HARDLINE. THIS LINE GOES FROM THE DRIER, UNDER THE PASSENGER SIDE RADIATOR SUPPORT. INSTALL ON DRIER, SEE FIGURE 3. LOCATE THE COMPRESSOR SAFETY SWITCH (BINARY TYPE). LUBRICATE THE THREADS AND FIRMLY SCREW THE SAFETY SWITCH ON DRIER. SEE FIGURE 3. LUBRICATE THE O'RINGS AND FITTING S (SEE FIGURE a, PAGE ) AND ROUTE THE LINE AS SHOWN ON THE PASSENGER SIDE. SEE FIGURE 3. CLAMP THE LINE WITH TWO (2) EACH #2 ADEL CLAMPS AND TWO (2) EACH #0/32 x /2 MACHINE SCREWS AND NUTS. SEE FIGURE 3, DRILL 3/6 HOLES IN THE INNER FENDER PANEL. RECAP THE END OF THE HARDLINE TO KEEP CLEAN. FIREWALL COVER FIREWALL PASSENGER INNER FENDER PANEL DRIVER SIDE INNER FENDER PANEL #2/#0 ADEL CLAMPS #0 SUCTION HOSE #0 ADEL CLAMP #8 DISCHARGE HOSE EVAP/ DRIER HARDLINE FFL #2 ADEL CLAMP OEM BRACE LONG #6 ALUMINUM HARDLINE FROM DRIER VCG 0/32 x /2 OUT COMPRESSOR SAFETY SWITCH (BINARY TYPE) SCREW ON DRIER ALTERNATOR SUPPORT FAN SHROUD (RECOMMENDED) IN RADIATOR DRIER COMPRESSOR CONDENSER FIGURE 3 TOP VIEW OF ENGINE COMPARTMENT #8 ALUM. HARDLINE 0970-FCD 0/32 x ½ SCREW #4 ADEL CLAMP INNER FENDER LOCK NUT FIGURE 3a DRILL 3/6 HOLE VCZ-A /22/05, 69 CAMARO w/o FAC. AIR INSTRUCTIONS PG 3 OF 20 3

14 969 CAMARO w/o FACTORY AIR A/C HOSE INSTALLATION STANDARD HOSE KIT LOCATE THE #8 COMPRESSOR A/C HOSE. LUBRICATE (2) #8 O-RINGS (SEE FIGURE a, PAGE ) AND CONNECT THE 35 w/ 34a SERVICE PORT FITTING TO THE #8 DISCHARGE PORT ON THE COMPRESSOR. ROUTE THE STRAIGHT MALE FITTING TO THE #8 CONDENSER HARDLINE. SEE FIGURE 3, PAGE3. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN FIGURE b, PAGE. LOCATE THE #0 COMPRESSOR A/C HOSE. LUBRICATE (2) #0 O-RINGS (SEE FIGURE a, PAGE ) AND CONNECT THE 35 FITTING TO THE #0 SUCTION PORT ON THE COMPRESSOR AND ROUTE THE STRAIGHT FEMALE w/ 34a SERVICE PORT FITTING TO THE #0 EVAPORATOR HARDLINE COMING THROUGH THE FIREWALL SEE FIGURE 3, PAGE 3 & FIGURE 4b, PAGE 5. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN FIGURE b, PAGE. (NOTE: WRAP THE #0 FITTING CONNECTIONS WITH PRESS TAPE. SEE FIGURE 4b, PAGE 5. LOCATE THE #6 EVAP/DRIER HARDLINE AND LUBRICATE (2) #6 O-RINGS (SEE FIGURE a, PAGE ) AND CONNECT THE HARDLINE TO THE #6 HARDLINE COMING THROUGH THE CORE SUPPORT FROM DRIER. ATTACH THE OTHER END OF THE HARDLINE WITH LUBRICATED O-RING TO THE #6 EVAPORATOR HARDLINE COMING THROUGH THE FIREWALL. SEE FIGURE 3, PAGE3 & FIGURE 4b, PAGE 5. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN FIGURE b, PAGE. USE A #2 ADEL CLAMP TO SECURE THE #6 EVAP/CORE HARDLINE TO THE INNER FENDERWELL AS SHOWN IN FIGURE 3 PAGES 3. SECURE THE ADEL CLAMP TO THE INNER FENDER USING A 0-32 x ½ MACHINE SCREW AND NUT. MODIFIED A/C HOSE KIT REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH MODIFIED HOSE KIT. #6 O-RING #6 EVAP HARDLINE (09692-FCL) 4 FIGURE VCZ-A /22/05, 69 CAMARO w/o FAC. AIR INSTRUCTIONS PG 4 OF 20

15 969 CAMARO w/o FACTORY AIR HEATER HOSE & HEATER CONTROL VALVE INSTALLATION ROUTE A PIECE OF HEATER HOSE FROM THE WATER PUMP, TO THE FIREWALL AND ATTACH IT TO THE HEATER LINE FROM EVAPORATOR AS SHOWN IN FIGURES 4a, BELOW. SECURE USING HOSE CLAMPS. ROUTE A PIECE OF HEATER HOSE FROM THE INTAKE MANIFOLD, TO THE FIREWALL AND ATTACH IT TO THE HEATER LINE FROM EVAPORATOR AS SHOWN IN FIGURES 4a, BELOW. NOTE: INSTALL HEATER CONTROL VALVE IN-LINE WITH INTAKE MANIFOLD (PRESSURE SIDE) HEATER HOSE, SECURE USING HOSE CLAMPS AS SHOWN IN FIGURE 4b, BELOW. NOTE PROPER FLOW DIRECTION. INSTALL FIREWALL COVER CAP USING (3) #0 x ½ SHEETMETAL SCREWS. SEE FIGURES 4a & 4b, BELOW. ROUTE VACUUM LINES THROUGH THE GROMMET WITH THE #6 EVAPORATOR HARDLINE AS SHOWN 4b, BELOW FIREWALL COVER CAP ENGINE & HEATER VALVE VACUUM FIGURE 4a (3) #0 SHEETMETAL SCREWS 5/8 HEATER HOSE TO INTAKE MAINIFOLD 5/8 HEATER HOSE TO WATER PUMP #0 O-RING #0 AC HOSE #6 O-RING HEATER VALVE ENGINE VACUUM #6 HARDLINE HEATER VALVE VACUUM HOSE CLAMP HOSE CLAMP FIGURE 4b 5/8 HEATER HOSE TO INTAKE MAINIFOLD 5/8 HEATER HOSE TO WATER PUMP VCZ-A /22/05, 69 CAMARO w/o FAC. AIR INSTRUCTIONS PG 5 OF 20 5

16 969 CAMARO w/o FACTORY AIR FRESH AIR COVER INSTALLATION /4-20 x BOLT w/ WASHER FRESH AIR CAP EVAPORATOR APPLY A /4 BEAD OF SILICONE AROUND THE BACK SIDE OF THE FRESH AIR CAP AS SHOWN IN FIGURE 5. ATTACH FRESH AIR CAP TO FIREWALL USING A /4-20 x " BOLT AND WASHER, SEE FIGURE 5. HOSE ADAPTER INSTALLATION S CLIPS SILICONE BACKSIDE OF FRESH AIR CAP FIGURE 5 ADAPTER ADAPTER FIGURE 6 #6 SCREWS DRIVER SIDE HOSE ADAPTER INSTALLS BY JUST PUSHING IT ONTO THE BACK OF THE OEM LOUVER HOUSING UNTIL THE S CLIPS ARE SECURE PASSENGER SIDE HOSE ADAPTER INSTALLS BY JUST PUSHING OVER THE BACK OF THE OEM LOUVER, SECURE WITH (2) #6 SCREWS SUPPLIED. GLOVE BOX INSTALLATION INSTALL GLOVE BOX PROVIDED, SECURE WITH #6 SCREWS THROUGH OEM HOLES. SEE FIGURE7 BELOW. NEW GLOVE BOX VCZ-A /22/05, 69 CAMARO w/o FAC. AIR INSTRUCTIONS PG 6 OF 20 FIGURE 7

17 969 CAMARO w/o FACTORY AIR CENTER LOUVER TEMPLATE USE TEMPLATE PROVIDED ON PAGE 9 TO CUT CENTER LOUVER HOLE IN DASH. SEE FIGURE8 BELOW. START ON OEM MARK ON BOARD 2 ½ 7 3/4 CUT THIS HOLE WITH TEMPLATE PROVIDED FIGURE 8 FINAL STEPS RE INSTALL ANY PREVIOUSLY REMOVED COMPONENTS (BATTERY BOX, BATTERY, GLOVE BOX DOOR, RADIO AND DASHBOARD). FILL RADIATOR WITH AT LEAST A 50/50 MIXTURE OF APPROVED ANTIFREEZE AND DISTILLED WATER. IT IS THE OWNERS 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. EVACUATE THE SYSTEM AT LEAST 30 MINUTES AND CHARGE ACCORDING TO CAPACITIES ON INSIDE COVER PAGE. CHECK COMPLETE A/C ASSEMBLY FOR PROPER OPERATION. VINTAGE AIR RECOMMENDS THAT ALL A/C SYSTEMS BE SERVICED BY A CERTIFIED AUTOMOTIVE AIR CONDITIONING TECHNICIAN ONLY. SEE INSIDE COVER FOR SERVICE INFORMATION VCZ-A /22/05, 69 CAMARO w/o FAC. AIR INSTRUCTIONS PG 7 OF 20 7

18 969 CAMARO w/o FACTORY AIR CAPILLARY TUBE COLDER CLOCKWISE THERMOSTAT (TYPICAL) ADJUSTABLE KNOB (TYPICAL) CAPILLARY TUBE TO EVAPORATOR COIL WARMER COUNTER CLOCKWISE FIGURE A ADJUSTABLE THERMOSTAT AIR CONDITIONING ADJUSTMENTS: THE AIR CONDITIONER THERMOSTAT CONTROLS COIL TEMPERATURE, IT IS SHIPPED ADJUSTED FULLY COLD (CLOCKWISE), IN THE MAJORITY OF CASES THE A/C WILL OPERATE CORRECTLY AS SHIPPED. TURNING THE KNOB ON THE THERMOSTAT TO THE RIGHT (CLOCKWISE) MAKES THE SYSTEM OPERATE COLDER. IF THE THERMOSTAT IS SET TOO COLD THE EVAPORATOR WILL "ICE UP" - THE EVAPORATOR COIL IS RESTRICTED WITH ICE AND COLD AIR FLOW WILL BE REDUCED. TURNING THE KNOB TO THE LEFT (COUNTER CLOCKWISE) MAKES THE SYSTEM OPERATE WARMER. THE COMPRESSOR CLUTCH WILL CYCLE OFF FREQUENTLY AND THE A/C SYSTEM WILL NOT GET AS COOL AS IT COULD. ADJUSTING A/C THERMOSTAT.) SYMPTOM: THE A/C WORKS WELL AT FIRST THEN QUITS COOLING. THE AIR FLOW FROM THE VENTS IS LOW AND THE COMPRESSOR CYCLES INFREQUENTLY. SOLUTION: THE THERMOSTAT IS SET TOO COLD AND THE EVAPORATOR IS "ICING UP" AND RESTRICTING AIR FLOW. ALLOW THE ICE TO MELT AND SET THE THERMOSTAT WARMER (COUNTER CLOCKWISE) 0% OF A TURN EACH ADJUSTMENT UNTIL THE SYMPTOMS DIMINISH. 2.) SYMPTOM: A/C NEVER GETS COLD AND THE COMPRESSOR CLUTCH CYCLES FREQUENTLY. SOLUTION: THE THERMOSTAT IS SET TOO WARM. SET THE THERMOSTAT COLDER (CLOCKWISE) 0% OF A TURN EACH ADJUSTMENT UNTIL THE COMPRESSOR CLUTCH CYCLES INFREQUENTLY. AVOID SETTING THE THERMOSTAT TOO COLD. 8 3.) SYMPTOM: THE A/C NEVER GETS COLD, SOMETIMES EVEN BLOWS HOT, AND THE A/C COMPRESSOR CLUTCH INFREQUENTLY CYCLES OFF. SOLUTION: THE HEATER MAY BE ON AT ALL TIMES. CAREFULLY FEEL AROUND THE HEATER HOSES AT THE FIREWALL. THEY SHOULD BE COLD WHEN THE A/C IS ON. IF THE HOSES ARE HOT... A) - THE HEATER CONTROL VALVE MAY BE INSTALLED BACKWARDS. CHECK THE FLOW DIRECTION ARROW ON THE VALVE AGAINST THE ILLUSTRATION IN YOUR INSTALLATION INSTRUCTIONS. B) - CABLE OPERATED: THE VALVE MAY BE MISADJUSTED. C) - HEATER CONTROL VALVE IS INSTALLED IN WRONG HEATER HOSE VCZ-A /22/05, 69 CAMARO w/o FAC. AIR INSTRUCTIONS PG 8 OF 20

19 969 CAMARO w/o FACTORY AIR WIRING DIAGRAM 969 CAMARO w/o FACTORY AIR WHITE VENT CENTER LOUVER TEMPLATE ENGINE VACUUM TUBING (BLACK) HEATER VALVE VACUUM TUBING (RED) PLACE ALONG EDGE OF DASH BOARD START ON OEM MARK ON DASH BOARD CENTER LOUVER TEMPLATE 2 ½ 7 3/ VCZ-A /22/05, 69 CAMARO w/o FAC. AIR INSTRUCTIONS PG 9 OF 20 9

20 969 CAMARO w/o FACTORY AIR CAMARO w/o FACTORY AIR EVAPORATOR KIT PACKING LIST No. QTY. PART No. DESCRIPTION 7669-VCE FCN EVAPORATOR SUBCASE 969 CAMARO w/o AC ACCESSORY KIT CHECKED BY: PACKED BY: DATE: EVAPORATOR KIT VCZ-A EVAPORATOR 7669-VCE 2 ACCESSORY KIT FCN VCZ-A /22/05, 69 CAMARO w/o FAC. AIR INSTRUCTIONS PG 20 OF 20

21 969 CAMARO w/o FACTORY AIR No. QTY. PART No. DESCRIPTION VUE VUE PCA VCI 3337-VUI 4988-VCI FCA VCI VCA VCA FCA VCZ FCA VUE FCA FCR VCH OFR 3335-VUI 969 CAMARO w/o FACTORY AIR ACCESSORY KIT ACCESSORY KIT PACKING LIST FCN 2" DUCT HOSE 2 /2" DUCT HOSE FRESH AIR CAP ASM DRIVER SIDE VENT ADAPTER GROMMET LARGE PASSENGER SIDE VENT ADAPTER 69 CAMARO W/O AC WIRING KIT GLOVE BOX 69 CAMARO PASS SIDE FRESH AIR COVER ASM 69 CAMARO DR SIDE FRESH AIR COVER ASM 69 CAMARO W/O AC INSTALLATION KIT DEFROST DUCT ASM 69 CAMARO W/O A/C CENTER LOUVER ASM S-CLIPS FIREWALL COVER ASM FIREWALL COVER CAP CABLE KIT 3/8 x ½ FOAM 3/8 GROMMET CHECKED BY: PACKED BY: DATE: FCN REV A /0/06, 69 CAMARO w/o FAC. AIR ACCESSORY KIT PG OF

22 969 CAMARO w/o FACTORY AIR 969 CAMARO w/o FACTORY AIR LOUVER ASM. KIT CENTER LOUVER ASM. KIT PACKING LIST FCA No. QTY. PART No. DESCRIPTION VUL VCE VUE 8234-VUB 69 CAMARO CENTER LOUVER 69 CAMARO CENTER LOUVER w/ (2) 2 HOSE ADPTR S CLIPS #4 x 3/4 COUNTER-SUNK SCREW CHECKED BY: PACKED BY: DATE: FCA REV A 2/6/05, 69 CAMARO w/o FAC. AIR CENTER LOUVER ASSEMBLY KIT PG OF

23 969 CAMARO w/o FACTORY AIR No. QTY. PART No. DESCRIPTION CAMARO w/o FACTORY AIR WIRING KIT PACKING LIST VUW 2343-VUW 2349-VUW 4975-VUI BUDDY CLIP WIRE HARNESS 30 BLACK JUMPER WIRE SINGLE WIRE DIODE WIRING KIT FCA CHECKED BY: PACKED BY: DATE: 2 WIRE HARNESS 4 SINGLE WIRE DIODE 3 JUMPER WIRE FCA 6/29/04, 69 CAMARO w/o FAC. AIR WIRING KIT PG OF

24 969 CAMARO w/o FACTORY AIR 969 CAMARO w/o FACTORY AIR INSTALLATION KIT INSTALLATION KIT PACKING LIST FCA No. QTY. PART No. DESCRIPTION " VUD 8290-VUB 4603-VUH 8233-VUB 8235-VUB 825-VUB VUP VCB VCB 8247-VUB FCL VUF ½" DRAIN HOSE ¼" x " COARSE BOLT HEATER CONTROL VALVE #6 x 3/8" PHILLIPS SCREW #8 x /2 PHILLIPS SCREW ¼" x ¾" FLAT WASHER PRESS TAPE FRONT EVAP. BRACKET BLOWER HOUSING BRACKET #0 x ½ SHEETMETAL SCREW 69 CAMARO w/o AC #6 EVAP HARDLINE #6 O-RING CHECKED BY: PACKED BY: DATE: FCA REV A 2/7/05, 69 CAMARO w/o FAC. AIR INSTALLATION KIT PG OF

25 969 CAMARO w/o FACTORY AIR 969 CAMARO w/o FACTORY AIR INSTALLATION KIT INSTALLATION KIT PACKING LIST VCE No. QTY. PART No. DESCRIPTION " 3050-VUD 8290-VUB 4603-VUH 8233-VUB 8235-VUB 825-VUB VUP VCB VCB ½" DRAIN HOSE ¼" x " COARSE BOLT HEATER CONTROL VALVE #6 x 3/8" PHILLIPS SCREW #8 x /2 PHILLIPS SCREW ¼" x ¾" FLAT WASHER PRESS TAPE FRONT EVAP. BRACKET BLOWER HOUSING BRACKET CHECKED BY: PACKED BY: DATE: VCE 6/29/04, 69 CAMARO w/o FAC. AIR INSTALLATION KIT PG OF