1957 CHEVY - Summitracing

1957 CHEVY - Summitracing
1957 CHEVY
w/o FACTORY AIR GEN IV
561057
18865 GOLL ST. - SAN ANTONIO, TX. - 78266 ph.210-654-7171 - fax 210-654-3113
901257 REV A 10/18/07, 1957 CHEVY w/o AC GEN IV INSTRUCTIONS PG 1 OF 25
1957 CHEVY w/o FACTORY AIR GEN IV
Table of Contents
PAGES
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
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17.
18.
19.
20.
21.
22.
23.
24.
25.
COVER
TABLE OF CONTENTS
PACKING LIST/PARTS DISCLAIMER
INFORMATION PAGE
WIRING NOTICE
ENGINE COMPARTMENT
FIGURE 1
PASSENGER COMPARTMENT
FIGURE 2
ENGINE COMPARTMENT & DEFROST DUCT INSTALLATION
FIGURE 3
EVAPORATOR INSTALLATION
FIGURES 4 & 5
EVAPORATOR INSTALLATION CONT.
FIGURES 6 & 7
DUCT HOSE ROUTING - CONTROL WIRING
FIGURE 8
PASSENGER & DRIVER SIDE UNDER DASH LOUVER INSTALLATION
FIGURE 9
HARDLINE INSTALLATION
O-RING LUBRICATING/FITTING TIGHTENING, FIGURES 10 & 11
HEATER CONTROL VALVE INSTALLATION FIGURE 12
A/C HOSE AND HARDLINE ROUTING
FIGURES 13-13b
FIREWALL COVER INSTALLATION/FRESH AIR CAP
FIGURE 14
FINAL STEPS/GLOVE BOX INSTALLATION
FIGURE 15
EVAPORATOR HARDLINE INSTALLATION
FIGURE 16
WIRING DIAGRAM
GEN IV WIRING CONNECTION INSTRUCTIONS
OPERATION OF CONTROLS
TROUBLE SHOOTING
TROUBLE SHOOTING CONT.
CORE SUPPORT TEMPLATE
EVAPORATOR KIT PACKING LIST
901257 REV A 10/18/07, 1957 CHEVY w/o AC GEN IV INSTRUCTIONS PG 2 OF 25
2
1957 CHEVY w/o FACTORY AIR GEN IV
EVAPORATOR KIT
561057
EVAPORATOR KIT PACKING LIST
No.
1.
2.
QTY.
1
1
PART No.
761157
781157
DESCRIPTION
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
INSIDE
DASH
FLOOR
DEF
COLD
OFF
OFF
HEAT
AIR
OUTSIDE
3
ACCESSORY KIT
781157
901257 REV A 10/18/07, 1957 CHEVY w/o AC GEN IV INSTRUCTIONS PG 3 OF 25
1957 CHEVY w/o FACTORY AIR GEN IV
1957 CHEVY
w/o FACTORY AIR GEN IV
IMPORTANT NOTICE-PLEASE READ
FOR MAXIMUM SYSTEM PERFORMANCE
VINTAGE AIR RECOMMENDS THE FOLLOWING:
*18” HEAVY DUTY FAN - 32918-VUF
*1955-57 CHEVY FAN SHROUD (V/8 RADIATOR POSITION)- 37155-VCF, OR
1955-57 CHEVY FAN SHROUD (6 cyl. RADIATOR POSITION)-32057-VCF
*16” SPAL AUXILIARY CONDENSER FAN PACKAGE - 32007-VUF
THIS KIT DOES NOT CONTAIN HEATER HOSE. YOU MUST PURCHASE 8 FEET OF 5/8” DIA.
HEATER HOSE FROM VINTAGE AIR(31800-VUD) OR FROM YOU LOCAL PARTS RETAILER
SAFETY SWITCHES:
YOUR VINTAGE AIR SYSTEM IS EQUIPPED WITH A BINARY PRESSURE SAFETY
SWITCH. A BINARY SWITCH (11078-VUS) DISENGAGES THE COMPRESSOR
CLUTCH IN CASE OF EXTREME LOW PRESSURE CONDITION (REFRIGERANT LOSS)
OR EXCESSIVELY HIGH HEAD PRESSURE (406 lb.), TO PREVENT COMPRESSOR
DAMAGE OR HOSE RUPTURE. A TRINARY SWITCH (11076-VUS) COMBINES
HI/LO PRESSURE PROTECTION WITH AN ELECTRIC FAN OPERATION SIGNAL AT
254 lbs., AND MAY BE SUBSTITUTED FOR USE WITH ELECTRIC CONDENSER FANS.
COMPRESSOR SAFETY SWITCHES ARE EXTREMELY IMPORTANT SINCE AN A/C SYSTEM
RELIES ON REFRIGERANT TO CARRY LUBRICATION THROUGH THE SYSTEM.
SERVICE INFO:
EVACUATE THE SYSTEM FOR 35-45 MINUTES WITH SYSTEM COMPONENTS
(DRIER, COMPRESSOR, EVAPORATOR AND CONDENSER) 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.
THE PROPER AMOUNT OF REFRIGERANT IS CRITICAL TO PROPER SYSTEM
OPERATION. VINTAGE AIR RECOMMENDS OUR SYSTEMS BE CHARGED BY
WEIGHT WITH A QUALITY CHARGING STATION OR SCALE.
REFRIGERANT CAPACITIES
134a SYSTEM
CHARGE WITH 1.8 lbs.
(1lbs. 12ozs) OF REFRIGERANT
R-12 SYSTEM
CHARGE WITH 2.0 lbs. OF REFRIGERANT
LUBRICANT CAPACITIES
NEW COMPRESSOR - NO ADDITIONAL OIL NEEDED
USED COMPRESSOR - CONSULT VINTAGE AIR
901257 REV A 10/18/07, 1957 CHEVY w/o AC GEN IV INSTRUCTIONS PG 4 OF 25
4
1957 CHEVY w/o FACTORY AIR GEN IV
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 TO THE 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 TURNING SOME OF THE VEHICLE'S OTHER SYSTEMS ON AND OFF. MODERN
COMPUTER OPERATED EQUIPMENT CAN BE SENSITIVE TO VOLTAGE SPIKES ON THEIR POWER
LEADS, WHICH CAN CAUSE UNEXPECTED RESETS, STRANGE BEHAVIOR, AND MAY ALSO CAUSE
PERMANENT DAMAGE.
VINTAGE AIR STRIVES TO HARDEN THEIR 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 & TRUCK PARTS
SUPPLIERS. THEY TYPICALLY ARE CYLINDRICAL IN SHAPE, A LITTLE OVER AN INCH LONG, A LITTLE
OVER A HALF INCH IN DIAMETER, THEY HAVE A SINGLE LEAD COMING FROM ONE END OF THE
CYLINDER WITH A TERMINAL ON THE END OF THE WIRE, AND THEY WILL HAVE 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.
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 ANY OTHER AUXILIARY DEVICE. SHORTING TO GROUND OR CONNECTING
TO A CONDENSER FAN OR ANY OTHER AUXILIARY DEVICE WILL CAUSE SEVERE DAMAGE
TO THE ECU.
WHEN INSTALLING GROUND LEADS ON GEN IV SYSTEMS, THE BLOWER CONTROL GROUND
AND ECU GROUND MUST BE CONNECTED DIRECTLY TO THE NEGATIVE BATTERY POST.
THE HEATER CONTROL VALVE IS A NORMALLY OPEN VALVE. IT MUST BE CONNECTED TO
THE ECU TO BLOCK WATER FLOW IN AC MODE.
5
901257 REV A 10/18/07, 1957 CHEVY w/o AC GEN IV INSTRUCTIONS PG 5 OF 25
1957 CHEVY w/o FACTORY AIR GEN IV
INSTALLATION INSTRUCTIONS FOR
1957-CHEVY
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 O.E.M. BLOWER ASSEMBLY FROM FIREWALL AND FENDER. KEEP THE TWO O.E.M FIREWALL COVER
RETAINING BRACKETS FOR USE WITH THE NEW FIREWALL COVER
REMOVE O.E.M 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
901257 REV A 10/18/07, 1957 CHEVY w/o AC GEN IV INSTRUCTIONS PG 6 OF 25
6
1957 CHEVY w/o FACTORY AIR GEN IV
PASSENGER COMPARTMENT
REMOVE CONTROL PANEL BEZEL
REMOVE THE O.E.M 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
CONTROL PANEL BEZEL
GLOVE BOX
GLOVE BOX DOOR
OEM HEATER ASSEMBLY
DEFROST DUCTS
7
901257 REV A 10/18/07, 1957 CHEVY w/o AC GEN IV INSTRUCTIONS PG 7 OF 25
1957 CHEVY w/o FACTORY AIR GEN IV
ENGINE COMPARTMENT
CONDENSER 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”
PANHEAD
SCREW
FIGURE 3
901257 REV A 10/18/07, 1957 CHEVY w/o AC GEN IV INSTRUCTIONS PG 8 OF 25
8
1957 CHEVY w/o FACTORY AIR GEN IV
EVAPORATOR INSTALLATION
ON A WORK BENCH, 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 THE FRONT MOUNTING BRACKET BOLT AND
NUT. TIGHTEN THE CENTER PLENUM MOUNTING BOLT LAST).
FIGURE 4
INSTALL EVAPORATOR UNIT FROM
PASSENGER SIDE FLOOR BOARD.
FIGURE 5
ROTATE EVAPORATOR UNIT SO LINES PASS THROUGH
OPENING IN FIREWALL AND LIFT INTO PLACE.
9
901257 REV A 10/18/07, 1957 CHEVY w/o AC GEN IV INSTRUCTIONS PG 9 OF 25
1957 CHEVY w/o FACTORY AIR GEN IV
FIGURE 6
ONCE INTO PLACE SECURE EVAPORATOR
UNIT TO FIREWALL.
1/4-20 x 1”
BOLT & WASHER
FIREWALL
ECU
MODULE
A/C-HEAT
BLEND
DOOR
NOTE: REMOVE
FIREWALL PAD RETENTION
PLUG AND RE PLACE
WITH BOLT
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 A 10/18/07, 1957 CHEVY w/o AC GEN IV INSTRUCTIONS PG 10 OF 25
10
1957 CHEVY w/o FACTORY AIR GEN IV
DUCT & DRAIN HOSE ROUTING
DRILL 5/8” HOLE IN FIREWALL FOR DRAIN HOSE, USE 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 1/2” x 42”
PASSENGER
SIDE
DEF. DUCT
2” x 10”
DRIVER SIDE
LOUVER
2 1/2” x 48”
DRIVER SIDE
DEF. DUCT
2” x 24”
FIGURE 8
11
901257 REV A 10/18/07, 1957 CHEVY w/o AC GEN IV INSTRUCTIONS PG 11 OF 25
1957 CHEVY w/o FACTORY AIR GEN IV
PASSENGER AND DRIVER SIDE UNDER DASH LOUVER INSTALLATION
UNDER DASH
LOUVER
(PASSENGER SIDE)
DASH
SIDE FLANGE
BOTTOM EDGE
OF DASH
#8 X 1/2”
PANHEAD
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 STRIP.
SLIDE LOUVER UP TOWARDS BOTTOM OF DASH UNTIL THE LOUVER IS SEATED AGAINST DASH, AND
SECURE TO KICK PANEL WITH SUPPLIED #8 x ½” PAN HEAD SCREW. SEE FIGURE 9 ABOVE.
901257 REV A 10/18/07, 1957 CHEVY w/o AC GEN IV INSTRUCTIONS PG 12 OF 25
12
1957 CHEVY w/o FACTORY AIR GEN IV
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 THRU THE BOTTOM HOLE IN 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 O.E.M 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 FIGURE 13-13b, PAGE 15. SECURE WITH
HOSE CLAMPS. NOTE: THIS KIT DOES NOT CONTAIN HEATER HOSE. YOU MUST PURCHASE
5/8” DIA. 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. 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 A 10/18/07, 1957 CHEVY w/o AC GEN IV INSTRUCTIONS PG 13 OF 25
1957 CHEVY w/o FACTORY AIR GEN IV
O-RING LUBRICATION
O-RING
TWIST WITH
THIS WRENCH
HOLD WITH
THIS WRENCH
FIGURE 10
#6 O'RING
O-RING
MALE
INSERT
#8 O'RING
#10 O'RING
SUPPLIED OIL
FOR O-RINGS
O-RING,INSTALES
OVER MALE INSERT
TO SWAGED LIP
FEMALE
NUT
FOR A PROPER SEAL OF FITTINGS:
INSTALL SUPPLIED O-RINGS AS SHOWN
AND LUBRICATE WITH SUPPLIED OIL.
FIGURE 11
HEATER CONTROL VALVE INSTALLATION
BSC
MODULE
ECU
MODULE
FLO
W
HEATER HOSE
TO
WA
TER
P
#6 LIQUID
LINE
UM
P
FR
O
M
IN
TA
K
E
#10 SUCTION
HOSE
FIGURE 12
901257 REV A 10/18/07, 1957 CHEVY w/o AC GEN IV INSTRUCTIONS PG 14 OF 25
14
1957 CHEVY w/o FACTORY AIR GEN IV
BSC
MODULE
PRESS
TAPE
EVAPORATOR
SUB CASE
ECU
MODULE
EXPANSION
VALVE
NOTE: COMPRESSOR HARDLINES
ARE INCLUDED WITH STANDARD
HOSE KIT ONLY.
AC/HEAT HOSE
& LINE ROUTING
FIREWALL
COVER
HEATER
CONTROL
VALVE
#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
BINARY SWITCH
INSTALLATION
ADEL
CLAMP
#8 COND. LINE
35018-VCG
#6 HARDLINE
35017-VCG
SPLIT RUBBER
GROMMET IN HOLE
IN CORE SUPPORT
#8 RUBBER
HOSE
BINARY SWITCH
FIGURE 13
#6 LIQUID LINE
#6 LIQUID LINE FROM
EXPANSION VALVE
TO DRIER
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
S
B
Y
HEATER
HOSE
O-RING
O-RING
#6 LIQUID LINE
FIGURE 13b
15
#6 LIQUID LINE
901257 REV A 10/18/07, 1957 CHEVY w/o AC GEN IV INSTRUCTIONS PG 15 OF 25
1957 CHEVY w/o FACTORY AIR GEN IV
FIREWALL COVER & FRESH AIR CAP
INSTALL FRESH AIR CAP TO FRESH AIR DUCT UNDER
PASSENGER SIDE FENDER AS SHOWN IN
FIGURE 14 BELOW.
FIREWALL
TINNERMAN
NUT
REAR
EVAPORATOR
BRACKET
GROMMETS:
33137-VUI
(2) HEATER
HOSE GROMMET
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
O.E.M.
PIN (4)
DRILLED
DRAIN
HOLE
90°
DRAIN
ELBOW
FRESH
AIR CAP
FENDER
WELL
#6 LIQUID
LINE
FRESH
AIR DUCT
FIGURE 14
OEM SLIDE
RETAINING BRACKETS
FENDER
901257 REV A 10/18/07, 1957 CHEVY w/o AC GEN IV INSTRUCTIONS PG 16 OF 25
16
1957 CHEVY w/o FACTORY AIR GEN IV
FINAL STEPS
INSTALL CONTROL PANEL AND WIRE ACCORDING TO WIRING DIAGRAM ON PAGE 19.
PLUG CONTROL WIRING HARNESS INTO ECU MODULE. SEE WIRING DIAGRAM ON PAGE 19 & 20.
INSTALL GLOVE BOX BOTTOM AND GLOVE BOX DOOR, SECURE TO DASH WITH (3) O.E.M. 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) O.E.M. SCREWS. SEE FIGURE 15 BELOW.
(4) S-CLIP
(3) O.E.M. SCREW
GLOVE
BOX DOOR
DASH
PLASTIC GLOVE
BOX BOTTOM
GLOVE
BOX HINGE
(5) O.E.M. SCREW
FIGURE 15
GLOVE
BOX TOP
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 AC MODE AND/OR FREEZING WEATHER, VOIDING YOUR WARRANTY.
DOUBLE CHECK ALL FITTINGS, BRACKETS AND BELTS FOR TIGHTNESS.
VINTAGE AIR RECOMMENDS THAT ALL AC 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 A 10/18/07, 1957 CHEVY w/o AC GEN IV INSTRUCTIONS PG 17 OF 25
901257 REV A 10/18/07, 1957 CHEVY w/o AC GEN IV INSTRUCTIONS PG 18 OF 25
18
#10 O-RING
(33859-VUF)
HEATER LINE
(EVAP TO
WATER PUMP)
09161-PCH
#10 SUCTION
LINE
(09159-PCS)
PRESS TAPE
# 10 SUCTION LINE
WRAP ALL EXPOSED METAL
(FITTINGS & TUBE)
WITH SUPPLIED
PRESS TAPE.
NOTE: AFTER INSTALLING
#6 LIQUID LINE
(09158-PCL)
#6
O-RING
(33857-VUF)
PASS. SIDE
(EVAP. BRKT)
64357-PCB
FIGURE 16
#10 O-RING
(33859-VUF)
TWIST WITH
THIS
WRENCH
DRIVER SIDE
(EVAP. BRKT)
HEATER LINE
(EVAP TO INTAKE) 64353-PCB
09160-PCH
ECU MODULE
EVAPORATOR HARD LINE INSTALLATION
LUBRICATE
O'RING
(SEE FIGURE 11,
PAGE14)
FIGURE 8
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)
1957 CHEVY w/o FACTORY AIR GEN IV
1957 CHEVY w/o FACTORY AIR GEN IV
WIRING DIAGRAM
RED
WHT
WHT/BLU
COLD
OFF
RED
WHT
WHT/RED
JF8
OFF
HEAT
RED
WHT
WHT/YEL
RED
GRN
YEL
BLU
GRN
BLK
JM3
OPTIONAL:
WIDE OPEN THROTTLE
SWITCH CONTACTS
CLOSE ONLY AT
FULL THROTTLE,
WHICH DISABLES
AC COMPRESSOR
DASH
FLR
DEF
RED
WHT
WHT/GRN
VIEWED FROM WIRE SIDE
VIEWED FROM BOARD TOP SIDE
STEPPER
DASH/FLOOR
RED
GRN
YEL
BLU
GRN
BLK
JM4
FAN
RED
GRN
YEL
BLU
GRN
BLK
GRY
JM5
RED
PRGM
YEL/BLK
WHT
N/A TACH
DASH LAMP
(NOT USED)
LT BLU
GRN
GRY
TAN
VIO
ORA
STEPPER
DEFROST/PLENUM
STEPPER
TEMPERTURE BLEND
NOT USED
JM6
JM9
WIDE OPEN
THROTTLE
SWITCH
(OPTIONAL)
JF8
JM8
JM2
BLK
BLK
JM1
RUN
GENIV WIRING DIAGRAM
REVISION B, 2006-05-04
BAT
IGNITION
SWITCH
EVAPORATOR
TEMPERATURE
SENSOR
VIO
GEN-IV ECU
+ 12v
WHT
RED
RED
WHT
WHT
30
85
87
30
86
85
87
86
COMPRESSOR
RELAY
GRN
DK BLU
WARNING: ALWAYS MOUNT CIRCUIT
BREAKER UNDER THE HOOD IN THE ENGINE
COMPARTMENT AND AS CLOSE TO
THE BATTERY AS POSSIBLE.
HCV
COMP
DRIER
THE GRAY WIRE IN THE GEN IV WIRING HARNESS IS FOR
FIELD CALIBRATION OF THE GEN IV UNIT. DO NOT GROUND
OR PROBE WITH TEST LIGHT, DOING SO WILL MAKE THE ECU
INOPERABLE AND THE ECU MUST BE RE-CALIBRATED. SEE FIELD
CALIBRATION PROCEDURE.
= CHASSIS
NOTE:
WHT
BINARY
OR TRINARY
SAFETY
SWITCH
NOTE:
N/A PRGM (GRAY PROGRAMMING WIRE)
19
NEG
BLOWER MOTOR
BLK
YEL
BLK
HEATER
CONTROL
VALVE
RELAY
DK BLU
BATTERY
POS
RED
BSC
CIRCUIT
BREAKER
30 AMP
ORA
GRY
SHLD
RED
BLWR-NEG
PWM
RED
BLWR-POS
BAT-NEG
SHLD
RED
RED
RED
BAT-POS
NOTE: IF USING ELECTRIC FAN, USE
TRINARY SWITCH- REFER TO
WIRING SCHEMATIC SUPPLIED
WITH TRINARY SAFETY SWITCH
FOR PROPER WIRING
INSTRUCTIONS.
GROUND
901257 REV A 10/18/07, 1957 CHEVY w/o AC GEN IV INSTRUCTIONS PG 19 OF 25
901257 REV A 10/18/07, 1957 CHEVY w/o AC GEN IV INSTRUCTIONS PG 20 OF 25
20
RED
E
WH
T
BLU
CIRCUIT BREAKER
30 AMP
(SUPPLIED
GROUND
WIRE, NOT
PART OF
HARNESS)
CONNECT
GRN
A/C
COMPRESSOR
RELAY
RED
WH
T
CONNECT
WARNING:
ALWAYS MOUNT CIRCUIT
BREAKER UNDER THE HOOD
IN THE ENGINE COMPARTMENT
AND AS CLOSE TO THE
BATTERY AS POSSIBLE.
RED
WH
T
HEATER
CONTROL
VALVE
HEATER
CONTROL
VALVE RELAY
NOTE:
MOUNT RELAYS
IN DESIRED
LOCATION
UNDER DASH
WHT
RED
CONNECT
RED
WH
T
CHASSIS
GROUND
WH
T
WH
T
+
FRONT SIDE
OF EVAPORATOR
BATTERY
NOTE: CONNECT WHITE
WIRES DIRECTLY TO
( ) BATTERY TERMINAL
COMPRESSOR
K
BLAC
CONNECT
LET
IGNITION
SWITCH
(IGNITION HOT
TERMINAL)
CONNECT
VIO
RUN
BAT
+12 V
NOTE:
YELLOW, ORANGE
& TAN COMING FROM
HARNESS ARE NOT USED.
GRAY WIRES IS USED
FOR PROGRAMING
CONTROLS IF APPLICABLE
(DO NOT GROUND OR
PROBE GRAY WIRE
WITH TEST LIGHT.)
WIRING
HARNESS
CONNECT
CONTROL
WIRING
HARNESS
NOTE: CONNECTERS SHOWN ARE
FOR SIMPLE REPRESENTATION.
REFER TO CONTROL PANEL
INSTRUCTIONS AND PLUG
IN ACCORDINGLY
NOTE: IF USING ELECTRIC FAN, USE
TRINARY SWITCH- REFER TO
WIRING SCHEMATIC SUPPLIED
WITH TRINARY SAFETY SWITCH
FOR PROPER WIRING
INSTRUCTIONS.
BINARY
SAFETY
SWITCH
BLUE
CONNECT
WHT
NOTE: THIS SUB CASE IS
FOR SIMPLE REPRESENTATION.
ACTUAL SUB CASE NAY VERY
CONNECT
BACK SIDE
OF EVAPORATOR
GEN IV WIRING CONNECTION
INSTRUCTIONS
1957 CHEVY w/o FACTORY AIR GEN IV
1957 CHEVY w/o FACTORY AIR GEN IV
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 RE-INITIALIZATION. DURING START UP, A LOW BATTERY MAY
DROP BELOW 7 VOLTS, TRIGGERING RE-INITIALIZATION.
SYSTEM OFF
HI
OFF
BLOWER SPEED
CONTROL
(LOW/MED/HI)
A/C MODE
HI
OFF
INSIDE
DASH
FLOOR
DEF
COLD
OFF
OFF
HEAT
AIR
INSIDE
DASH
FLOOR
DEF
COLD
OFF
OFF
HEAT
OUTSIDE
DEFROST MODE
HEAT MODE
HI
OFF
HI
OFF
INSIDE
INSIDE
DASH
FLOOR
DEF
COLD
OFF
OFF
HEAT
AIR
DASH
FLOOR
DEF
COLD
OFF
OFF
HEAT
NOTE: THERE ARE TWO BI-LEVEL POSITIONS: BETWEEN DASH-FLOOR
BETWEEN FLOOR-DEF
BI-LEVEL A/C MODE
HI
BI-LEVEL HEAT MODE
HI
OFF
INSIDE
DASH
FLOOR
DEF
COLD
OFF
OFF
HEAT
AIR
INSIDE
DASH
FLOOR
DEF
OUTSIDE
21
AIR
OUTSIDE
OUTSIDE
OFF
AIR
OUTSIDE
901257 REV A 10/18/07, 1957 CHEVY w/o AC GEN IV INSTRUCTIONS PG 21 OF 25
COLD
OFF
OFF
HEAT
AIR
OUTSIDE
901257 REV A 10/18/07, 1957 CHEVY w/o AC GEN IV INSTRUCTIONS PG 22 OF 25
22
3. COMPRESSOR WILL NOT TURN
OFF (ALL OTHER FUNCTIONS
WORK)
2. COMPRESSOR WILL NOT TURN
ON (ALL OTHER FUNCTIONS
WORK)
BLOWER STAYS ON HIGH
SPEED WHEN IGNITION IS ON
OR OFF.
1. BLOWER STAYS ON HIGH
SPEED WHEN IGNITION IS ON
SYMPTOM
SEE BLOWER SWITCH CHECK PROCEDURE
(CONTACT VINTAGE AIR TECH SUPPORT)
LOSS OF GROUND ON THIS WIRE WILL RENDER
CONTROL HEAD INOPERABLE
NOTES
REPLACE ECU.
REPLACE RELAY
REFER TO INTSRUCTIONS "'55-56 CONTROL PANEL
CONVERSION REV B 6 17 05" PDF OR 903055-PCA REV C
8/10/05 OR LATER INSRUCTION MANUAL.
CHECK FOR FAULTY A/C RELAY
FOR '55-56 CHEV. CHECK FOR PROPER PANEL
CONVERSION. CONTROL LEVERS SHOULD TRAVEL
TO WITHIN 1/8" OF BOTH ENDS OF THE SLOTS.
CHECK CONTINUITY ACROSS SWITCH
(CHECK FOR FAULTY PRESSURE SWITCH)
EARLY INSTRUCTIONS ON '55-56 CHEV. DID NOT
INCLUDE PANEL MOD PROCEEDURE FOR
CONTROL WITH LOWER POT BRACKET OFFSET
BACK FROM CASTING. IF LEVERS ONLY TRAVEL
2/3 TO 3/4 UP, THIS PROCEEDURE MUST BE
PERFORMED
RED WIRE @ A/C POT SHOULD HAVE APPROX. 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 AND DOWN.
CHECK TWO PIN CONNECTOR AT ECU
HOUSING.
CHECK FOR DISCONNECTED OR FAULTY
THERMISTOR.
REPAIR/REPLACE POT/CONTROL WIRING
REPLACE SWITCH
CHECK CONTINUITY TO GROUND ON WHITE CONTROL
HEAD WIRE. CHECK FOR 5V ON RED CONTROL HEAD
WIRE.
CHECK FOR FAULTY A/C POT OR ASSOC. WIRING
SYSTEM IS CHARGED
CHECK FOR FAULTY A/C POT OR ASSOC. WIRING
TO CHECK FOR PROPER POT FUNCTION, CHECK
VOLTAGE AT WHITE/BLUE WIRE. VOLTAGE
SHOULD BE BETWEEN 0 AND 5V, AND WILL VARY
WITH POT LEVER POSITION.
DISCONNECTED OR FAULTY THERMISTOR WILL
CAUSE COMPRESSOR TO BE DISABLED.
CHARGE SYSTEM OR BYPASS PRESSURE SWITCH .
DANGER- NEVER BYPASS SAFETY SWITCH WITH
ENGINE RUNNING, SERIOUS INJURY CAN RESULT
REPLACE BSC. (THIS WILL REQUIRE EVAPORATOR TO BE NO OTHER PART REPLACEMENTS SHOULD BE
REMOVED FROM VEHICLE. )
NECESSARY.
CHECK TO INSURE THAT NO BSC WIRING IS DAMAGED OR
SHORTED TO VEHICLE GROUND. THE BSC OPERATES
THE BLOWER BY GROUND SIDE PWM 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 SMALL, 20GA. WHITE GROUND WIRE IS
CONNECTED TO THE BATTERY GROUND POST. IF IT IS,
REPLACE ECU.
VERIFY ALL PINS ARE INSERTED INTO PLUG. INSURE NO
PINS ARE BENT OR DAMAGED IN ECU.
VERIFY CONTINUITY TO CHASSIS GROUND WITH WHITE
CONTROL HEAD WIRE AT VARIOUS POINTS.
ACTIONS
SYSTEM MUST BE CHARGED FOR COMP. TO
ENGAGE.
UN-PLUG 3 WIRE BSC CONTROL CONNECTOR
FROM ECU. IF BLOWER STAYS RUNNING, THE BSC
IS EITHER IMPROPERLY WIRED, OR DAMAGED.
CHECK FOR DAMAGED PINS OR WIRES IN CONTROL
HEAD PLUG.
CHECK FOR DAMAGED GROUND WIRE (WHITE) IN
CONTROL HEAD HARNESS.
CHECK FOR DAMAGED BLOWER SWITCH OR POT
AND ASSOCIATED WIRING.
UN-PLUG 3 WIRE BSC CONTROL CONNECTOR
FROM ECU. IF BLOWER SHUTS OFF, ECU IS EITHER
IMPROPERLY WIRED, OR DAMAGED.
CHECKS
SYSTEM IS NOT CHARGED
ALL OTHER FUNCTIONS WORK
NO OTHER FUNCTIONS WORK
CONDITION
TROUBLE SHOOTING INFORMATION
1957 CHEVY w/o FACTORY AIR GEN IV
23
901257 REV A 10/18/07, 1957 CHEVY w/o AC GEN IV INSTRUCTIONS PG 23 OF 25
CHECK FOR DAMAGED STEPPER MOTOR OR
WIRING
CHECK FOR DAMAGED MODE SWITCH OR POT AND
ASSOCIATED WIRING
CHECK FOR OBSTRUCTED OR BINDING MODE
DOORS
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.
CONNECT TO GAUGE BACK LIGHT WIRE (0-12V) WHICH
WHICH CONTROLS DIMMING OF PANEL BACK LIGHT
CONNECT TO GAUGE BACK LIGHT WIRE (0-12V) WHICH
WHICH CONTROLS DIMMING OF PANEL BACK LIGHT
TAN WIRE IN MAIN HARNESS IS NOT CONNECTED
TO 0-12V GAUGE BACK LIGHT WIRE.
TAN WIRE IN MAIN HARNESS NOT CONNECTED.
VINTAGE AIR SUPPLIED PANELS
ONLY.
VINTAGE AIR SUPPLIED PANELS
ONLY.
9. BACKLIGHTING ON CONTROL
PANEL ALWAYS ON.
10. BACKLIGHTING ON CONTROL
PANEL ALWAYS OFF.
RUN RED POWER WIRE DIRECTLY TO BATTERY.
THIS IS AN INDICATOR THAT THE SYSTEM HAS
BEEN RE-SET. 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 EVEN FOR A SPLIT SECOND, THE SYSTEM WILL
RE-SET.
8. WHEN THE IGNITION IS TURNED
ON, THE BLOWER MOMENTARILY
COMES ON, THEN SHUTS OFF.
THIS IS WITH THE BLOWER
SWITCH IN THE OFF POSITION.
REPAIR OR REPLACE
INSURE ALL SYSTEM GROUNDS AND POWER
CONNECTIONS ARE CLEAN AND TIGHT.
CHARGE BATTERY
CHECK FOR POSITIVE POWER AT HEATER VALVE GREEN
WIRE. AND BLOWER RED WIRE. CHECK FOR GROUND
ON CONTROL HEAD WHITE WIRE.
VERIFY PROPER METER FUNCTION BY CHECKING A
KNOWN GOOD BATTERY'S VOLTAGE.
INSTALL CAPACITORS ON IGN. COIL, AND ALTERNATOR.
ENSURE GOOD GROUND AT ALL POINTS.RE-LOCATE COIL
AND ASSOCIATED WIRING AWAY FROM ECU AND ECU
WIRING. CHECK FOR BURNED OR LOOSE PLUG WIRES.
CHECK FOR DAMAGED SWITCH OR POT AND
ASSOCIATED WIRING
BATTERY VOLTAGE IS AT LEAST CHECK FOR AT LEAST 12V BETWEEN GREEN
12V
HEATER VALVE WIRE AND CHASSIS GROUND.
CHECK FOR FAULTY BATTERY OR ALTERNATOR
BATTERY VOLTAGE IS LESS
THAN 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 4, BUT
POSSIBLE ON ALL VERSIONS)
7. ERATIC FUNCTIONS OF
BLOWER, MODE, TEMP, ETC.
6. BLOWER TURNS ON AND OFF
RAPIDLY
5. LOSS OF MODE DOOR
FUNCTION
4. SYSTEM WILL NOT TURN ON OR
RUNS INTERMITTENTLY
TAN WIRE IS ONLY USED ON SYSTEMS WITH
ENTIRE CONTROL PANEL SUPPLIED BY VINTAGE
AIR.
SYSTEM SHUTS OFF BLOWER AT 10V. POOR
CONNECTIONS OR WEAK BATTERY CAN CAUSE
SHUT DOWN 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 OSCILISCOPE. SPIKES
GREATER THAN 16V WILL SHUT DOWN ECU.
INSTALL A RADIO CAPACITOR AT THE POSITIVE
POST OF THE IGNITION COIL (SEE RADIO
CAPACITOR INSTALLATION BULLETEN). A FAULTY
ALTERNATOR OR WORN OUT BATTERY CAN ALSO
RESULT IN THIS CONDITION. BATTERY MUST BE
IN GOOD CONDITION FOR ALTERNATOR
REGULATOR TO FUNCTION PROPERLY.
TROUBLE SHOOTING INFORMATION CONT.
1957 CHEVY w/o FACTORY AIR GEN IV
2-3/4”
(TOP)
2-3/8”
2-1/8”
3-9/16”
PASSENGER SIDE FENDER
FIREWALL
DRAIN HOLE
TEMPLATE
FOLD PAGE AT THIS LINE AND POSITION AT EDGE OF CORE SUPPORT (REMOVABLE PANEL)
1/2”
CORE SUPPORT
TEMPLATE
(FROM INSIDE CAR)
5/8” DIAMETER
DRAIN HOLE
2-5/16”
2-1/4”
OPENING
IN
FIREWALL
CUT ALONG DOTTED LINE (LINE UP OPENING IN FIREWALL & PLACE EDGE
AGAINST FIREWALL SUPPORT
1-1/4” DIAMETER
EXISTING
HOLES
5/16” DIAMETER
901257 REV A 10/18/07, 1957 CHEVY w/o AC GEN IV INSTRUCTIONS PG 24 OF 25
24
1957 CHEVY w/o FACTORY AIR GEN IV
EVAPORATOR KIT
561057
EVAPORATOR KIT PACKING LIST
No.
1.
2.
QTY.
1
1
PART No.
761157
781157
DESCRIPTION
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
INSIDE
DASH
FLOOR
DEF
COLD
OFF
OFF
HEAT
AIR
OUTSIDE
ACCESSORY KIT
781157
901257 REV A 10/18/07, 1957 CHEVY w/o AC GEN IV INSTRUCTIONS PG 25 OF 25
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