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1963 CHEVY IMPALA WITHOUT FACTORY AIR

561063

903063 REV C 7/7/14 1963 IMPALA w/o EVAP INST PG 1 OF 25

an ISO 9001:2008 Registered Company

2903063 REV C 7/7/14, 1963 IMPALA w/o EVAP INST PG 2 OF 25

PAGES

Table of Contents

1. COVER 2. TABLE OF CONTENTS 3. PACKING LIST / PARTS DISCLAIMER 4. INFORMATION PAGE 5. WIRING NOTICE 6. ENGINE COMPARTMENT FIGURE 1 7. CONDENSER ASSEMBLY, COMPRESSOR & BRACKET, PULLEYS, & PASSENGER COMPARTMENT FIGURES 2, 2a & 3 8. DEFROST DUCT INSTALLATION & FRESH AIR COVER INSTALLATION FIGURES 4 & 5 9. KICK PANEL INSTALLATION & FIGURES 6, 6a, 7 & 7a10.

& 8a 11. FIGURE 9 & 9a12. FIREWALL CAP INSTALLATION & DRAIN HOSE INSTALLATION FIGURES 10,10a & 1113.

FIGURES 12,12a & 13 & 13a 14. LUBRICATING O-RINGS, A/C HOSE INSTALLATION, & MODIFIED A/C HOSE KIT FIGURE 1415. HEATER HOSE & HEATER CONTROL VALVE INSTALLATION FIGURE 1516. AC & HEATER HOSE ROUTING FIGURE 16 17. FINAL STEPS & GLOVE BOX INSTALLATION FIGURES 17,18 & 18a18.

20. WIRING DIAGRAM21. GEN IV WIRING CONNECTION INSTRUCTIONS22. OPERATION OF CONTROLS23. TROUBLE SHOOTING INFORMATION24. 25. EVAPORATOR KIT PACKING LIST

19. EVAPORATOR HARDLINE INSTALLATION FIGURE 20

TROUBLE SHOOTING INFORMATION CONT.

FIREWALL COVER INSTALLATION

EVAPORATOR INSTALLATION FIGURES 8

EVAPORATOR INSTALLATION CONT.

DRIVER SIDE UNDER DASH LOUVER INSTALLATION & CENTER/ PASSENGER SIDE UNDER DASH LOUVER INSTALLATION

CONTROL PANEL & DUCT HOSE ROUTING FIGURE 19


** 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.

EVAPORATOR KIT PACKING LISTEVAPORATOR KIT

561063No. QTY. PART No. DESCRIPTION

1.2.

11 784063

744004-VUE

1

ACCESSORY KIT784063

2

GEN IV 4 VENTAP. SUB CASE

EV

744004-VUE

GEN IV 4 VENT EVAP. SUB CASE 1963 IMPALA w/o AC ACC. KIT

NOTE: IMAGES MAY NOT DEPICT ACTUAL PARTS AND QUANTITIES.REFER TO PACKING LIST FOR ACTUAL PARTS AND QUANTITIES.


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.


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.

•

•

•


INSTALLATION INSTRUCTIONS FOR 1963 IMPALA w/o AC

ENGINE COMPARTMENT

BEFORE STARTING THE AIR CONDITIONER INSTALLATION, CHECK FOR PROPER OPERATION OF ALL COMPONENTS (RADIO,LIGHTS, WIPERS, ETC.). STUDY THE INSTRUCTIONS, ILLUSTRATIONS AND DIAGRAMS. FOR EASE OF INSTALLATION

CHECK OFF ( ) EACH PROCEDURE PRIOR TO MOVING ON TO THE NEXT STEP.

FIGURE 1

DISCONNECT BATTERY AND REMOVEDRAIN RADIATORREMOVE O.E.M. HEATER/ BLOWER ASSEMBLY (DISCARD) SEE FIGURE 1 TO REMOVE OEM HEATER/ BLOWER ASSEMBLY. THE FACTORY MANUAL INDICATES DOING THE FOLLOWING, .

REMOVE RIGHT INNER FENDER

O.E.M. HEATER/BLOWER

ASSEMBLY

RIGHT INNERFENDER


O.E.M.HEATER

ASSEMBLY

O.E.M.DEF DUCTASSEMBLY

RADIO

INSTRUMENT PANEL

GLOVE BOX

DOOR

SPEAKER

O.E.M.CONTROL PANEL

REMOVE INSTRUMENT PANEL, SEE FIGURE 2 BELOW.REMOVE THE OEM CONTROL PANEL ASM. SEE FIGURE 2 BELOWREMOVE GLOVE BOX DOOR

DEFROSTREMOVE O.E.M HEATER ASSM BLY SEE FIGURE 2a BELOW.REMOVE O.E.M DUCT ASSEMBLY, SEE FIGURE 2a & 3 BELOW.(REMOVE SPOT WELDS ON DEF DUCT BY CHISEL OR DIE GRINDER. SEE FIGURE 3 BELOW.)

REMOVE GLOVE BOX (DISCARD)REMOVE RADIO,SPEAKER (RETAIN)

E

PASSENGER COMPARTMENT

CONDENSER ASSEMBLY & INSTALLATION

REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH THE CONDENSER KIT TO INSTALL THE CONDENSER.BINARY SWITCH INSTALLATION (REFER TO CONDENSER INSTRUCTIONS)

REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH THE BRACKET KIT TO INSTALL THE COMPRESSOR BRACKET.

IN MOST INSTANCES THE BELT LENGTHS WILL REMAIN THE SAME.

COMPRESSOR & BRACKETS

PULLEYS

FIGURE 2

FIGURE 2aFIGURE 3

USE A CHISEL ORDIE GRINDER TO

BREAK SPOT-WELDS

DEFROST DUCT

ASSEMBLY

INNER COWL

DASH SUPPORT


DEFROST DUCT

INSTALLATION

FIGURE 4

(2) #10 X 1/2” SHEET METAL

SCREWS

1/4-20 x 1”BOLT w/ WASHER

FRESH AIR COVER INSTALLATIONAPPLY A 1/4“ BEAD OF SILICONE AROUND THE BACK SIDE OF THE FRESH AIR CAP AS SHOWN IN FIGURE 5, BELOW.

ATTACH FRESH AIR CAP TO FIREWALL USING A 1/4-20 x 1" BOLT AND WASHER, SEE FIGURE 5, BELOW.

SILICONE OEM HEATER HOLES

BACK SIDEOF FRESH AIR

CAP

FRESH AIRCAP

FIGURE 5

PLACE DEFROST DUCT UNDER DASH, ALIGN WITH O.E.M. DEFROST OPENING IN DASH. DRILL (2) 1/8 HOLES IN COWL USING DEFROST DUCT HOLE AS TEMPLATE. SECURE USING (2) #10 x 1/2 SHEET METAL SCREWS AS SHOWN BELOW IN FIGURE 4.


FIGURE 7

FIREWALL COVER INSTALLATION

APPLY A 1/4” BEAD OF SILICONE AROUND THE FIREWALL COVER AS SHOWN IN FIGURE 7a.

FROM INSIDE THE CAR, INSTALL FIREWALL COVER ON FIREWALL SEE FIGURE 7. FROM THE ENGINE COMPARTMENT SECURE FIREWALL COVER TO FIREWALLUSING (3) 1/4-20 x 1” HEX BOLTS WITH WASHERS AND 1/4-20 COARSE NUT w/ STARWASHER. SEE FIGURE 7.

INSTALL GROMMET ON FIREWALL COVER AS SHOWN IN FIGURE 7.

(3) 1/4-20 COARSE NUT w/ STARWASHER

(3) 1/4-20 x 1” HEX BOLTS

w/ FLAT WASHERS

VIEW SHOWN FROM INSIDE CAR.

33144-VUIGROMMET

7/8 OD x 3/8 ID

ENGINE SIDEOF FIREWALL

COVER

FIGURE 7a

SILICONE

643166FIREWALLCOVER

KICK PANEL INSTALLATION

REMOVE THE PASSENGER SIDE KICK PANEL BY REMOVING THE (2) #10 x 1” PH PAN HEAD SCREWS, DISCONNECT THE FRESH AIR CABLE FROM DOOR AND DISCARD CABLE ASSEMBLY. CLOSE FRESH AIR DOOR ASSEMBLY IN KICK PANEL AND SEAL DOOR w/ 1/4” BEAD OF SILICONE AROUND DOOR AS SHOWN IN FIGURE 6.

INSTALL PASSENGER SIDE KICK PANEL USING THE (2) OEM SCREWS AS SHOWN IN FIGURE 6a.

