1968-76 Chevrolet Corvette - Vintage Air · 1968-76 Chevrolet Corvette without Factory Air...
Transcript of 1968-76 Chevrolet Corvette - Vintage Air · 1968-76 Chevrolet Corvette without Factory Air...
an ISO 9001:2015 Registered Company
1968-76 Chevrolet Corvette without Factory Air
Evaporator Kit(561174-PCZ)
901174-PCZ REV K 08/26/20, PG 1 OF 29
18865 Goll St. San Antonio, TX 78266 Phone: 800-862-6658
Sales: [email protected] Support: [email protected]
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901174-PCZ REV K 08/26/20, PG 2 OF 29
Cover..................................................................................................................................Table of Contents.................................................................................................................Packing List/Parts Disclaimer..................................................................................................Information Page..................................................................................................................Wiring Notice.......................................................................................................................Engine Compartment Disassembly..........................................................................................Passenger Compartment Disassembly..................................................................................... Astro Air Ventilation Duct Removal, Fresh Air Cap Installation....................................................Condenser Assembly and Installation, Compressor and Brackets, Pulleys.....................................Defrost Duct Replacement...................................................................................................Passenger and Driver Side A/C Duct Hose Adapter Installation................................................. Passenger Side Dash Modification......................................................................................... Center Louver Assembly Installation.....................................................................................Firewall Modification, Evaporator Installation.......................................................................... Evaporator Installation (Cont.).............................................................................................Drain Hose Installation........................................................................................................ Firewall Cover....................................................................................................................A/C Hose Installation, Heater Hose & Heater Control Valve Installation, Lubricating O-rings......... Hose Routing.................................................................................................................... Final Steps........................................................................................................................ Control Panel & Duct Hose Routing....................................................................................... Evaporator Hardline Installation...........................................................................................Wiring Diagram..................................................................................................................Gen IV Wiring Connection Instruction...................................................................................Operation of Controls..........................................................................................................Troubleshooting Guide........................................................................................................Troubleshooting Guide (Cont.).............................................................................................Firewall Modification Template, Passenger Compartment Modification Template..........................Packing List.......................................................................................................................
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Table of Contents
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901174-PCZ REV K 08/26/20, PG 3 OF 29
Packing List: Evaporator Kit (561174-PCZ)
No. 1.2.
Qty.11
Part No.764172781174-PCN
DescriptionGen IV Evaporator Sub CaseAccessory 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.
NOTE: Images may not depict actual parts and quantities. Refer to packing list for actual parts and quantities.
1
2
Gen IV Evaporator Sub Case764172
Accessory Kit781174-PCN
WIPER OFFHI
COLD
DASH
HOT
DEF
HI
OFF
A/C
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901174-PCZ REV K 08/26/20, PG 4 OF 29
Important Notice—Please ReadFor Maximum System Performance, Vintage Air Recommends the Following:
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).
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. (28.8 oz.) or 816 grams 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:
Safety Switches
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 remain 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.
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.
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.
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901174-PCZ REV K 08/26/20, PG 5 OF 29
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 and 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 and 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 or the compressor relay, and/or cause a malfunction.
When installing ground leads on Gen IV systems, the blower control ground and ECU ground must be connected directly to the negative battery post.
For proper system operation, the heater control valve must be connected to the ECU.
•
•
•
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901174-PCZ REV K 08/26/20, PG 6 OF 29
Engine Compartment Disassembly
1.2.3.4.5.
Disconnect battery.Remove hood to ease installation (retain).Drain radiator.Remove OEM blower assembly and cover (discard).Remove OEM heater core and cover (discard).
NOTE: Before starting the installation, check the function of the vehicle (horn, lights, etc.) for proper operation, and study the instructions, illustrations, & diagrams.Perform the Following:
Figure 1
Heater Hoses
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901174-PCZ REV K 08/26/20, PG 7 OF 29
Passenger Compartment Disassembly
1.2.3.4.
5.6.7.8.
Remove the passenger side dash (retain).Disconnect the center dash (retain) and pull forward to remove the OEM center dash bezel (discard).Remove the OEM radio (retain).Remove the OEM control panel (discard panel, retain mounting support bracket). Refer to control panel kitinstruction for installation of new control panel.Drop the steering column from the console.Disconnect the driver side dash and pull forward.Remove the defrost duct and floor heater duct (discard) (See Figure 3, below) .Remove the heater (discard).
Perform the Following:
Figure 2
Figure 3
CORVETTE
Driver SideDash
CenterDashSteering
Column
Center DashBezel
ControlPanel
Radio
Passenger SideDash
HeaterFloor Heater
Duct
DefrostDuct
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901174-PCZ REV K 08/26/20, PG 8 OF 29
Astro Air Ventilation Duct Removal 1.2.
3.
4.5.
Remove driver and passenger side astro air ventilation ducts (discard) (See Figure 4, below).Remove passenger side dash support brace (discard) and cut off the mounting tab on the kick panel as shown in Figure 4, below.Remove the driver and passenger side astro air ventilation duct mounting brackets as shown in Figure 4, below.Install (2) S-clips on inside fresh air caps as shown in Figure 4a, below.Install inside fresh air caps onto the driver and passenger side as shown in Figure 4a, below.
Figure 4b
Fresh Air Cover Installation1.2.
Apply a 1/4” bead of silicone around the back side of the fresh air cap as shown in Figure 4b, below.Attach the fresh air cap to the firewall using a 1/4-20 x 1” bolt and washer (See Figure 4b, below).
Figure 4a
Figure 4
RemoveDash
SupportBrace
Cut
Astro AirVentilation
Duct
Driver SideKick Panel
Passenger SideKick Panel
Astro AirVentilation
Duct
Cut
S-clipS-clip
Inside Fresh Air Cap
Cut
Silicone Back Sideof Fresh Air
Cap
Fresh AirCap
1/4-20 x 1”Bolt withWasher
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901174-PCZ REV K 08/26/20, PG 9 OF 29
Figure 5
Figure 6
Condenser Assembly and Installation1.
2.
Refer to separate instructions included with the condenser kit to install the condenser (See Figure 5, below, for condenser location).Binary switch installation (Refer to condenser instructions).
FLOW
FLOW
Compressor and Brackets1. Refer to separate instructions included with the bracket kit to install the compressor bracket (See Figure 6,
below, for compressor mounting location).
Pulleys1. In most instances, the belt lengths will remain the same (See Figure 6, below).
Tab“C”
Tab“G”
Tab“A”
Tab“E”
Compressor
Water PumpPulley
CrankshaftPulley
Generatoror
Alternator
Mount theCompressorUsing Tabs“G” & “C”
NOTE: Belt routing may varywith different bracket sets.Always refer to instructions included with brackets.
#6 Drier/CoreSupport Hardline
Drier
OEMRadiator
CoreSupport
#8 Condenser/CoreSupport Hardline
Out In
BinarySwitch
22503-VCA - Water Pump Pulley (2-Groove)22506-VCA - Crankshaft Pulley (2-Groove) (with Power Steering, a 3-Groove Crank Pulley is Required)22507-VCA - Crankshaft Pulley (3-Groove)
735002 - Water Pump Pulley (3-Groove)Fits 1966-70 (5/8” Shaft)735003 - Water Pump Pulley (3-Groove)Fits 1971-74 (3/4” Shaft)
Pulleys available through Vintage Air:
Short Pump Small Block Chevy
Short Pump Big Block Chevy
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901174-PCZ REV K 08/26/20, PG 10 OF 29
Defrost Duct Replacement 1.
2.
3.4.
Remove screws attaching the OEM defrost duct (retain (2) screws attaching the duct to the dash pad) (See Photo 1, below).Remove remaining screws attaching the dash pad to the dash, and remove the dash pad from the vehicle (retain) (See Photo 1, below).Place new defrost duct on the dash pad, in place of the OEM defrost duct (See Photo 2, below).Attach using (2) screws removed in Step #1. Tighten and reinstall the dash pad using the OEM screws previously removed (See Photo 3, below).
Photo 1 Photo 2
Photo 3
DashPad
DashPad
OEM ScrewLocation
OEM ScrewLocation Defrost Duct
625090
OEMScrew
OEMScrew
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901174-PCZ REV K 08/26/20, PG 11 OF 29
Passenger and Driver SideA/C Duct Hose Adapter Installation
1.2.
3.
4.
5.
Remove (2) vent knobs as shown in Figure 7, below (retain).Remove the passenger and driver side vent adapters (discard) as shown in Figure 8, below. NOTE: Retain mounting hardware.Install the inner and outer A/C duct hose adapters as shown in Figure 8, below. Use OEM screws to secure the adapters to the dash.Install the vent knob as shown using a 10-24 x 1 ¼” pan head screw and 3/16” flat washer. NOTE: Thepassenger side installation is shown below in Figure 8. Repeat the same steps for the driver sideinstallation.See Figure 8a, below, for a completely assembled view of the A/C duct hose adapter.
Figure 7
Figure 8
Figure 8a
RemoveVent Knob
RemoveVent Knob
10-24 x 1 ¼”Pan Head Screw 3/16” Flat
Washer
(3) OEMScrews
Vent Knob
Outer A/C DuctHose Adapter
Inner A/C DuctHose Adapter
Vent Adapter
OEMAssembly
AssembledView of
A/C DuctHose Adapter
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901174-PCZ REV K 08/26/20, PG 12 OF 29
Passenger Side Dash Modification1.
2.3.
Align the template (provided on Page 28) on the back side of the passenger side dash as shown in Figure 9, below.Using a pencil or scribe, mark along the edge of the template as shown.Remove the template and cut along the dotted line. Remove the plastic portion of the dash. NOTE: Do not cut through the foam dash pad on the back side of the plastic (See Figure 9a, below).
