1961-62 chevrolet impala - vintage air · an iso 9001:2008 registered company 1961-62 chevrolet...

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an ISO 9001:2008 Registered Company 1961-62 Chevrolet Impala with Factory Air Evaporator Kit (564062) 18865 Goll St. San Antonio, TX 78266 Phone: 210-654-7171 Fax: 210-654-3113 www.vintageair.com 904062 REV E 11/04/15, PG 1 OF 26

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an ISO 9001:2008 Registered Company

1961-62 Chevrolet Impala with Factory AirEvaporator Kit

(564062)

18865 Goll St. San Antonio, TX 78266 Phone: 210-654-7171

Fax: 210-654-3113www.vintageair.com

904062 REV E 11/04/15, PG 1 OF 26

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904062 REV E 11/04/15, PG 2 OF 26

Thank you for purchasing this evaporator kit from Vintage Air. When installing these components as part of a complete SureFit™ system, Vintage Air recommends working from front to back on the vehicle, installing the condenser kit, hose kit, and compressor first, followed by the wiring, evaporator, and finally the control panel.

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............................................................................... Evaporator Installation (Cont.)............................................................................................. Firewall Cover Installation................................................................................................... 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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904062 REV E 11/04/15, PG 3 OF 26

Packing List: Evaporator Kit (564062)

No. 1.2.

Qty.11

Part No.744004-VUE784062

DescriptionGen IV Evaporator Sub Case Accessory 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

Gen IV Evaporator Sub Case

744004-VUE

Accessory Kit784062

4

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904062 REV E 11/04/15, 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. (1 lb., 12 oz.) of R134a, charged by weight with a quality charging station or scale. NOTE: Use of the proper type and amount of refrigerant is critical to system operation and performance.Other Systems: Consult manufacturer’s guidelines.

Lubricant Capacities:

Safety Switches

Service Info:Protect Your Investment: Prior to assembly, it is critical that the compressor, evaporator, A/C hoses and fittings, hardlines, condenser and receiver/drier remained capped. Removing caps prior to assembly will allow moisture, insects and debris into the components, possibly leading to reduced performance and/or premature failure of your A/C system. This is especially important with the receiver/drier. Additionally, when caps are removed for assembly, BE CAREFUL! Some components are shipped under pressure with dry nitrogen.Evacuate the System for 35-45 Minutes: Ensure that system components (Drier, compressor, evaporator and condenser) are at a temperature of at least 85° F. On a cool day, the components can be heated with a heat gun or by running the engine with the heater on before evacuating. Leak check and charge to specifications.

Your Vintage Air system is equipped with a binary pressure safety switch. A binary switch disengages the compressor clutch in cases of extreme low pressure conditions (Refrigerant Loss) or excessively high head pressure (406 PSI) to prevent compressor damage or hose rupture. A trinary switch combines Hi/Lo pressure protection with an electric fan operation signal at 254 PSI, and should be substituted for use with electric fans. Compressor safety switches are extremely important since an A/C system relies on refrigerant to circulate lubricant.

Bolts Passing Through Cowl and/or Firewall:To ensure a watertight seal between the passenger compartment and the vehicle exterior, for all bolts passing through the cowl and/or firewall, Vintage Air recommends coating the threads with silicone prior to installation.

Heater Hose (Not Included With This Kit):Heater hose may be purchased from Vintage Air (Part# 31800-VUD) or your local parts retailer. Routing and required length will vary based on installer preference.

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904062 REV E 11/04/15, 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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904062 REV E 11/04/15, PG 6 OF 26

Engine Compartment Disassembly

1.2.3.4.5.6.7.8.9.

Disconnect battery.Remove battery.Drain radiator.Evacuate the A/C system if necessary.Remove the OEM condenser and drier (discard) (See Figure 1, below).Remove the OEM A/C lines from the compressor to the evaporator (discard) (See Figure 1, below).Remove the OEM A/C compressor and compressor bracket (discard) (See Figure 1, below).Remove the OEM blower assembly (discard) (See Figure 1, below).To remove the OEM evaporator assembly, the factory manual indicates doing the following: Remove the right fender and skirt.

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 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

AssemblyOEM

EvaporatorAssembly

OEM A/CLine

OEMCompressor

Fender

OEMDrier

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904062 REV E 11/04/15, PG 7 OF 26

Passenger Compartment Disassembly

1.2.3.4.5.6.7.8.9.