#10 x 1” PHPAN HEADSCREWS

PASSENGER SIDEKICK PANEL

FRESH AIR DOOR

1/4” BEADOF

SILICONE

FIGURE 6 FIGURE 6a


INSTALL (2) 1/4-20 x 1” HEX BOLT AND 1/4” PUSH-ON NUT ON EVAP REAR BRKT AS SHOWN IN FIGURE 8a BELOW. INSTALL EVAPORATOR FRONT & REAR MOUNTING BRACKETS ON EVAPORATOR USING (6)1/4-20 x 1/2” HEX BOLTS AND TIGHTEN AS SHOWN IN FIGURE 8 & 8a BELOW. INSTALL (2) A/C HARDLINES WITH PROPERLY

ON A WORK BENCH INSTALL (2) HEATER LINE WITH PROPERLY LUBRICATED O-RINGS. (SEE FIGURE 13 PAGE 14, AND FIGURE 19 PAGE 19.)

LUBRICATED O-RINGS. (SEE FIGURE 13 PAGE 14, AND FIGURE 19 PAGE 19.)

EVAPORATOR INSTALLATION

FIGURE 8

FIGURE 8a

EVAP FRONTBRKT

643163

(2) 18290-VUB1/4-20 x 1”HEX BOLT

189125-MUR1/4” PUSH NUTBOLT RETAINER

18287-VUB(2)1/4-20 x ½”

HEX BOLT

18287-VUB(2) 1/4-20 x ½”

HEX BOLT

18287-VUB(2) 1/4-20 x ½”

HEX BOLT

EVAP REARBRKT

643164


FIGURE 9

EVAPORATOR INSTALLATION CONT.

LIFT EVAPORATOR UNIT UP UNDER THE DASHBOARD SEE FIGURE . SECURE 9 LOOSELY TO THE FIREWALL FROM THE ENGINE COMPARTMENT SIDE USING (2) 1/4-20 NUTS w/ STAR WASHER AND FLAT WASHERS, SEE FIGURE 9. USING OEM SCREW SECURE THE FRONT EVAPORATOR MOUNTING BRACKET TO OEM SPEAKER MOUNTING BRKT. SEE FIGURE 9 AND 9a.

VERIFY THAT EVAPORATOR UNIT IS LEVEL AND SQUARE TO THE DASH, THEN TIGHTEN ALL MOUNTING BOLTS.(NOTE: TIGHTEN THE BOLT ON FIREWALL FIRST, THEN THE FRONT MOUNTING BRACKET SCREWS.)

FIGURE 9a

EVAPORATORBRACKET

MOUNTING HOLES

OEMFASTENER

SPEAKERBRKT OEM

SCREW

EVAP FRONTBRKT


DRAINHOSE

EVAPORATORCASE

1”

1”2 1/2”

FIREWALL CAP INSTALLATION INSTALL GROMMETS ON FIREWALL CAP AS SHOWN IN FIGURE 10 BELOW.

PASS LINES THROUGH FIREWALL CAP, AND SECURE WITH (3) #10 x 1/2 SHEET METAL SCREWS. SEE FIGURE 10 BELOW.

APPLY A 1/4“ BEAD OF SILICONE AROUND THE BACK SIDE OF THE FIREWALL CAP AS SHOWN IN FIGURE 10a BELOW.

FIGURE 10

FIGURE 10a

IN-LINE WITH DRAIN, LIGHTLY MAKE A MARK ON THE FIREWALL MEASURE 1” DOWN AND 2 1/2” TO THE LEFT AND DRILL A 5/8” HOLE THROUGH THE FIREWALL. SEE FIGURE 11 BELOW.

INSTALL DRAIN HOSE TO BOTTOM OF EVAPORATOR UNIT AND ROUTE THROUGH FIREWALL. SEE FIGURE 11 BELOW.

LOCATE EVAPORATOR DRAIN ON BOTTOM OF EVAPORATOR CASE.

DRAIN HOSE INSTALLATION

FIGURE 11

SILICONE

643167FIREWALL

CAP

33137-VUI

33135-VUI

(3) 18247-VUB#10 x 1/2

SHEET METALSCREWS


(3) LOUVERS 49157-VUL

CENTER/PASSENGER SIDE UNDER DASH LOUVER INSTALLATION

(3) 10/32 x 1/2”PAN HEAD SCREWS

w/ NUT w/STAR WASHER

OEMHOLE

PLACE LOUVER BEZEL UNDER DASH AND ALIGN WITH O.E.M. HOLE IN PASSENGER SIDE DASH SEE FIGURE 13 BELOW. ALIGN LOUVER BEZEL UNDER DASH AND USE LOUVER BEZEL HOUSING AS YOUR GUIDETO MARK AND DRILL (2) 3/16 HOLES UNDER DASH.SECURE LOUVER BEZEL UNDER DASH USING (3) 10/32 x 1/2” PAN HEAD SCREW w/ 10/32 NUTS w/ STAR WASHERSEE FIGURE 13 BELOW.INSTALL LOUVER IN UNDER DASH BEZEL AS SHOWN IN FIGURE 13a BELOW.

FIGURE 13

DRIVER SIDE UNDER DASH LOUVER INSTALLATION

PLACE LOUVER BEZEL UNDER DASH AND ALIGN TO DASH.

SECURE LOUVER BEZEL UNDER DASH USING (2) 10/32 x 1/2” PAN HEAD SCREW w/ 10/32 NUT w/ STAR WASHER

INSTALL LOUVER IN UNDER DASH BEZEL AS SHOWN IN FIGURE 12a BELOW.

ALIGN LOUVER BEZEL UNDER DASH AND USE LOUVER BEZEL HOUSING AS YOUR GUIDETO MARK AND DRILL (2) 3/16 HOLES UNDER DASH.

SEE FIGURE 12 BELOW.

FIGURE 12a

FIGURE 12

(2) 10/32 x 1/2PAN

HEAD SCREWSw/NUT w/ STAR WASHER

49157-VUL LOUVERS

FINAL ASSEMBLY

FIGURE 13a


LOCATE THE #8 COMPRESSOR A/C HOSE. LUBRICATE (2) #8 O-RINGS (SEE FIGURE 14, ABOVE) AND CONNECTTHE 135° FEMALE FITTING w/134a SERVICE PORT TO THE #8 DISCHARGE PORT ON THE COMPRESSOR.ROUTE THE STRAIGHT FEMALE FITTING TO THE #8 CONDENSER HARDLINE COMING THROUGH 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 w/134a SERVICE PORT TO THE #10 SUCTION PORT ON THE COMPRESSOR. 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 14 ABOVE.

LOCATE THE #6 EVAP/CORE HARDLINE AND LUBRICATE (2) #6 O-RINGS (SEE FIGURE 14 , ABOVE) 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 16, PAGE 16. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN FIGURE 14, ABOVE.

USE A #2 & #10 ADEL CLAMP TO SECURE THE #6 EVAP/ CORE HARDLINE AND THE 5/8” HEATER HOSE TO THEINNER FENDERWELL AS SHOWN IN FIGURE 16, PAGE 16. SECURE THE ADEL CLAMP TO THE INNER FENDER USING(2)10-32 x ½” PH PAN HEAD SCREWS w/ NUTS.

(NOTE: WRAP THE #10 FITTING CONNECTIONS WITH PRESS TAPE. SEE FIGURE 15, PAGE 15.

A/C HOSE INSTALLATIONSTANDARD HOSE KIT

REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH MODIFIED HOSE KIT.

MODIFIED A/C HOSE KIT

LUBRICATING O-RINGS

#6 O-RING

#8 O-RING #10 O-RING

HOLD WITHTHIS WRENCH

FOR A PROPER SEAL OF FITTINGS:INSTALL SUPPLIED O-RINGS AS SHOWNAND LUBRICATE WITH SUPPLIED OIL.

O-RING

SUPPLIED OIL FOR O-RINGS O-RING, INSTALLS

OVER MALE INSERTTO SWAGED LIP

MALEINSERT

FEMALENUT

O-RING

TWIST WITHTHIS WRENCH

FIGURE 14


ROUTE A PIECE OF HEATER HOSE FROM THE WATER PUMP TO THE HEATER LINE COMING THROUGH THE FIREWALLAS SHOWN IN FIGURE 15 . SECURE USING HOSE CLAMPS.

INSTALL HEATER CONTROL VALVE IN-LINE WITH INTAKE MANIFOLD (PRESSURE SIDE) HEATER HOSE, SECURE USING HOSE CLAMPS AS SHOWN IN FIGUREBELOW.

, BELOW

ROUTE A PIECE OF HEATER HOSE FROM THE INTAKE TO THE HEATER LINE COMING THROUGH THE FIREWALLAS SHOWN IN FIGURE 15, BELOW. NOTE:

15, NOTE PROPER FLOW DIRECTION.

HEATER HOSE & HEATER CONTROL VALVE INSTALLATIONNOTE: VINTAGE AIR SYSTEMS REQUIRE (2) 5/8 HOSE NIPPLES (NOT SUPPLIED). ONE ONE FOR THE WATER PUMP (SUCTION) - IF REQUIRED REMOVE EXISTING HOSE NIPPLE OR NIPPLES AND INSTALL NEW 5/8 HOSE NIPPLES IN INTAKE AND WATER PUMP.

FOR THE INTAKE (PRESSURE) AND

ECUMODULE

PRESSTAPE

#10 SUCTIONLINE (INSULATED)

091671EXPANSION

VALVE

O-RING

HEATERHOSE

PRESS TAPE

FROM HEATER CONTROL VALVE

NOTE: FLOW DIRECTION FOLLOWS MOLDED ARROW ON VALVE.

FROM INTAKE

FIGURE 15

#10 SUCTIONHOSE

096059

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FINAL STEPSINSTALL DUCT HOSES AS SHOWN IN FIGURE 19, PAGE 18.ROUTE A/C WIRES THROUGH 3/8” GROMMET AS SHOWN ON FIGURE 16 ( 12 VOLT/ GROUND/ BINARY SWITCH/ HEATER VALVE)

PLUG THE CONTROL PANEL HARNESS INTO THE ECU MODULE ON SUB CASE AS SHOWN IN PAGE 18.

REINSTALL ALL PREVIOUSLY REMOVED ITEMS (BATTERY RADIO, SPEAKER, INSTRUMENT PANEL).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 CORRODEPREMATURELY AND POSSIBLY BURST IN AC MODE AND/OR FREEZING WEATHER, VOIDING YOUR WARRANTY.DOUBLE CHECK ALL FITTINGS, BRACKETS AND BELTS FOR TIGHTNESS.VINTAGE AIR RECOMMENDS THAT ALL AC SYSTEMS BE SERVICED BY A CERTIFIED AUTOMOTIVE AIR CONDITIONINGTECHNICIAN.EVACUATE THE SYSTEM FOR A MINIMUM OF 45 MINUTES PRIOR TO CHARGING AND LEAK CHECK PRIOR TO SERVICING.

CHARGE THE SYSTEM TO THE CAPACITIES STATED ON THE INFORMATION PAGE (PAGE 4) OF THIS INSTRUCTION MANUAL.

INSTALL CONTROL PANEL ASM.

PLUG THE WIRING HARNESS INTO THE ECU MODULE ON SUB CASE AS SHOWN IN FIGURE 19, PAGE 18. (WIRE ACCORDING TO WIRING DIAGRAM ON PAGE 20 & 21.)

CONTROL PANEL MUST BE CALIBRATED. (REFER TO CONTROL PANEL INSTRUCTIONS FOR CALIBRATION PROCEDURES.GLOVE BOX INSTALLATION ( SEE FIGURE 18)NOTE:

GLOVE BOX INSTALLATIONTHE NEW GLOVE BOX IS MADE IN TWO (2) PIECES FOR EASY INSTALLATION.INSERT BOTTOM HALF OF NEW GLOVE BOX, INTO GLOVE BOX OPENING AND POSITION IN PLACE.INSERT TOP HALF OF GLOVE BOX AND FASTEN TO BOTTOM HALF USING (4) #6 x 3/8" BLACK PAN HEAD PHILLIPS SCREWS (SEE FIGURE 18, BELOW).INSTALL GLOVE BOX DOOR USING (3) OEM SCREWS THROUGH THE TINNERMAN NUTS.INSTALL GLOVE BOX USING (2) OEM SCREWS SEE FIGURE 18a.

GLOVE BOX TOP

624163

(4)#6 x 3/8PH PAN HEAD

SCREWS

FIGURE 18

FIGURE 18a

OEM SCREWS

OEM SCREWS

TINNERMAN NUTS

GLOVE BOX BOTTOM624164

FIREWALLCOVER

3/8” GROMMET

FIGURE 17

WIRING HARNESS(12 VOLT/GROUNDS/BINARY SWITCH)

WIRING HARNESS(HEATER CONTROL VALVE)


CONTROL PANEL & DUCT HOSE ROUTING

DRIVER SIDEDEF. DUCT2” x 15”

DRIVER SIDE LOUVER

2 ½” x 38”

CENTER

DRIVER SIDE2 ½” x 12”

LOUVER

PASS. SIDEDEF. DUCT2” x 15”

PASSENGER

SIDE LOUVER2 ½” x 38”

FIGURE 19

CENTER

PASS. SIDE2 ½” x 16”

LOUVER

PLUGFROM

CONTROLWIRING

HARNESS232002-VUA

PLUGFROM

WIRINGHARNESS

232001-VUR

DRIVER SIDE

LOUVER

PASSENGER

SIDELOUVER

CENTER

DRIVER SIDELOUVER

CENTER

PASSENGER SIDE

LOUVER


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FIG

UR

E 2

0


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


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.


OPERATION OF CONTROLS

NOTE: WHEN BATTERY POWER IS FIRST CONNECTED TO THE ECU, THE COMPUTER GOES THROUGH AN INITIALIZATION SEQUENCE. THIS INITIALIZATION MAY TAKE UP TO 30 SECONDS. DURING INITIALIZATION THE BLOWER WILL NOT OPERATE, BUT THE DOORS INSIDE THE UNIT WILL BE OPERATING. A LOW BATTERY OR DISCONNECTING THE BATTERY MAY ALSO TRIGGER A RE-INITIALIZATION. DURING START UP, A LOW BATTERY MAY DROP BELOW 7 VOLTS, TRIGGERING RE-INITIALIZATION.

BLOWER SPEEDSLIDE THE FAN LEVER

UP OR DOWNTO SELECT DESIRE

FAN SPEED(SLIDE LEVER ALL THE WAY

DOWN FOR MAXIMUMFAN SPEED)


UP OR DOWN TO SELECT DESIRE FAN

SPEED (SLIDE LEVER ALL THE WAY DOWN FOR MAXIMUM

FAN SPEED)


UP OR DOWN TO SELECT DESIRE FAN

SPEED (SLIDE LEVER ALL THE WAY DOWN FOR MAXIMUM

FAN SPEED)

BLOWER SPEEDTHIS LEVER CONTROLS

THE BLOWER SPEED,FROM OFF TO HI

DEFROST MODEHEAT MODE

MODELEVER

THERMOSTATLEVER

SYSTEM OFFA/C MODE

BLOWER SPEED

NOTE: ORIGINAL BLOWER SWITCH WILL NOT BE USED.

THERMOSTAT LEVERIN A/C MODE SLIDE THETEMP LEVER ALL THE WAY

UP TO ENGAGE COMPRESSOR FOR

MAXIMUM COOLING.(SLIDE LEVER UP OR DOWN TO

ADJUST DESIRED TEMPERATURE)

THERMOSTAT LEVERIN HEAT MODE SLIDE THETEMP LEVER ALL THE WAY

DOWN FOR MAXIMUM HEATING.(SLIDE LEVER UP OR DOWN TO

ADJUST DESIRED TEMPERATURE)

THERMOSTAT LEVERIN DEF MODE SLIDE THETEMP LEVER ALL THE WAY

UP TO

(SLIDE LEVER UP OR DOWN TO ADJUST DESIRED TEMPERATURE)

ENGAGE COMPRESSOR FOR MAXIMUM COOLING.

THERMOSTAT LEVERTHIS LEVER CONTROLS

THE TEMPERATUREFROM HOT TO COLD

MODE LEVERSLIDE THE MODE LEVER ALL THE

WAY UP FOR DASH MODE

MODE LEVERSLIDE THE MODE LEVER

TO THE CENTER FOR FLOOR MODE

(SLIDE LEVER UP OR DOWN TO BLEND BETWEEN DESIRED

MODE POSITIONS)

MODE LEVERSLIDE THE MODE LEVER

ALL THE WAY DOWN FOR DEFROST MODE

(SLIDE LEVER UP OR DOWN TO BLEND BETWEEN DESIRED

MODE POSITIONS)

MODE LEVER

THE MODE POSITIONSFROM DASH TO FLOOR

TO DEFROST

THIS LEVER CONTROLS

FANFAN

MODEMODE

TEMPTEMP

FANFAN MODEMODE TEMPTEMP

FAN MODE TEMP

NOTE: CONTROLS MUST BE CALIBRATED PRIOR TO FIRST OPERATION- REFER TO CONTROL PANEL INSTRUCTIONS


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

evap

ora

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

.


Sym

pto

m

C

on

dit

ion

C

heck

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.


CHECKED BY:PACKED BY:

DATE:

EVAPORATOR KIT PACKING LISTEVAPORATOR KIT

561063No. QTY. PART No. DESCRIPTION

1.2.

11 784063

744004-VUE GEN IV 4 VENT EVAP. SUB CASE 1963 IMPALA w/o AC ACC. KIT

1

ACCESSORY KIT784063

2

GEN IV 4 VENTAP. SUB CASE

EV

744004-VUE

NOTE: IMAGES MAY NOT DEPICT ACTUAL PARTS AND QUANTITIES.REFER TO PACKING LIST FOR ACTUAL PARTS AND QUANTITIES.

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