PASSENGER SIDE DASH
MODIFICATION TEMPLATE
Figure 9Figure 9a
Back Side ofPassenger Side
Dash
Template
RemoveShaded Portion
Foam Pad
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901174-PCZ REV K 08/26/20, PG 13 OF 29
Center Louver Assembly Installation1.
2.
3.
4.5.
Remove the OEM center dash bezel, OEM wiper switch knob and OEM wiper switch as shown in Figure 10, below.Secure the wiper switch and ground wire to the wiper switch bracket using (2) 10-32 x 1/2” pan head screws and (2) nuts with star washers as shown in Photo 4, below.Install the OEM wiper switch assembly onto the supplied center louver bezel using (2) #6 x 3/8” pan head screws as shown in Photo 5, below.Reinstall the wiper knob onto the wiper switch.Install the center louver bezel assembly into the dash using the OEM mounting scews. As shown in Photo 5, below, secure the ground wire between the louver bezel assembly and the dash.
Figure 10
Photo 4
Photo 5
CORVETTE
Remove OEMWiper Switch
Remove OEMScrews and Bezel
Ground Wire(If Equipped)
(2) 10-32 x 1/2” Pan Head Screws
(2) 10-32 Nutswith Star Washer
(2) #6 x 3/8”Pan Head Screws
MountingHole
MountingHole
MountingHole
Secure Ground WireBetween Bezel Assembly
and Dash
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901174-PCZ REV K 08/26/20, PG 14 OF 29
Figure 12 Figure 12a
Firewall Modification1.
2.
3.
Cut out the firewall modification template provided on Page 28. Working in the engine compartment, place the template on the firewall as shown in Figure 12, below.Once the template is aligned correctly and taped into place, mark around the dotted line (See Figure 12, below). Once you have marked around the dotted line, remove the template. Cut along the dotted line to remove the shaded portion of the firewall as shown in Figure 12a, below.
Cut AlongDotted LineTemplate
Mark AlongDotted Line
Evaporator Installation
1.
2.
3.4.
5.
6.
7.
On a workbench, install the evaporator rear bracket, and install the evaporator hardlines with properly lubricated O-rings (See Figure 22, Page 22, and Figure 17, Page 18).Install the front mounting bracket onto the evaporator using (2) 1/4-20 x 1/2” hex bolts, and tighten as shown in Figure 13, Page 15.Place the polyethylene sheet over the stepper motors (See Figure 14, Page 15).Lift the evaporator unit up under the dashboard (See Figure 14, Page 15). Secure loosely to the firewall using a 1/4-20 x 1” bolt and washer (See Figure 14, Page 15). NOTE: To ensure proper drainage, it is very important that the evaporator is level, both left-right and fore-aft. Check for level on the flatportions of the case around the drain.Using a #14 x 3/4” sheet metal screw, secure the front evaporator mounting bracket to the inner cowl by aligning the right hole in the front evaporator mounting bracket with the OEM hole in the inner cowl (See Figure 14, Page 15).To secure the left side of the front mounting bracket, with the evaporator mounting bracket in place, drill a 3/16” hole in the inner cowl using the left mounting bracket hole as a guide. Secure the bracket to the inner cowl using a #14 x 3/4” sheet metal screw (See Figure 14, Page 15).Verify that the evaporator unit is level and square to the dash; then tighten all mounting bolts. NOTE: Tighten the bolt on the firewall first. Then tighten the front mounting bracket screws.
NOTE: To ensure a watertight seal between the passenger compartment and the vehicle exterior, for all bolts passing through the firewall, Vintage Air recommends coating the threads with silicone prior to installation.
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901174-PCZ REV K 08/26/20, PG 15 OF 29
Figure 14
Figure 13
Evaporator Installation (Cont.)
FIGURE 7
10-32 x 1/2”Screw
LeftMounting
HoleRight
MountingHole
Evaporator FrontBracket
643071-PCA
(2) 1/4-20 x 1/2”Hex Bolts
4-VentA/C Plenum
1/4-20 x 1”Bolt & Washer
(Install Bolt & WasherFrom Engine
Compartment Side)
Place PolyethyleneSheet Over theStepper Motors
Once Bracket isin Place, Drill a 3/16”
Mounting Hole
(2) #14 x 3/4”Sheet Metal Screws
NOTE: InstallThis Screw First
OEMHole
InnerCowl
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901174-PCZ REV K 08/26/20, PG 16 OF 29
Figure 15
Drain Hose Installation1.
2.
In line with the drain, lightly make a mark on the firewall. Measure 1” down and drill a 5/8” hole through the firewall (See Figure 15, below).Install the drain hose to the bottom of the evaporator unit, and route through the firewall (See Figure 15, below).
DrainHose
Drain
1”
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901174-PCZ REV K 08/26/20, PG 17 OF 29
Firewall Cover1.2.3.
4.5.