Remove the passenger side OEM A/C duct assembly (See Figure 2, below).Remove the driver side OEM A/C duct and louver (See Figure 2, below).Remove the OEM center louver assembly (See Figure 2, below).Remove the OEM control panel assembly (See Figure 2, below).Remove the OEM heater assembly (See Figure 2, below).Remove the glove box (discard).Remove the radio and speaker (retain) (See Figure 2, below).Remove the OEM defrost duct assembly (discard) (See Figure 3, below).Remove the (3) spot welds on the defrost duct using a chisel or die grinder (See Figure 3, below).

Perform the Following:

Figure 3

Figure 2

Speaker Radio

OEMA/C Duct

Hose

OEMDriver Side

Louver AssemblyGlove Box

OEM Control Panel

OEMCenter Louver

Assembly

OEMPassenger Side

Louver Assembly

OEMHeater Plenum

OEMDefrost Duct

DashSupport

DashSupport

Defrost Duct

InnerCowlUse a Chisel or

Die Grinder toBreak Spot Welds

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904062 REV E 11/04/15, 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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904062 REV E 11/04/15, 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 14, Page 14, and Figure 20, 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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904062 REV E 11/04/15, PG 10 OF 26

Figure 7

Evaporator Installation (Cont.)1.

2.

3.

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 7, 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 7 & 7a, 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.

1/4-20 Nut andFlat Washer

1/4-20 Nut andFlat Washer

Rear Evaporator

Bracket

Rear Evaporator

Bracket

Figure 7a

Bracket

Dash

1/4-20Well Nut

1/4” Flat washer

1/4-20 x 1 ¼”Pan Head

Screw

Evaporator

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904062 REV E 11/04/15, PG 11 OF 26

Figure 8

Firewall Cover Installation1.2.

3.

4.

5.6.7.8.

Apply a 1/4” bead of silicone around the mating surface of the A/C block-off plate as shown in Figure 8, below.Install the A/C block-off plate onto the firewall using (9) #14 x 3/4” sheet metal screws as shown in Figure 8, below.Apply a 1/4” bead of silicone around the mating surface of the heater/blower cover as shown in Figure 8, below.Install the heater/blower cover onto the firewall using (5) #14 x 3/4” sheet metal screws as shown in Figure 8, below.Drill (2) 1/8” holes into the firewall using the heater/blower cover as a template (See Figure 8, below).Use the remaining (2) #14 x 3/4” sheet metal screws to finish securing the heater/blower cover to the firewall.Apply a 1/4” bead of silicone around the mating surface of the firewall cover as shown in Figure 8, below.Pass lines through the firewall cover, and secure the cover to the firewall using (5) 7/16” panel retainers (See Figure 8, below).

Heater/BlowerCover

627063

A/C Block-Off Plate

627064

(5) 7/16”Panel RetainersFirewall

Cover627062

(7) #14 x 3/4”Sheet Metal

Screws

(9) #14 x 3/4”Sheet Metal

Screws

Drill (2) 1/8” Holes

Mating Surfaceof Firewall

Cover

Mating Surfaceof A/C Block-Off

Plate

Retainers

Silicone

Silicone

Silicone

Mating Surfaceof Heater/Blower

Cover

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904062 REV E 11/04/15, PG 12 OF 26

Figure 9

Figure 10

Figure 11

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 9, 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 10, below. Make sure the OEM holes line up with the holes on the template as shown in Figure 10, 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 10, below).

Using the (2) OEM dimples under the dash, drill (2) 3/16” holes in the dash as shown in Figure 11, below.

1” DrainHose

Drill (2) 3/16”Holes

Drill (2) 3/16”Holes

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904062 REV E 11/04/15, PG 13 OF 26

Figure 13b

Figure 13

Figure 13a

Figure 12Figure 12a

Driver Side Under Dash Louver Installation

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) 10-32 x 1/2” pan head screws and (2) 10-32 nuts with star washers (See Figure 12, below).Install the louver into the under dash bezel as shown in Figure 12a, below.

Center/Passenger Side Under Dash Louver Installation

1.2.

3.

4.5.

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 (2) 10-32 x 1/2” pan head screws and (2) 10-32 nuts with star washers (See Figure 13, below).Install the center louver hose adapter onto the OEM center louver housing using (2) #8 x 1/2” pan headscrews and (2) 3/16” washers as shown in Figure 13a, below.Install the OEM center louver housing under the dash using (2) OEM screws as shown in Figure 13b, below. Install the OEM louver into the passenger side under dash bezel as shown in Figure 13b, below.

(2) 10-32 x 1/2”Pan Head Screwsand (2) Nuts with

Star Washers

(2) 10-32 x 1/2”Pan Head Screwsand (2) Nuts with

Star Washers

Driver Side Louver Bezel

Assembly494164

OEMLouver

OEMLouverHousing

OEMLouverHousing

OEMLouver

Passenger SideLouver Assembly (2) 3/16”

Flat Washers

(2) #8 x 1/2”Pan Head Screws

Center LouverHose Adapter

Assembly

(2) OEMScrews

Final Assembly

14

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904062 REV E 11/04/15, PG 14 OF 26

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 14

A/C Hose Installation

1.

2.

3.

4.

Locate the #8 compressor A/C hose. Lubricate (2) #8 O-rings (See Figure 14, 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 16, Page 16). Tighten each fitting connection as shown in Figure 14, above.Locate the #10 compressor A/C hose. Lubricate (2) #10 O-rings (See Figure 14, 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 16, Page 16). Tighten each fitting connection as shown in Figure 14, above. NOTE: Wrap the #10 fitting connections with press tape (See Figure 15, Page 15).Locate the #6 evaporator/core hardline. Lubricate (2) #6 O-rings (See Figure 14, 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 16, Page 16). Tighten each fitting connection as shown in Figure 14, 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 16, 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:

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904062 REV E 11/04/15, PG 15 OF 26

Figure 15

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 15, below. Secure using hose clamps.Route the heater hose from the intake to the heater line coming through the firewall as shown in Figure 15, 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.

ECUModule

Press Tape

#10 Suction Line (Insulated)09151-PCS

ExpansionValve

#6 Hardline091067

5/8” Heater Line(Intake)091065

5/8” Heater Line(Water Pump)

091066#10 O-ring #6 O-ring

#10 SuctionHose

096063

#6 Hardline091062

HeaterHose

From Heater Control Valve

FromIntake

Heater ControlValve

Press Tape

NOTE: Flow Direction FollowsMolded Arrow on Valve.

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16 904062 REV E 11/04/15, PG 16 OF 26

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17

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904062 REV E 11/04/15, PG 17 OF 26

Figure 17 Figure 18

Final Steps1.2.

3.4.

5.

6.7.8.

9.10.11.

12.13.

Install duct hoses as shown in Figure 19, Page 18.Route A/C wires (12 volt/grounds/binary switch/heater control valve) through 3/8” grommet as shown in Figure 18, 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 19, 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 17, 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.

Grommet33144-VUI

FirewallCover

627062

(3) OEMScrews

18

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904062 REV E 11/04/15, PG 18 OF 26

Figure 19

Control Panel & Duct Hose Routing

Driver SideCenter Louver

Driver SideLouver

Passenger SideCenter Louver

Passenger SideLouver

Driver SideLouver

2 ½” x 36”

Driver SideCenter Louver

2 ½” x 12”

Passenger SideCenter Louver

2 ½” x 12”

Passenger SideDefrost Duct

2” x 15”

Plug FromWiring

Harness232001-VUR

Passenger SideLouver

2 ½” x 38”

Plug FromControlWiring

Harness232002-VUA

Driver SideDefrost Duct

2” x 15”

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19 904062 REV E 11/04/15, PG 19 OF 26

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F

20

www.vintageair.com

904062 REV E 11/04/15, 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 D, 5/6/2014

GEN IV ECU

PROGRAM

Wiring Diagram

TEMP

MODE

FAN

A/C(IF USED)

232007-VUR

232002-VUA

** CIRCUITBREAKER30 AMP

*** WIDE OPENTHROTTLESWITCH

(OPTIONAL)

* DASH LAMP(IF USED)

Dash Lamp Is Used Only With Type 232007-VUR Harness.Warning: Always Mount Circuit Breaker As Close to the Battery As Possible. (NOTE: Wire BetweenBattery and Circuit Breaker Is Unprotected and Should Be Carefully Routed to Avoid a ShortCircuit).Wide Open Throttle Switch Contacts Close Only at Full Throttle, Which Disables A/C Compressor.

JF8

BLK

ORA

TAN

VIEWED FROM WIRE SIDE

••

HEATERCONTROL VALVE

21

www.vintageair.com

904062 REV E 11/04/15, 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.

Tan Wire Used Only With Vintage Air Supplied Control Panel With LED Back Light.

Binary: Connect As Shown (Typical Compressor Wiring). Be Sure Compressor Body Is Grounded.

Trinary Switch: Connect According To Trinary Switch Wiring Diagram.

Install With Servo Motor Facing Down, As Shown. Note Flow Direction Arrow Molded Into Valve Body, And Install Accordingly.

White Must Run To (-) Battery. Red May Run To (+) Battery Or Starter. Mount Circuit Breaker As Close to Battery As Possible.

Heater Control Valve:

Binary/Trinary & Compressor:

Circuit Breaker/Battery:

CONTROL WIRING HARNESS

NOTE: YELLOW & ORANGE

COMING FROM HARNESS ARE NOT

USED.

WIRING HARNESS

GRAY WIRE IS USED FOR PROGRAMING CONTROLS

IF APPLICABLE

WIRING HARNESS

Gen IV Wiring Connection Instruction

HEATERCONTROL VALVE

WARNING: ALWAYS MOUNT CIRCUIT BREAKER

AS CLOSE TO THE BATTERY AS POSSIBLE. (NOTE: WIRE BETWEEN BATTERY AND CIRCUIT BREAKER IS UNPROTECTED

AND SHOULD BE CAREFULLY ROUTED TO AVOID A SHORT CIRCUIT).

NOTE: HEATER CONTROL VALVE CONNECTION AND CHASSIS GROUND MAY BE LOCATED ON EITHER SIDE OF THE FIREWALL. ENSURECONNECTOR IS LATCHED

FIRMLY.

22

www.vintageair.com

904062 REV E 11/04/15, 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 904062 REV E 11/04/15, PG 23 OF 26

Sym

pto

m

C

on

dit

ion

C

heck

s

Act

ion

s

N

ote

s

Blo

wer

sta

ys o

n

hig

h s

pee

d w

hen

ig

nitio

n is

on.

1a.

No o

ther

funct

ions

work

.

Chec

k fo

r dam

aged

pin

s or

wires

in c

ontr

ol hea

d p

lug.

Ver

ify

that

all

pin

s ar

e in

sert

ed into

plu

g.

Ensu

re t

hat

no

pin

s ar

e ben

t or

dam

aged

in E

CU

.

Chec

k fo

r dam

aged

gro

und

wire

(white)

in c

ontr

ol hea

d

har

nes

s.

Ver

ify

continuity

to c

has

sis

gro

und w

ith w

hite

contr

ol

hea

d w

ire

at v

ario

us

poin

ts.

Loss

of gro

und o

n t

his

wire

render

s co

ntr

ol hea

d

inoper

able

.

All

oth

er f

unct

ions

work

.Chec

k fo

r dam

aged

blo

wer

sw

itch

or

pote

ntiom

eter

and

asso

ciat

ed w

irin

g.

Blo

wer

sta

ys o

n

hig

h s

pee

d w

hen

ig

nitio

n is

on o

r off.

Unplu

g 3

-wire

BSC c

ontr

ol

connec

tor

from

ECU

. If

blo

wer

sh

uts

off,

ECU

is

eith

er

impro

per

ly w

ired

or

dam

aged

.

Be

sure

the

smal

l, 2

0 G

A w

hite

gro

und w

ire

is c

onnec

ted

to t

he

bat

tery

gro

und p

ost

. If

it

is,

repla

ce t

he

ECU

.

Unplu

g 3

-wire

BSC c

ontr

ol

connec

tor

from

ECU

. If

blo

wer

st

ays

runnin

g,

BSC is

eith

er

impro

per

ly w

ired

or

dam

aged

.

Chec

k to

ensu

re t

hat

no B

SC w

irin

g is

dam

aged

or

short

ed t

o v

ehic

le g

round.

The

BSC o

per

ates

the

blo

wer

by

gro

und s

ide

puls

e w

idth

modula

tion s

witch

ing.

The

posi

tive

wire

to t

he

blo

wer

will

alw

ays

be

hot.

If th

e “g

round”

side

of

the

blo

wer

is

short

ed t

o c

has

sis

gro

und,

the

blo

wer

will

run o

n H

I.

Rep

lace

BSC (

This

will

req

uire

rem

oval

of ev

apora

tor

from

veh

icle

).N

o o

ther

par

t re

pla

cem

ents

sh

ould

be

nec

essa

ry.

Com

pre

ssor

will

not

turn

on

(All

oth

er funct

ions

work

).

2.

Sys

tem

is

not

char

ged

.Sys

tem

must

be

char

ged

for

com

pre

ssor

to e

ngag

e.Char

ge

syst

em o

r byp

ass

pre

ssure

sw

itch

.

Dan

ger:

Never

byp

ass

sa

fety

sw

itch

wit

h

en

gin

e r

un

nin

g.

Seri

ou

s in

jury

can

resu

lt.

Sys

tem

is

char

ged

.

1b

.

Tro

ub

lesh

oo

tin

g G

uid

e

Chec

k fo

r fa

ulty

A/C

pote

ntiom

eter

or

asso

ciat

ed

wirin

g (

Not

applic

able

to 3

-pot

contr

ols

).

Chec

k fo

r dis

connec

ted o

r fa

ulty

ther

mis

tor.

Chec

k co

ntinuity

to g

round o

n w

hite

contr

ol hea

d w

ire.

Chec

k fo

r 5V o

n r

ed c

ontr

ol hea

d w

ire.

Chec

k 2-p

in c

onnec

tor

at E

CU

housi

ng.

To c

hec

k fo

r pro

per

pot

funct

ion,

chec

k vo

ltag

e at

w

hite/

blu

e w

ire.

Voltag

e sh

ould

be

bet

wee

n 0

V a

nd

5V,

and w

ill v

ary

with p

ot

leve

r posi

tion.

Dis

connec

ted o

r fa

ulty

ther

mis

tor

will

cau

se

com

pre

ssor

to b

e dis

able

d.

Red

wire

at A

/C p

ot

should

hav

e ap

pro

xim

atel

y 5V

with ignitio

n o

n.

White

wire

will

hav

e co

ntinuity

to

chas

sis

gro

und.

White/

Blu

e w

ire

should

var

y bet

wee

n 0

V a

nd 5

V w

hen

le

ver

is m

oved

up o

r dow

n.

3. Com

pre

ssor

will

not

turn

off

(A

ll oth

er funct

ions

work

).

Chec

k fo

r fa

ulty

A/C

pote

ntiom

eter

or

asso

ciat

ed

wirin

g.

Chec

k fo

r fa

ulty

A/C

rel

ay.

Rep

air

or

repla

ce p

ot/

contr

ol w

irin

g.

Rep

lace

rel

ay.

See

blo

wer

sw

itch

chec

k pro

cedure

.

ww

w.v

inta

gea

ir.c

om

24 904062 REV E 11/04/15, PG 24 OF 26

Sym

pto

m

C

on

dit

ion

Ch

eck

s

Act

ion

s

N

ote

s

Sys

tem

will

not

turn

on,

or

runs

inte

rmitte

ntly.

4.

Work

s w

hen

engin

e is

not

runnin

g;

shuts

off w

hen

en

gin

e is

sta

rted

(T

ypic

ally

ear

ly G

en I

V,

but

poss

ible

on a

ll ve

rsio

ns)

.

Nois

e in

terf

eren

ce f

rom

either

ig

nitio

n o

r al

tern

ator.

Inst

all ca

pac

itors

on ignitio

n c

oil

and a

lter

nat

or. E

nsu

re

good g

round a

t al

l poin

ts.

Rel

oca

te c

oil

and a

ssoci

ated

w

irin

g a

way

fro

m E

CU

and E

CU

wirin

g.

Chec

k fo

r burn

edor

loose

plu

g w

ires

.

Ver

ify

connec

tions

on p

ow

er

lead

, ig

nitio

n lea

d,

and b

oth

white

gro

und w

ires

.

Ver

ify

pro

per

met

er f

unct

ion b

y ch

ecki

ng t

he

conditio

n o

f a

know

n g

ood b

atte

ry.

Ignitio

n n

ois

e (r

adia

ted o

rco

nduct

ed)

will

cau

se t

he

syst

em t

o s

hut

dow

n d

ue

tohig

h v

oltag

e sp

ikes

. If

this

is s

usp

ecte

d,

chec

k w

ith a

qual

ity

osc

illosc

ope.

Spik

esgre

ater

than

16V w

ill s

hut

dow

n t

he

ECU

. In

stal

l a

radio

cap

acitor

at t

he

posi

tive

post

of th

e ig

nitio

nco

il (S

ee r

adio

cap

acitor

inst

alla

tion b

ulle

tin).

A

faulty

alte

rnat

or

or

worn

out

bat

tery

can

als

o r

esult

in t

his

conditio

n.

Will

not

turn

on u

nder

an

y co

nditio

ns.

Ver

ify

bat

tery

voltag

e is

gre

ater

than

10 v

olts

and les

sth

an 1

6.

Loss

of m

ode

door

funct

ion.

No m

ode

chan

ge

at a

ll.Chec

k fo

r dam

aged

mode

switch

or

pote

ntiom

eter

and

asso

ciat

ed w

irin

g.

Part

ial fu

nct

ion o

f m

ode

doors

.

Typic

ally

cau

sed b

y ev

apora

tor

housi

ng

inst

alle

d in a

bin

d in t

he

vehic

le.

Be

sure

all

mounting loca

tions

line

up

and d

on’t h

ave

to b

e fo

rced

in

to p

osi

tion.

Blo

wer

turn

s on

and o

ff r

apid

ly.

6.

Bat

tery

voltag

e is

at

leas

t 12V.

Chec

k fo

r at

lea

st 1

2V a

t ci

rcuit b

reak

er.

Ensu

re a

ll sy

stem

gro

unds

and p

ow

er c

onnec

tions

are

clea

n a

nd t

ight.

Bat

tery

voltag

e is

les

s th

an 1

2V.

5.

Tro

ub

lesh

oo

tin

g G

uid

e (

Co

nt.

)

Chec

k fo

r fa

ulty

bat

tery

or

alte

rnat

or.

Char

ge

bat

tery

.

Sys

tem

shuts

off b

low

er a

t 10V.

Poor

connec

tions

or

wea

k bat

tery

can

cau

se

shutd

ow

n a

t up t

o 1

1V.

7. When

ignitio

n is

turn

ed o

n,

blo

wer

m

om

enta

rily

co

mes

on,

then

sh

uts

off.

This

occ

urs

with t

he

blo

wer

sw

itch

in

the

OFF

posi

tion.

This

is

an indic

ator

that

the

syst

em h

as b

een r

eset

. Be

sure

the

red p

ow

er w

ire

is o

nth

e bat

tery

post

, an

d n

ot

on a

sw

itch

ed s

ourc

e. A

lso,

if

the

syst

em is

pulle

d b

elow

7V f

or

even

a s

plit

sec

ond,

the

syst

em w

ill r

eset

.

Run r

ed p

ow

er w

ire

direc

tly

to b

atte

ry.

Chec

k fo

r posi

tive

pow

er a

t hea

ter

valv

e gre

en w

ire

and

blo

wer

red

wire.

Chec

k fo

r gro

und o

n c

ontr

ol hea

d w

hite

wire.

Chec

k fo

r obst

ruct

ed o

r bin

din

g m

ode

doors

.

Chec

k fo

r dam

aged

ste

pper

m

oto

r or

wirin

g.

Err

atic

funct

ions

of

blo

wer

, m

ode,

te

mp,

etc.

Chec

k fo

r dam

aged

sw

itch

or

pot

and a

ssoci

ated

wirin

g.

Rep

air

or

repla

ce.

8.

25

www.vintageair.com

904062 REV E 11/04/15, PG 25 OF 26

Templates: Driver Side Under Dash Louver Bezel

& Defrost Duct Mounting

Drill 3/16”

Drill 3/16”

Cut

Alo

ng D

otte

d Li

ne

Dri

ver

Sid

e U

nd

er D

ash

Lou

ver

Tem

pla

te

3.375”

Defrost D

uct M

oun

ting

Temp

late

Align This Edge AgainstDash Brace

Cut A

long Dotted Line

Cut

Alo

ng D

otte

d Li

ne

26

www.vintageair.com

904062 REV E 11/04/15, PG 26 OF 26

Packing List: Evaporator Kit (564062)

No. 1.2.

Qty.11

Part No.744004-VUE784062

DescriptionGen IV Evaporator Sub CaseAccessory 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 Kit784062

Checked By:Packed By:

Date: