Classic AutoAir Perfect Fit-Elite Series Installation manual

Installation Manual
19641/2 – 1966 Mustang
DOCUMENT #1-2025
©2013 ClassicAutoAir / 3.13vs2
www.classicautoair.com • 866.435.7801
PAGE
3
You have just purchased the highest quality, best performing
A/C system ever designed for your Mustang.
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
PAGE
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 During the installation you might find the opportunity to repair or upgrade non-working or out of date components.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 where o-rings seat in fittings. 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
PAGE
5
A Basic Overview of Automotive A/C...
1
OUTSIDE AIR
Evaporator with Blower Fan 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
4
Receiver/Drier The drier not only dries refrigerant, it also filters the refrigerant and stores it
#8 Discharge Hose
Suction
Valve
out of the interior of the car is expelled here.
Receiver
Drier
Condenser
Compressor
under certain operating conditions.
5
Discharge
Valve
High Pressure Switch A pressure switch is used to shut down the system if high or low
#10 Suction Hose
#6 Liquid Hose
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
GE
HAR
E
POW
ER
GRO
UND
COLD AIR INTO VEHICLE
5
4
SE
Evaporator Unit
HOS
DISC
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
PAGE
6
CONTROL & OPERATING INSTRUCTIONS
FAN SWITCH
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...
FACE
Left Lever Postion
The FAN switch works like the OEM switch, the
far left position is OFF (all power to the system
is OFF in this position)
MODE LEVER
Unused
There are 11
levels of
adjustment
within the range
of the
DASH/FLOOR
lever
1
2
3
4
5
6
7
8
9
10
11
DASH
HI
COLD
The
COLD/HOT
positions
works like
any
traditional
adjustment
lever
DEF
FLR
DEF
OFF
HOT
NOTE: When the TEMP lever is in the "FULL
COLD" position (TOP), the compressor is ON,
no matter what position the DASH / FLR lever is
in (think of it as a compressor-override function)
FLOOR
TEMP LEVER
Compressor
State
Distribution
1
Face A/C
100%
2
Face A/C
Defrost
80%
20%
3
Face A/C
Defrost
60%
40%
4
Face A/C
Defrost
40%
60%
5
Face A/C
Defrost
20%
80%
6
Defrost
100%
7
Floor
Defrost
20%
80%
8
Floor
Defrost
40%
60%
9
Floor
Defrost
60%
40%
10
Floor
Defrost
80%
20%
11
Floor
100%
ON
ON
www.classicautoair.com • 866.435.7801
PAGE
7
Remove Glove box, Glovebox door, Ashtray, and Radio, and set them aside for reinstall later (see figure 1).
Note: If vehicle is equipped with a console, remove entire console and set aside.
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 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 air inlet (see figure 4).
FIGURE 2
FIGURE 3
FIGURE 4
www.classicautoair.com • 866.435.7801
PAGE
8
Locate blower motor on the firewall (Passenger Side) in the engine compartment. Remove all 4 nuts around
blower. Also disconnect the electrical connector from the blower motor (see figure 5A). Cut wires at grommet in
firewall.
A
B
1"
UPP
ER
R
OW O
BL OT
M
DRAIN COOLANT FROM RADIATOR. Store safely to reuse or recycle accordingly. Cut heater hose
approximately 1” from firewall (see figure 5B). 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.
HE
SE
HO E
ER OS
AT TER H
ER
HE
LOW
ER
A
Located on top of instrument panel is the radio speaker cover plate, carefully remove the screws and retain. Under
the cover there are two OEM defrost adaptors. Remove and discard adaptors and the defrost flex duct that is
attached (see figure 7). Remove all heater assembly and
defrost flex ducting. Discard (or save and pass along to a fellow
Mustang enthusiast, if reusable).
FIGURE 5
OEM Heater Unit
(Not reinstalled)
FIGURE 7
FIGURE 6
Remove adaptors
and hose
www.classicautoair.com • 866.435.7801
PAGE
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
Cable Integrators
Fan
Plug
Two #8 - 20x3/8" Screws
Wire Harness Power Supply
Blower Switch
Connection
Relay
OFF
Blower Switch Knob
PN# 525235
DASH
HI
COLD
Two - Cable Clips
PN# 25-1015
DEF
FLR
Blower Switch
PN# 4M-235
Blower Switch Bracket
PN# 0023-8
Illustrations NOT shown actual size
HOT
Face Plate Sticker
0118-1
Three #6 - 20x3/8" Screws
www.classicautoair.com • 866.435.7801
PAGE
10
REMOVE THE HEATER CONTROL HEAD FROM THE DASH.
1) On the back side of the control head there are two nuts and retaining clips. Remove and
retain. Remove the control head assembly (see figure 8).
2) Using an allen wrench, remove blower switch knob. Remove the control cables and the
original blower switch and set aside (will not be reused).
FIGURE 8
3) Attach the blower switch bracket to the top part of the back of the face plate (see figure 9),
utilizing the OEM screw (A) and the #6 - 20x3/8" screws we provided (B). So as not to interfere
with the operation of the lever, install the lower screw from the inside to the outside (C). Then
attach the NEW blower switch (D).
#6 - 20x3/8" Screws
B
TECH TIPS
Retain all of the original
hardware and components
until you are completely
finished.
D
A
Remove and retain for
later use these two
OEM nuts AND
retainers
(OEM switch
not reinstalled)
C
#6 20x3/8"
Screw
FIGURE 9
www.classicautoair.com • 866.435.7801
PAGE
11
Within Bag Kit A we included our exclusive
Cable Integrators, which you will now attach to your OEM
control head (as shown in Figure 12). Placing the control head on a flat work area, attach them exactly as shown
with the integrator marked "MODE" (it has Yellow, Blue, Green wires) on the upper brace by attaching cable
clip to cable integrators as shown in figure 12. Route the extended wire from the integrator thru the upper hole in
the lever as shown, making sure it is flush with the OEM component. Repeat the same process for the other
Cable Integrator (B), it will be labeled "TEMP" (Brown, Purple, and White wires).
Attaching the cable integrators to the control head is accomplished by using the supplied cable clamps to secure
the integrators to the levers (see figure 11). The first step is to insert the wire end of the integrators into the
appropriate lever ends, then while making sure the integrators are flush to the edge of the control head, secure by
tightening down the cable clamps (two views are shown in figure 12).
MODE
UNUS
ED
FIGURE 11
B
MP
TE
Cable Integrators should be
installed flush to the outside
edge of the OEM component.
FIGURE 12
Plug the blower switch connector
into the new control switch
www.classicautoair.com • 866.435.7801
PAGE
12
To insert the control head back into the dash you will need to perform a simple procedure first
that will allow you to install from the inside dash outward. First remove all three knobs using an
allenhead wrench, and remove the lower OEM screw holding the faceplate to the lever
mechanisms. Then remove the face plate by removing the screw you installed earlier to hold the
new blower switch.
Making sure the face plate surface is clean, oil and smudge-free, peel and apply the included
faceplate sticker (optional). Apply using firm pressure from one side to the other. You can use
this sticker to temporarily get accustomed the new controls, or leave it on (we understand that
for some vehicles our sticker may not be asthesically pleasing, so this step is optional.
Otherwise, just refer to control descriptions for operation procedures).
PLUG THE HARNESS BLOWER SWITCH CONNECTION into the back of the control
head and insert the entire harness and switch component back into the dash from the
inside outward (see figure 13). With the control head coming thru the hole in the dash
resecure the blower switch, bracket, and faceplate.
COLD
DASH
OFF
TEMP
DEF
DEF
HEAT
FLR
COLD
DEF
TEMP
HOT
HI
OFF
DASH
DEF
HEAT
FIGURE 13
COLD
DASH
DEF
DEF
FLR
HI
HOT
FLR
TEMP
HI
HEAT
OFF
HOT
Position the entire control head back flush with the lower dash and secure with the OEM
retainers and nuts you removed earlier.
Reinstalling the knobs is easy. However, the HEAT/DEF knobs will need to be rotated 180
degrees (upside down) and then reinstalled on the opposite side from where you removed them.
The TEMP knob will also be rotated 180 degrees (but it’s reinstalled in it’s original position. Also
install the new blower switch knob at this time. Because of the curved nature of the lower dash,
you will not be able to see the indicator letters on the knobs (which are now upside down).
www.classicautoair.com • 866.435.7801
PAGE
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
Four #10 - 16 x 3/4" Tek Screws
Evap Support Bracket
PN# 0023-7
Fresh Air Inlet Block Off
PN# 10-1025-2
Four #10 - 10 x 5/8" Phillips Screws
One Male Spade Connector
One 1/2" Washer
Defrost/Heat Duct Assembly
PN# 2-2025-2
One J-Clip
Illustrations NOT shown actual size
www.classicautoair.com • 866.435.7801
PAGE
14
Locate the original wiring harness that supplied power to the original heater motor (these wires
were previously cut on the engine side of the firewall). Reaching thru the glove box opening
pull these wires out of their grommet. Measure 4” from harness and cut both wires (see figure
16). 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.
From inside of the vehicle drill a 5/8" dia. hole for the drain tube. TEMPLATE NOTIFICATION! A
handy drilling template is included in this manual (example shown in figure 17).
CAUTION: On the engine side of the firewall there is a brake line. Be careful not to drill through
the brake line. It may be necessary to carefully push this line out of the way, securing it a bit
lower is usually all that is necessary (see figure 18)
FIGURE 16
All preliminary modifications to the vehicle are complete.
THIS IS
FROM THE
INSIDE
OF THE
CAR!
YOU CAN
DRILL A
SMALL
PILOT
TECH TIPS
HOLE IN
THIS LOCATION FIRST
WITH A SMALLER DRILL
BIT (LIKE A 9/32"), THEN
PROCEED WITH THE
5/8" BIT ONCE YOU
KNOW YOU HAVE CLEAR
SPACE.
HEATER MOTOR
HOLE
E
KE
1 3/8"
3/4”
U
CA
N!
TIO
LIN
A
BR
FIGURE 18
5/8" HOLE
FIGURE 17
www.classicautoair.com • 866.435.7801
PAGE
15
Locate the fresh Air inlet block off. Install over hole in inlet cowl as shown (see figure 19A).
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
19B).
Remove evaporator unit from box and place on a clean work bench.
Locate defrost / heat duct assembly and attach to the evaporator using two #10 - 10 x 5/8"
Phillips screws (see figure 20). NOTE: Be sure that the s-clips are pushed over rear
flange on evaporator.
A
Take a minute to familiarize yourself with the evaporator unit:
B
FIGURE 19
Actuator Motor
Blower Motor
Bracket
Floor/Face
Vent Door
Evaporator
Support Bracket
Holes
Thermostat
Blower Motor Plug
FIGURE 20
www.classicautoair.com • 866.435.7801
PAGE
16
FIREWALL
DASH
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 21). 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 22).
LEVEL
FIGURE 21
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 22
1/4 - #20 x 5/8" bolts and
a 1/4” washer
www.classicautoair.com • 866.435.7801
PAGE
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 23).
Locate the UPPER MOUNTING BRACKET and attach to evaporator unit using two #10 - 10
x 5/8" Phillips screws. Attach other end to the cowling. Attach with #10 - 16 x 3/4" Tek
Screws supplied (see figure 24). IMPORTANT NOTE: On the side of the main unit you will see
several holes for mounting holes... ONLY USE THE ONES ON THE FAR LEFT FOR THIS
BRACKET! Do not tap into the other holes for any reason (see Figure 25). Also, use a
screwdriver and hand-power and do not over-tighten so you don't strip the holes.
FIGURE 23
#10 x 5/8"
Screws
NO!
YES
NO!
FIGURE 24
#10 - 16 x 3/4" Tek Screw
FIGURE 25
www.classicautoair.com • 866.435.7801
PAGE
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
PN# 16-1081-2
Firewall Block Off
PN# 10-1025-1
Two 1" Cap Plugs
Six Worm Gear Clamps
Two #10 - 16 x 3/4" Tek Screws
Refrigerant Tape
Illustrations NOT shown actual size
www.classicautoair.com • 866.435.7801
PAGE
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 six #10 - 16 x 3/4" Tek
screws. 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.
IMPORTANT
NOTICE: PROPER
INSTALLATION OF
WATER VALVE
INSTRUCTIONS!!!
FIGURE 26
This inlet is
connected
to the intake
manifold
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 installed per these
instructions!... (if not, your system will not work
properly... and that’s an absolute fact).
COR
E
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.
AT
PU
MP
ER
HE
F
TA OLL
TW GS. OW
.
PR ICE . CH THE
OC BE EC SE
EE FO K I
DI RE T
NG
!
ER
T
WA
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 and route to the connection on the water
pump.
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.
www.classicautoair.com • 866.435.7801
PAGE
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.
ROL
CONT
WATER
VALVE
The ECU will be in it’s own box, within this bag kit.
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
PAGE
21
Orang
eH
arn
e
Wiring Diagram/Overview
To 12V Power Supply (min. 20 amp fuse)
ss
Electronic Water Valve
Re
d
/W
hite
Compressor
Wi
re
r
G
Wh
Pressure Switch
Ground
Wire
ite
Blower Switch
r
Ha
n
ee
s
ire
W
e
Blu
s
nes
ECU
Relay
Thermostat
Blu
eW
ire
ness
ire
W
Red Wire
ss
Evaporator
Blu
e
r ne
Servo for Face/Floor Ducts
Blue Har
Yello w H a
Cable Integrators
Ground
Servo for Defrost Ducts
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
PAGE
22
INSTALL (2)
1” dia. CAP PLUGS
OVER HOLES.
SLOT ONE FOR THE CABLE.
We’ve included enough extra cable 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 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 28). Using one of the
CAP PLUGS provided, slot it and install over the heater hose/cable. 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.
FIGURE 28
CONTR
WATER
VALVE
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.
ST
OL
POWER
DEFRO
FIREWALL
R
FLOO
FACE/
www.classicautoair.com • 866.435.7801
PAGE
Temporarily reconnect the car battery at this time. You will need a full 12 volts to complete the calibration.
23
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
DASH
E
VALV
ST
TR
N
CO
DEF
HI
DASH
COLD
#4
OFF
COLD
HI
DASH
DEF
COLD
DEF
O
LED N
R
WE
PO
FLR
tion
ibra
Cal
OFF
HI
DASH
FLR
HOT
HOT
FLR
HOT
Key
Move FAN control to medium
in one motion...
Position your controls
like this example.
Plug CALIBRATION KEY into ECU
#5
OFF
#3
HI
DEF
RO
R
OO
/FL
CE
FA
OL
OFF
After 1 second the
LED turns back ON
#6
COLD
O
LED N
#7
1 Second
Later...
OFF
DASH
Move MODE control to
DASH in one motion...
D OFF
LE
HI
D OFF
LE
1 Second
Later...
#8
COLD
ER
WAT
O
LED N
DEF
DEF
O
LED N
Move TEMP control to
HOT in one motion...
1 Second
Later...
D OFF
LE
FLR
You may be able to
hear the internal door(s) move
back and forth...
Approx. 30
Seconds
Later...
D OFF
LE
HOT
Move the FAN knob to OFF
(powers off unit)
C
FA
OR
DEF
LO
E/F
L
O
TR
N
HOT
ST
RO
CO
FLR
E
VALV
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....
PAGE
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
Bag F
Two Louver Ball Assemblies
PN# 2-1005
Bag G
Two Louver Ball Assemblies
PN# 2-1005
Defrost Adaptor Defusers
PN# C5ZZ18490-A
Defrost Adaptor Reducers
PN# 2-1025-3
Four V Clips
Two Duct Hoses, 2" I.D.
Face Duct Assembly
PN# 2-2025-1
Four #10 - 16 x 3/4" Tek Screws
Two Duct Hoses, 2" I.D.
Four Zip-Ties
Four Zip-Ties
Two Duct Hoses, 2" I.D.
Four #10 - 16 x 3/4" Tek Screws
Four Zip-Ties
Illustrations NOT shown actual size
www.classicautoair.com • 866.435.7801
PAGE
25
The following steps are for left and right Defrost Diffusers: Locate and route the duct hoses
from the defrost/heat duct assembly (see figure 29) upward toward the defrost adaptor
defusers. Next locate and install defrost adaptor defusers from the top of the dash and secure
with v-clips supplied. Attach flex hose to the defrost defuser adaptors using zip-ties. Push
adaptors onto defusers from below. The other end of the duct hose is installed over the
defrost/heat duct assembly outlets on main unit (see figure 30 and the diagram below).
Reinstall radio speaker cover plate over the defrost defusers using the original screws.
FIGURE 29
The face duct assembly comes preinstalled with s-clips which allow you to install onto the
evaporator unit quickly and securely (see figure 31).
V-clips
TOP OF DASH
Defrost Adaptor
Defusers
S-clips (already installed)
Defrost Adaptor Defuser
Duct Hose
(Secured with zip-tie)
FIGURE 30
FIGURE 31
Defrost Adaptor
Reducer
Defrost Adaptor
Defuser
www.classicautoair.com • 866.435.7801
PAGE
26
Bag Kit F: Attach a louver ball assembly to the bottom edge of
instrument panel as shown below. Use two #10 - 16 x 3/4" Tek
screws through top of the louver ball assembly.
Bag Kit G: Repeat the previous attachment instructions for the center
louver ball assemblies. Mount these where you feel you’ll get the
most benefit from the airflow.
Route supplied flex hoses as shown below. Take your time and
route them so they don’t become kinked or torn. The smoother the
route the better the airflow.
Attach duct hose to left face duct assembly outlet. This will then be
routed down to the louvers as shown. The duct hose will be routed
from the remaining face/floor assembly outlet over the defrost duct
hose and across to the passenger side louver ball assembly.
Attach a louver ball assembly to the passenger side using two #10 16 x 3/4" Tek screws.
To defrost defuser adaptors
During installation of the hoses be aware
of the eventual movement of the wiper
arm components. Also, the smoother the
route of the flex hoses the better the
TECH TIPS airflow.
www.classicautoair.com • 866.435.7801
PAGE
27
Locate the new glove box provided in kit. Install using original hardware (see figure 32-33).
Caution: Carefully check under the Instrument Panel for all cables, electrical
harness, or Flex Hose that might interfere with the safe operation of the vehicle.
Make sure that you cycle the windshield Wipers to insure proper clearance of
mechanism.
Reinstall the Glove box door and Ashtray.
FIGURE 32
Glove Box Insert
FIGURE 33
www.classicautoair.com • 866.435.7801
PAGE
28
3"
1 1/4"
REMOVE
FIGURE 34
GOOD IDEA
Retaining all the
non-resintalled OEM parts is
a good idea, but that’s your
choice.
If you have any questions before you move
on the final phase of this installation, call us.
888.791.6384
If your vehicle was equipped with a center console (which you removed
earlier), you may need to modify it as shown (see figure 34) and reinstall.
Test fit your console first.
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
PAGE
29
THESE ARE THE PARTS YOU WILL NEED FOR THE
ENGINE COMPARTMENT INSTALLATION
You’ll find all of these parts within the main box
A
Condenser Brackets
PN# 0019-53
Liquid Tube
PN# 0019-93
B
Drier
PN# 12-1008
Drier Bracket
PN# 19-1003
Condenser Brackets
PN# 0019-52
Condenser
PN# 11-1093
#10 1
Bag of O-rings and Mineral Oil Tube
ose
Eight #10 - 20x5/8" Screws
ti o
3/3
S
uc
81
#
Four Zip-Ties
nH
/16" Liquid Hose
#6 5
Splice and
Bullet Connector
Pressure Switch
2" D
ischa
rge Hos
e
Pressure Switch Harness
/2"
Two #8 - 20 x 5/8" Bolts and Lock Nuts
Three Refrigerant Hoses
www.classicautoair.com • 866.435.7801
PAGE
30
ENGINE COMPARTMENT INSTRUCTIONS
STEP ONE: IF YOU HAVE NOT ALREADY, DISCONNECT THE BATTERY.
STEP TWO: 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, horn(s), and latch support
assembly (see figure 35). Be sure to retain all the mounting screws – you’ll reinstall these
pieces in the exact reverse order with the OEM screws.
FIGURE 35
STEP THREE: 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 easy to follow
instructions specifically written for your engine. Once you’ve installed the complete compressor
kit, continue on to the next step. We believe that this is the finest compressor kit available, and
you’re bound to notice the excellent fit and quality once this step is completed.
www.classicautoair.com • 866.435.7801
PAGE
31
TECH TIPS
STEP FOUR: 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). The drier is
conveniently mounted 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 using the two #8 - 20 x 5/8"
Bolts and Lock Nuts, making sure that the drier bracket is bolted to the condenser from the
backside. Tighten connections at either end using supplied o-rings on both ends and a few
drops of mineral oil to each o-ring.
Reminder...
Use two
wrenches to
tighten o-ring
fittings
Brackets angles outward
A
STEP FIVE: Screw the high-pressure switch into the port at the lower end of the drier liquid
tube. Go ahead and plug the pressure switch harness into the switch at this time (black
electrical boot with two long white wires).
Four #10-5/8" screws
6th, 7th Holes
11th, 12th Holes
STEP SIX: Install the upper condenser bracket (A) using four #10 - 20 x 5/8
screws in the 6th, 7th, 11th and 12th holes on the condenser from the left,
be sure the bend on the bracket is facing towards you. Next, attach the
lower bracket (B) using four #10-20x5/8 screws in the 6th, 7th, 13th and
14th hole from the left hand side. This bracket has a large hole that
corresponds to the OEM latch support previously removed from the
vehicle.
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.
6th, 7th Holes
13th, 14th Holes
Four #10-5/8" screws
Final Configuration
B
www.classicautoair.com • 866.435.7801
PAGE
32
STEP SEVEN: Your OEM radiator support was designed to support a A/C condenser and
conveniently has two small indentations on the drivers side for drilling the holes needed for this
part of the installation (see figure 36, aftermarket core supports may or may not have these
indentations). If your vehicle was already equipped with a OEM A/C, one of these holes may
already be drilled. Locate these two small indentations and drill a 1 3/8” hole thru each (be
sure to check for any obstructions before drilling, and remove any sharp burrs from the drilling
before continuing, see figure 36). You’ll notice that the hole closest to the upper condenser
fitting is level with the connection fitting (the discharge hose to the compressor will go thru this
hole). The other hole is to accommodate the liquid hose and the wiring harness plug for the
high-pressure switch.
Drill two 1 3/8" holes
FIGURE 36
STEP EIGHT: Place the condenser/drier unit into place, locating it so that the holes in the
condenser brackets align with the holes in the core support used to attach the hood latch (it
will rest on the lower radiator core brace, see figure 37).
CONNECTING THE HOSES:
1) Attach the #8 Discharge Hose (13/32") to the upper connection of the condenser and
route thru the hole previously drilled in 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 drier and route thru the remaining hole previously
drilled into the core support and along the underside of the fenderbraces and and behind
the engine to the connection at the firewall on the evaporator unit. 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. For attachment route, see figure 37 on next page. 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.
TECH TIPS
If you want to verify that you have the correct indentations in sight before drilling,
place fit the condenser into it’s final location. Also, the holes on the upper bracket
are larger than needed to allow for small adjustments. The condenser is held in
place when the hood latch is reinstalled at a later time.
FIGURE 37
www.classicautoair.com • 866.435.7801
PAGE
33
Fe
nd
er
St
ru
ts
STEP NINE: Connecting the wires from the pressure switch will be done as follows, connect one
wire to the connection on the compressor, and the other wire will be routed along with the
liquid hose along the underside of the fender supports and connected to the blue lead you
put thru the firewall during the interior installation. We’ve included a bullet and slice connector
to make these connections, use a crimp tool to secure these properly (for attachment route,
see figure 37).
FIGURE 37
FINAL STEPS: You can now complete this portion of the installation by reinstalling the grill,
horns, and latch support in reverse order. NOTE: The OEM screws for the hood latch support
will hold your new condenser in place, so be sure to fully tighten these during this step. Take a
look around at your installation and check all fitting and bolts for tightness, check the heater
hose clamps for tightness, and make sure nothing is routed in a way to obstruct any moving
parts. You can refill the radiator and reconnect the battery at this time.
WAY TO GO! You’ve just completed the installation of your new A/C system.
The final step is to fully charge and test your new system.
On the next page you’ll find specifications for proper final preparation for your A/C technician.
www.classicautoair.com • 866.435.7801
PAGE
34
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
PAGE
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 ( 150-250 PSI ) *Note- general rule of thumb is
two times the ambient (daytime) temperature, plus 15-20%.
2. LOW-SIDE PRESSURES ( 15-25 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
PAGE
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
PAGE
37
www.classicautoair.com • 866.435.7801
LEVEL
HEATER MOTOR
HOLE
THIS TEMPLATE IS USED
FROM THE INSIDE OF THE CAR!
Note: bottom of template is parallel with floor pan
IF YOU PRINTED THIS MANUAL
PLEASE READ THIS...
Just as a cautionary step, please
measure this box and make sure it
is 1” x 1”. Some copiers/printers
may not print at 100% of actual size.
PAGE
39
www.classicautoair.com • 866.435.7801