Apply a 1/4” bead of silicone around the back side of the firewall cover as shown in Figure 16, below.Pass the lines through the firewall cover, and secure with (2) 7/16” panel retainers (See Figure 16, below).Once the firewall cover is in place, locate the hole on the left side of the firewall cover. Drill a 3/8” hole through the firewall. Install a 7/16” panel retainer to secure the left side of the firewall cover to the firewall (See Figure 16, below).Install (2) grommets in the firewall cover cap as shown in Figure 16, below.Apply a 1/4” bead of silicone around the back side of the firewall cover cap as shown in Figure 16, below.Using (2) #8 x 1/2” pan head screws, install the firewall cover cap as shown.
S B
Y
Figure 16
Back Sideof FirewallCover Cap
Drill 3/8”Hole
FirewallCap
Silicone
Back Sideof Firewall
Cover
Silicone
(3) 7/16”Panel
Retainers
LargeGrommet #10 Suction
Line
#6 LiquidLine
1 ¼” x 1” with 3/8” Hole
Grommet
(2) #8 x 1/2”Pan Head Screws
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901174-PCZ REV K 08/26/20, PG 18 OF 29
A/C Hose Installation
Heater Hose & Heater Control Valve Installation
1.
2.
3.
1.
2.
Locate the #8 compressor A/C hose. Lubricate (2) #8 O-rings (See Figure 17, below) and connect the 135° female fitting to the #8 discharge port on the compressor. Then route the 45° female fitting to the #8 condenser hardline coming through the core support (See Figure 18, Page 19). Tighten each fitting connection as shown in Figure 17, below.Locate the #10 compressor A/C hose. Lubricate (2) #10 O-rings (See Figure 17, below) and connect the 45° female fitting with 134a service port to the #10 suction port on the compressor. Then route the straight fitting to the #10 evaporator hardline coming through the firewall (See Figure 18, Page 19). Tighten each fitting connection as shown in Figure 17, below. NOTE: Wrap the #10 fitting connections at the firewall with press tape (See Figure 18, Page 19).Locate the #6 A/C hose. Lubricate (2) #6 O-rings (See Figure 17, below) and connect the 90° fitting to the #6 hardline coming through the core support from the drier. Attach the straight fitting with 134a service port to the #6 evaporator hardline coming through the firewall (See Figure 18, Page 19). Tighten each fitting connection as shown in Figure 17, below. Use a #6 Adel clamp to secure the #6 A/C hose to the inner fender well as shown in Figure 18, Page 19. Secure the Adel clamp to the inner fender using a 10-32 x 1/2” machine screw and nut.
Route a piece of heater hose from the water pump to the heater line coming through the firewall as shown in Figure 19, Page 20. Secure using hose clamps.Route a piece of heater hose from the intake to the heater line coming through the firewall as shown in Figure 19, Page 20. NOTE: Install heater control valve in line with the intake manifold (pressure side) heater hose, and secure using hose clamps as shown in Figure 19, Page 20. Also note proper flow direction.
Standard Hose Kit:
1. Refer to separate instructions included with modified hose kit.Modified Hose Kit:
Figure ##
O-ring Installs Over Male Insert to Swaged Lip
O-ring#6 O-ring
#8 O-ring #10 O-ring
O-ring
Supplied Oil for O-rings
Male Insert
Female Nut
Hold With This Wrench
Twist With This Wrench
Lubricating O-rings For a proper seal of fittings: Install supplied O-rings as shown and lubricate with supplied oil.
NOTE: Standard torque specifications:#6: 11 to 13 ft-lb.#8: 15 to 20 ft-lb.
#10: 21 to 27 ft-lb.
Figure 17
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19 901174-PCZ REV K 08/26/20, PG 19 OF 29
FLO
W
Fig
ure
18
Ou
t
Hos
e R
outi
ng
Evap
orat
orSub
Cas
e
Fire
wal
lCov
er
ECU
Mod
ule
Pres
sTa
pe
Pres
sTa
pe
Hea
ter
Con
trol
Valv
e
#10
A/C
Suc
tion
Hos
e(C
ompr
esso
r/Ev
apor
ator
)
#6
A/C
Hos
e(D
rier
/Eva
pora
tor)
#8
A/C
Dis
char
ge H
ose
(Com
pres
sor/
Con
dens
er H
ardl
ine)
Bin
ary
Switc
h
In
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901174-PCZ REV K 08/26/20, PG 20 OF 29
Final Steps1.
2.3.4.
5.6.
7.8.
9.10.11.
12.13.
Using the supplied tie wraps and a #10 x 3/4” sheet metal screw, install the driver side louver adapter assembly as shown in Figure 20, below. NOTE: Use the tie wraps to raise and secure the louver adapter assembly.Install the duct hoses as shown in Figure 21, Page 21.Reinstall the center dash assembly.Reinstall the control panel assembly. Refer to control panel instructions. NOTE: Controls must be calibrated for proper operation. Refer to control panel instructions.Plug the control panel harness into the ECU module on the sub case as shown in Figure 21, Page 21.Plug the wiring harnesses into the ECU module on the sub case. Wire according to wiring diagrams on Pages 23 & 24.Reinstall all previously removed items.Fill radiator with at least a 50/50 mixture of approved antifreeze and distilled water. It is the owner’s responsibility to keep the freeze protection at the proper level for the climate in which the vehicle is operated. Failure to follow antifreeze recommendations will cause heater core to corrode prematurely and possibly burst in A/C mode and/or freezing weather, voiding your warranty.Double check all fittings, brackets and belts for tightness.Vintage Air recommends that all A/C systems be serviced by a licensed automotive A/C technician.Evacuate the system for a minimum of 45 minutes prior to charging, and perform a leak check prior to servicing.Charge the system to the capacities stated on Page 4 of this instruction manual.See Operation of Controls procedures on Page 25.
FROM INTAKE
TO WATER PUMP FROM HTR CNTRL VLV
Figure 19
Figure 20
NOTE: Flow Direction FollowsMolded Arrow on Valve.
ECUModule
PressTape
#10Suction
Line(Insulated)
ExpansionValve
FirewallCover Cap
FirewallCover
HeaterHose
#6 A/CHose
#10 SuctionHose
O-ring
#10 x 3/4”Sheet Metal
Screw
Driver Side LouverAdapter Assembly
496137
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901174-PCZ REV K 08/26/20, PG 21 OF 29
COLD
DASH
HOT
DEF
HI
OFF
A/C
Figure 21
Control PanelWiring Harness232007-VUA
PassengerSide Louver2 ½” x 30”
PassengerSide Louver2 ½” x 20”
(Evaporator Side)
Passenger SideDuct Extension
Assembly605173-PCA
Defrost Duct2 ½” x 15”
Driver Side2 ½” x 22”
Driver Side Center Louver
2 ½” x 18”
Passenger Side Center Louver
2 ½” x 18”
Plug FromWiring Harness232600-VUA
Control Panel & Duct Hose Routing
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22 901174-PCZ REV K 08/26/20, PG 22 OF 29
FIG
UR
E 8
Fig
ure
22
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TE:
Aft
er in
stal
ling
th
e#
10
su
ctio
n li
ne,
wra
p a
llex
pos
ed m
etal
(fi
ttin
gs
&tu
be)
wit
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up
plie
d p
ress
tap
e.
Evap
orat
or H
ard
line
Inst
alla
tion
#10
O-r
ing
(2)
#10
O-r
ings
ECU
Mod
ule
Pres
s Ta
pe#
6 O
-rin
g
#10
Suc
tion
Line
(091
51-P
CS)
Hea
ter
Line
(Hea
ter
to W
ater
Pum
p)09
152-
PCH
Hea
ter
Line
(Hea
ter
to I
ntak
e)09
153-
PCH
(2)
1/4-
20 x
1/2
” Bol
ts(L
ocat
ed o
n Sub
Cas
e)
Hol
d w
ithTh
is W
renc
h
Twis
t w
ithTh
is W
renc
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ee F
igur
e 17
, Pa
ge 1
8
#6
Liqu
id L
ine
(091
50-P
CL)
23
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901174-PCZ REV K 08/26/20, PG 23 OF 29
WHT/GRN
WHT/YELWHT/RED
RED
WHTBACKLIGHT NEG
FAN WIPER
MODE WIPER
TEMP WIPER
5V-SW
GND
BACKLIGHT POS
AC ANNUNCIATOR
PRE-WIRED
GEN IV WIRING DIAGRAMREV E, 10/6/2017
GEN IV ECU
PROGRAM
Wiring Diagram
TEMP
MODE
FAN
A/C(IF USED)
232007-VUR
232002-VUA
** CIRCUITBREAKER30 AMP
*** WIDE OPENTHROTTLESWITCH
(OPTIONAL)
* DASH LAMP(IF USED)
Dash lamp is used only with type 232007-VUR harness.Warning: Always mount circuit breaker as close to the battery as possible. (NOTE: Wire betweenbattery and circuit breaker is unprotected and should be carefully routed to avoid a shortcircuit).Wide open throttle switch contacts close only at full throttle, which disables A/C compressor.
JF8
BLK
ORA
TAN
VIEWED FROM WIRE SIDE
* **
***
HEATERCONTROL VALVE
24
www.vintageair.com
901174-PCZ REV K 08/26/20, PG 24 OF 29
RED
CIRCUIT BREAKER30 AMP
+
+
-
BLACK
REDWHITE
RED
CHASSIS GROUND
A/CCOMPRESSOR
RELAY
Ignition Switch:
Dash Light:
NOTE: MOUNT RELAYIN DESIRED LOCATION
UNDER DASH
GREEN
FIREWALL
BLUE
BLUE
RED &
WHITE
VIOLET
(IGNITION HOTTERMINAL)
IGNITION SWITCH
DASH BACK LIGHT+0-12vTAN
GRAY
BLUE
WHITE
WHITE
REDRED
WHITE
COMPRESSOR
BATTERY
NOTE: CONNECT WHITEWIRES DIRECTLY TO
(-) BATTERY TERMINAL
BATRUN
12V
RED GREEN
RED
RED
BLUE
LATCH
BLACK
BINARYSAFETYSWITCH
YELLOW
ORANGE
WIRING HARNESS
Violet 12V ignition switch source (key on accessory) position must be switched.
