1-2055FA INSTALL INSTRUCTIONS

1-2055FA INSTALL INSTRUCTIONS
©
1967-68 Camaro/Firebird Factory Air
DOCUMENT #1-2055FA
©2012 ClassicAutoAir / 3.12vs.a
Congratulations...
You have just purchased the highest quality, best performing
A/C system ever designed for your Classic Vehicle.
To obtain the high level of performance and dependability our systems are known for, please pay close attention to the
following instructions. Our installation steps and procedures are derived from a long history of research and
development and the combined experience achieved thru thousands of successful installations (and feedback from
customers like you). Please remember that our #1 goal is that you’ll have a successful installation and a system that
performs at a very high level for many years to come.
Before starting, read the instructions carefully, from beginning to end, and follow the proper sequence. On the next
page you’ll find a safety and general checklist that you should read before starting your installation.
Again, thank you from our entire staff.
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4
Check List, Pre-Installation:
Before beginning the installation check the shipping box for the correct components. YOUR BOXED UNIT INCLUDES A LIST OF
MAJOR COMPONENTS AND A LIST OF BAGGED PARTS. We have a 5 stage check process to make sure you have everything you’ll
need.
If your vehicle has been or is being modified, some procedures will need to be adjusted to fit your particular application.
A basic cleaning of the engine compartment and interior before beginning will make things go more smoothly.
Check condition of engine mounts. Excessive engine movement can damage hoses to A/C and/or heater.
Before starting, check vehicle interior electrical functions (interior lights, radio, horn, etc). Make a note of anything that does not work as
it’s supposed to. During the installation you might find the opportunity to repair or upgrade non-working or out of date components.
When you’re ready to start the installation, DISCONNECT THE BATTERY FIRST.
Drain the radiator. Retain the coolant and reuse, or dispose of properly.
SAFETY FIRST: Wear eye protection while drilling/cutting, deburr sharp edges, and never get in a hurry or force a part.
Tools: Your installation only requires the basic tools everyone has in their garage, nothing exotic or specific to A/C or Heat equipment.
Procedures, During Installation:
Fittings: Use one or two drops of mineral oil (supplied with your kit) on ALL rubber o-rings, threads and rear of bump for o-ring where
female nut rides. Do not use thread tape or sealants.
Measure twice (or more), cut once
Should you have any technical questions, or feel you have defective components (or missing items), call us immediately,
we will be glad to assist you. Our toll-free number is listed on every page, we’re here to help!
YOU CAN NOW BEGIN THE INSTALLATION...
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5
A Basic A/C Overview
OUTSIDE AIR
Evaporator with Blower Fan
1
In order to remove the heat from the air in the vehicle, the A/C
evaporator allows the refrigerant to absorb the heat from the air passing over it. The blower fan moves cool air out into the car
interior.
2
Compressor The compressor pumps and circulates the refrigerant through the system.
3
Condenser The condenser is a heat exchanger mounted at the front of the vehicle. Heat drawn out of the interior of
4
the car is expelled here.
Receiver/Drier The drier not only dries refrigerant, it also filters the refrigerant and stores it under certain
Suction
Valve Discharge
Valve
Receiver
Drier
Condenser
Compressor
operating conditions.
5
High Pressure Switch A pressure switch is used to shut down the system if high or low pressure is
detected, basically it acts as a safety switch.
Firewall
Expansion Valve
AIR FROM INSIDE VEHICLE
COO
LED
AIR
1
SUC
3
LIQ
TIO
UID
NH
OS
E
2
DIS
SE
GRO
POW
ER
UND
COLD AIR INTO VEHICLE
5
4
SE
Evaporator Unit
E HO
RG
CHA
HO
The air conditioning system in your car is comprised of a compressor, condenser,
expansion valve, receiver/drier, and evaporator. Refrigerant (also known as Freon) is
compressed in the compressor and turns into a gas. In the condenser, this gas is cooled to a
liquid state and travels to the expansion valve. As the liquid refrigerant goes through the
expansion valve it rapidly cools in the evaporator. A fan blows over the evaporator and cools the
air that blows out your vents. The receiver-drier separates gas and liquid.
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PAGE
6
Control & Operating Instructions
Your new Perfect Fit-Elite system offers complete comfort capabilities in virtually every driving condition. This
includes temperature control in all of the modes. This system also provides the ability to blend the air between Face,
Heat, and Defrost modes simultaneously. To illustrate the various ways you can adjust the airflow direction and
temperature - we’ve provided these handy illustrations and chart to show exactly how you can adjust your Perfect
Fit-Elite for maximum comfort...
The FAN switch works like the OEM switch,
the far left position is OFF (all power to the
system is OFF in this position)
UNUSED
FAN
DEFROST
TEMP LEVER
MODE LEVER
HI
COLD
HOT
DASH
FLOOR
FAN SWITCH
There are 11 levels of adjustment within
the range of the DASH/FLOOR lever
DASH
Left Lever Postion
Distribution
Compressor State
DEF
FLOOR
1
2
3
4
5
6
7
Face A/C
100%
Face A/C
80%
Face A/C
60%
Face A/C
40%
Face A/C
20%
Defrost
100%
Floor
20%
Defrost
20%
Defrost
40%
Defrost
60%
Defrost
80%
Defrost
80%
ON
The COLD/HOT positions works like any
traditional adjustment lever
8
9
10
11
Floor
60%
Floor
40%
Floor
80%
Floor
100%
Defrost
40%
Defrost
60%
Defrost
20%
ON
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7
INTERIOR
COMPARTMENT
Remove Glovebox, Console (optional)
Radio and Bezel, and set them aside
for reinstall later
(see figure 1).
The removal of the Original Heater Assembly can be
accomplished by disconnecting three control cables. One is
attached to the Heat/Defrost door (see figure 2). One is
attached to the Temperature door, and one is attached to the
Vent / Heat door (see figure 3). Disconnect the electrical
harness from the assembly. Also remove attachment screw
located in front of the air inlet (see figure 4).
When retaining parts it’s a
good idea to store parts in a
zip lock bag, labeled with
GOOD IDEA info where the parts came
from and what size/type of
tool is needed to reinstall. Cleaning
the parts before you need to reinstall
them is a good idea too.
FIGURE 2
FIGURE 3
FIGURE 4
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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.
Faceplate Sticker
PN#00118-20
FLOOR
DEF
DASH
HOT
COLD
Two #8 - 20x3/8" Screws
Cable Integrators
PN#16-2030
Push Nuts
PN#PD156007PG
Blower Switch
PN#3T-235
NOTE: Illustrations NOT shown actual size
D.E.R. Controller
PN #16-3054
Two - Cable Clips
PN#25-1015
Blower Switch Bracket
PN#0047-30
Blower Switch Knob
PN#525235
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9
Remove The Control Head From The Dash.
1) Remove the OEM blower switch and knob. Retain the screws, you will use
them again shortly. Remove the control cables and the original blower switch
and set aside (these will not be reused). Remove the OEM vacuum switch also.
2) Attach the new blower switch bracket as shown in the sequence below,
utilizing the OEM screws (you will use one of the crews from the OEM vacuum
switch). Then attach the new blower switch and attach the included knob.
This completes this portion of the control modification.
Two #8 - 20x3/8" Screws
OEM SCREWS
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PAGE
10
Flip the control head over and continue on...
Preparing the EZ Cable Integrators for installation: First place the included cable clips
over the ends of the EZ Integrators (as shown in figure 5). Prepare both integrators
the same way.
Next, attach the TEMP EZ Cable Integrator to the control head
as shown here. Position this integrator up and into the center of the
control head so that you can attach the looped cable end to the
post on the middle lever. Secure the looped end with a push nut.
Use an OEM screw and secure the integrator to the control head
frame. Test fit this integrator into it’s final position first, and
make sure the cable clip is orientated correctly before
securing it. Make sure the integrator has a clean and
complete path of travel by moving the appropriate lever back
and forth several times.
Test the operation one last time of all the levers
(except for the top one, it’s unused). Tighten all
screws and make sure all pushnuts are pushed
down on the posts and won’t slip off with
extended use.
NEW!: if your control head has
excessively deteriorated with age, we
offer a complete replacement control
head that is ready to “plug-n-play” into our
A/C system. Our new D.E.R. units are sturdy,
made in America, and can greatly speed up
installation time.
OEM Screw
P
M
TE
Pushnut
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PAGE
10.5
It is very important that you place the cable clips over
the end of the integrators very securely and evenly.
Place the cable clip over the end, press it firmly into
place (using needle-nose pliers is recommended).
IMPORTANT: Test fit each integrator into place
to get the perfect orientation and position for the
cable clip first! Also, make sure the integrators
have a clean and complete path of travel by
moving the appropriate lever back and forth
several times.
Next, attach the MODE EZ Cable Integrator to the
control head as shown below. Push the looped end of
the wire cable over the post on the lower lever, and
then secure it with one of the included push nuts. Use
the screw that originally held the OEM cable and
secure the integrator to the control head.
DE
MOODE
M
Pushnut
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11
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.
Suction Tube
PN#0034-10
Liquid Tube
PN#0034-9
#6 and #10 O-ring
Evaporator Support Brackets
PN#0023-7
Fresh Air Inlet Block Off
PN#10-1048-2
Two #10 - 16 x 3/4" Tek Screws
One Bulb Clamp
One Flange Nut
Cap Plug
Defrost/Heat Duct Assembly
PN#2-2025-2
One Male Spade Connector
Six #10 - 10 x 5/8" Phillips Screws
Illustrations NOT shown actual size
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12
Locate the original wiring harness that supplied power to the original heater motor.
Reaching thru the glove box opening pull these wires out of their grommet (see figure
6). (GM normally used a brown wire for power). After the removal of the wire, and
vacuum harness there will be a hole in the firewall. Using the 1 ½” cap plug we’ve
included you can plug the hole. 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 included template, piece it together from the two pages and use to drill
the drain hole. Attach to the firewall using the two OEM holes as guides as shown
below.
Follow directions on the templates and drill the holes for the evaporator.
From inside of the vehicle drill the hole for the drain tube.
FIGURE 6
You can now begin
installing your Classic
Air Perfect Fit Elite
System.
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13
Within the engine compartment area, Install a Fresh Air inlet block off over the
OEM vent opening using the original bolts.
COWL
Remove evaporator unit from box and place on a flat work surface.
Locate defrost / heat duct assembly and attach to the evaporator using two
#10 - 10 x 5/8" Phillips screws (see figure 7). NOTE: Be sure that the s-clips are
pushed over rear flange on evaporator.
Remove Passenger and Drivers side ball louvers. Retain original hardware.
Located behind the OEM astro vents louvers you will find a flex duct connected
to the air inlet adapter. Remove the duct and the air inlet adapter.
Take a minute to familiarize yourself with the evaporator unit:
Evaporator Mouting Stud
Actuator Motor
Floor/Face
Vent Door
Evaporator
Support Bracket
Holes
Thermostat
Blower Motor Plug
FIGURE 7
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14
DASH
FIREWALL
Installing the complete evaporator unit under the dash will go much easier with
the help of a friend. One person can take the unit within the car and “roll” up
and under the dash while the other person can be ready at the firewall area with
the included flange nut to secure the unit in place (see figure 8). Now the unit
will be easy to level and secure. Leveling the unit is very important to insure
proper drainage of condensation.
Flange Nut attached to stud protruding
thru original mounting hole
FIGURE 8
LEVEL
TECH TIPS
Be sure to align the evaporator unit level with the bottom of
instrument panel (assuming the vehicle is sitting level) as shown to
the left, but with a small degree of tilt toward the back to allow
proper drain of condensation.
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15
Locate in the UPPER MOUNTING BRACKETS and attach to evaporator unit
using four #10 - 10 x 5/8" Phillips screws. Attach other end to the cowling
with a #10 - 16 x 3/4" Tek Screws (see figure 9). 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 AND RIGHT FOR THESE
BRACKETS! Do not tap into the other holes for any reason (see figure 10).
Also, use a screwdriver and hand-power and do not over-tighten so you don't
strip the holes.
#10 - 16 x 3/4" Tek Screw
YES
FIGURE 10
NO!
FIGURE 9
YES
#10 x 5/8"
Screws
#10 x 5/8"
Screws
LEVEL
TECH TIPS
Be sure to align the evaporator unit level with the bottom of
instrument panel (assuming the vehicle is sitting level) as shown to
the left, but with a small degree of tilt toward the back to allow
proper drain of condensation.
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16
Install liquid line onto the Expansion valve (TXV) as
shown. Use #6 o-ring and (2) drops of mineral oil on
the o-ring and tighten securely.
Install Suction Tube to the outlet on the unit as
shown. Use #10 o-ring and (2) drops of mineral oil
on the o-ring and tighten securely.
We’ve included a bulb clamp, Which you will use to
attach coil to the Suction Tube.
CAUTION: YOUR SYSTEM WILL NOT
FUNCTION PROPERLY IF THE SENSING COIL
IS NOT CLAMPED IN THE CORRECT
POSITION. SEE THE DIAGRAM BELOW.
Once the sensing coil is installed, wrap suction tube
and coil with refrigerant tape. Be sure that all of the
exposed metal is covered.
O-RING
O-RING
CLAMP
LB
BU
NO!
YES
TECH TIPS
Reminder...
Use two
wrenches to
tighten o-ring
fittings
NO!
NO!
Suction Tube
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17
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
Six Worm Gear Clamps
Refrigerant Tape
Firewall Block Off
PN#10-2055FA-1
Six #10 - 16 x 3/4" Tek Screws
Illustrations NOT shown actual size
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PAGE
18
Heater
Tubes
A/C
Tubes
It may be necessary to manipulate
the tubes slightly to get proper
fittment thru the block-off plate
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 (you’ll need to loosen your hood
hinge and tuck one corner behind it). 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 block off plate, it will be plugged into the
electronic 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.
IMPORTANT
NOTICE: PROPER
INSTALLATION OF
WATER VALVE
INSTRUCTIONS!!!
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.
PU
H
MP
ER
T
EA
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.
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THESE ARE THE PARTS YOU WILL FIND IN BAG KIT D
You will use all of these parts and hardware during the next series of installation steps.
CONT
R VA
WATE
LVE
The ECU will be shipped in it’s own box,
along with the calibration key.
ROL
T
LOOR
R
DEFROS
FACE/F
POWE
Five #10 - 16 x 3/4" Tek Screws
Pressure Switch
(engine compartment)
Ground
Ground
Yellow
ECU
Orange
Thermostat
Blue
OEM Power
Supply
Fan
Plug
Wire Harness System
Wire Harness Power Supply
PN#0105-36
Blower Switch
Connection
Relay
Illustrations NOT shown actual size
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20
We’ve included enough wire length to allow you to mount the ECU in a variety
of places. It is very important that you mount this in a place where it will stay dry
and that vibration is at a minimum. Also make sure that where ever you mount it
does not interfere with any moving controls or cables. We recommend
mounting it just above the right hand side of the main unit using the included
tek-screws. IMPORTANT! DON’T MOUNT THE ECU PERMANENTLY JUST
YET. THAT CAN BE DONE AFTER YOU CALIBRATE THE UNIT.
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 12). Using one of the CAP
PLUGS provided, slot it and install over the heater hose/cable.
Figure 12
CONT
FIREWALL
WATER
VALVE
NOTE: The GREEN harness connection will be made from the harness you
previously installed, just plug the loose connection in the CONTROL
port on the ECU.
ROL
ST
LOOR
POWER
DEFRO
FACE/F
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21
Orang
eH
arn
e
Wiring Diagram/Overview
To 12V Power Supply
ss
Electronic Water Valve
Re
d
/W
hite
Compressor
Wi
re
r
G
Wh
Pressure Switch
Ground
Wire
ite
Blower Switch
res
Wi
e
Blu
ess
arn
H
n
ee
ECU
Servo for Defrost Ducts
Relay
Blu
eW
ire
Thermostat
ire
W
Red Wire
ness
Blu
e
Servo for Face/Floor Ducts
Blue Har
ss
r ne
Yello w H a
Cable Integrators
Ground
Evaporator
Bl
ue
W ire
Ground
REMINDER: BE SURE THAT THE WIRING HARNESS DOES NOT INTERFERE WITH THE OPERATION OF ANY CONTROLS.
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PAGE
Temporarily reconnect the car battery at this time. You will need a full 12 volts to complete the calibration.
22
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
LVE
VA
#3
FAN OFF
NT
CO
DEF
R
FAN HIGH
WE
PO
FAN OFF
COLD
ST
RO
R
OO
/FL
CE
FA
L
RO
tion
ibra
Cal
DASH
HOT
DEF
FAN OFF
COLD
FLOOR
FAN HIGH
HOT
DEF
DASH
#5
COLD
FLOOR
FAN HIGH
O
LED N
Key
Move FAN control to medium
in one motion...
Position your controls
like this example.
Plug CALIBRATION KEY into ECU
After 1 second the
LED turns back ON
#6
FAN OFF
O
LED N
1 Second
Later...
D OFF
LE
HOT
DEF
DASH
Move MODE control to
DASH in one motion...
D OFF
LE
1 Second
Later...
#7
FLOOR
#8
FAN OFF
COLD
FAN HIGH
#4
HOT
DEF
DASH
O
LED N
1 Second
Later...
D OFF
LE
COLD
O
LED N
FLOOR
Move TEMP control to
HOT in one motion...
ER
WAT
FAN HIGH
You may be able to
hear the internal door(s) move
back and forth...
Approx. 30
Seconds
Later...
D OFF
LE
DASH
HOT
DEF
FLOOR
Move the FAN knob to OFF
(powers off unit)
E
VALV
ST
RO
C
FA
CO
OR
DEF
LO
E/F
OL
R
NT
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....
23
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
Ball Louver Adaptors
(2 piece assembly)
PN#2-1055-1
Bag G
Center Dash Vent Adaptor
PN# 2-1054-3
Two Defrost Diffuser
PN#2-1054-2
Two Duct Hoses, 2" I.D.
Two Duct Hoses, 2" I.D.
Four Zip-Ties
Two Duct Hoses, 2" I.D.
Face/Floor Assembly
PN#2-2025-1
Four Zip-Ties
Two #6 - 20x3/8" Screws
Four Zip-Ties
Illustrations NOT shown actual size
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24
Bag Kit E. The following steps are for left and right Defrost Diffusers...
Locate and route the duct hoses from the defrost/heat duct assembly upward
toward defrost vents. Attach the flex hose to the defrost defuser using zip-ties.
The other end of the duct hose is installed over the defrost/heat duct assembly
outlets on main unit (see figures 13 and 14).
The face/floor assembly comes preinstalled with s-clips which allow you to
install it onto the evaporator unit quickly and securely (see figure 15).
TOP OF DASH
FIGURE 13
FIGURE 14
Push defrost adaptors onto
lip of dash tab (below defrost vents,
inside of dash), S-clips (already installed)
will hold the adaptors securely
FIGURE 15
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25
Insert original ball into the original louver housing. Attach hose adaptors to the
back of housing (applying pressure will keep your louver ball in place).
Reinstall louver assemblies into original holes using original hardware.
GOOD IDEA
The smoother the route of the flex hoses
the better the airflow.
ptors
Route supplied flex hoses as shown below.
Take your time and route them so they
don’t become kinked or torn.
To defrost defuser ada
During installation of the hoses be
aware of the eventual movement of
the wiper arm components.
OEM Housing
OEM Ball
Louver
Two-Piece
Adaptor
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26
Install center hose adaptor from behind the opening as shown. Secure
using (2) #10 x 5/8” pan head screws.
Cut (1) piece of flex hose 24” long, and one piece 19” long. Attach
longest piece to the right hose adapter using (1) #10 x 5/8” pan head
screw. Other piece attaches to the left adaptor using (1) #10 x 5/8” pan
head screw.
Route the hoses from the center vent to the two
remaining openings on the Face/Floor assembly on
the evaporator. Reinstall the bezel using the original hardware.
You can reinstall the glove box at this time, and any other interior
components that we’re removed.
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....
If you have any questions before you move
on the final phase of this installation, call us.
888.791.6384
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27
THESE ARE THE PARTS YOU WILL NEED FOR THE
ENGINE COMPARTMENT INSTALLATION
You’ll find all of these parts within the main box
Drier Bracket
Bottom Condenser Brackets
PN#0049-51
Condenser
PN#11-1089
Core Support Bracket
PN#0049-62
Core Support Bracket
PN#19-151
Eleven #10 - 20x1/4" Screws
Liquid
Tube
(drier to
rad support)
Pressure Switch and harness,
Bag of O-rings and Mineral Oil Tube
Discharge
Tube
(condenser
to rad support)
#10 1
ti o
S
uc
81
#
ose
Liquid
Tube
(condenser
to drier)
3/3
Six #10 - 16 x 3/4" Tek Screws
/16" Liquid Hose
#6 5
nH
Splice and
Bullet Connector
Top Condenser Bracket
PN#0049-50
2" D
ischa
rge Hos
e
Drier
/2"
Three Refrigerant Hoses
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28
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 left side (the larger connection
will be on top). The drier is conveniently mounted on the left hand side of the
condenser. First insert the drier into the drier mounting bracket (it’s basically a
sleeve for the drier). Attach the drier liquid tube to the drier and also to the
connection on the condenser (tighten connections at either
end using supplied o-rings on both ends and a few drops of
mineral oil to each o-ring). With these two components
combined it will easy to find the correct place to attach the
drier bracket to the condenser with the included #10-20 x
Two
#10 - 20x1/4"
1/4” screws (attach drier and bracket from the front of the
Screws
condenser).
PRESSURE SWITCH: Screw the high-pressure switch into
the port on the top of the drier. Go ahead and plug the
pressure switch harness into the switch at this time (black
electrical boot with two long white wires).
Fit brackets with #10 - 20x1/4" Screws, fitted loosely into the
top two holes of the condenser, both sides
Pressure
Switch
BRACKETS: Install the upper condenser bracket using four
#10 - 20 x 1/4“ screws in the top two holes on each side.
Next, attach the lower brackets using the bottom two holes,
with the same size screws. These brackets have a bend that
will face away from you.
Fit brackets with #10 - 20x1/4" Screws, fitted loosely into the
top two holes of the condenser, both sides
TECH TIPS
Reminder...
Use two
wrenches to
tighten o-ring
fittings
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.
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29
Remove the hood latch assembly. Retain original
hardware. Slide condenser assembly down in front of the
radiator.
Discharge Tube
Locate condenser in the center of
the radiator. Attach top condenser
brackets to the bulkhead using (2)
#10 Tek screws.
Two #10 - 16 x 3/4" Tek Screws
Located behind the air damn and at
the lower radiator bulkhead, attach
the lower condenser brackets using
(2) # 10 Tek screws.
Reinstall hood latch assembly using
original hardware.
Liquid Tube
Locate the Liquid tube, Discharge tube, (1) #6 o-ring,
and (1) #8 o-ring. Attach Liquid tube to the drier using the #6
o-ring and a few drops of mineral oil. Attach Discharge tube to the
condenser using #8 o-ring and a few drops of mineral oil.
Two #10 - 16 x 3/4" Tek Screws
(upward from bottom)
Locate the tube support bracket, the tube clamp, and (2)
#10 x ¾” tek screws, and (1) #10 x ½” hex head screw.
Attach the support bracket to the radiator bulkhead using (2) #10 x
¾” tek screws.
Attach liquid and discharge tubes using the tube clamp, using (1)
#10 x ½” screw.
#10 - 20x1/4"
Screw
Two #10 - 16x3/4"
Tek Screws
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30
Time to install the compressor kit. Included in your box is a premium
compressor kit with all the parts you’ll need to install the compressor. This kit
includes instructions specifically written for your engine. Once you’ve installed
the complete compressor kit, continue on to connecting the hoses.
#6 H
ose
#10 Hose
#8 Hose
CO
COMMPLETE
PRES
KIT SOR
CONNECTING THE HOSES:
1) Attach the #8 Discharge Hose (13/32") from the connection under 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") from the connection under the core support
connection at the firewall on the evaporator unit (see figure 41). Tighten fittings
using o-rings and mineral oil supplied in kit.
Passenger Side Compresssor
#6 H
ose
#10 Hose
#8 Hose
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.
Drivers Side Compresssor
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31
Connect the pressure switch by first connecting one wire to the connection on
the compressor, and the other wire will be routed along with the liquid hose and
connected to the blue lead you put thru the firewall during the interior installation
(for attachment route. We’ve included a bullet and slice connector to make these
connections, use a crimp tool to secure these properly.
FINAL STEPS: Take a look around at your installation and check all fittings 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 very 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.
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32
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.
!
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)
Centerline of the Oil Plug
90˚
90˚
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
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TROUBLESHOOTING GUIDE
TEST CONDITIONS USED TO DETERMINE SYSTEM OPERATION
(THESE TEST CONDITIONS WILL SIMULATE THE AFFECT OF
DRIVING THE VEHICLE AND GIVE THE TECHNICIAN THE THREE
CRITICAL READINGS THAT THEY WILL NEED TO DIAGNOSE ANY
POTENTIAL PROBLEMS).
B. CONNECT GAUGES OR SERVICE EQUIPMENT TO HIGH/LOW
CHARGING PORTS.
C. PLACE BLOWER FAN SWITCH ON MEDIUM.
D. CLOSE ALL DOORS AND WINDOWS ON VEHICLE.
E. PLACE SHOP FAN IN FRONT OF CONDENSER.
F. RUN ENGINE IDLE UP TO 1500 RPM.
ACCEPTABLE OPERATING PRESSURE RANGES (R134A TYPE)
1. HIGH-SIDE PRESSURES ( 160-250 PSI ) *Note- general rule of thumb is
two times the ambient (daytime) temperature, plus 15-20%.
2. LOW-SIDE PRESSURES ( 06-22 PSI in a steady state).
C.
D.
E.
CHARGE AS FOLLOWS: R134A = 24 OZ.
NO ADDITIONAL OIL IS NECESSARY IN OUR NEW COMPRESSORS.
TYPICAL PROBLEMS ENCOUNTERED IN CHARGING SYSTEMS
NOISY COMPRESSOR. A noisy compressor is generally caused by charging a compressor with
liquid or overcharging
A. If the system is overcharged both gauges will read abnormally high readings. This is
causing a feedback pressure on the compressor causing it to rattle or shake from the
increased cylinder head pressures. System must be evacuated and re-charged to exact
weight specifications.
B. Heater control valve installation - Installing the heater control valve in the incorrect hose.
Usually when this occurs the system will cool at idle then start to warm up when raising the
RPM’s of the motor. THE HEATER CONTROL IS A DIRECTIONAL VALVE; MAKE SURE THE
WATER FLOW IS WITH THE DIRECTION OF THE ARROW. As the engine heats up that water
transfers the heat to the coil, thus overpowering the a/c coil. A leaking or faulty valve will
F.
G.
H.
have a more pronounced affect on the unit’s cooling ability. Installing the valve improperly
(such as having the flow reversed) will also allow water to flow through, thus inhibiting
cooling. Check for heat transfer by disconnecting hoses from the system completely. By
running down the road with the hoses looped backed through the motor, you eliminate the
possibility of heat transfer to the unit.
Evaporator freezing - Freezing can occur both externally and internally on an evaporator
core. External freeze up occurs when the coil cannot effectively displace the condensation
on the outside fins and the water forms ice (the evaporator core resembles a block of solid
ice), it restricts the flow of air that can pass through it, which gives the illusion of the air not
functioning. The common cause of external freezing is the setting of the thermostat and the
presence of high humidity in the passenger compartment. All door and window seals should
be checked in the event of constant freeze-up. A thermostat is provided with all units to
control the cycling of the compressor.
Internal freeze up occurs when there is too much moisture inside the system. The
symptoms of internal freeze up often surface after extended highway driving. The volume of
air stays constant, but the temperature of the air gradually rises. When this freezing occurs
the low side pressure will drop, eventually going into a vacuum. At this point, the system
should be checked by a professional who will evacuate the system and the drier will have
to be changed.
Inadequate airflow to condenser - The condenser works best in front of the radiator with
a large supply of fresh air. Abnormally high pressures will result from improper airflow.
Check the airflow requirements by placing a large capacity fan in front of the condenser
and running cool water over the surface. If the pressures drop significantly, this will indicate
the need for better airflow.
Incorrect or inadequate condenser capacity - Incorrect condenser capacity will cause
abnormally high head pressures. A quick test that can be performed is to run cool water
over the condenser while the system is operating, if the pressures decrease significantly, it
is likely a airflow or capacity problem.
Expansion valve failure - An expansion valve failure is generally caused by dirt or debris
entering the system during assembly. If an expansion valve fails it will be indicated by
abnormal gauge readings. A valve that is blocked will be indicated by high side that is
unusually high, while the low side will be unusually low or may even go into a vacuum. A
valve that is stuck open will be indicated by both the high and low pressures rising to
unusually high readings, seeming to move toward equal readings on the gauges.
Restrictions in system - A restriction in the cooling system will cause abnormal readings
on the gauges. A high-side restriction ( between the compressor and the drier inlet ) will be
indicated by the discharge gauges reading excessively high. These simple tests can be
performed by a local shop and can help determine the extent of the systems problem.
www.classicautoair.com • 866.435.7801
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
DRILL
1/4” DIA.
HOLE
OEM HOLE
IN FIREWALL
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.
DRILL
3/4” DIA.
DRAIN HOLE
OEM HOLE
IN FIREWALL
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.
Camaro Factory Air
Template
DRILL
1 3/8” DIA.
HOLE
DRILL
1” DIA.
HOLE
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