1957 chevy - Vintage Air

an ISO 9001:2008 Registered Company
1957 CHEVY
WITHOUT FACTORY AIR
561057
901257 REV D 6/30/16, 1957 CHEVY w/o AC GEN IV EVAP INST PG 1 OF 25
Table of Contents
PAGES
1. COVER
2. TABLE OF CONTENTS
3. PACKING LIST/PARTS DISCLAIMER
4. INFORMATION PAGE
5. WIRING NOTICE
6. ENGINE COMPARTMENT
FIGURE 1
7. PASSENGER COMPARTMENT
FIGURE 2
8. ENGINE COMPARTMENT & DEFROST DUCT INSTALLATION
FIGURE 3
9. EVAPORATOR INSTALLATION
FIGURES 4 & 5
10. EVAPORATOR INSTALLATION CONT.
FIGURES 6 & 7
11. DUCT HOSE ROUTING & CONTROL WIRING
FIGURE 8
12. PASSENGER & DRIVER SIDE UNDER DASH LOUVER INSTALLATION
13. HARDLINE INSTALLATION
14. O-RING LUBRICATING/FITTING TIGHTENING & HEATER CONTROL
VALVE INSTALLATION
FIGURES 10, 11 & 12
15. A/C HOSE AND HARDLINE ROUTING
FIGURES 13, 13a & 13b
16. FIREWALL COVER INSTALLATION & FRESH AIR CAP
FIGURE 14
17. FINAL STEPS/GLOVE BOX INSTALLATION
FIGURE 15
18. EVAPORATOR HARDLINE INSTALLATION
PHOTO 1 AND FIGURE 16
19. WIRING DIAGRAM
20. GEN IV WIRING CONNECTION INSTRUCTIONS
21. OPERATION OF CONTROLS
22. TROUBLESHOOTING
23. TROUBLESHOOTING CONT.
24. CORE SUPPORT TEMPLATE
25. EVAPORATOR KIT PACKING LIST
901257 REV D 6/30/16, 1957 CHEVY w/o AC GEN IV EVAP INST PG 2 OF 25
2
EVAPORATOR KIT PACKING LIST
EVAPORATOR KIT
561057
No.
QTY.
PART No.
DESCRIPTION
1.
2.
1
1
761157
781157
57 CHEVY w/o AC GEN IV EVAP SUB CASE
1957 CHEV. CAR 4 LEVER WO AC ACC. 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
57 CHEVY w/o AC
GEN IV EVAP
SUB CASE 761157
2
3
ACCESSORY KIT
781157
901257 REV D 6/30/16, 1957 CHEVY w/o AC GEN IV EVAP INST PG 3 OF 25
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
901257 REV D 6/30/16, 1957 CHEVY w/o AC GEN IV EVAP INST PG 4 OF 25
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.
5
• For proper system operation, the heater control valve must be connected to the
ECU.
901257 REV D 6/30/16, 1957 CHEVY w/o AC GEN IV EVAP INST PG 5 OF 25
BEFORE STARTING THE AIR CONDITIONER INSTALLATION, CHECK FOR PROPER OPERATION OF ALL
COMPONENTS (RADIO, LIGHTS, WIPERS, ETC.). STUDY THE INSTRUCTIONS, ILLUSTRATIONS AND DIAGRAMS.
FOR EASE OF INSTALLATION, CHECK OFF ( ) EACH PROCEDURE PRIOR TO MOVING ON TO THE NEXT STEP.
ENGINE COMPARTMENT
DISCONNECT BATTERY AND REMOVE.
REMOVE BATTERY TRAY.
REMOVE AIR CLEANER.
DRAIN RADIATOR.
DISCONNECT HEATER HOSES.
REMOVE OEM BLOWER ASSEMBLY FROM FIREWALL AND FENDER. KEEP THE TWO OEM FIREWALL COVER
RETAINING BRACKETS FOR USE WITH THE NEW FIREWALL COVER.
REMOVE OEM HEATER CONTROL VALVE AND DISCARD.
INSTALL HEATER CONTROL VALVE BLOCK-OFF PLATE AS SHOWN IN FIGURE 1, BELOW.
HEATER CONTROL
VALVE BLOCK-OFF
PLATE
FIGURE 1
6
901257 REV D 6/30/16, 1957 CHEVY w/o AC GEN IV EVAP INST PG 6 OF 25
PASSENGER COMPARTMENT
REMOVE CONTROL PANEL BEZEL.
REMOVE THE OEM CONTROL PANEL ASSEMBLY & DISCONNECT CABLES (RETAIN OEM CONTROL
PANEL AND DISCARD CABLES) AS SHOWN IN FIGURE 2, BELOW. REFER TO CONTROL PANEL
CONVERSION KIT INSTRUCTIONS FOR INSTALLATION OF CONTROLS.
REMOVE GLOVE BOX (DISCARD).
REMOVE GLOVE BOX DOOR.
REMOVE RADIO (OPTIONAL).
REMOVE CLOCK.
REMOVE AND DISCARD THE OEM HEATER ASSEMBLY AND HEATER DUCT.
REMOVE AND DISCARD DEFROSTER DUCT.
RADIO
CLOCK
FIGURE 2
CONTROL PANEL
GLOVE BOX
GLOVE BOX DOOR
OEM HEATER ASSEMBLY
7
DEFROST DUCTS
901257 REV D 6/30/16, 1957 CHEVY w/o AC GEN IV EVAP INST PG 7 OF 25
ENGINE COMPARTMENT
CONDERSER ASSEMBLY & INSTALLATION
REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH THE CONDENSER KIT TO INSTALL THE CONDENSER.
BINARY SWITCH INSTALLATION (REFER TO CONDENSER INSTRUCTIONS).
COMPRESSOR & BRACKETS
REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH THE BRACKET KIT TO INSTALL THE COMPRESSOR
BRACKET.
PULLEYS
IN MOST INSTANCES, THE BELT LENGTHS WILL REMAIN THE SAME.
DEFROST DUCT INSTALLATION
INSTALL DEFROST DUCTS WITH 2” DUCT HOSE (PASSENGER SIDE: 2” x 10”) (DRIVER SIDE: 2” x 24”).
SEE FIGURE 3, BELOW, & FIGURE 8, PAGE 11.
#8 X 1/2”
PAN HEAD
SCREW
FIGURE 3
8
901257 REV D 6/30/16, 1957 CHEVY w/o AC GEN IV EVAP INST PG 8 OF 25
EVAPORATOR INSTALLATION
ON A WORKBENCH, INSTALL EVAPORATOR REAR BRACKETS, AND INSTALL EVAPORATOR HARDLINES WITH
PROPERLY LUBRICATED O-RINGS (SEE FIGURE 16, PAGE 18, AND FIGURE 13b, PAGE 15).
INSTALL FRONT MOUNTING BRACKET TO EVAPORATOR UNIT WITH 1/4-20 x 1/2” BUTTON HEAD SCREW &
WASHER. TIGHTEN AS SHOWN IN FIGURE 7, PAGE 10. LOOSELY ATTACH FRONT MOUNTING BRACKET TO
DASH WITH 1/4-20 x 1” BOLT, WASHER AND NUT. SEE FIGURE 7, PAGE 10.
LIFT EVAPORATOR UNIT UP & UNDER THE DASHBOARD (SEE FIGURES 4 & 5, BELOW, & FIGURE 6, PAGE 10).
SECURE LOOSELY TO THE FIREWALL FROM THE ENGINE COMPARTMENT SIDE WITH (2) 1/4-20 x 1” BOLTS
AND WASHERS. SEE FIGURE 7, PAGE 10, & FIGURE 14, PAGE 16.
INSTALL CENTER A/C PLENUM TO EVAPORATOR WITH (2) 10/32 X 1/2” SCREWS. SEE FIGURE 7, PAGE 10.
LOOSELY SECURE THE CENTER PLENUM TO DASH WITH THE CENTER PLENUM MOUNTING BRACKET, USING
A 1/4-20 x 1” BOLT AND WASHER. SEE FIGURE 7, PAGE 10.
VERIFY THAT EVAPORATOR UNIT IS LEVEL AND SQUARE TO THE DASH, THEN TIGHTEN ALL SECURING BOLTS.
NOTE: TIGHTEN THE TWO BOLTS ON FIREWALL FIRST. THEN TIGHTEN THE FRONT MOUNTING
BRACKET BOLT AND NUT. TIGHTEN THE CENTER PLENUM MOUNTING BOLT LAST.
FIGURE 4
INSTALL EVAPORATOR UNIT FROM
PASSENGER SIDE FLOORBOARD.
FIGURE 5
9
ROTATE EVAPORATOR UNIT SO LINES PASS THROUGH
OPENING IN FIREWALL, AND LIFT INTO PLACE.
901257 REV D 6/30/16, 1957 CHEVY w/o AC GEN IV EVAP INST PG 9 OF 25
FIGURE 6
ONCE INTO PLACE, SECURE EVAPORATOR
UNIT TO FIREWALL.
1/4-20 x 1”
BOLT & WASHER
FIREWALL
NOTE: REMOVE
FIREWALL PAD RETENTION
PLUG AND REPLACE
WITH BOLT
A/C-HEAT
BLEND
DOOR
ECU
MODULE
DEFROST
DOOR
1/4-20
NUT
FRONT
MOUNTING
BRACKET
DASH/FLOOR
DOOR
1/4-20 x 1/2”
BUTTON HEAD
SCREW
1/4-20 x 1”
1/4-20 x 1”
BOLT & WASHER
BOTTOM LIP OF DASH
WASHER
CENTER PLENUM
MOUNTING BRACKET
FIGURE 7
CENTER
A/C PLENUM
CENTER
A/C PLENUM
DASH
SIDE VIEW
10/32 x 1/2”
SCREW
10/32 x 1/2”
SCREW
901257 REV D 6/30/16, 1957 CHEVY w/o AC GEN IV EVAP INST PG 10 OF 25
10
DUCT & DRAIN HOSE ROUTING
DRILL 5/8” HOLE IN FIREWALL FOR DRAIN HOSE, USING FIREWALL HOLE TEMPLATE ON PAGE 24. SEE
FIGURE 14, PAGE 16.
CONNECT DRAIN HOSE TO BOTTOM OF EVAPORATOR UNIT AND ROUTE TO FIREWALL (SEE FIGURE 14,
PAGE 16).
INSTALL DUCT HOSES AS SHOWN IN FIGURE 8, BELOW.
INSTALL DRIVER & PASSENGER UNDER-DASH LOUVERS. SEE FIGURE 9, PAGE 12.
CONTROL WIRING
ECU
MODULE
PASSENGER
SIDE LOUVER
2 ½” x 42”
PASSENGER
SIDE
DEFROST DUCT
2” x 10”
DRIVER
SIDE LOUVER
2 ½” x 48”
DRIVER SIDE
DEFROST DUCT
2” x 24”
FIGURE 8
11
901257 REV D 6/30/16, 1957 CHEVY w/o AC GEN IV EVAP INST PG 11 OF 25
PASSENGER AND DRIVER SIDE UNDER DASH LOVUER INSTALLATION
DASH
UNDER DASH
LOUVER
(PASSENGER SIDE)
SIDE FLANGE
BOTTOM EDGE
OF DASH
#8 x 1/2”
PAN HEAD
SCREW
FIGURE 9
KICK PANEL
RETAINING
STRIP
END VIEW
DRIVER SIDE
INSTALL PASSENGER AND DRIVER SIDE BALL LOUVERS BY SLIDING THE SIDE FLANGE OF BALL LOUVER
BETWEEN THE KICK PANEL AND KICK PANEL RETAINING STIP.
SLIDE LOUVER UP TOWARD BOTTOM OF DASH UNTIL LOUVER IS SEATED AGAINST DASH, AND SECURE
TO KICK PANEL WITH SUPPLIED #8 x 1/2” PAN HEAD SCREW. SEE FIGURE 9, ABOVE.
12
901257 REV D 6/30/16, 1957 CHEVY w/o AC GEN IV EVAP INST PG 12 OF 25
HARDLINE & HOSE INSTALLATION
STANDARD HOSE KIT
LOCATE THE TWO COMPRESSOR ALUMINUM HARDLINE EXTENSIONS. SEE FIGURE 13, PAGE 15.
LOCATE THE #8 COMPRESSOR ALUMINUM HARDLINE. LUBRICATE (1) #8 O-RING AND INSTALL ON THE
FEMALE O-RING END. CONNECT THIS LINE TO THE #8 DISCHARGE PORT ON THE COMPRESSOR AND
TIGHTEN. SEE FIGURE 13, PAGE 15.
LOCATE THE #10 COMPRESSOR ALUMINUM HARDLINE. LUBRICATE (1) #10 O-RING AND INSTALL ON
THE FEMALE O-RING END. CONNECT THIS LINE TO THE #10 SUCTION PORT ON THE COMPRESSOR
AND TIGHTEN. SEE FIGURE 13, PAGE 15.
SECURE THE TWO COMPRESSOR HARDLINES TO THE COMPRESSOR USING THE SUPPLIED CLAMP.
SEE FIGURE 13a, PAGE 15.
LOCATE THE #8 RUBBER HOSE. THIS HOSE WILL CONNECT TO THE #8 ALUMINUM COMPRESSOR
HARDLINE AND #8 ALUMINUM HARDLINE FROM CONDENSER. LUBRICATE (2) #8 O-RINGS, AND INSTALL
ONE ON EACH END OF THE #8 RUBBER HOSE. ROUTE HOSE AS SHOWN IN FIGURE 13, PAGE 15, AND
TIGHTEN. NOTE: THE 90° DEGREE HOSE END CONNECTS TO THE CONDENSER HARDLINE.
PASS THE #6 LIQUID LINE THROUGH THE BOTTOM HOLE IN THE FIREWALL COVER. SEE FIGURE 13b,
PAGE 15.
PULL FIREWALL COVER BACK AND INSTALL THE #6 LIQUID LINE, LUBRICATE (1) #6 O-RING AND TIGHTEN.
SEE FIGURE 13b, PAGE 15.
SECURE THE FIREWALL COVER USING TWO OEM RETAINING BRACKETS. SEE FIGURE 14, PAGE 16.
LOCATE THE #10 RUBBER HOSE. THIS HOSE WILL CONNECT TO THE #10 ALUMINUM COMPRESSOR
HARDLINE AND #10 ALUMINUM HARDLINE FROM EVAPORATOR. LUBRICATE (2) #10 O-RINGS AND INSTALL
ONE ON EACH END OF THE #10 RUBBER HOSE. ROUTE HOSE AS SHOWN IN FIGURE 13, PAGE 15,
AND TIGHTEN. NOTE: THE 90° DEGREE HOSE END CONNECTS TO THE COMPRESSOR HARDLINE.
INSTALL HEATER HOSES TO HEATER LINES AND ROUTE AS SHOWN IN FIGURES 13-13b, PAGE 15. SECURE
WITH HOSE CLAMPS. NOTE: THIS KIT DOES NOT CONTAIN HEATER HOSE. IT WILL BE NECESSARY TO
PURCHASE 5/8” DIAMETER HEATER HOSE FROM YOUR LOCAL PARTS RETAILER.
MODIFIED HOSE KIT
REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH MODIFIED HOSE KIT.
HEATER CONTROL VALVE & #6 LIQUID LINE
INSTALL HEATER CONTROL VALVE IN LINE WITH INTAKE MANIFOLD (PRESSURE SIDE) HEATER HOSE.
SEE FIGURE 12, PAGE 14.
INSTALL THE #6 LIQUID LINE TO DRIER WITH LUBRICATED O-RING AND TIGHTEN. SEE FIGURE 13, PAGE 15.
INSTALL BINARY SWITCH ON #6 LIQUID LINE. SEE FIGURE 13, PAGE 15.
SECURE THE #6 LIQUID LINE TO THE FENDER USING THE SUPPLIED ADEL CLAMP. SEE FIGURE 13, PAGE 15.
13
901257 REV D 6/30/16, 1957 CHEVY w/o AC GEN IV EVAP INST PG 13 OF 25
O-RING LUBRICATION
O-RING
TWIST WITH
THIS WRENCH
HOLD WITH
THIS WRENCH
#6 O-RING
FIGURE 10
O-RING
#8 O-RING
#10 O-RING
SUPPLIED OIL
FOR O-RINGS
MALE
INSERT
FEMALE
NUT
FOR A PROPER SEAL OF FITTINGS:
INSTALL SUPPLIED O-RINGS AS SHOWN
AND LUBRICATE WITH SUPPLIED OIL
O-RING, INSTALLS
OVER MALE INSERT
TO SWAGED LIP
FIGURE 11
HEATER CONTROL VALVE INSTALLATION
BSC
MODULE
ECU
MODULE
HEATER HOSE
NOTE: FLOW DIRECTION FOLLOWS
MOLDED ARROW ON VALVE.
TO
WAT
ER
FIGURE 12
#6 LIQUID
LINE
PUM
P
FRO
M
MA INTAK
NIF
OLD E
#10 SUCTION
HOSE
14
901257 REV D 6/30/16, 1957 CHEVY w/o AC GEN IV EVAP INST PG 14 OF 25
BSC
MODULE
PRESS
TAPE
EVAPORATOR
SUB CASE
ECU
MODULE
EXPANSION
VALVE
A/C & HEATER HOSE
AND HARDLINE ROUTING
FIREWALL
COVER
HEATER
CONTROL
VALVE
NOTE: COMPRESSOR HARDLINES
ARE INCLUDED WITH STANDARD
HOSE KIT ONLY
#8 COMPRESSOR
ALUMINUM HARDLINE
EXT. (DISCHARGE SIDE)
35038-VUG-A
HEATER
HOSES
#10 COMPRESSOR
ALUMINUM
HARDLINE EXT.
(SUCTION SIDE)
35037-VUG-A
PRESS
TAPE
#10 RUBBER
SUCTION HOSE
ADEL
CLAMP
BINARY SWITCH
INSTALLATION
#8 CONDENSER LINE
35018-VCG
#6 HARDLINE
35017-VCG
#8 RUBBER
HOSE
BINARY SWITCH
FIGURE 13
#6 LIQUID LINE
SPLIT RUBBER
GROMMET IN HOLE
IN CORE SUPPORT
#6 LIQUID LINE FROM
DRIER TO
EXPANSION VALVE
09157-PFL
FIGURE 13a
NOTE: MODIFIED HOSE KITS INCLUDE
(2) 135° COMPRESSOR FITTINGS (REFER
TO MODIFIED HOSE KIT INSTRUCTIONS
INCLUDED WITH HOSE KIT).
ECU
MODULE
ALUMINUM
CLAMP
(STANDARD
HOSE KIT
ONLY)
#10 SUCTION
LINE (INSULATED)
BSC
MODULE
FIREWALL
COVER
HEATER
HOSE
O-RING
O-RING
#6 LIQUID LINE
FIGURE 13b
15
#6 LIQUID LINE
901257 REV D 6/30/16, 1957 CHEVY w/o AC GEN IV EVAP INST PG 15 OF 25
FIREWALL COVER & FRESH AIR CAP
INSTALL FRESH AIR CAP TO FRESH AIR DUCT UNDER
PASSENGER SIDE FENDER AS SHOWN IN FIGURE 14, BELOW.
GROMMETS:
33137-VUI
(2) HEATER
HOSE GROMMETS
FIREWALL
TINNERMAN
NUT
REAR
EVAPORATOR
BRACKET
33137-VUI
#10 SUCTION
LINE GROMMET
1/4-20 x 1”
BOLT
w/ FLAT WASHER
33135-VUI
#6 LIQUID
LINE GROMMET
FIREWALL
62757-PCR
FIREWALL COVER
FIREWALL
COVER
HEATER LINE
FROM INTAKE TO
HEATER CORE
HEATER LINE
(SUCTION TO
WATER PUMP)
#10 SUCTION LINE
(4) OEM
PINS
DRILLED
DRAIN
HOLE
90°
DRAIN
ELBOW
FRESH
AIR CAP
FENDER
WELL
#6 LIQUID
LINE
FRESH
AIR DUCT
FIGURE 14
FENDER
901257 REV D 6/30/16, 1957 CHEVY w/o AC GEN IV EVAP INST PG 16 OF 25
OEM SLIDE
RETAINING BRACKETS
16
FINAL STEPS
INSTALL CONTROL PANEL AND WIRE ACCORDING TO WIRING DIAGRAM ON PAGE 19.
PLUG CONTROL WIRING HARNESS INTO ECU MODULE. SEE WIRING DIAGRAMS ON PAGES 19 & 20.
REMOVE THE BACKING FROM THE VELCRO STRIP ON THE INSIDE OF THE ECU COVER, AND INSTALL
THE ECU COVER ONTO THE ECU AS SHOWN IN PHOTO 1, BELOW. NOTE: ENSURE MATING SURFACES
ARE CLEAN AND FREE OF GREASE.
INSTALL GLOVE BOX BOTTOM AND GLOVE BOX DOOR, AND SECURE TO DASH WITH (3) OEM SCREWS.
SEE FIGURE 15, BELOW.
WITH GLOVE BOX BOTTOM AND DOOR IN PLACE, INSTALL GLOVE BOX TOP TO THE S-CLIPS ON THE
GLOVE BOX BOTTOM, AND SECURE TOP TO DASH WITH (5) OEM SCREWS. SEE FIGURE 15, BELOW.
ECU COVER
620901
PHOTO 1
(3) OEM
SCREWS
DASH
PLASTIC GLOVE
GLOVE
BOX BOTTOM BOX HINGE
(4) S-CLIPS
GLOVE
BOX DOOR
(5) OEM
SCREWS
GLOVE
BOX TOP
FIGURE 15
REINSTALL ALL PREVIOUSLY REMOVED ITEMS (BATTERY BOX & BATTERY).
FILL RADIATOR WITH AT LEAST A 50/50 MIXTURE OF APPROVED ANTIFREEZE AND 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.
DOUBLE CHECK ALL FITTINGS, BRACKETS AND BELTS FOR TIGHTNESS.
VINTAGE AIR RECOMMENDS THAT ALL A/C SYSTEMS BE SERVICED BY A CERTIFIED AUTOMOTIVE AIR
CONDITIONING TECHNICIAN.
EVACUATE THE SYSTEM FOR A MINIMUM OF 45 MINUTES PRIOR TO CHARGING, AND LEAK CHECK
PRIOR TO SERVICING.
CHARGE THE SYSTEM TO THE CAPACITIES STATED ON THE INFORMATION PAGE (PAGE 4) OF THIS
INSTRUCTION MANUAL.
17
901257 REV D 6/30/16, 1957 CHEVY w/o AC GEN IV EVAP INST PG 17 OF 25
901257 REV D 6/30/16, 1957 CHEVY w/o AC GEN IV EVAP INST PG 18 OF 25
18
PRESS TAPE
#10 O-RING
(33859-VUF)
HEATER LINE
(EVAP TO WATER PUMP)
09161-PCH
#10 SUCTION
LINE
(09159-PCS)
NOTE: AFTER INSTALLING
#10 SUCTION LINE, WRAP
ALL EXPOSED METAL
(FITTINGS & TUBE) WITH
SUPPLIED PRESS TAPE.
#6 LIQUID LINE
(09158-PCL)
#6
O-RING
(33857-VUF)
PASSENGER SIDE
(EVAP. BRACKET)
64357-PCB
FIGURE 16
#10 O-RING
(33859-VUF)
DRIVER SIDE
(EVAP. BRKT)
64353-PCB
TWIST WITH
THIS WRENCH
HEATER LINE
(EVAP TO INTAKE)
09160-PCH
ECU MODULE
EVAPORATOR HARDLINE INSTALLATION
LUBRICATE
O-RING
(SEE FIGURE 11,
PAGE 14)
HOLD WITH
THIS WRENCH
1/4-20 x 1/2”
BOLT
(LOCATED ON
SUB CASE)
1/4-20 x 1/2”
BOLT
(LOCATED ON
SUB CASE)
Wiring Diagram
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).
19
• Wide Open Throttle Switch Contacts Close Only at Full Throttle, Which Disables A/C
Compressor.
901257 REV D 6/30/16, 1957 CHEVY w/o AC GEN IV EVAP INST PG 19 OF 25
Gen IV Wiring
Connection Instruction
WIRING
HARNESS
CONTROL
WIRING
HARNESS
RED
&
WHITE
A/C
COMPRESSOR
RELAY
RED
BLUE
RED
WH
IT
E
NOTE:
MOUNT RELAY
IN DESIRED
LOCATION
UNDER DASH
Ignition Switch:
VIOLET
+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
BLACK BLUE
Heater Control Valve:
RED
WHITE
LATCH
CHASSIS GROUND
WIRING
HARNESS
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
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
COMPRESSOR
WHITE
NOTE: CONNECT WHITE
WIRES DIRECTLY TO
(-) BATTERY TERMINAL
WHITE
RED
RED
CIRCUIT BREAKER
30 AMP
Dash Light:
Tan Wire Used Only With Vintage Air
Supplied Control Panel With LED Back
Light.
RED
GREEN
FIREWALL
BLUE
Violet 12V Ign Switch Source (Key On
Accessory) Position Must Be Switched.
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.
Circuit Breaker/Battery:
White Must Run To (-) Battery. Red May
Run To (+) Battery Or Starter. Mount
Circuit Breaker As Close to Battery As
Possible.
BATTERY
901257 REV D 6/30/16, 1957 CHEVY w/o AC GEN IV EVAP INST PG 20 OF 25
20
OPERATION OF CONTROLS
FOR MAXIMUM COOLING AND HEATING, THE AIR LEVER MUST BE IN “INSIDE MODE” POSITION
NOTE: WHEN BATTERY POWER IS FIRST CONNECTED TO THE ECU, THE COMPUTER GOES THROUGH
AN INITIALIZATION SEQUENCE. THIS INITIALIZATION MAY TAKE UP TO 30 SECONDS. DURING
INITIALIZATION THE BLOWER WILL NOT OPERATE, BUT THE DOORS INSIDE THE UNIT WILL BE
OPERATING. A LOW BATTERY OR DISCONNECTING THE BATTERY MAY ALSO TRIGGER A
REINITIALIZATION. DURING START UP, A LOW BATTERY MAY DROP BELOW 7 VOLTS, TRIGGERING
REINITIALIZATION.
SYSTEM OFF
BLOWER SPEED
CONTROL
(LOW/MED/HI)
HEAT MODE
NOTE: THERE ARE TWO BI-LEVEL POSITIONS: BETWEEN DASH-FLOOR
BETWEEN FLOOR-DEF
BI-LEVEL A/C MODE
A/C MODE
DEFOST MODE
BI-LEVEL HEAT MODE
21
901257 REV D 6/30/16, 1957 CHEVY w/o AC GEN IV EVAP INST PG 21 OF 25
901257 REV D 6/30/16, 1957 CHEVY w/o AC GEN IV EVAP INST PG 22 OF 25
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.
22
System is charged.
System is not charged.
All other functions work.
No other functions work.
Condition
Check 2-pin connector at ECU housing.
Repair or replace pot/control wiring.
Replace relay.
Check for faulty A/C
potentiometer or associated
wiring.
Check for faulty A/C relay.
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 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
Symptom
901257 REV D 6/30/16, 1957 CHEVY w/o AC GEN IV EVAP INST PG 23 OF 25
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.
23
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
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.)
2 ⅛”
1/2”
FIREWALL
DRAIN HOLE
TEMPLATE
3 9/16”
PASSENGER SIDE FENDER
CORE SUPPORT
TEMPLATE
5/8” DIAMETER
DRAIN HOLE
2 5/16”
2 ¼”
(FROM INSIDE CAR)
CUT ALONG DOTTED LINE (LINE UP OPENING IN FIREWALL & PLACE EDGE
AGAINST FIREWALL SUPPORT
1¼” DIAMETER
FOLD PAGE AT THIS LINE AND POSITION AT EDGE OF CORE SUPPORT (REMOVABLE PANEL)
(TOP)
2 ¾”
2 ⅜”
EXISTING
HOLES
5/16” DIAMETER
24
901257 REV D 6/30/16, 1957 CHEVY w/o AC GEN IV EVAP INST PG 24 OF 25
EVAPORATOR KIT
561057
EVAPORATOR KIT PACKING LIST
No.
QTY.
PART No.
DESCRIPTION
1.
2.
1
1
761157
781157
57 CHEVY w/o AC GEN IV EVAP SUB CASE
1957 CHEV. CAR 4 LEVER WO AC ACC. KIT
CHECKED BY:
PACKED BY:
DATE:
1
57 CHEVY w/o AC
GEN IV EVAP
SUB CASE 761157
2
ACCESSORY KIT
781157
901257 REV D 6/30/16, 1957 CHEVY w/o AC GEN IV EVAP INST PG 25 OF 25
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