Chevrolet - Impala - Workshop Manual - 1961 - 1962

an ISO 9001:2015 Registered Company 1961-62 Chevrolet Impala without Factory Air Evaporator Kit (561062) 18865 Goll St. San Antonio, TX 78266 Phone: 800-862-6658 Sales: [email protected] Tech Support: [email protected] www.vintageair.com 903062 REV H 08/12/19, PG 1 OF 26 www.vintageair.com Table of Contents Cover.................................................................................................................................. 1 Table of Contents................................................................................................................. 2 Packing List/Parts Disclaimer.................................................................................................. 3 Information Page.................................................................................................................. 4 Wiring Notice....................................................................................................................... 5 Engine Compartment Disassembly, Condenser Assembly and Installation, Compressor and Brackets, Pulleys.................................................................................................................. 6 Passenger Compartment Disassembly..................................................................................... 7 Defrost Duct Installation....................................................................................................... 8 Speaker Mounting, Evaporator Installation............................................................................... 9 Fresh Air Cap Installation, Firewall Cover Installation.............................................................. 10 Evaporator Installation (Cont.)............................................................................................. 11 Drain Hose Installation, Driver Side Under Dash Louver Mounting Holes, Passenger Side Under Dash Louver Mounting Holes ............................................................................................... 12 Driver Side Under Dash Louver Installation, Center/Passenger Side Under Dash Louver Installation........................................................................................................................ 13 Lubricating O-rings, A/C Hose Installation.............................................................................. 14 Heater Hose & Heater Control Valve Installation..................................................................... 15 A/C & Heater Hose Routing.................................................................................................. 16 Final Steps........................................................................................................................ 17 Control Panel & Duct Hose Routing....................................................................................... 18 Evaporator Hardline Installation........................................................................................... 19 Wiring Diagram.................................................................................................................. 20 Gen IV Wiring Connection Instruction................................................................................... 21 Operation of Controls.......................................................................................................... 22 Troubleshooting Guide......................................................................................................... 23 Troubleshooting Guide (Cont.).............................................................................................. 24 Templates: Driver Side Under Dash Louver Bezel & Defrost Duct Mounting................................. 25 Packing List....................................................................................................................... 26 2 903062 REV H 08/12/19, PG 2 OF 26 Packing List: Evaporator Kit (561062) www.vintageair.com No. 1. 2. Qty. 1 1 Part No. 744044-VUE 784061 Description Gen 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. 1 Gen IV Evaporator Sub Case 744044-VUE 2 Accessory Kit 784061 NOTE: Images may not depict actual parts and quantities. Refer to packing list for actual parts and quantities. 3 903062 REV H 08/12/19, PG 3 OF 26 www.vintageair.com Important Notice—Please Read For Maximum System Performance, Vintage Air Recommends the Following: 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: 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). Safety Switches 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. 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. 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. 4 903062 REV H 08/12/19, PG 4 OF 26 www.vintageair.com 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. 5 903062 REV H 08/12/19, PG 5 OF 26 www.vintageair.com Engine Compartment Disassembly 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: 1. Disconnect battery. 2. Remove battery (retain). 3. Drain radiator. 4. Remove passenger side hood hinge (retain) (See Figure 1a, below). 5. Remove OEM blower assembly (discard) (See Figure 1, below). Hood Hinge OEM Heater/Blower Assembly Figure 1a Figure 1 Condenser Assembly and Installation 1. Refer to separate instructions included with the condenser kit to install the condenser. 2. Binary switch installation (Refer to condenser instructions). Compressor and Brackets 1. Refer to separate instructions included with the bracket kit to install the compressor bracket. Pulleys 1. In most instances, the belt lengths will remain the same. 6 903062 REV H 08/12/19, PG 6 OF 26 Passenger Compartment Disassembly www.vintageair.com Perform the Following: 1. Remove the OEM control panel assembly (retain) (See Figure 2, below). 2. Remove the OEM heater assembly (discard) (See Figure 2, below). 3. Remove the glove box (discard) (See Figure 2, below). 4. Remove the radio and speaker (retain) (See Figure 2, below). 5. Remove the OEM defrost duct assembly (discard) (See Figures 2 & 3, below). 6. Remove the (3) spot welds on the defrost duct with a chisel or die grinder (See Figure 3, below). Speaker OEM Defrost Duct Radio OEM Control Panel Glove Box OEM Heater Plenum Figure 2 Dash Support Dash Support Inner Cowl Use a Chisel or Die Grinder to Break Spot Welds Defrost Duct Figure 3 7 903062 REV H 08/12/19, PG 7 OF 26 Defrost Duct Installation www.vintageair.com 1. Cut out the defrost duct mounting template on Page 25. 2. Place the template onto the inner cowl. Once aligned, tape the template into place (See Figure 4, below). 3. Using a center punch or scribe, mark the (2) mounting holes on the inner cowl (See Figure 4, below). 4. Once the holes are marked, remove the template and drill (2) 1/8” holes into the inner cowl. 5. Install a J-nut onto the end of the speaker bracket as shown in Figure 4a, below. 6. 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. 7. 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). Tape Dash Support Brace Mark Mounting Holes Inner Cowl Template View Shown Through Glove Box Opening in Dash. Figure 4 J-nut Defrost Duct Figure 4a 8 (2) #10 x 1/2” Sheet Metal Screws 903062 REV H 08/12/19, PG 8 OF 26 Speaker Mounting www.vintageair.com 1. Using a #10 x 1/2” sheet metal screw, secure the speaker bracket to the bracket on the defrost duct (See Figure 5, below). Speaker Bracket #10 x 1/2” Sheet Metal Screw Figure 5 Evaporator Installation 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. 2. Install the hardlines with properly lubricated O-rings (See Figure 15, Page 14, and Figure 21, Page 19). 1/4-20 x 1/2” Hex Bolt Front Evaporator Bracket 643062 1/4-20 x 1/2” Hex Bolt Figure 6 Driver Side Rear Evaporator Bracket 643064 (2) 1/4-20 x 1/2” Hex Bolts Figure 6a Passenger Side Rear Evaporator Bracket 643063 (2) 1/4-20 x 1/2” Hex Bolts 9 1/4-20 x 1 ½” Coarse Bolt with Flat Washer 1/4” Push Nut Bolt Retainer 3/4” Nylon Spacer 903062 REV H 08/12/19, PG 9 OF 26 Fresh Air Cap Installation www.vintageair.com 1. Apply a 1/4” bead of silicone around the mating surface of the fresh air cap as shown in Figure 7, below. 2. Attach the fresh air cap to the firewall using a 1/4-20 x 1” bolt and washer (See Figure 7, below). 1/4-20 x 1” Bolt and Washer Fresh Air Cap Silicone Mating Surface of Fresh Air Cap Figure 7 Firewall Cover Installation 1. 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. Passenger Compartment View Figure 8 Mating Surface of Firewall Cover 10 Silicone 903062 REV H 08/12/19, PG 10 OF 26 www.vintageair.com Evaporator Installation (Cont.) 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). 1. Remove the #6 grommet (See Figure 9, below). 2. Lift the evaporator unit up under the dashboard, and secure loosely to the firewall from the engine compartment side using (2) 1/4-20 nuts and washers (See Figure 9, below). 3. 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). 4. 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. 5. Once the evaporator is installed, install a #6 grommet over the #6 hardline from the engine compartment. #6 Grommet 33145-VUI Remove Firewall Insulation Retainer If Equipped Rear Evaporator Bracket 1/4-20 Nut and Flat Washer 1/4-20 Nut and Flat Washer Figure 9 Bracket Dash Rear Evaporator Bracket Evaporator Figure 9a 11 1/4-20 Well Nut 1/4” Flat washer 1/4-20 x 1 ¼” Pan Head Screw 903062 REV H 08/12/19, PG 11 OF 26 Drain Hose Installation www.vintageair.com 1. Locate the evaporator drain on the bottom of the evaporator case. 2. 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). 3. Install the drain hose onto the evaporator drain on the bottom of the unit, and route it through the firewall. 1” Figure 10 Drain Hose Driver Side Under Dash Louver Mounting Holes 1. 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. 2. 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). Drill (2) 3/16” Holes Figure 11 Passenger Side Under Dash Louver Mounting Holes 1. Using the (2) OEM dimples under the dash, drill (2) 3/16” holes in the dash as shown in Figure 12, below. Figure 12 Drill (2) 3/16” Holes 12 903062 REV H 08/12/19, PG 12 OF 26 Driver Side Under Dash Louver Installation www.vintageair.com 1. Place the louver bezel under the dash, and align it with the 3/16” holes in the dash. 2. 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). 3. Install the louver into the under dash bezel as shown in Figure 13a, below. (2) 10-24 x 3/8” Pan Head Screws and (2) Nuts with Star Washers Louver Figure 13a Figure 13 Center/Passenger Side Under Dash Louver Installation 1. Place the louver bezel under the dash, and align it with the OEM holes in the dash. 2. 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). 3. Install the louvers into the under dash bezel as shown in Figure 14a, below. (3) Louvers Figure 14 Figure 14a (3) 10-24 x 3/8” Pan Head Screws and (3) Nuts with Star Washers Final Assembly 13 903062 REV H 08/12/19, PG 13 OF 26 Lubricating O-rings www.vintageair.com Male O-ring Insert Female Nut #6 O-ring #8 O-ring #10 O-ring For a proper seal of fittings: Install supplied O-rings as shown, and lubricate with supplied oil. O-ring Supplied Oil for O-rings NOTE: Standard torque specifications: #6: 11 to 13 ft-lb. #8: 15 to 20 ft-lb. #10: 21 to 27 ft-lb. O-ring Installs Over Male Insert to Swaged Lip Figure 15 Figure ## Twist With This Wrench Hold With This Wrench A/C Hose Installation Standard Hose Kit: 1. 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. 2. 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). 3. 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. 4. 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. Modified Hose Kit: 1. Refer to separate instructions included with modified hose kit. 14 903062 REV H 08/12/19, PG 14 OF 26 www.vintageair.com Heater Hose & Heater Control Valve Installation 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. 1. 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. 2. 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. ECU Module NOTE: Flow Direction Follows Molded Arrow on Valve. Press Tape From Heater Control Valve Heater Hose #10 Suction Line (Insulated) 091671 Expansion Valve From Intake #6 O-ring Heater Control Valve #6 Hardline 091078 5/8” Heater Line (Intake) 091661 #10 O-ring 5/8” Heater Line (Water Pump) 091661 #10 Suction Hose 096059 #6 Hardline 091061 To Water Pump Figure 16 Press Tape 15 903062 REV H 08/12/19, PG 15 OF 26 16 #10 Adel Clamp 31601-VUD Heater Hose O-rings #2 Adel Clamp 31600-VUD Inner Fender 10-32 x 1/2” Pan Head Screw and Nut 10-32 x 1/2” Pan Head Screw #6 Drier/Condenser Hardline 35117-VCG #8 A/C Discharge Hose (Compressor/Condenser) 096062 10-32 Nut with Star Washer Figure 17 Inner Fender #6 Drier/Core Hardline 091063 #8 Condenser Hardline 091064 #10 A/C Suction Hose (Compressor/Evaporator) 096059 Heater Control Valve Evaporator Sub Case #6 Evaporator/Core Hardline 091061 ECU Module #6 Evaporator/Core Hardline 091061 10-32 x 1/2” Pan Head Screw and Nut Firewall Cover 627003 Expansion Valve #10 Suction Line (Insulated) 091671 Press Tape www.vintageair.com 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. Compressor Safety Switch (Binary Type Screw on Drier) (Refer to Condenser Instruction) A/C & Heater Hose Routing 903062 REV H 08/12/19, PG 16 OF 26 Final Steps www.vintageair.com 1. Install duct hoses as shown in Figure 20, Page 18. 2. Route A/C wires (12 volt/grounds/binary switch/heater control valve) through 3/8” grommet as shown in Figure 19, below). 3. Install control panel assembly. Refer to control panel instructions. 4. 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. 5. Install supplied glove box, and secure using (3) OEM screws through the OEM holes as shown in Figure 18, below. 6. Reinstall glove box door. 7. Reinstall all previously removed items. 8. 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. 9. Double check all fittings, brackets and belts for tightness. 10. Vintage Air recommends that all A/C systems be serviced by a licensed automotive A/C technician. 11. Evacuate the system for a minimum of 45 minutes prior to charging, and perform a leak check prior to servicing. 12. Charge the system to the capacities stated on Page 4 of this instruction manual. 13. See Operation of Controls procedures on Page 22. Grommet 33144-VUI (3) OEM Screws Figure 19 Figure 18 17 903062 REV H 08/12/19, PG 17 OF 26 www.vintageair.com Control Panel & Duct Hose Routing Passenger Side Louver 2 ½” x 38” Plug From Control Wiring Harness 232002-VUA Driver Side Defrost Duct 2” x 15” Plug From Wiring Harness 232600-VUA Driver Side Louver 2 ½” x 36” Passenger Side Defrost Duct 2” x 15” Driver Side Center Louver 2 ½” x 12” Passenger Side Louver Passenger Side Center Louver 2 ½” x 12” Driver Side Louver Figure 20 Passenger Side Center Louver Driver Side Center Louver 18 903062 REV H 08/12/19, PG 18 OF 26 19 903062 REV H 08/12/19, PG 19 OF 26 #10 Suction Line 091671 Press Tape www.vintageair.com Heater Line (Evaporator to Intake) 091661 #6 O-ring 33857-VUF Heater Line (Evaporator to Water Pump) 091661 #10 O-ring 33859-VUF ECU Module #6 Hardline 091078 Figure 21 (2) #10 O-rings 33859-VUF Evaporator Hardline Installation Wiring Diagram www.vintageair.com 232007-VUR TAN ORA BLK WHT JF8 RED WHT/RED WHT/YEL WHT/GRN AC ANNUNCIATOR BACKLIGHT POS BACKLIGHT NEG GND 5V-SW TEMP WIPER MODE WIPER FAN WIPER PRE-WIRED VIEWED FROM WIRE SIDE 232002-VUA A/C (IF USED) GEN IV ECU GEN IV WIRING DIAGRAM REV E, 10/6/2017 TEMP MODE FAN PROGRAM * DASH LAMP (IF USED) *** WIDE OPEN THROTTLE SWITCH (OPTIONAL) ** CIRCUIT BREAKER 30 AMP HEATER CONTROL VALVE * Dash Lamp Is Used Only With Type 232007-VUR Harness. ** 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). *** Wide Open Throttle Switch Contacts Close Only at Full Throttle, Which Disables A/C Compressor. 20 903062 REV H 08/12/19, PG 20 OF 26 Gen IV Wiring Connection Instruction www.vintageair.com WIRING HARNESS CONTROL WIRING HARNESS RED & WHITE A/C COMPRESSOR RELAY RED BLUE NOTE: MOUNT RELAY IN DESIRED LOCATION UNDER DASH RED WH IT E Ignition Switch: VIOLET Violet 12V Ign Switch Source (Key On Accessory) Position Must Be Switched. +12V NOTE: WIRING YELLOW & ORANGE (IGNITION HOT HARNESS COMING FROM TERMINAL) HARNESS ARE NOT USED. YELLOW RUN BAT IGNITION SWITCH ORANGE TAN DASH BACK LIGHT+0-12v GRAY GRAY WIRE IS USED FOR PROGRAMING CONTROLS IF APPLICABLE RED GREEN RED GREEN FIREWALL BLACK BLUE Heater Control Valve: RED LATCH WIRING HARNESS WHITE CHASSIS GROUND NOTE: HEATER CONTROL VALVE CONNECTION AND CHASSIS GROUND MAY BE LOCATED ON EITHER SIDE OF THE FIREWALL. ENSURE CONNECTOR IS LATCHED FIRMLY. HEATER CONTROL VALVE K BLAC BLUE COMPRESSOR WHITE NOTE: CONNECT WHITE WIRES DIRECTLY TO (-) BATTERY TERMINAL WHITE RED RED CIRCUIT BREAKER 30 AMP Install With Servo Motor Facing Down, As Shown. Note Flow Direction Arrow Molded Into Valve Body, And Install Accordingly. Binary/Trinary & Compressor: Binary: Connect As Shown (Typical Compressor Wiring). Be Sure Compressor Body Is Grounded. BINARY SAFETY SWITCH BLUE Dash Light: When Using A Vintage Air Supplied Control Panel, Connect The Tan Wire From The Gen IV Evaporator Wiring Harness To The Factory Dash Lights To Enable Panel Backlighting. Circuit Breaker/Battery: White Must Run To (-) Battery. Red May Run To (+) Battery Or Starter. Mount Circuit Breaker As Close to Battery As Possible. RED 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). + Trinary Switch: Connect According To Trinary Switch Wiring Diagram. - BATTERY 21 903062 REV H 08/12/19, PG 21 OF 26 Operation of Controls www.vintageair.com 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 This lever/knob controls blower speed, from OFF to HI. Mode Control This lever/knob controls the mode positions, from DASH to FLOOR to DEFROST, with a blend in between. Temperature Control This lever/knob controls the temperature, from HOT to COLD. NOTE: Original blower switch will not be used. Blower Speed Temperature Control Mode Control A/C Operation Blower Speed Adjust to desired speed. Mode Control Adjust to desired mode position (DASH position recommended). Temperature Control For A/C operation, adjust to coldest position to engage compressor (Adjust between HOT and COLD to reach desired temperature). Heat Operation Blower Speed Adjust to desired speed. Mode Control Adjust to desired mode position (FLOOR position recommended). Temperature Control For maximum heating, adjust to hottest position (Adjust between HOT and COLD to reach desired temperature). Defrost/De-fog Operation Blower Speed Adjust to desired speed. Temperature Control Adjust to desired temperature. Mode Control Adjust to DEFROST position for maximum defrost, or between FLOOR and DEFROST positions for a bi-level blend (Compressor is automatically engaged). 22 903062 REV H 08/12/19, PG 22 OF 26 23 903062 REV H 08/12/19, PG 23 OF 26 Symptom Compressor will not turn off (All other functions work). 3. Compressor will not turn on (All other functions work). 2. Blower stays on high speed when ignition is on or off. 1b. Blower stays on high speed when ignition is on. 1a. System is charged. System is not charged. All other functions work. No other functions work. Condition www.vintageair.com Repair or replace pot/control wiring. Replace relay. Check for faulty A/C relay. Check 2-pin connector at ECU housing. Check continuity to ground on white control head wire. Check for 5V on red control head wire. Charge system or bypass pressure switch. Replace BSC (This will require removal of evaporator from vehicle). Check to ensure that no BSC wiring is damaged or shorted to vehicle ground. The BSC operates the blower by ground side pulse width modulation switching. The positive wire to the blower will always be hot. If the “ground” side of the blower is shorted to chassis ground, the blower will run on HI. Be sure the small, 20 GA white ground wire is connected to the battery ground post. If it is, replace the ECU. Verify continuity to chassis ground with white control head wire at various points. Verify that all pins are inserted into plug. Ensure that no pins are bent or damaged in ECU. Actions Check for faulty A/C potentiometer or associated wiring. Check for disconnected or faulty thermistor. Check for faulty A/C potentiometer or associated wiring (Not applicable to 3-pot controls). System must be charged for compressor to engage. Unplug 3-wire BSC control connector from ECU. If blower stays running, BSC is either improperly wired or damaged. Unplug 3-wire BSC control connector from ECU. If blower shuts off, ECU is either improperly wired or damaged. Check for damaged ground wire (white) in control head harness. Check for damaged blower switch or potentiometer and associated wiring. Check for damaged pins or wires in control head plug. Checks Red wire at A/C pot should have approximately 5V with ignition on. White wire will have continuity to chassis ground. White/ Blue wire should vary between 0V and 5V when lever is moved up or down. Disconnected or faulty thermistor will cause compressor to be disabled. To check for proper pot function, check voltage at white/blue wire. Voltage should be between 0V and 5V, and will vary with pot lever position. Danger: Never bypass safety switch with engine running. Serious injury can result. No other part replacements should be necessary. See blower switch check procedure. Loss of ground on this wire renders control head inoperable. Notes Troubleshooting Guide 24 903062 REV H 08/12/19, PG 24 OF 26 Symptom 8. When ignition is turned on, blower momentarily comes on, then shuts off. This occurs with the blower switch in the OFF position. Erratic functions of blower, mode, temp, etc. 7. Blower turns on and off rapidly. 6. Loss of mode door function. 5. System will not turn on, or runs intermittently. 4. This is an indicator that the system has been reset. Be sure the red power wire is on the battery post, and not on a switched source. Also, if the system is pulled below 7V for even a split second, the system will reset. Run red power wire directly to battery. Repair or replace. Charge battery. Check for faulty battery or alternator. Battery voltage is less than 12V. Check for damaged switch or pot and associated wiring. Ensure all system grounds and power connections are clean and tight. Verify proper meter function by checking the condition of a known good battery. Check for positive power at heater valve green wire and blower red wire. Check for ground on control head white wire. Install capacitors on ignition coil and alternator. Ensure good ground at all points. Relocate coil and associated wiring away from ECU and ECU wiring. Check for burned or loose plug wires. Actions Check for at least 12V at circuit breaker. Check for damaged stepper motor or wiring. Check for obstructed or binding mode doors. Check for damaged mode switch or potentiometer and associated wiring. Verify battery voltage is greater than 10 volts and less than 16. Verify connections on power lead, ignition lead, and both white ground wires. Noise interference from either ignition or alternator. Checks Battery voltage is at least 12V. Partial function of mode doors. No mode change at all. Will not turn on under any conditions. Works when engine is not running; shuts off when engine is started (Typically early Gen IV, but possible on all versions). Condition www.vintageair.com System shuts off blower at 10V. Poor connections or weak battery can cause shutdown at up to 11V. Typically caused by evaporator housing installed in a bind in the vehicle. Be sure all mounting locations line up and don’t have to be forced into position. Ignition noise (radiated or conducted) will cause the system to shut down due to high voltage spikes. If this is suspected, check with a quality oscilloscope. Spikes greater than 16V will shut down the ECU. Install a radio capacitor at the positive post of the ignition coil (See radio capacitor installation bulletin). A faulty alternator or worn out battery can also result in this condition. Notes Troubleshooting Guide (Cont.) 25 Cut Along Dotted Line 3.375” Cut Along Dotted Line Drill 3/16” Defrost Duct Mounting Template Driver Side Under Dash Louver Template Drill 3/16” Align This Edge Against Dash Brace Cut Along Dotted Line www.vintageair.com Templates: Driver Side Under Dash Louver Bezel & Defrost Duct Mounting 903062 REV H 08/12/19, PG 25 OF 26 www.vintageair.com Part No. No. Qty. 744004-VUE 1. 1 784061 2. 1 Packing List: Evaporator Kit (561062) Description Gen IV Evaporator Sub Case Accessory Kit Checked By: Packed By: Date: 1 Gen IV Evaporator Sub Case 744004-VUE 2 Accessory Kit 784061 NOTE: Images may not depict actual parts and quantities. Refer to packing list for actual parts and quantities. 26 903062 REV H 08/12/19, PG 26 OF 26