1964-65 Chevrolet Chevelle

an ISO 9001:2008 Registered Company
1964-65 Chevrolet Chevelle
without Factory Air
Evaporator Kit
(561065)
18865 Goll St. San Antonio, TX 78266
Phone: 210-654-7171
Fax: 210-654-3113
www.vintageair.com
901163 REV D 12/02/16, PG 1 OF 23
www.vintageair.com
Table of Contents
Thank you for purchasing this evaporator kit from Vintage Air. When installing these
components as part of a complete SureFit™ system, Vintage Air recommends working
from front to back on the vehicle, installing the condenser kit, hose kit, and compressor
first, followed by the wiring, evaporator, and finally the control panel.
Cover.................................................................................................................................. 1
Table of Contents................................................................................................................. 2
Packing List/Parts Disclaimer.................................................................................................. 3
Information Page.................................................................................................................. 4
Wiring Notice....................................................................................................................... 5
Engine Compartment Disassembly.......................................................................................... 6
Condenser Assembly and Installation, Compressor and Brackets, Passenger Compartment
Disassembly........................................................................................................................ 7
Kick Panel Modification, Defrost Duct Installation...................................................................... 8
Firewall Cover Installation, Evaporator Bracket & Heater Fitting Installation................................. 9
Evaporator Bracket & Heater Fitting Installation (Cont.)........................................................... 10
Fresh Air Cap Installation, Kick Panel Fresh Air Cap Installation................................................ 11
Evaporator Installation........................................................................................................ 12
Drain Hose Installation, Lubricating O-rings, A/C Hose Installation............................................ 13
Heater Hose & Heater Control Valve Installation, A/C and Heater Hose Routing........................... 14
Final Steps........................................................................................................................ 15
Control Panel & Duct Hose Routing........................................................................................ 16
Driver Side Under Dash Louver Installation, Center/Passenger Side Under Dash Louver
Installation........................................................................................................................ 17
Wiring Diagram.................................................................................................................. 18
Gen IV Wiring Connection Instruction................................................................................... 19
Operation of Controls.......................................................................................................... 20
Troubleshooting Guide......................................................................................................... 21
Troubleshooting Guide (Cont.).............................................................................................. 22
Packing List....................................................................................................................... 23
2
901163 REV D 12/02/16, PG 2 OF 23
Packing List:
Evaporator Kit (561065)
www.vintageair.com
No.
1.
2.
Qty.
1
1
Part No.
744004-VUE
784159
Description
Gen IV Magnum 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 Magnum
Evaporator Sub Case
744004-VUE
2
Accessory Kit
784159
NOTE: Images may not depict actual parts and quantities.
Refer to packing list for actual parts and quantities.
3
901163 REV D 12/02/16, PG 3 OF 23
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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. (1 lb., 12 oz.) of R134a, charged by weight with a quality charging station or
scale. NOTE: Use of the proper type and amount of refrigerant is critical to system operation and
performance.
Other Systems: Consult manufacturer’s guidelines.
Lubricant Capacities:
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
901163 REV D 12/02/16, PG 4 OF 23
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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
901163 REV D 12/02/16, PG 5 OF 23
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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 the battery.
2. Remove the battery and the battery tray (retain).
3. Drain and remove the radiator (retain).
4. Remove the OEM blower assembly (discard). NOTE: To remove the blower assembly (under hood)
and the air distribution system (under dash), the factory manual recommends removing the
passenger side inner fender.
5. Remove the OEM heater hoses (discard) (See Figure 1, below).
6. Remove the OEM heater wiring (discard) (See Figure 1, below).
Battery
Tray
OEM
Blower Motor
Assembly
Inner
Fender
Figure 1
Heater
Hoses
6
901163 REV D 12/02/16, PG 6 OF 23
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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.
Passenger Compartment Disassembly
Perform the Following:
1. Remove glove box door (retain).
2. Remove glove box (discard).
3. Disconnect all wires and cables from control panel and radio.
4. Remove control panel and radio.
5. Remove OEM heater assembly.
6. Using a chisel or die grinder, remove (3) spot welds on the defrost duct (See Figure 2, below).
7. Remove OEM defrost duct assembly (See Figure 3, below).
Dash
Support
Inner
Cowl
Figure 2
NOTE: Use a chisel
or die grinder to
break spot welds.
Defrost
Duct
Defrost
Duct
Figure 3
Control
Panel
7
Radio
OEM
Heater
Assembly
Glove
Box
901163 REV D 12/02/16, PG 7 OF 23
Kick Panel Modification
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1. Remove the kick panel.
2. Remove the kick panel fresh air door assembly by removing (5) OEM screws.
3. Disconnect the pull cable assembly from under the dash (discard) (See Figure 4, below).
4. Modify the passenger side kick panel as shown in Figure 4a, below.
Cut
3”
5”
Fresh Air Door
Assembly
Figure 4
Figure 4a
Defrost Duct Installation
1. Install the defrost duct under the dash, and align it with the OEM opening. Attach the defrost duct to the cowl
using (2) #10 x 1/2” sheet metal screws (See Figure 5, below). NOTE: Apply silicone to the screws to
ensure a leak-free installation.
OEM
Defrost Duct
Opening
Figure 5
(2) #10 x 1/2”
Sheet Metal
Screws
Defrost
Duct
8
901163 REV D 12/02/16, PG 8 OF 23
Firewall Cover Installation
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NOTE: To ensure a watertight seal between the passenger compartment and the vehicle exterior, for
all bolts passing through the firewall, Vintage Air recommends coating the threads with silicone prior
to installation.
1. Apply a 1/4” bead of silicone around the mating surface of the firewall cover as shown in Figure 6, below.
2. From the passenger compartment, install the firewall cover onto the firewall. Secure the firewall cover to the
firewall using (3) 1/4-20 x 1” hex bolts, (3) 1/4” flat washers and (3) 1/4-20 nuts with star washers as shown
in Figure 6, below.
Firewall Cover
648169
(3) 1/4-20 x 1”
Hex Bolts
Hole Not
Used
(3) 1/4”
Flat Washers
Mating Surface of
Firewall Cover
Silicone
(3) 1/4-20
Nuts with Star
Washers
Figure 6
Evaporator Bracket &
Heater Fitting Installation
1. On a workbench, install (2) heater fittings with properly lubricated O-rings (See Figure 14, Page 13, and
Figure 8, Page 10).
2. Install (2) 1/4-20 x 1” hex bolts and (2) 1/4” push nut bolt retainers onto the evaporator rear mounting
bracket as shown in Figure 8, Page 10.
3. Install the evaporator front and rear mounting brackets onto the evaporator using (6) 1/4-20 x 1/2” hex bolts,
(supplied on the evaporator sub case) and tighten as shown in Figure 7, below, and Figure 8, Page 10.
4. Place the evaporator sub case on the passenger side floorboard. Using properly lubricated O-rings, install the
A/C hoses onto the evaporator (See Figure 14, Page 13, and Figure 11, Page 12). NOTE: Wrap the #10
fitting connections with press tape (See Figure 11, Page 12).
5. Install the heater hoses, securing them with hose clamps (See Figure 11, Page 12).
(2) 1/4-20 x 1/2”
Hex Bolts
(Supplied on Sub
Case)
Evaporator Front
Mounting Bracket
643060
Figure 7
9
901163 REV D 12/02/16, PG 9 OF 23
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Evaporator Bracket &
Heater Fitting Installation (Cont.)
(2) Heater
Fittings
1/4-20 x 1”
Hex Bolt
1/4” Push Nut
Bolt Retainer
Evaporator Rear
Mounting Bracket
643059
Figure 8
(2) 1/4-20 x 1/2”
Hex Bolts
(Supplied on Sub
Case)
1/4” Push Nut
Bolt Retainer
1/4-20 x 1”
Hex Bolt
(2) 1/4-20 x 1/2”
Hex Bolts
(Supplied on Sub
Case)
10
901163 REV D 12/02/16, PG 10 OF 23
Fresh Air Cap Installation
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NOTE: To ensure a watertight seal between the passenger compartment and the vehicle exterior, for
all bolts passing through the firewall, Vintage Air recommends coating the threads with silicone prior
to installation.
1. Install (4) grommets into the fresh air cap (See Figure 9, below).
2. Apply a 1/4” bead of silicone around the mating surface of the fresh air cap as shown in Figure 9, below.
3. Attach the fresh air cap to the firewall using the fresh air cap bracket, a 1/4-20 x 1 ½” bolt, and a washer as
shown in Figure 9, below. NOTE: The fresh air cap installs on the engine side of the firewall.
Fresh Air Cap
Bracket
Fresh Air Cap
(4) Grommets
33137-VUI
1/4-20 x 1 ½”
Bolt & Washer
Silicone
Engine
Compartment
Side of Firewall
Figure 9
Mating Surface
of Fresh Air Cap
Kick Panel Fresh Air Cap Installation
1. Install (4) grommets into the kick panel fresh air cap (See Figure 10a, below).
2. Route the A/C and heater hoses through the fresh air cap and kick panel fresh air cap as shown in Figures 10
and 10b, below.
3. Apply a 1/4” bead of silicone around the mating surface of the kick panel fresh air cap as shown in Figure 10a,
below.
4. Secure the kick panel fresh air cap using OEM screws as shown in Figure 10b, below.
Mating Surface
of Kick Panel
Fresh Air Cap
Silicone
(4) Grommets
33137-VUI
Figure 10a
(5) OEM
Screws
#10
A/C Hose
#10
A/C Hose
Figure 10
(2) Heater Hoses
#6
A/C Hose
(2) Heater Hoses
11
#6
A/C Hose
Figure 10b
901163 REV D 12/02/16, PG 11 OF 23
Evaporator Installation
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NOTE: To ensure a watertight seal between the passenger compartment and the vehicle exterior, for
all bolts passing through the firewall, Vintage Air recommends coating the threads with silicone prior
to installation.
1. Lift the evaporator unit up under the dashboard. Secure loosely to the firewall using (2) 1/4-20 nuts and (2)
flat washers (See Figure 12, below). NOTE: To ensure proper drainage, it is very important that the
evaporator is level, both left-right and fore-aft. Check for level on the flat portions of the case
around the drain.
2. Using (2) #14 x 3/4” sheet metal screws, secure the front evaporator mounting bracket to the cowl (See
Figure 12, below).
3. Verify that the evaporator unit is level and square to the dash. Then, tighten all mounting bolts. NOTE:
Tighten the bolt on the firewall first. Then tighten the front mounting bracket.
Press
Tape
#6
A/C Hose
(2) Heater Hoses
Hose
Clamps
#10
A/C Hose
Figure 11
Kick Panel
Fresh Air Cap
(2) 1/4-20 Nuts &
(2) 1/4” Flat Washers
(2) #14 x 3/4”
Sheet Metal
Screws
Figure 12
12
901163 REV D 12/02/16, PG 12 OF 23
Drain Hose Installation
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1. Locate the evaporator drain on the bottom of the evaporator case.
2. In line with the drain, lightly make a mark on the firewall. Measure 1” down, and drill a 5/8” hole through the
firewall (See Figure 13, below).
3. Attach the drain hose to the outlet on the bottom of the evaporator unit, and route it through the firewall.
4. Install a 1/2” 90° drain elbow onto the drain hose (See Figure 13, below).
1”
Evaporator
Case
1”
Drain
Hose
Figure 13
Lubricating O-rings
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 14
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 14, above) and connect the 90°
fitting to the #8 discharge port on the compressor. Then route the 45° fitting with 134a service port to the #8
condenser hardline coming through the core support (See Figure 15, Page 14). Tighten each fitting connection
as shown in Figure 14, above.
2. Locate the #10 compressor A/C hose. Lubricate (2) #10 O-rings (See Figure 14, above) and connect the 45°
fitting with 134a service port to the #10 suction port on the compressor. Then route the 90° fitting to the #10
fitting on the evaporator (See Figure 11, Page 12, and Figure 15, Page 14) . Tighten each fitting connection as
shown in Figure 14, above.
3. Locate the #6 evaporator A/C hose. Lubricate (2) #6 O-rings (See Figure 14, above) and connect the 90°
fitting to the drier. Then route the 90° fitting to the #6 fitting on the evaporator (See Figure 11, Page 12, and
Figure 15, Page 14). Tighten each fitting connection as shown in Figure 14, above.
Modified Hose Kit:
1. Refer to separate instructions included with modified hose kit.
13
901163 REV D 12/02/16, PG 13 OF 23
14
From Intake
Manifold to
Heater Control
Valve
#6 Hose
096066
NOTE: Flow Direction Follows
Molded Arrow on Valve.
From Heater Core
to Water Pump
Heater
Hoses
From Heater
Control Valve
to Heater Core
Heater Hose
(Heater Core to
Water Pump)
(4) Tie Wraps
#10 Suction
Hose
096068
Compressor
Safety Switch
(Binary Type)
Screw On Drier
(Refer to Condenser
Instructions)
#8 Discharge
Hose
096067
Heater Hose
(Intake/Heater
Control Valve)
#6 Drier/Condenser
Hardline
091166
#8 Condenser/
Compressor
Hardline
091167
Figure 15
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.
A/C and Heater Hose Routing
www.vintageair.com
Heater Hose
& Heater Control Valve Installation
1. Route a piece of heater hose from the water pump to the left heater core fitting as shown in Figure 10, Page
11, and Figure 15, below. Secure using hose clamps.
2. Route a piece of heater hose from the intake to the heater control valve, and from the heater control valve
to the right heater core fitting as shown in Figure 10, Page 11, and Figure 15, below. NOTE: Install the
heater control valve in line with the intake manifold (pressure side) heater hose, and secure using
hose clamps. Also note proper flow direction.
901163 REV D 12/02/16, PG 14 OF 23
Final Steps
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1. Install the duct hoses as shown in Figure 18, Page 16.
2. Route the A/C wires (12 volt/ground/binary switch/heater control valve) through the 3/8” grommet as shown
in Figure 16, below.
3. Install the control panel assembly. Refer to the control panel instructions.
4. Plug the wiring harnesses into the ECU module on the sub case as shown in Figure 18, Page 16. Wire
according to the wiring diagrams on Pages 18 and 19.
5. Install the glove box using (4) #8 x 1/2” pan head screws (See Figure 17, below).
6. Reinstall kick panel.
7. Install louvers as shown on Page 17.
8. Reinstall all previously removed items.
9. 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.
10. Double check all fittings, brackets and belts for tightness.
11. Vintage Air recommends that all A/C systems be serviced by a licensed automotive A/C technician.
12. Evacuate the system for a minimum of 45 minutes prior to charging, and perform a leak check prior to
servicing.
13. Charge the system to the capacities stated on Page 4 of this instruction manual.
14. See Operation of Controls procedures on Page 20.
A/C Wires
(12 Volt, Ground,
Binary Switch, Heater
Control Valve)
3/8” Grommet
33144-VUI
Figure 16
Glove Box
625663
(4) #8 x 1/2”
Pan Head
Screws
Figure 17
15
901163 REV D 12/02/16, PG 15 OF 23
Control Panel & Duct Hose Routing
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Control Panel
Harness From ECU
232002-VUA
Defrost Duct
Passenger Side
2” x 12”
Defrost Duct
Driver Side
2” x 20”
Passenger Side
Under Dash
Louver
2 ½” x 44”
Plug From
Wiring Harness
232600-VUA
Driver Side
Under Dash
Louver
2 ½” x 30”
Center
Under Dash
Louver
2 ½” x 16”
Figure 18
16
901163 REV D 12/02/16, PG 16 OF 23
Driver Side
Under Dash Louver Installation
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1. Place the louver housing under the dash, and align it with the OEM holes.
2. Secure the louver housing under the dash using (2) 10-32 x 3/4” pan head screws, (4) 3/16” flat washers
and (2) 10-32 nuts with star washers as shown in Figure 19, below.
3. Install the louver into the louver housing as shown in Figure 19a, below.
(4) 3/16”
Flat Washers
(2) 10-32
Nuts with Star
Washers
(2) 10-32 x 3/4”
Pan Head Screws
Figure 19
Figure 19a
Driver Side
Under Dash
Louver Housing
626662
Ball Louver
49053-VUL
Center/Passenger Side
Under Dash Louver Installation
1. Place the passenger side louver bezel under the dash, and align it with the OEM holes.
2. Secure the louver bezel under the dash using (3) 10-32 x 3/4” pan head screws, (6) 3/16” flat washers and
(3) 10-32 nuts with star washers as shown in Figure 20, below.
3. Install the louvers into the louver bezel as shown in Figure 20a, below.
(6) 3/16”
Flat Washers
(3) 10-32
Nuts with Star
Washers
(3) 10-32 x 3/4”
Pan Head Screws
Passenger Side
Under Dash
Louver Bezel
626661
(2) Louvers
49157-VUL
Figure 20
Figure 20a
Ball Louver
49053-VUL
17
901163 REV D 12/02/16, PG 17 OF 23
Wiring Diagram
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232007-VUR
TAN
ORA
BLK
WHT
RED
WHT/RED
WHT/YEL
JF8
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 D, 5/6/2014
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.
18
901163 REV D 12/02/16, PG 18 OF 23
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:
Tan Wire Used Only With Vintage Air
Supplied Control Panel With LED Back
Light.
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
19
901163 REV D 12/02/16, PG 19 OF 23
Operation of Controls
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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 the 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.
Mode
Control
Blower
Speed
Temperature Control
This lever/knob controls
the temperature,
from HOT to COLD.
AIR
DEF
TEMP
DEF
TEMP
Temperature
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).
AIR
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).
DEF
AIR
TEMP
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).
20
TEMP
AIR
DEF
901163 REV D 12/02/16, PG 20 OF 23
21
901163 REV D 12/02/16, PG 21 OF 23
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
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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
22
901163 REV D 12/02/16, PG 22 OF 23
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
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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.)
www.vintageair.com
Part No.
No.
Qty.
744004-VUE
1.
1
784159
2.
1
Packing List:
Evaporator Kit (561065)
Description
Gen IV Magnum Evaporator Sub Case
Accessory Kit
Checked By:
Packed By:
Date:
1
Gen IV Magnum
Evaporator Sub Case
744004-VUE
2
Accessory Kit
784159
NOTE: Images may not depict actual parts and quantities.
Refer to packing list for actual parts and quantities.
23
901163 REV D 12/02/16, PG 23 OF 23
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