an ISO 9001:2015 Registered Company

1961-62 Chevrolet Impala without Factory Air

Evaporator Kit(561062)

903062 REV H 08/12/19, PG 1 OF 26

18865 Goll St. San Antonio, TX 78266 Phone: 800-862-6658

Sales: sales@vintageair.comTech Support: tech@vintageair.com

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903062 REV H 08/12/19, PG 2 OF 26

Cover..................................................................................................................................Table of Contents.................................................................................................................Packing List/Parts Disclaimer..................................................................................................Information Page..................................................................................................................Wiring Notice.......................................................................................................................Engine Compartment Disassembly, Condenser Assembly and Installation, Compressor and Brackets, Pulleys..................................................................................................................Passenger Compartment Disassembly..................................................................................... Defrost Duct Installation.......................................................................................................Speaker Mounting, Evaporator Installation............................................................................... Fresh Air Cap Installation, Firewall Cover Installation.............................................................. Evaporator Installation (Cont.)............................................................................................. Drain Hose Installation, Driver Side Under Dash Louver Mounting Holes, Passenger Side Under Dash Louver Mounting Holes ............................................................................................... Driver Side Under Dash Louver Installation, Center/Passenger Side Under Dash Louver Installation........................................................................................................................Lubricating O-rings, A/C Hose Installation..............................................................................Heater Hose & Heater Control Valve Installation.....................................................................A/C & Heater Hose Routing..................................................................................................Final Steps........................................................................................................................ Control Panel & Duct Hose Routing....................................................................................... Evaporator Hardline Installation...........................................................................................Wiring Diagram..................................................................................................................Gen IV Wiring Connection Instruction...................................................................................Operation of Controls..........................................................................................................Troubleshooting Guide.........................................................................................................Troubleshooting Guide (Cont.)..............................................................................................Templates: Driver Side Under Dash Louver Bezel & Defrost Duct Mounting.................................Packing List.......................................................................................................................

1 2 3 4 5

6 7 8 91011

12

1314 151617181920212223242526

Table of Contents

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903062 REV H 08/12/19, PG 3 OF 26

Packing List: Evaporator Kit (561062)

No. 1.2.

Qty.11

Part No.744044-VUE784061

DescriptionGen IV Evaporator Sub CaseAccessory 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.

NOTE: Images may not depict actual parts and quantities. Refer to packing list for actual parts and quantities.

1

2

Accessory Kit784061

Gen IV Evaporator Sub Case

744044-VUE

4

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903062 REV H 08/12/19, PG 4 OF 26

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. (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:

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.

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903062 REV H 08/12/19, PG 5 OF 26

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.

•

•

•

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903062 REV H 08/12/19, PG 6 OF 26

Engine Compartment Disassembly

1.2.3.4.5.

Disconnect battery.Remove battery (retain).Drain radiator.Remove passenger side hood hinge (retain) (See Figure 1a, below).Remove OEM blower assembly (discard) (See Figure 1, below).

NOTE: Before starting the installation, check the function of the vehicle (horn, lights, etc.) for proper operation, and study the instructions, illustrations, & diagrams.Perform the Following:

Figure 1a

Figure 1

Condenser Assembly and Installation1.2.

Refer to separate instructions included with the condenser kit to install the condenser.Binary switch installation (Refer to condenser instructions).

Compressor and Brackets1. Refer to separate instructions included with the bracket kit to install the compressor bracket.

Pulleys1. In most instances, the belt lengths will remain the same.

OEMHeater/Blower

Assembly

Hood Hinge

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903062 REV H 08/12/19, PG 7 OF 26

Passenger Compartment Disassembly

1.2.3.4.5.6.

Remove the OEM control panel assembly (retain) (See Figure 2, below).Remove the OEM heater assembly (discard) (See Figure 2, below).Remove the glove box (discard) (See Figure 2, below).Remove the radio and speaker (retain) (See Figure 2, below).Remove the OEM defrost duct assembly (discard) (See Figures 2 & 3, below).Remove the (3) spot welds on the defrost duct with a chisel or die grinder (See Figure 3, below).

Perform the Following:

Figure 2

Figure 3

Speaker

Radio

Glove Box

OEMControl Panel

OEMDefrost Duct

OEM HeaterPlenum

Dash Support Dash

Support

Use a Chisel orDie Grinder to

Break Spot Welds DefrostDuct

InnerCowl

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903062 REV H 08/12/19, PG 8 OF 26

Defrost Duct Installation1.2.3.4.5.6.

7.

Cut out the defrost duct mounting template on Page 25.Place the template onto the inner cowl. Once aligned, tape the template into place (See Figure 4, below).Using a center punch or scribe, mark the (2) mounting holes on the inner cowl (See Figure 4, below).Once the holes are marked, remove the template and drill (2) 1/8” holes into the inner cowl.Install a J-nut onto the end of the speaker bracket as shown in Figure 4a, below.Place the defrost duct under the dash, and align it with the OEM defrost opening in the dash and the mounting holes in the inner cowl.Once the defrost duct and speaker bracket are aligned, secure the defrost duct and the speaker bracket to the inner cowl using (2) #10 x 1/2” sheet metal screws (See Figure 4a, below).

Figure 4a

Figure 4

Tape

MarkMounting

Holes

Inner CowlTemplate

Dash SupportBrace

J-nut

DefrostDuct

(2) #10 x 1/2” Sheet Metal

Screws

View Shown Through GloveBox Opening in Dash.

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903062 REV H 08/12/19, PG 9 OF 26

Evaporator Installation

Speaker Mounting

1.

2.

1.

On a workbench, install the evaporator front and rear mounting brackets onto the evaporator using (6) 1/4-20 x 1/2” hex bolts, and tighten as shown in Figures 6 & 6a, below.Install the hardlines with properly lubricated O-rings (See Figure 15, Page 14, and Figure 21, Page 19).

Using a #10 x 1/2” sheet metal screw, secure the speaker bracket to the bracket on the defrost duct (See Figure 5, below).

Figure 6

Figure 6a

Figure 5SpeakerBracket

#10 x 1/2”Sheet Metal

Screw

1/4-20 x 1/2”Hex Bolt

1/4-20 x 1/2”Hex Bolt

Front EvaporatorBracket 643062

Driver Side RearEvaporator Bracket

643064

Passenger Side RearEvaporator Bracket

643063

(2) 1/4-20 x 1/2”Hex Bolts

(2) 1/4-20 x 1/2”Hex Bolts

1/4-20 x 1 ½”Coarse Bolt

with Flat Washer

1/4” Push NutBolt Retainer

3/4” NylonSpacer

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903062 REV H 08/12/19, PG 10 OF 26

Fresh Air Cap Installation

Firewall Cover Installation

1.2.

1.

Apply a 1/4” bead of silicone around the mating surface of the fresh air cap as shown in Figure 7, below.Attach the fresh air cap to the firewall using a 1/4-20 x 1” bolt and washer (See Figure 7, below).

Apply a 1/4” bead of silicone around the mating surface of the firewall cover, and secure it to the firewall using (5) 1/4-20 x 1/2” bolts, (10) flat washers and (5) nuts as shown in Figure 8, below.

Fresh AirCap

1/4-20 x 1”Bolt and Washer

Silicone

Silicone

Mating Surfaceof Fresh Air Cap

Mating Surfaceof Firewall

Cover

Figure 7

Figure 8

Passenger Compartment View

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903062 REV H 08/12/19, PG 11 OF 26

Figure 9a

Figure 9

Evaporator Installation (Cont.)

1.2.

3.

4.

5.

Remove the #6 grommet (See Figure 9, below).Lift the evaporator unit up under the dashboard, and secure loosely to the firewall from the enginecompartment side using (2) 1/4-20 nuts and washers (See Figure 9, below).Using a 1/4-20 x 1 ¼” pan head screw with a 1/4” flat washer, secure the front evaporator mounting bracket to the dash (See Figures 9 & 9a, below).Verify that the evaporator unit is level and square to the dash, and then tighten all mounting bolts. NOTE: Tighten the bolt on the firewall first. Then tighten the front mounting bracket screws.Once the evaporator is installed, install a #6 grommet over the #6 hardline from the engine compartment.

1/4-20 Nut and Flat Washer

1/4-20 Nut and Flat Washer

#6 Grommet33145-VUI

Rear Evaporator

Bracket

Rear Evaporator

Bracket

Bracket

Dash

1/4-20Well Nut

1/4” Flat washer

1/4-20 x 1 ¼”Pan Head

Screw

Evaporator

NOTE: Before the installation of the evaporator unit, there may be firewall insulation retainers located on the firewall that will interfere with the installation of the evaporator brackets (See Figure 7, below).

Remove Firewall Insulation Retainer If Equipped

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903062 REV H 08/12/19, PG 12 OF 26

Figure 10

Figure 11

Figure 12

Drain Hose Installation

Driver Side Under Dash Louver Mounting Holes

Passenger Side Under Dash Louver Mounting Holes

1.2.

3.

1.

2.

1.

Locate the evaporator drain on the bottom of the evaporator case.In line with the drain, lightly make a mark on firewall. Then, measure 1” down and drill a 5/8” hole through the firewall (See Figure 10, below).Install the drain hose onto the evaporator drain on the bottom of the unit, and route it through the firewall.

Cut out the template provided on Page 25. Place the template under the dash on the driver side by aligning the left side of the template against the edge of the dash as shown in Figure 11, below. Make sure the OEM holes line up with the holes on the template as shown in Figure 11, below.Once the template is aligned correctly and taped into place, mark the mounting holes on the dash. Once the holes are marked in the correct location, drill (2) 3/16” holes into the dash for the driver side louver bezel (See Figure 11, below).

Using the (2) OEM dimples under the dash, drill (2) 3/16” holes in the dash as shown in Figure 12, below.

1” DrainHose

Drill (2) 3/16”Holes

Drill (2) 3/16”Holes

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903062 REV H 08/12/19, PG 13 OF 26

Driver Side Under Dash Louver Installation

Center/Passenger Side Under Dash Louver Installation

1.2.

3.

1.2.

3.

Place the louver bezel under the dash, and align it with the 3/16” holes in the dash.Secure the louver bezel under the dash using (2) 10-24 x 3/8” pan head screws and (2) 10-24 nuts with star washers (See Figure 13, below).Install the louver into the under dash bezel as shown in Figure 13a, below.

Place the louver bezel under the dash, and align it with the OEM holes in the dash.Secure the louver bezel under the dash using (3) 10-24 x 3/8” pan head screws and (3) 10-24 nuts with star washers (See Figure 14, below).Install the louvers into the under dash bezel as shown in Figure 14a, below.

Figure 14

Figure 13Figure 13a

Figure 14a

(2) 10-24 x 3/8”Pan Head Screwsand (2) Nuts with

Star Washers

Louver

(3) Louvers

Final Assembly

(3) 10-24 x 3/8”Pan Head Screwsand (3) Nuts with

Star Washers

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903062 REV H 08/12/19, PG 14 OF 26

A/C Hose Installation

1.

2.

3.

4.

Locate the #8 compressor A/C hose. Lubricate (2) #8 O-rings (See Figure 15, above) and connect the 135° female fitting with 134a service port to the #8 discharge port on the compressor. Then route the straight female fitting to the #8 condenser hardline coming through the core support (See Figure 17, Page 16). Tighten each fitting connection as shown in Figure 15, above.Locate the #10 compressor A/C hose. Lubricate (2) #10 O-rings (See Figure 15, above) and connect the #10 135° female fitting with 134a service port to the #10 suction port on the compressor. Then route the 45° female fitting to the #10 evaporator hardline coming through the firewall (See Figure 17, Page 16). Tighten each fitting connection as shown in Figure 15, above. NOTE: Wrap the #10 fitting connections with press tape (See Figure 16, Page 15).Locate the #6 evaporator/core hardline. Lubricate (2) #6 O-rings (See Figure 15, above) and connect the hardline to the #6 hardline coming through the core support from the drier. Then attach the other end of the hardline with lubricated O-ring to the #6 evaporator hardline coming through the firewall (See Figure 17, Page 16). Tighten each fitting connection as shown in Figure 15, above.Use a #2 and a #10 Adel clamp to secure the #6 evaporator/core hardline and the 5/8” heater hose to the inner fenderwell as shown in Figure 17, Page 16. Secure the Adel clamps to the inner fender using (2) 10-32 x 1/2” pan head screws with nuts.

Standard Hose Kit:

1. Refer to separate instructions included with modified hose kit.Modified Hose Kit:

Figure ##

O-ring Installs Over Male Insert to Swaged Lip

O-ring#6 O-ring

#8 O-ring #10 O-ring

O-ring

Supplied Oil for O-rings

Male Insert

Female Nut

Hold With This Wrench

Twist With This Wrench

Lubricating O-rings For a proper seal of fittings: Install supplied O-rings as shown, and lubricate with supplied oil.

NOTE: Standard torque specifications:#6: 11 to 13 ft-lb.#8: 15 to 20 ft-lb.

#10: 21 to 27 ft-lb.

Figure 15

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903062 REV H 08/12/19, PG 15 OF 26

Heater Hose & Heater Control Valve Installation

1.

2.

Route the heater hose from the water pump to the heater line coming through the firewall as shown in Figure 16, below. Secure using hose clamps.Route the heater hose from the intake to the heater line coming through the firewall as shown in Figure 16, below. NOTE: Install the heater control valve in line with the intake manifold (pressure side) heater hose, and secure using hose clamps. Also note proper flow direction.

NOTE: Vintage Air systems use 5/8” heater connections. On engines equipped with 3/4” hose nipples, these will need to be removed and replaced with 5/8” nipples (not supplied). For water pumps with a cast-in 3/4” heater outlet, a 3/4” x 5/8” reducer fitting (not supplied) will need to be installed in the heater hose.

Figure 16

ECUModule

Press Tape

Press Tape

#10 Suction Line (Insulated)

091671

ExpansionValve

#6 Hardline091078

5/8” Heater Line(Intake)091661

5/8” Heater Line(Water Pump)

091661

#10 O-ring

#6 O-ring

#10 SuctionHose

096059

#6 Hardline091061

HeaterHose From

Intake

To Water Pump

Heater ControlValve

From Heater Control Valve

NOTE: Flow Direction FollowsMolded Arrow on Valve.

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16 903062 REV H 08/12/19, PG 16 OF 26

A/C & Heater Hose Routing

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17

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903062 REV H 08/12/19, PG 17 OF 26

Figure 18 Figure 19

Final Steps1.2.

3.4.

5.

6.7.8.

9.10.11.

12.13.

Install duct hoses as shown in Figure 20, Page 18.Route A/C wires (12 volt/grounds/binary switch/heater control valve) through 3/8” grommet as shown in Figure 19, below).Install control panel assembly. Refer to control panel instructions.Plug the wiring harnesses into the ECU module on the sub case as shown in Figure 20, Page 18. Wire according to wiring diagrams on Pages 20 & 21.Install supplied glove box, and secure using (3) OEM screws through the OEM holes as shown in Figure 18, below.Reinstall glove box door.Reinstall all previously removed items.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 licensed automotive A/C technician.Evacuate the system for a minimum of 45 minutes prior to charging, and perform a leak check prior to servicing.Charge the system to the capacities stated on Page 4 of this instruction manual.See Operation of Controls procedures on Page 22.

(3) OEMScrews

Grommet33144-VUI

18

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903062 REV H 08/12/19, PG 18 OF 26

Figure 20

Control Panel & Duct Hose Routing

Driver SideCenter Louver

2 ½” x 12”

Driver SideCenter Louver

Driver SideLouver

Driver SideLouver

2 ½” x 36”

Passenger SideCenter Louver

2 ½” x 12”

Passenger SideCenter Louver

Passenger SideLouver

2 ½” x 38”

Passenger SideLouver

Passenger SideDefrost Duct

2” x 15”

Driver SideDefrost Duct

2” x 15”

Plug FromWiring

Harness232600-VUA

Plug FromControlWiring

Harness232002-VUA

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19 903062 REV H 08/12/19, PG 19 OF 26

Fig

ure

21

Evap

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ECU

Mod

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#10

O-r

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3385

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#10

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#6

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0916

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20

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903062 REV H 08/12/19, PG 20 OF 26

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 E, 10/6/2017

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

21

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903062 REV H 08/12/19, PG 21 OF 26

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.

When Using A Vintage Air SuppliedControl Panel, Connect The Tan WireFrom The Gen IV Evaporator WiringHarness To The Factory Dash Lights ToEnable Panel Backlighting.

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.

22

www.vintageair.com

903062 REV H 08/12/19, PG 22 OF 26

Operation of Controls

Adjust to desiredspeed.

Blower SpeedAdjust to desired

speed.

Adjust to desiredmode position (DASH position recommended).

Adjust to desiredspeed.

Adjust to DEFROST position for maximum defrost, or between FLOOR and DEFROST positions for a bi-level

blend (Compressor is automatically engaged).

Adjust to desired temperature.

For A/C operation, adjust tocoldest position to engage

compressor (Adjust between HOT and COLD to reachdesired temperature).

A/C Operation

Heat Operation

Defrost/De-fog Operation

On Gen IV systems with three lever/knob controls, the temperature control toggles between heat and A/C operations. To activate A/C, move the temperature lever/knob all the way to cold and then back it off to the desired vent temperature. For heat operation, move the temperature lever/knob all the way to hot and then adjust to the desired vent temperature. The blower will momentarily change speed, each time you toggle between operations, to indicate the change. NOTE: For proper control panel function, refer to control panel instructions for calibration procedure.

Blower Speed

Blower Speed

This lever/knob controlsblower speed, from

OFF to HI.

This lever/knob controls the mode positions,from DASH to FLOORto DEFROST, with a blend in between.

This lever/knob controlsthe temperature,

from HOT to COLD.

Blower Speed

Mode Control

Temperature Control

Blower Speed

TemperatureControl

Temperature Control

Temperature Control

Temperature Control

Mode Control

Mode Control

Mode Control

For maximum heating, adjust to hottest position (Adjust between HOT and COLD to reach desired temperature).Adjust to desired

mode position(FLOOR position recommended).

ModeControl

NOTE: Original blower switch will not be used.

ww

w.v

inta

gea

ir.c

om

23 903062 REV H 08/12/19, PG 23 OF 26

Sym

pto

m

Con

dit

ion

Ch

ecks

A

ctio

ns

Not

es

Blo

wer

sta

ys o

n hi

gh s

peed

whe

n ig

nitio

n is

on.

1a.

No

othe

r fu

nctio

ns w

ork.

Che

ck f

or d

amag

ed p

ins

or

wires

in c

ontr

ol h

ead

plug

.Ve

rify

tha

t al

l pin

s ar

e in

sert

ed in

to p

lug.

Ens

ure

that

no

pins

are

ben

t or

dam

aged

in E

CU

.Che

ck f

or d

amag

ed g

roun

d w

ire

(whi

te)

in c

ontr

ol h

ead

harn

ess.

Verify

con

tinui

ty t

o ch

assi

s gr

ound

with

whi

te c

ontr

ol

head

wire

at v

ario

us p

oint

s.

Loss

of gr

ound

on

this

wire

rend

ers

cont

rol h

ead

inop

erab

le.

All

othe

r fu

nctio

ns w

ork.

Che

ck f

or d

amag

ed b

low

er

switc

h or

pot

entio

met

er a

nd

asso

ciat

ed w

irin

g.

Blo

wer

sta

ys o

n hi

gh s

peed

whe

n ig

nitio

n is

on

or o

ff.

Unp

lug

3-w

ire

BSC c

ontr

ol

conn

ecto

r fr

om E

CU

. If

blo

wer

sh

uts

off,

ECU

is e

ither

im

prop

erly

wired

or

dam

aged

.

Be

sure

the

sm

all,

20 G

A w

hite

gro

und

wire

is c

onne

cted

to

the

bat

tery

gro

und

post

. If

it is

, re

plac

e th

e EC

U.

Unp

lug

3-w

ire

BSC c

ontr

ol

conn

ecto

r fr

om E

CU

. If

blo

wer

st

ays

runn

ing,

BSC is

eith

er

impr

oper

ly w

ired

or

dam

aged

.

Che

ck t

o en

sure

tha

t no

BSC w

irin

g is

dam

aged

or

shor

ted

to v

ehic

le g

roun

d. T

he B

SC o

pera

tes

the

blow

er

by g

roun

d si

de p

ulse

wid

th m

odul

atio

n sw

itchi

ng.

The

posi

tive

wire

to t

he b

low

er w

ill a

lway

s be

hot

. If

the

“g

roun

d” s

ide

of t

he b

low

er is

sho

rted

to

chas

sis

grou

nd,

the

blow

er w

ill r

un o

n H

I.

Repl

ace

BSC (

This

will

req

uire

rem

oval

of ev

apor

ator

fr

om v

ehic

le).

No

othe

r pa

rt r

epla

cem

ents

sh

ould

be

nece

ssar

y.

Com

pres

sor

will

no

t tu

rn o

n (A

ll ot

her

func

tions

w

ork)

.

2.

Syst

em is

not

cha

rged

.Sy

stem

mus

t be

cha

rged

for

co

mpr

esso

r to

eng

age.

Cha

rge

syst

em o

r by

pass

pre

ssur

e sw

itch.

Dan

ger

: N

ever

byp

ass

safe

ty s

wit

ch w

ith

en

gin

e ru

nn

ing

. S

erio

us

inju

ry c

an r

esu

lt.

Syst

em is

cha

rged

.

1b

.

Trou

ble

shoo

tin

g G

uid

e

Che

ck f

or f

aulty

A/C

po

tent

iom

eter

or

asso

ciat

ed

wirin

g (N

ot a

pplic

able

to

3-po

t co

ntro

ls).

Che

ck f

or d

isco

nnec

ted

or

faul

ty t

herm

isto

r.

Che

ck c

ontin

uity

to

grou

nd o

n w

hite

con

trol

hea

d w

ire.

Che

ck f

or 5

V o

n re

d co

ntro

l hea

d w

ire.

Che

ck 2

-pin

con

nect

or a

t EC

U h

ousi

ng.

To c

heck

for

pro

per

pot

func

tion,

che

ck v

olta

ge a

t w

hite

/blu

e w

ire.

Vol

tage

sh

ould

be

betw

een

0V a

nd

5V,

and

will

var

y w

ith p

ot

leve

r po

sitio

n.

Dis

conn

ecte

d or

fau

lty

ther

mis

tor

will

cau

se

com

pres

sor

to b

e di

sabl

ed.

Red

wire

at A

/C p

ot s

houl

d ha

ve a

ppro

xim

atel

y 5V

w

ith ig

nitio

n on

. W

hite

w

ire

will

hav

e co

ntin

uity

to

chas

sis

grou

nd.

Whi

te/

Blu

e w

ire

shou

ld v

ary

betw

een

0V a

nd 5

V w

hen

leve

r is

mov

ed u

p or

dow

n.

3. Com

pres

sor

will

no

t tu

rn o

ff

(All

othe

r fu

nctio

ns

wor

k).

Che

ck f

or f

aulty

A/C

po

tent

iom

eter

or

asso

ciat

ed

wirin

g.

Che

ck f

or f

aulty

A/C

rel

ay.

Repa

ir o

r re

plac

e po

t/co

ntro

l wirin

g.

Repl

ace

rela

y.

See

blo

wer

sw

itch

chec

k pr

oced

ure.

ww

w.v

inta

gea

ir.c

om

24 903062 REV H 08/12/19, PG 24 OF 26

Sym

pto

m

Con

dit

ion

Ch

ecks

A

ctio

ns

Not

es

Syst

em w

ill n

ot

turn

on,

or

runs

in

term

itten

tly.

4.

Wor

ks w

hen

engi

ne is

not

runn

ing;

shu

ts o

ff w

hen

engi

ne is

sta

rted

(T

ypic

ally

ear

ly G

en I

V,

but

poss

ible

on

all

vers

ions

).

Noi

se in

terf

eren

ce f

rom

eith

er

igni

tion

or a

ltern

ator

.

Inst

all c

apac

itors

on

igni

tion

coil

and

alte

rnat

or.

Ensu

re

good

gro

und

at a

ll po

ints

. Re

loca

te c

oil a

nd a

ssoc

iate

d w

irin

g aw

ay f

rom

ECU

and

ECU

wirin

g. C

heck

for

bur

ned

or lo

ose

plug

wires

.

Verify

con

nect

ions

on

pow

er

lead

, ig

nitio

n le

ad,

and

both

whi

te g

roun

d w

ires

.

Verify

pro

per

met

er f

unct

ion

by c

heck

ing

the

cond

ition

of

a kn

own

good

bat

tery

.

Igni

tion

nois

e (r

adia

ted

orco

nduc

ted)

will

cau

se t

he

syst

em t

o sh

ut d

own

due

tohi

gh v

olta

ge s

pike

s. I

f th

isis

sus

pect

ed,

chec

k w

ith a

qu

ality

osc

illos

cope

. Spi

kes

grea

ter

than

16V

will

shu

t do

wn

the

ECU

. In

stal

l a

radi

o ca

paci

tor

at t

he

posi

tive

post

of th

e ig

nitio

nco

il (S

ee r

adio

cap

acito

r in

stal

latio

n bu

lletin

). A

fa

ulty

alte

rnat

or o

r w

orn

out

batt

ery

can

also

res

ult

in t

his

cond

ition

.

Will

not

tur

n on

und

er

any

cond

ition

s.Ve

rify

bat

tery

vol

tage

is

grea

ter

than

10

volts

and

less

than

16.

Loss

of m

ode

door

fu

nctio

n.

No

mod

e ch

ange

at

all.

Che

ck f

or d

amag

ed m

ode

switc

h or

pot

entio

met

er a

nd

asso

ciat

ed w

irin

g.

Part

ial f

unct

ion

of m

ode

door

s.

Typi

cally

cau

sed

by

evap

orat

or h

ousi

ng

inst

alle

d in

a b

ind

in t

he

vehi

cle.

Be

sure

all

mou

ntin

g lo

catio

ns li

ne u

p an

d do

n’t

have

to

be for

ced

into

pos

ition

.

Blo

wer

tur

ns o

n an

d of

f ra

pidl

y.

6.

Bat

tery

vol

tage

is a

t le

ast

12V.

Che

ck f

or a

t le

ast

12V a

t ci

rcui

t br

eake

r.En

sure

all

syst

em g

roun

ds a

nd p

ower

con

nect

ions

are

cl

ean

and

tight

.

Bat

tery

vol

tage

is le

ss

than

12V

.

5.

Trou

ble

shoo

tin

g G

uid

e (C

ont.

)

Che

ck f

or f

aulty

bat

tery

or

alte

rnat

or.

Cha

rge

batt

ery.

Syst

em s

huts

off b

low

er a

t 10

V. P

oor

conn

ectio

ns o

r w

eak

batt

ery

can

caus

e sh

utdo

wn

at u

p to

11V

.

7. Whe

n ig

nitio

n is

tu

rned

on,

blo

wer

m

omen

tarily

co

mes

on,

the

n sh

uts

off.

This

oc

curs

with

the

bl

ower

sw

itch

in

the

OFF

pos

ition

.

This

is a

n in

dica

tor

that

the

sy

stem

has

bee

n re

set.

Be

sure

the

red

pow

er w

ire

is o

nth

e ba

tter

y po

st,

and

not

on a

sw

itche

d so

urce

. Als

o, if

the

sy

stem

is p

ulle

d be

low

7V f

orev

en a

spl

it se

cond

, th

e sy

stem

will

res

et.

Run

red

pow

er w

ire

dire

ctly

to

batt

ery.

Che

ck f

or p

ositi

ve p

ower

at

heat

er v

alve

gre

en w

ire

and

blow

er r

ed w

ire.

Che

ck f

or g

roun

d on

con

trol

hea

d w

hite

w

ire.

Che

ck f

or o

bstr

ucte

d or

bi

ndin

g m

ode

door

s.Che

ck f

or d

amag

ed s

tepp

er

mot

or o

r w

irin

g.

Erra

tic fun

ctio

ns o

fbl

ower

, m

ode,

te

mp,

etc

.

Che

ck f

or d

amag

ed s

witc

h or

po

t an

d as

soci

ated

wirin

g.Re

pair o

r re

plac

e.

8.

25

www.vintageair.com

903062 REV H 08/12/19, PG 25 OF 26

Drill 3/16”

Drill 3/16”

Cut

Alo

ng D

otte

d Li

ne

Cut A

long Dotted Line

Cut

Alo

ng D

otte

d Li

ne

Align This Edge AgainstDash Brace

Dri

ver

Sid

e U

nd

er D

ash

Lou

ver

Tem

pla

te

Defrost D

uct M

oun

ting

Temp

late

3.375”

Templates: Driver Side Under Dash Louver Bezel

& Defrost Duct Mounting

26

www.vintageair.com

903062 REV H 08/12/19, PG 26 OF 26

Packing List: Evaporator Kit (561062)

No. 1.2.

Qty.11

Part No.744004-VUE784061

DescriptionGen IV Evaporator Sub Case Accessory Kit

NOTE: Images may not depict actual parts and quantities. Refer to packing list for actual parts and quantities.

1

2

Gen IV Evaporator Sub Case

744004-VUE

Accessory Kit784061

Checked By:Packed By:

Date: