Classic AutoAir 1971-1973 Mustang A/C system Installation manual

Installation Manual
©
1971-1973 Mustang
DOCUMENT #1-2028
©2013 ClassicAutoAir / 2-1vs.b
Congratulations...
You have just purchased the highest quality, best performing
A/C system ever designed for your Classic Vehicle.
To obtain the high level of performance and dependability our systems are known for, please pay close attention to the
following instructions. Our installation steps and procedures are derived from a long history of research and
development and the combined experience achieved thru thousands of successful installations (and feedback from
customers like you). Please remember that our #1 goal is that you’ll have a successful installation and a system that
performs at a very high level for many years to come.
Before starting, read the instructions carefully, from beginning to end, and follow the proper sequence. On the next
page you’ll find a safety and general checklist that you should read before starting your installation.
Again, thank you from our entire staff.
www.classicautoair.com • 866.435.7801
4
Check List, Pre-Installation:
Before beginning the installation check the shipping box for the correct components. YOUR BOXED UNIT INCLUDES A LIST OF
MAJOR COMPONENTS AND A LIST OF BAGGED PARTS. We have a 5 stage check process to make sure you have everything you’ll
need.
If your vehicle has been or is being modified, some procedures will need to be adjusted to fit your particular application.
A basic cleaning of the engine compartment and interior before beginning will make things go more smoothly.
Check condition of engine mounts. Excessive engine movement can damage hoses to A/C and/or heater.
Before starting, check vehicle interior electrical functions (interior lights, radio, horn, etc). Make a note of anything that does not work as
it’s supposed to. During the installation you might find the opportunity to repair or upgrade non-working or out of date components.
When you’re ready to start the installation, DISCONNECT THE BATTERY FIRST.
Drain the radiator. Retain the coolant and reuse, or dispose of properly.
SAFETY FIRST: Wear eye protection while drilling/cutting, deburr sharp edges, and never get in a hurry or force a part.
Tools: Your installation only requires the basic tools everyone has in their garage, nothing exotic or specific to A/C or Heat equipment.
Procedures, During Installation:
Fittings: Use one or two drops of mineral oil (supplied with your kit) on ALL rubber o-rings, threads and rear of bump for o-ring where
female nut rides. Do not use thread tape or sealants.
Measure twice (or more), cut once
Should you have any technical questions, or feel you have defective components (or missing items), call us immediately,
we will be glad to assist you. Our toll-free number is listed on every page, we’re here to help!
YOU CAN NOW BEGIN THE INSTALLATION...
www.classicautoair.com • 866.435.7801
5
A Basic A/C Overview
OUTSIDE AIR
Evaporator with Blower Fan
1
In order to remove the heat from the air in the vehicle, the A/C
evaporator allows the refrigerant to absorb the heat from the air passing over it. The blower fan moves cool air out into the car
interior.
2
Compressor The compressor pumps and circulates the refrigerant through the system.
3
Condenser The condenser is a heat exchanger mounted at the front of the vehicle. Heat drawn out of the interior of
4
the car is expelled here.
Receiver/Drier The drier not only dries refrigerant, it also filters the refrigerant and stores it under certain
Suction
Valve Discharge
Valve
Receiver
Drier
Condenser
Compressor
operating conditions.
5
High Pressure Switch A pressure switch is used to shut down the system if high or low pressure is
detected, basically it acts as a safety switch.
Firewall
Expansion Valve
AIR FROM INSIDE VEHICLE
COO
LED
AIR
1
SUC
3
LIQ
TIO
UID
NH
OS
E
2
DIS
SE
GRO
POW
ER
UND
COLD AIR INTO VEHICLE
5
4
SE
Evaporator Unit
E HO
RG
CHA
HO
The air conditioning system in your car is comprised of a compressor, condenser,
expansion valve, receiver/drier, and evaporator. Refrigerant (also known as Freon) is
compressed in the compressor and turns into a gas. In the condenser, this gas is cooled to a
liquid state and travels to the expansion valve. As the liquid refrigerant goes through the
expansion valve it rapidly cools in the evaporator. A fan blows over the evaporator and cools the
air that blows out your vents. The receiver-drier separates gas and liquid.
www.classicautoair.com • 866.435.7801 • OVERVIEW
6
Control & Operating Instructions
Your new Perfect Fit-Elite system offers complete comfort capabilities in
virtually every driving condition. This includes temperature control in all of the
modes. This system also provides the ability to blend the air between Face,
Heat, and Defrost modes simultaneously. To illustrate the various ways you can
adjust the airflow direction and temperature - we’ve provided these handy
illustrations and chart to show exactly how you can adjust your Perfect
Fit-Elite for maximum comfort...
The FAN switch works like the OEM switch, the DOWN position is OFF
(all power to the system is OFF in this position).
MODE LEVER
There are 11 levels of adjustment within the range of the MODE lever.
The COLD/HOT positions works like any traditional adjustment lever.
FAN SWITCH
NOTE: When the TEMP lever is in the "FULL COLD" position the
compressor is ON, no matter what position the MODE lever is in (think
of it as a compressor-override function).
TEMP LEVER
DASH
Left Lever Postion
Distribution
Compressor State
1
Face A/C
100%
ON
DEF
2
3
4
5
Face
80%
Face
60%
Face
40%
Face
20%
Defrost
20%
Defrost
40%
Defrost
60%
Defrost
80%
6
Defrost
100%
FLOOR
7
8
9
10
Floor
20%
Floor
40%
Floor
60%
Floor
80%
Defrost
80%
Defrost
60%
Defrost
40%
Defrost
20%
11
Floor
100%
ON
www.classicautoair.com • 866.435.7801
7
INTERIOR
COMPARTMENT
Remove Glovebox, Console (optional), Facia, Radio and Bezel, and set them aside for reinstall later (see figure 1). The removal of the Original Heater Assembly can be accomplished by disconnecting three control cables. One is attached to the Heat/Defrost door (see figure 2). One is attached to the Temperature door, and one is attached to the Vent / Heat door (see figure 3). Disconnect the electrical harness from the assembly. Also remove attachment screw located in front of the air inlet (see figure 4). FIGURE 1
When retaining parts it’s a good idea to store parts in a zip lock bag, labeled with GOOD IDEA info where the parts came from and what size/type of tool is needed to reinstall. Cleaning the parts before you need to reinstall them is a good idea too.
FIGURE 2
FIGURE 3
FIGURE 4
www.classicautoair.com • 866.435.7801
8
Remove all 4 nuts around blower (as indicated by arrows to right, on passenger
side of firewall). Cut wires at firewall.
Next, remove the OEM defrost duct and set aside for later modification.
DRAIN COOLANT FROM RADIATOR and store safely to reuse or recycle
accordingly. Cut heater hose approximately 1” from firewall. Also, to prevent
forgetting to refill the coolant when the installation is completed, do not put the
cap back into place - instead put the cap to the side and cover radiator hole
with a clean rag or something similar (this will help remind you to add coolant
before starting the engine at the end of the installation).
OEM Heater Unit
(Not reinstalled)
www.classicautoair.com • 866.435.7801
9
THESE ARE THE PARTS YOU WILL FIND IN BAG KIT A
You will use all of these parts and hardware during the next series of installation steps.
Pressure Switch
(engine compartment)
Ground
Ground
Ground
ECU
Thermostat
OEM Power
Supply
Fan
Plug
Cable Integrators
Wire Harness Power Supply
Blower Switch
Connection
Relay
Faceplate Sticker
Blower Switch Knob
Blower Switch Bracket
Blower Switch
Two #6 - 20x3/8" Screws
NOTE: Illustrations NOT shown actual size
Two - Cable Clips
www.classicautoair.com • 866.435.7801
10
Remove The Heater Control Head From The Dash.
1) There are four OEM screws that hold your control head to the dash. Remove
and retain these screws. Remove the control head assembly (see figure 7).
2) Remove the OEM blower switch knob. Retain the screw, you will use it again
shortly. Remove the control cables and the original blower switch and set aside
(these will not be reused, see figure 8).
3) Attach the new blower switch bracket to the top part of the back of the face
plate (see figure 9-10), utilizing the OEM screw, and then attach the blower
switch to the bracket with the two supplied #6 - 20x3/8" screws.
FIGURE 7
(OEM switch
not reinstalled)
FIGURE 8
Retain this
OEM screw
FIGURE 9
Retain all the OEM parts that
you remove, at least until the
installation is completed.
GOOD IDEA
#6 - 20x3/8" Screws
FIGURE 10
www.classicautoair.com • 866.435.7801
11
Preparing the TEMP EZ Cable Integrator for
installation:
First place a cable clip over the end of the
Integrator (see figure A). Press it firmly into place
(using needle-nose pliers is recommended).
Figure A
Figure B
Hook loop end of integrator wire over the end of
the control head lever, see figure B.
Using the OEM screw mount the integrator to the
control head pedestal as shown in figure D. Make
sure orientation is correct, using figure C as a
guide.
OEM Screw
TEMP
Figure C
Securely fasten wire end with a push nut (see
figure E).
Lastly, move LOWER lever side to side
making sure you have smooth
operation of the cable integrator.
Figure E
Figure D
12
13
THESE ARE THE PARTS YOU WILL FIND IN BAG KIT B
You will use all of these parts and hardware during the next series of installation steps.
Two 1/4 - #20 x 5/8" Bolts
Evaporator Support Bracket
Fresh Air Inlet Block Off
One Male Spade Connector
Defrost/Heat Duct Assembly
One J-Clip
Four #10 - 16 x 3/4" Tek Screws
Four #10 - 10 x 5/8" Phillips Screws
One 1/2" Washer
Illustrations NOT shown actual size
www.classicautoair.com • 866.435.7801
14
Locate the original wiring harness that supplied power to the original heater
motor. Measure 4” from harness and cut both wires (see figure 15). On the OEM
power supply wire attach a 1/4” insulated male spade connector. Within the
OEM fuse box upgrade the factory HEATER fuse with a 20 amp fuse (VERY
IMPORTANT).
4"
Locate the bottom left mounting hole in the firewall that attached the original
heater motor. TEMPLATE NOTIFICATION! A handy drilling template is
included in this manual (example shown in figure 17). Tape the template to the
firewall, lining up the hole indicators for the OEM lower right heater hose outlet
and a lower bolt hole. From inside of the vehicle drill a 5/8" dia. hole for the
drain tube, and 4” round hole as shown.
CAUTION: Be aware of components like brakes (on the engine side) and
wires (on the interior side) of the firewall before drilling.
ALL PRELIMINARY
MODIFICATIONS TO THE
VEHICLE ARE COMPLETE.
YOU CAN NOW BEGIN
INSTALLING YOUR CLASSIC AIR
PERFECT FIT ELITE SYSTEM.
FIGURE 15
YOU CAN DRILL A
SMALL PILOT
HOLE IN THIS
LOCATION FIRST
S
TIP
TECH
WITH A SMALLER
DRILL BIT (LIKE 3/16"), THEN
PROCEED WITH THE 5/8" BIT
ONCE YOU KNOW YOU HAVE
CLEAR SPACE.
FIGURE 16
www.classicautoair.com • 866.435.7801
15
Locate the Fresh Air inlet block off. Install over hole in inlet cowl as shown on
the passenger side (see figure 17A). Attach with three #10 - 16 x 3/4" Tek
Screws. Locate the mounting tab location as shown and attach the 1/4" 20
J-clip supplied (see figure 17B).
Remove evaporator unit from box and place on a flat work surface.
Locate defrost / heat duct assembly and attach to the evaporator using two
#10 - 10 x 5/8" Phillips screws (see figure 18). NOTE: Be sure that the s-clips
are pushed over rear flange on evaporator.
A
B
FIGURE 17
Take a minute to familiarize yourself with the evaporator unit:
Actuator Motor
Blower Motor
Bracket
Floor/Face
Vent Door
Evaporator
Support Bracket
Holes
FIGURE 19
Thermostat
Blower Motor Plug
FIGURE 18
www.classicautoair.com • 866.435.7801
16
DASH
FIREWALL
Installing the complete evaporator unit under the dash will go much easier with
the help of a friend. One person can take the unit within the car and “roll” up
and under the dash while the other person can be ready at the firewall area with
one of the 1/4" - #20 x 5/8" bolts to secure the unit in place (see figure 20).
Now the unit will be easy to level and secure. Leveling the unit is very important
to insure proper drainage of condensation.
On back side of the evaporator is a mounting bracket with a 1/4"-20 J-clip. This
bracket will go flush with the inside firewall and you will secure the evaporator
by inserting one 1/4" - #20 x 5/8" bolt with a 1/4” washer (from the engine side)
using the bottom right hole (that originally attached the original heater assembly,
see figure 21).
FIGURE 20
LEVEL
TECH TIPS
Be sure to align the evaporator unit level with the bottom of instrument
panel (assuming the vehicle is sitting level) as shown above, but with a small
degree of tilt toward the back to allow proper drain of condensation.
FIGURE 21
1/4 - #20 x 5/8" bolts and
a 1/4” washer
www.classicautoair.com • 866.435.7801
17
The second 1/4 - #20 x 5/8" bolt attaches the blower motor mounting
bracket in the same location as the original heater mounting in front of the Air
Inlet. The blower support bracket will have an additional hole behind the 1/4 #20 x 5/8" Bolts. Install a #10 - 16 x 3/4" Tek screw through this hole and into
the cowling (see figure 22).
Locate in the Bag Kit B the Evaporator Mounting Bracket and attach to
evaporator unit using two #10 - 10 x 5/8" Phillips screws. Attach other end to
the cowling with a #10 - 16 x 3/4" Tek Screw (see figure 23). IMPORTANT
NOTE: On the side of the main unit you will see several holes for
mounting holes... ONLY USE THE ONES IN THE CENTER FOR THIS
BRACKET! Do not tap into the other holes for any reason (see figure 24).
Also, use a screwdriver and hand-power and do not over-tighten so you
don't strip the holes.
FIGURE 22
#10 - 16 x 3/4" Tek Screw
FIGURE 24
NO!
YES
NO!
FIGURE 23
#10 x 5/8"
Screws
www.classicautoair.com • 866.435.7801
18
THESE ARE THE PARTS YOU WILL FIND IN BAG KIT C
You will use all of these parts and hardware during the next series of installation steps.
Clear Plastic Drain Tube
Electronic Water Control Valve
Two 1 1/4" Cap Plugs
Six Worm Gear Clamps
Firewall Block Off
Two #10 - 16 x 3/4" Tek Screws
Refrigerant Tape
Illustrations NOT shown actual size
www.classicautoair.com • 866.435.7801
19
Water valve hose connects to this connection
In Bag Kit C you’ll find the firewall block off. Install this over the hose connections coming
thru the firewall within the engine compartment. Attach with two #10 - 16 x 3/4" Tek screws
(see figure 25). TIP: This would be a good time to “jump” ahead a bit, and remove the
ORANGE cable from Bag Kit D and route it thru the block off plate (it will be plugged
into the electronic water valve). The cable for the electronic water valve can share
the hole with smaller liquid line opening. Seal around the tubes with the included
refrigerant tape. This will keep unwanted moisture and debris from entering thru the firewall...
so seal carefully and thoroughly.
IMPORTANT
NOTICE: PROPER
INSTALLATION OF
WATER VALVE
INSTRUCTIONS!!!
FIGURE 25
This inlet is
connected
to the intake
manifold
installed per these instructions!... (if not, your system
will not work properly... and that’s an absolute fact).
The lower connection on the tubes coming thru the block
off assembly is going to be routed to the water outlet on the
intake manifold. Attach your hose with cable clamps on both
ends and route where it will not interfere with linkage or come
in contact with exhaust manifolds or headers.
CO
RE
The upper port coming thru the firewall will be routed to and thru your new your electronic water
valve (the water valve is marked for easy installation). First Attach a 6” piece of 5/8” dia. heater hose
with the supplied worm gear clamp. Attach to the inlet side of
the water valve using another supplied hose clamp. Attach a
heater hose from the outlet side of the electronic water valve
FIGURE 26
and route to the connection on the water pump.
AT
PU
MP
ER
T
WA
ER
HE
Classic Auto Air has done extensive testing on the correct
method to install the water valve in order to get a repeatable and
progressive temperature control. Your water valve MUST be
Insert a 6" piece of the clear, 1/2" drain tube we included
through the hole previously drilled and attach over the drain
nipple. Seal around tube with refrigerant tape (see figure 26).
1/2" Clear Drain Tube
Refrigerant Tape
www.classicautoair.com • 866.435.7801
20
THESE ARE THE PARTS YOU WILL FIND IN BAG KIT D
You will use all of these parts and hardware during the next series of installation steps.
CONT
WATER
VALVE
The ECU will be found
in it’s own box
ROL
ST
LOOR
POWER
DEFRO
FACE/F
Five #10 - 16 x 3/4" Tek Screws
Yellow
Orange
Blue
Wire Harness System
Illustrations NOT shown actual size
www.classicautoair.com • 866.435.7801
21
We’ve included enough wire length to allow you to mount the ECU in a variety
of places. It is very important that you mount this in a place where it will stay dry
and that vibration is at a minimum. Also make sure that where ever you mount it
does not interfere with any moving controls or cables. We recommend
mounting it just above the right hand side of the main unit using the included
tek-screws. IMPORTANT! DON’T MOUNT THE ECU PERMANENTLY JUST
YET. THAT CAN BE DONE AFTER YOU CALIBRATE THE UNIT (SEE NEXT
PAGE).
In Bag Kit D you will find three wiring harnesses with connections at each end.
Plug the harness with YELLOW band into the YELLOW ECU port and the other
end into the servo motor on the main unit (motor is marked with YELLOW
INDICATOR). Repeat this process for the other two harnesses, following the
color coding indicated on cables and ports. Attach cable in the engine
compartment to the electronic water valve (see figure 27). Using one of the CAP
PLUGS provided, slot it and install over the heater hose/cable.
INSTALL (2) CAP PLUGS
OVER HOLES.
SLOT ONE FOR THE CABLE.
FIGURE 27
FIREWALL
ROL
CONT
WATER
VALVE
NOTE: The GREEN harness connection will be made from the harness you
previously installed, just plug the loose connection in the CONTROL
port on the ECU.
ST
LOOR
POWER
DEFRO
FACE/F
www.classicautoair.com • 866.435.7801
22
Orang
eH
arn
e
Wiring Diagram/Overview
To 12V Power Supply
ss
Electronic Water Valve
Re
d
/W
hite
Compressor
Wi
re
r
G
Wh
Pressure Switch
Ground
Wire
ite
Blower Switch
res
Wi
e
Blu
ess
arn
H
n
ee
ECU
Servo for Defrost Ducts
Relay
Blu
eW
ire
Thermostat
ire
W
Red Wire
ness
Blu
e
Servo for Face/Floor Ducts
Blue Har
ss
r ne
Yello w H a
Cable Integrators
Ground
Evaporator
Bl
ue
W ire
Ground
REMINDER: BE SURE THAT THE WIRING HARNESS DOES NOT INTERFERE WITH THE OPERATION OF ANY CONTROLS.
www.classicautoair.com • 866.435.7801
23
Temporarily reconnect the car battery at this time. You will need a full 12 volts to complete the calibration.
WELCOME TO EZ CALIBRATION... Follow these directions carefully and your unit will be calibrated in just a few minutes.
Before we boxed and shipped your unit, we tested and calibrated it to factory specifications to make sure it is capable of operating at maximum efficiency. However,
the unit must still be calibrated to your specific vehicle and controls. This is an easy process that can be done in a few steps. If for any reason your unit does not
calibrate properly the first time, just turn off the unit and rerun the setup process. NOTE: When you move a knob to a new position, do it in ONE continuous motion.
#1
#2
ER
WAT
E
#3
FAN HIGH
VALV
DASH
C
FA
OR
DE
COLD
R
tion
ibra
HOT
COLD
HOT
HOT
COLD
After 1 second the
LED turns back ON
O
LED N
D OFF
LE
1 Second
Later...
#8
FAN HIGH
DEF
COLD
FLOOR
ER
WAT
HOT
D OFF
LE
You may be able to
hear the internal door(s) move
back and forth...
Approx. 30
Seconds
Later...
D OFF
LE
Move the FAN knob to OFF
(powers off unit)
E
VALV
ST
RO
FAN OFF
C
FA
OR
DEF
LO
E/F
L
RO
NT
Move TEMP control to
HOT in one motion...
D OFF
LE
1 Second
Later...
#7
DASH
O
LED N
HOT
Move MODE control to
DASH in one motion...
CO
1 Second
Later...
FLOOR
FAN OFF
Move FAN control to medium
in one motion...
FLOOR
FAN OFF
O
LED N
DEF
DASH
FAN OFF
Position your controls
like this example.
#6
COLD
FLOOR
O
LED N
#5
DEF
FAN HIGH
DEF
Key
Plug CALIBRATION KEY into ECU
DASH
DASH
FAN OFF
Cal
FAN HIGH
FLOOR
T
WE
PO
DEF
S
FRO
LO
E/F
L
RO
NT
CO
#4
FAN HIGH
R
WE
PO
tion
ibra
Cal
Key
REMOVE KEY
AND STORE IN
SAFE PLACE
That’s it. Your unit is now fully calibrated. Disconnect the battery and move on to the next phase....
www.classicautoair.com • 866.435.7801
24
THESE ARE THE PARTS YOU WILL FIND IN BAG KITS E, F, and G
You will use all of these parts and hardware during the next series of installation steps.
Bag E
Defrost Adaptor
PN#2-1028-1
Bag F
Bag G
Two Louver Adaptors
PN#2-1028-3
Center Dash Vent
PN#1-1028-2
To Center
Louver
Two Duct Hoses, 2" I.D.
Capped
(unused)
To Drivers
Side Louver
Two Duct Hoses, 2" I.D.
Face/Duct
Assembly
To Passenger
Side Louver
Four Zip-Ties
Four Zip-Ties
Four #10 - 10 x 5/8” Screws
Two Duct Hoses
2" I.D.
Four Zip-Ties
Illustrations NOT shown actual size
www.classicautoair.com
• 866.435.7801
• PAGE 18
www.classicautoair.com
• 866.435.7801
25
Bag Kit E. Attach the included defrost adaptor to the OEM duct assembly.
Pre-installed S-Clips will hold it in place (trim flange as needed).
Attach flex hoses to the adapter and route to the assembly on the top of the
evaporator (see figure 29).
The face/duct assembly comes s-clips pre-installed which allow you to install it
onto the evaporator unit quickly and securely (see figure 30).
FIGURE 29
FIGURE 30
www.classicautoair.com • 866.435.7801
26
Attach louver adaptors to the back
side of OEM louvers, both sides.
S-Clips will hold them in place.
Route supplied flex hoses as
shown below. Take your time and
route them so they don’t become
kinked or torn.
TECH TIPS
During installation of the hoses be aware of the eventual movement
of the wiper arm components. Also, the process for installing the
center louver vent will require a small amount of cutting. This is
outlined on the next page.
GOOD IDEA
The smoother the route of the flex hoses
the better the airflow.
OEM VENT
During installation of the hoses be
aware of the eventual movement of
the wiper arm components.
Adaptor
www.classicautoair.com • 866.435.7801
27
Bag Kit G: Installing the center louver vent requires some cutting to the upper pocket slot in the center dash area. Your goal is to open
the back enough to insert the included center louver unit into the hole and then attach the flex hose.
Once the hole is the right size, insert the new center louver and attach the flex hose using ty-wraps to secure. Route to the face/duct
asembly on the evaporator.
FIGURE 32
Remove this
area, keep edges
smooth
GOOD IDEA
As you cut the hole thru the dash, keep the new center
louver handy and test fit occasionally.
www.classicautoair.com • 866.435.7801
28
You can reinstall the glove box, radio, bezel, facia and the
console at this time.
This completes the interior portion of the PERFECT
FIT-ELITE installation process. This is a good time to make
a final check that all the controls still move freely and that
nothing is loose or hanging down.
The interior of your car should look pretty much the same as
before you started (or better). Plus you probably got to know
the underside of your dash a lot better and might even have
repaired or upgraded components that needed attention.
Good Job... Let's move on to the major components
within the engine compartment....
www.classicautoair.com • 866.435.7801
29
THESE ARE THE PARTS YOU WILL NEED FOR THE
ENGINE COMPARTMENT INSTALLATION
You’ll find all of these parts within the main box
Liquid Tube
Left Condenser
Upper
PN# 0022-100
Right Condenser
Upper
PN# 0046-50
Left Condenser
Lower
PN# 0022-101
Right Condenser
Lower
PN# PN# 0046-51
Drier Bracket
Drier
Liquid Tube
Drier to Evaporator
Condenser
PN# 11-1043
Discharge Tube
Core Support Spacer
3/8”
Four Zip-Ties
#10 1
Three Refrigerant Hoses
ose
Four #14 - 16 x 3/4" Tek Screws
ti o
S
uc
#
Bag of O-rings and Mineral Oil Tube
nH
2" D
ischa
rge Hos
e
Splice and
Bullet Connector
3/3
Pressure Switch
/16" Liquid Hose
#6 5
81
Pressure Switch Harness
Tube Support Bracket
PN#19-151
/2"
Ten #10 - 10x3/8" Hex Screws
www.classicautoair.com • 866.435.7801
30
ENGINE COMPARTMENT
INSTRUCTIONS
ENGINE
COMPARTMENT
FIRST THING: IF YOU HAVE NOT
DONE SO ALREADY, DISCONNECT
THE BATTERY.
During the next steps you’ll be installing the condenser, drier,
and routing the high/low pressure lines and the liquid line.
Since much of this is installed in the OEM location for the
condenser, you’ll need to remove the center grill section, and
latch support assembly (see figure 33). Be sure to retain all the
mounting screws – you’ll reinstall these pieces in the exact
reverse order with the OEM screws.
FIGURE 33
www.classicautoair.com • 866.435.7801
31
DRIER AND CONDENSER PREPARATION. You can perform most of the
following steps on a clean flat surface like a workbench. Lay the condenser
down so that both hose connections are on the right side (the larger connection
will be on top). We’ve provided four brackets, 2 upper and 2 lowers, each
designed to mounted to the correct side of the condenser. Use the diagram
below to install the brackets in the correct places (plus, once you slide the
condenser into place in the car, the bolt holes on the brackets will align to the
OEM holes in the support, so you can adjust if necessary).
Use the #10 x 3/8” screws to mount the brackets to the
condenser.
TECH TIPS
You can easily find the
correct position for mounting
the drier to the condenser by
using the drier liquid tube as
a gauge.
Install the drier on the right hand side of the condenser.
First insert the drier into the drier mounting bracket (it’s
basically a sleeve for the drier). Attach the drier liquid tube
to the drier and also to the connection on the lower
condenser (tighten connections at either end using
supplied o-rings on both ends and a few drops of mineral
oil to each o-ring). With these two components combined
it will easy to find the correct place to attach the drier
bracket to the condenser with the included tek screws.
Place the condenser into place in the vehicle. Secure
brackets to holes in OEM support with included Tek
screws.
TECH TIPS
Reminder...
Use two
wrenches to
tighten o-ring
fittings
www.classicautoair.com • 866.435.7801
32
Screw the high-pressure switch into the port at the top of the drier. Plug in harness.
Just to the left of the hole that you will route the tubes thru the support is a
dimple (see illustration to the right). Drill a 3/16” hole thru the dimple, and mount
the included tube support spacer.
Locate the Liquid Tube, and the Discharge Tube. Using (1) #6 o-ring and a few
drops of mineral oil attach liquid tube to drier and pass through the opening in the
radiator core support. Using (1) #8 o-ring and a few drops of mineral oil attach
discharge tube to the condenser and pass through the opening.
Attach bracket over tubes. Insert screw through bracket, spacer and then through
previosly drilled hole. Attach using the #10 nut.
Route wires from high-pressure switch out thru the tube hole and along the
discharge tube into the engine compartment.
Spacer
Bracket
www.classicautoair.com • 866.435.7801
33
rS
de
Fe
n
CO
COMMPLETE
PRES
KIT SOR
tru
ts
Time to install the compressor kit. Included in your box is a premium
compressor kit with all the parts you’ll need to install the compressor. This kit
includes instructions specifically written for your engine. Once you’ve installed
the complete compressor kit, continue on to connecting the hoses.
FIGURE 37
1) Attach the #8 Discharge Hose (13/32") to the connection coming thru the core
support and route to the compressor. Tighten fittings using o-rings and mineral
oil provided.
2) Attach the #6 liquid hose (5/16") to the connection coming thru the core
support and route along the underside of the fender struts, around the engine,
and to the connection at the firewall on the evaporator unit (see figure 41). Using
supplied zip-ties you’ll attach this hose, the suction hose and the lead from the
high pressure switch to the strut braces, securing all three at once. Tighten
fittings using o-rings and mineral oil supplied in kit.
3) Attach the #10 suction hose (1/2”) to the compressor and route as mentioned
above. Tighten fittings using o-rings and mineral oil supplied in the kit.
www.classicautoair.com • 866.435.7801
34
PREP
PAGE
New A/C System Preparation... A MUST READ!
Please read thru these procedures before completing this new A/C system charging operation.
A licensed A/C technician should be utilized for these procedures to insure
that your new system will perform at it’s peak, and that your compressor will
not be damaged.
Centerline of the Oil Plug
90˚
90˚
1) Your radiator/cooling system is an integral part of your new system. Please insure that
you have a 50/50 mix of distilled water and antifreeze. The heater coil MUST be purged
(cycle heater control valve) to make sure no water, without antifreeze, is in the heater coil
before you charge the A/C system.
2) Evacuate the system for 45 minutes (minimum).
3) Your new compressor MUST be hand-turned 15-20 revolutions before
and after charging with liquid. Failure to do this may cause the reed
valves to become damaged (this damage is NOT covered by your warranty).
4) Your new system requires 134a refrigerant. It will require 1.5 lbs (or 24 oz).
5) Your new compressor comes charged with oil - NO additional oil is needed.
6) Insure that the new belt is tight.
7)
DO NOT CHARGE SYSTEM WITH LIQUID WHILE THE ENGINE IS RUNNING!
RECOMMENDED TEST CONDITIONS: (After system has been fully charged and tested for basic operation)
• Determine the temperature outside of the car
• Connect gauges or service equipment to high/low charging ports
• Place blower fan switch on medium
• Close all doors and windows on vehicle
• Place shop fan directly in front of condenser
• Run engine idle up to approx. 1500 rpm
ACCEPTABLE OPERATING PRESSURE RANGES:
1. HIGH-SIDE PRESSURES (150-250 PSI)
2. LOW-SIDE PRESSURES (15-25 PSI in a steady state)
CAUTION! When mounting your compressor
and/or adjusting the belt, use caution not to tilt
the compressor up to or more than 90˚ off the
centerline of the oil fill plug. This can cause
compressor failure.
!
Do NOT tilt, shake or
turn refrigerant can
upside-down OR use a
charging station to
install refrigerant while
the engine is running. Doing
so will direct liquid refrigerant into the
compressor piston chamber, causing damage
to reed valves and/or pistons and/or other components,
as well as potentially seizing the compressor. Allow a
minimum of 30 minutes for liquid to "boil off.” You must
hand turn the compressor hub (not the pulley) a
minimum of 15 complete revolutions prior to starting
the engine with the clutch engaged.
Readings above are based on an ambient temperature of 90˚ with an adequate airflow on condenser
www.classicautoair.com • 866.435.7801
35
TROUBLESHOOTING GUIDE
TEST CONDITIONS USED TO DETERMINE SYSTEM OPERATION
(THESE TEST CONDITIONS WILL SIMULATE THE AFFECT OF
DRIVING THE VEHICLE AND GIVE THE TECHNICIAN THE THREE
CRITICAL READINGS THAT THEY WILL NEED TO DIAGNOSE ANY
POTENTIAL PROBLEMS).
B. CONNECT GAUGES OR SERVICE EQUIPMENT TO HIGH/LOW
CHARGING PORTS.
C. PLACE BLOWER FAN SWITCH ON MEDIUM.
D. CLOSE ALL DOORS AND WINDOWS ON VEHICLE.
E. PLACE SHOP FAN IN FRONT OF CONDENSER.
F. RUN ENGINE IDLE UP TO 1500 RPM.
ACCEPTABLE OPERATING PRESSURE RANGES (R134A TYPE)
1. HIGH-SIDE PRESSURES ( 160-250 PSI ) *Note- general rule of thumb is
two times the ambient (daytime) temperature, plus 15-20%.
2. LOW-SIDE PRESSURES ( 06-22 PSI in a steady state).
C.
D.
E.
CHARGE AS FOLLOWS: R134A = 24 OZ.
NO ADDITIONAL OIL IS NECESSARY IN OUR NEW COMPRESSORS.
TYPICAL PROBLEMS ENCOUNTERED IN CHARGING SYSTEMS
NOISY COMPRESSOR. A noisy compressor is generally caused by charging a compressor with
liquid or overcharging
A. If the system is overcharged both gauges will read abnormally high readings. This is
causing a feedback pressure on the compressor causing it to rattle or shake from the
increased cylinder head pressures. System must be evacuated and re-charged to exact
weight specifications.
B. Heater control valve installation - Installing the heater control valve in the incorrect hose.
Usually when this occurs the system will cool at idle then start to warm up when raising the
RPM’s of the motor. THE HEATER CONTROL IS A DIRECTIONAL VALVE; MAKE SURE THE
WATER FLOW IS WITH THE DIRECTION OF THE ARROW. As the engine heats up that water
transfers the heat to the coil, thus overpowering the a/c coil. A leaking or faulty valve will
F.
G.
H.
have a more pronounced affect on the unit’s cooling ability. Installing the valve improperly
(such as having the flow reversed) will also allow water to flow through, thus inhibiting
cooling. Check for heat transfer by disconnecting hoses from the system completely. By
running down the road with the hoses looped backed through the motor, you eliminate the
possibility of heat transfer to the unit.
Evaporator freezing - Freezing can occur both externally and internally on an evaporator
core. External freeze up occurs when the coil cannot effectively displace the condensation
on the outside fins and the water forms ice (the evaporator core resembles a block of solid
ice), it restricts the flow of air that can pass through it, which gives the illusion of the air not
functioning. The common cause of external freezing is the setting of the thermostat and the
presence of high humidity in the passenger compartment. All door and window seals should
be checked in the event of constant freeze-up. A thermostat is provided with all units to
control the cycling of the compressor.
Internal freeze up occurs when there is too much moisture inside the system. The
symptoms of internal freeze up often surface after extended highway driving. The volume of
air stays constant, but the temperature of the air gradually rises. When this freezing occurs
the low side pressure will drop, eventually going into a vacuum. At this point, the system
should be checked by a professional who will evacuate the system and the drier will have
to be changed.
Inadequate airflow to condenser - The condenser works best in front of the radiator with
a large supply of fresh air. Abnormally high pressures will result from improper airflow.
Check the airflow requirements by placing a large capacity fan in front of the condenser
and running cool water over the surface. If the pressures drop significantly, this will indicate
the need for better airflow.
Incorrect or inadequate condenser capacity - Incorrect condenser capacity will cause
abnormally high head pressures. A quick test that can be performed is to run cool water
over the condenser while the system is operating, if the pressures decrease significantly, it
is likely a airflow or capacity problem.
Expansion valve failure - An expansion valve failure is generally caused by dirt or debris
entering the system during assembly. If an expansion valve fails it will be indicated by
abnormal gauge readings. A valve that is blocked will be indicated by high side that is
unusually high, while the low side will be unusually low or may even go into a vacuum. A
valve that is stuck open will be indicated by both the high and low pressures rising to
unusually high readings, seeming to move toward equal readings on the gauges.
Restrictions in system - A restriction in the cooling system will cause abnormal readings
on the gauges. A high-side restriction ( between the compressor and the drier inlet ) will be
indicated by the discharge gauges reading excessively high. These simple tests can be
performed by a local shop and can help determine the extent of the systems problem.
www.classicautoair.com • 866.435.7801
36
Trouble Shooting Your Classic Auto Air A/C System
PROBLEM: system is not cooling properly
ISSUE: cold at idle, warmer when raising engine RPM’s
Make sure the Water Valve is positioned correctly
The water valve is a directional valve and should be installed with the arrow pointing towards the
water pump, it should be connected to the heater hose that runs from the heater core to the
water pump. If the water valve is connected to the incorrect hose it allows water to circulate
through the system via the heater core over powering the cooling effect of the A/C coil, (normally
the air conditioning is functioning properly).
Step 1: Check placement of the water valve, correct if needed. (In some cases changing the
location of the water valve may not fix the above problem.) Continue to next step.
Step 2 If changing the location of the water valve does not rectify the issue, then possibly the
water valve is permanently damaged and may need to be replaced. To check the integrity of the
water valve completely remove the water hoses for the heater core and “loop” together. (This will
remove the heater system completely from the possibilities) If the system now cools, replace the
water valve
Verify Adequate Air Flow to Condenser
For an air conditioning system to function properly there has to be adequate airflow across
the condenser. The function of the condenser is to dissipate heat, without proper
airflow your system will not cool correctly in the cabin of your vehicle.
Step 1: connect gauges to a/C hoses. The pressures should be: with the ambient temp is
90, low side pressures should be between 8-25 psi, high side pressures should be
between 160-260psi
Step 2: IF the low side pressures are normal and the high side pressures are high then
there might be an airflow issue, continue to next step.
If the paper is held in place you are at least getting some air flow. If the high side
decreases during test 2 & 3 then your condenser is not getting enough air which is
causing your system to not cool properly. To correct this issue you will need a more
powerful mechanical fan.
Step 3: Confirm correct Refrigerant charge in System
All of our systems should be charged with 24oz or 1.8lbs of R134 Refrigerant only. If
overcharged you will need to evacuate the system and recharge with the correct
amount.*
What measurements mean:
Low Temp and High Pressure seem to be equal...
You have a malfunctioning expansion valve that is stuck open.
High Side is extremely high and Low Side is extremely low (possibly into vacuum)...
There is a blockage in the system. Remove hoses and blow compressed air through in both
directions. If pressures don’t change its possible that your expansion valve is stuck
closed and would have to be replaced.
*Compressor Concerns:
This is often misdiagnosed as a problem for the system not cooling properly. If you have a noisy
compressor it is due to improper charging of refrigerant. An overcharged (more than 24oz or
1.8lbs R134) compressor can cause rattling. If charged with pure liquid there is a high probability
you have bent reed valves that are causing tapping sound.
To test air flow to Condenser do the following three tests:
1. Place a piece of paper on the condenser with the car in idle and see if paper is held in
place.
2. With car in idle, attach gages, and place a large capacity fan in front of the condenser.
What happens to the pressures?
3. With car still in idle and gages attached, pour water down the front of the condenser.
What happens to the pressures?
www.classicautoair.com • 866.435.7801
OEM
HOLE
Lower Right
OEM Heater
Hose Hole
DRILL 9/32’ HOLE
CUT 4” DIAMETER HOLE
IF YOU PRINTED THIS MANUAL
PLEASE READ THIS...
DRILL 5/8’
HOLE
THIS IS FROM
THE INSIDE
OF CAR!
1971-1973
TEMPLATE
37
38