When using a Vintage Air suppliedcontrol panel, connect the tan wirefrom the Gen IV evaporator wiringharness to the factory dash lights toenable panel backlighting.
Binary: Connect as shown (typical compressor wiring). Be sure compressor body is grounded.
Trinary Switch: Connect according to trinary switch wiring diagram.
Install with servo motor facing down, as shown. Note flow direction arrow molded into valve body and install accordingly.
White must run to (-) battery. Red may run to (+) battery or starter. Mount circuit breaker as close to battery as possible.
Heater Control Valve:
Binary/Trinary & Compressor:
Circuit Breaker/Battery:
CONTROL WIRING HARNESS
NOTE: YELLOW & ORANGE
COMING FROM HARNESS ARE NOT
USED.
WIRING HARNESS
GRAY WIRE IS USED FOR PROGRAMING CONTROLS
IF APPLICABLE
WIRING HARNESS
Gen IV Wiring Connection Instruction
HEATERCONTROL VALVE
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).
NOTE: HEATER CONTROL VALVE CONNECTION AND CHASSIS GROUND MAY BE LOCATED ON EITHER SIDE OF THE FIREWALL. ENSURECONNECTOR IS LATCHED
FIRMLY.
25
www.vintageair.com
901174-PCZ REV K 08/26/20, PG 25 OF 29
Operation of Controls
Adjust to desiredspeed.
Blower SpeedAdjust to desired
speed.
Adjust to desiredmode position (DASH position recommended).
Adjust to desiredspeed.
Adjust to DEFROST position for maximum defrost, or between FLOOR and DEFROST positions for a bi-level
blend (Compressor is automatically engaged).
Adjust to desired temperature.
For A/C operation, adjust tocoldest position to engage
compressor (Adjust between HOT and COLD to reachdesired temperature).
A/C Operation
Heat Operation
Defrost/De-fog Operation
Blower Speed
Blower Speed
This lever/knob controlsblower speed, from
OFF to HI.
This lever/knob controls the mode positions,
from DEFROST to FLOORto DASH, with a blend in between.
This lever/knob controlsthe temperature,
from HOT to COLD.
Blower Speed
Mode Control
Temperature Control
Temperature Control
Temperature Control
Temperature Control
Mode Control
Mode Control
Mode Control
For maximum heating, adjust to hottest position (Adjust between HOT and COLD to reach desired temperature).Adjust to desired
mode position(FLOOR position recommended).
On Gen IV systems with three lever/knob controls, the temperature control toggles between heat and A/C operations. To activate A/C, move the temperature lever/knob all the way to cold and then back it off to the desired vent temperature. For heat operation, move the temperature lever/knob all the way to hot and then adjust to the desired vent temperature. The blower will momentarily change speed, each time you toggle between operations, to indicate the change. NOTE: For proper control panel function, refer to the control panel instructions forcalibration procedure.
COLD
DASH
HOT
FLOOR
DEF
HI
OFF
A/C
COLD
DASH
HOT
FLOOR
DEF
HI
OFF
A/C
COLD
DASH
HOT
FLOOR
DEF
HI
OFF
A/C
COLD
DASH
HOT
FLOOR
DEF
HI
OFF
A/C
Blower Speed
Mode Control
Temperature Control
ww
w.v
inta
gea
ir.c
om
26 901174-PCZ REV K 08/26/20, PG 26 OF 29
Sym
pto
m
Con
dit
ion
Ch
ecks
A
ctio
ns
Not
es
Blo
wer
sta
ys o
n hi
gh s
peed
whe
n ig
nitio
n is
on.
1a.
No
othe
r fu
nctio
ns w
ork.
Che
ck f
or d
amag
ed p
ins
or
wires
in c
ontr
ol h
ead
plug
.Ve
rify
tha
t al
l pin
s ar
e in
sert
ed in
to p
lug.
Ens
ure
that
no
pins
are
ben
t or
dam
aged
in E
CU
.Che
ck f
or d
amag
ed g
roun
d w
ire
(whi
te)
in c
ontr
ol h
ead
harn
ess.
Verify
con
tinui
ty t
o ch
assi
s gr
ound
with
whi
te c
ontr
ol
head
wire
at v
ario
us p
oint
s.
Loss
of gr
ound
on
this
wire
rend
ers
cont
rol h
ead
inop
erab
le.
All
othe
r fu
nctio
ns w
ork.
Che
ck f
or d
amag
ed b
low
er
switc
h or
pot
entio
met
er a
nd
asso
ciat
ed w
irin
g.
Blo
wer
sta
ys o
n hi
gh s
peed
whe
n ig
nitio
n is
on
or o
ff.
Unp
lug
3-w
ire
BSC c
ontr
ol
conn
ecto
r fr
om E
CU
. If
blo
wer
sh
uts
off,
ECU
is e
ither
im
prop
erly
wired
or
dam
aged
.
Be
sure
the
sm
all,
20 G
A w
hite
gro
und
wire
is c
onne
cted
to
the
bat
tery
gro
und
post
. If
it is
, re
plac
e th
e EC
U.
Unp
lug
3-w
ire
BSC c
ontr
ol
conn
ecto
r fr
om E
CU
. If
blo
wer
st
ays
runn
ing,
BSC is
eith
er
impr
oper
ly w
ired
or
dam
aged
.
Che
ck t
o en
sure
tha
t no
BSC w
irin
g is
dam
aged
or
shor
ted
to v
ehic
le g
roun
d. T
he B
SC o
pera
tes
the
blow
er
by g
roun
d si
de p
ulse
wid
th m
odul
atio
n sw
itchi
ng.
The
posi
tive
wire
to t
he b
low
er w
ill a
lway
s be
hot
. If
the
“g
roun
d” s
ide
of t
he b
low
er is
sho
rted
to
chas
sis
grou
nd,
the
blow
er w
ill r
un o
n H
I.
Repl
ace
BSC (
This
will
req
uire
rem
oval
of ev
apor
ator
fr
om v
ehic
le).
No
othe
r pa
rt r
epla
cem
ents
sh
ould
be
nece
ssar
y.
Com
pres
sor
will
no
t tu
rn o
n (A
ll ot
her
func
tions
w
ork)
.
2.
Syst
em is
not
cha
rged
.Sy
stem
mus
t be
cha
rged
for
co
mpr
esso
r to
eng
age.
Cha
rge
syst
em o
r by
pass
pre
ssur
e sw
itch.
Dan
ger
: N
ever
byp
ass
safe
ty s
wit
ch w
ith
en
gin
e ru
nn
ing
. S
erio
us
inju
ry c
an r
esu
lt.
Syst
em is
cha
rged
.
1b
.
Trou
ble
shoo
tin
g G
uid
e
Che
ck f
or f
aulty
A/C
po
tent
iom
eter
or
asso
ciat
ed
wirin
g (n
ot a
pplic
able
to
3-po
t co
ntro
ls).
Che
ck f
or d
isco
nnec
ted
or
faul
ty t
herm
isto
r.
Che
ck c
ontin
uity
to
grou
nd o
n w
hite
con
trol
hea
d w
ire.
Che
ck f
or 5
V o
n re
d co
ntro
l hea
d w
ire.
Che
ck 2
-pin
con
nect
or a
t EC
U h
ousi
ng.
To c
heck
for
pro
per
pot
func
tion,
che
ck v
olta
ge a
t w
hite
/blu
e w
ire.
Vol
tage
sh
ould
be
betw
een
0V a
nd
5V,
and
will
var
y w
ith p
ot
leve
r po
sitio
n.
Dis
conn
ecte
d or
fau
lty
ther
mis
tor
will
cau
se
com
pres
sor
to b
e di
sabl
ed.
Red
wire
at A
/C p
ot s
houl
d ha
ve a
ppro
xim
atel
y 5V
w
ith ig
nitio
n on
. W
hite
w
ire
will
hav
e co
ntin
uity
to
chas
sis
grou
nd.
Whi
te/
Blu
e w
ire
shou
ld v
ary
betw
een
0V a
nd 5
V w
hen
leve
r is
mov
ed u
p or
dow
n.
3. Com
pres
sor
will
no
t tu
rn o
ff
(All
othe
r fu
nctio
ns
wor
k).
Che
ck f
or f
aulty
A/C
po
tent
iom
eter
or
asso
ciat
ed
wirin
g.
Che
ck f
or f
aulty
A/C
rel
ay.
Repa
ir o
r re
plac
e po
t/co
ntro
l wirin
g.
Repl
ace
rela
y.
See
blo
wer
sw
itch
chec
k pr
oced
ure.
ww
w.v
inta
gea
ir.c
om
27 901174-PCZ REV K 08/26/20, PG 27 OF 29
Sym
pto
m
Con
dit
ion
Ch
ecks
A
ctio
ns
Not
es
Syst
em w
ill n
ot
turn
on,
or
runs
in
term
itten
tly.
4.
Wor
ks w
hen
engi
ne is
not
runn
ing;
shu
ts o
ff w
hen
engi
ne is
sta
rted
(t
ypic
ally
ear
ly G
en I
V,
but
poss
ible
on
all
vers
ions
).
Noi
se in
terf
eren
ce f
rom
eith
er
igni
tion
or a
ltern
ator
.
Inst
all c
apac
itors
on
igni
tion
coil
and
alte
rnat
or.
Ensu
re
good
gro
und
at a
ll po
ints
. Re
loca
te c
oil a
nd a
ssoc
iate
d w
irin
g aw
ay f
rom
ECU
and
ECU
wirin
g. C
heck
for
bur
ned
or lo
ose
plug
wires
.
Verify
con
nect
ions
on
pow
er
lead
, ig
nitio
n le
ad,
and
both
whi
te g
roun
d w
ires
.
Verify
pro
per
met
er f
unct
ion
by c
heck
ing
the
cond
ition
of
a kn
own
good
bat
tery
.
Igni
tion
nois
e (r
adia
ted
orco
nduc
ted)
will
cau
se t
he
syst
em t
o sh
ut d
own
due
tohi
gh v
olta
ge s
pike
s. I
f th
isis
sus
pect
ed,
chec
k w
ith a
qu
ality
osc
illos
cope
. Spi
kes
grea
ter
than
16V
will
shu
t do
wn
the
ECU
. In
stal
l a
radi
o ca
paci
tor
at t
he
posi
tive
post
of th
e ig
nitio
nco
il (s
ee r
adio
cap
acito
r in
stal
latio
n bu
lletin
). A
fa
ulty
alte
rnat
or o
r w
orn
out
batt
ery
can
also
res
ult
in t
his
cond
ition
.
Will
not
tur
n on
und
er
any
cond
ition
s.Ve
rify
bat
tery
vol
tage
is
grea
ter
than
10
volts
and
less
than
16.
Loss
of m
ode
door
fu
nctio
n.
No
mod
e ch
ange
at
all.
Che
ck f
or d
amag
ed m
ode
switc
h or
pot
entio
met
er a
nd
asso
ciat
ed w
irin
g.
Part
ial f
unct
ion
of m
ode
door
s.
Typi
cally
cau
sed
by
evap
orat
or h
ousi
ng
inst
alle
d in
a b
ind
in t
he
vehi
cle.
Be
sure
all
mou
ntin
g lo
catio
ns li
ne u
p an
d do
n’t
have
to
be for
ced
into
pos
ition
.
Blo
wer
tur
ns o
n an
d of
f ra
pidl
y.
6.
Bat
tery
vol
tage
is a
t le
ast
12V.
Che
ck f
or a
t le
ast
12V a
t ci
rcui
t br
eake
r.En
sure
all
syst
em g
roun
ds a
nd p
ower
con
nect
ions
are
cl
ean
and
tight
.
Bat
tery
vol
tage
is le
ss
than
12V
.
5.
Trou
ble
shoo
tin
g G
uid
e (C
ont.
)
Che
ck f
or f
aulty
bat
tery
or
alte
rnat
or.
Cha
rge
batt
ery.
Syst
em s
huts
off b
low
er a
t 10
V. P
oor
conn
ectio
ns o
r w
eak
batt
ery
can
caus
e sh
utdo
wn
at u
p to
11V
.
7. Whe
n ig
nitio
n is
tu
rned
on,
blo
wer
m
omen
tarily
co
mes
on,
the
n sh
uts
off.
This
oc
curs
with
the
bl
ower
sw
itch
in
the
OFF
pos
ition
.
This
is a
n in
dica
tor
that
the
sy
stem
has
bee
n re
set.
Be
sure
the
red
pow
er w
ire
is o
nth
e ba
tter
y po
st,
and
not
on a
sw
itche
d so
urce
. Als
o, if
the
sy
stem
is p
ulle
d be
low
7V f
orev
en a
spl
it se
cond
, th
e sy
stem
will
res
et.
Run
red
pow
er w
ire
dire
ctly
to
batt
ery.
Che
ck f
or p
ositi
ve p
ower
at
heat
er v
alve
gre
en w
ire
and
blow
er r
ed w
ire.
Che
ck f
or g
roun
d on
con
trol
hea
d w
hite
w
ire.
Che
ck f
or o
bstr
ucte
d or
bi
ndin
g m
ode
door
s.Che
ck f
or d
amag
ed s
tepp
er
mot
or o
r w
irin
g.
Erra
tic fun
ctio
ns o
fbl
ower
, m
ode,
te
mp,
etc
.
Che
ck f
or d
amag
ed s
witc
h or
po
t an
d as
soci
ated
wirin
g.Re
pair o
r re
plac
e.
8.
28
www.vintageair.com
901174-PCZ REV K 08/26/20, PG 28 OF 29
Firewall Modification Template
Passenger Compartment Modification Template
Do Not CutAlign with Edge
of Firewall Opening
RemoveShaded Portion
Firewall ModificationTemplate
Passenger Side DashModification Template
Cut Along Dotted Line
Cut Along Dotted Line
29
www.vintageair.com
901174-PCZ REV K 08/26/20, PG 29 OF 29
WIPER OFFHI
COLD
DASH
HOT
DEF
HI
OFF
A/C
Packing List: Evaporator Kit (561174-PCZ)
No. 1.2.
Qty.11
Part No.764172781174-PCN
DescriptionGen IV Evaporator Sub CaseAccessory Kit
NOTE: Images may not depict actual parts and quantities. Refer to packing list for actual parts and quantities.
1
2
Gen IV Evaporator Sub Case 764172
Accessory Kit781174-PCN
Checked By:Packed By:
Date: