1970-72 Oldsmobile Cutlass - Vintage AirRemove the OEM defrost duct assembly by straightening the...
Transcript of 1970-72 Oldsmobile Cutlass - Vintage AirRemove the OEM defrost duct assembly by straightening the...
an ISO 9001:2008 Registered Company
1970-72 Oldsmobile Cutlass with Factory AirEvaporator Kit
(564171)
18865 Goll St. San Antonio, TX 78266 Phone: 210-654-7171
Fax: 210-654-3113www.vintageair.com
904144 REV C 10/09/15, PG 1 OF 25
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904144 REV C 10/09/15, PG 2 OF 25
Thank you for purchasing this evaporator kit from Vintage Air. When installing these components as part of a complete SureFit™ system, Vintage Air recommends working from front to back on the vehicle, installing the condenser kit, hose kit, and compressor first, followed by the wiring, evaporator, and finally the control panel.
Cover..................................................................................................................................Table of Contents.................................................................................................................Packing List/Parts Disclaimer..................................................................................................Information Page..................................................................................................................Wiring Notice.......................................................................................................................Engine Compartment Disassembly, Condenser Assembly and Installation, Compressor andBrackets, Pulleys.................................................................................................................Passenger Compartment Disassembly..................................................................................... Defrost Duct Installation, Hose Adapter Installation..................................................................Center Louver Installation..................................................................................................... Fresh Air Cap Installation, Kick Panel Fresh Air Cap Installation................................................ Firewall Cover Installation, Evaporator Installation..................................................................Evaporator Installation (Cont.)............................................................................................. Evaporator Installation (Final).............................................................................................. Drain Hose Installation, Lubricating O-rings, A/C Hose Installation............................................ Heater Hose and Heater Control Valve Installation, A/C and Heater Hose Routing........................ Passenger Side Under Dash Louver Hose Adapter Installation................................................... Driver Side Under Dash Louver Hose Adapter Installation......................................................... Final Steps, Glove Box Installation........................................................................................Control Panel & Duct Hose Routing....................................................................................... Wiring Diagram..................................................................................................................Gen IV Wiring Connection Instruction...................................................................................Operation of Controls..........................................................................................................Troubleshooting Guide.........................................................................................................Troubleshooting Guide (Cont.)..............................................................................................Packing List.......................................................................................................................
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Table of Contents
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904144 REV C 10/09/15, PG 3 OF 25
OFF
DASH
HOT
AC
FAN HI
DEF
FLRCOLD
Packing List: Evaporator Kit (564171)
No. 1.2.
Qty.11
Part No.762171784156
DescriptionGen IV 6-Vent Evaporator Sub Case with 204 ECUAccessory 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 6-Vent Evaporator Sub Case
w/ 204 ECU762171
Accessory Kit784156
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904144 REV C 10/09/15, PG 4 OF 25
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. (1 lb., 12 oz.) of R134a, charged by weight with a quality charging station or scale. NOTE: Use of the proper type and amount of refrigerant is critical to system operation and performance.Other Systems: Consult manufacturer’s guidelines.
Lubricant Capacities:
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 remained capped. Removing caps prior to assembly will allow moisture, insects and debris into the components, possibly leading to reduced performance and/or premature failure of your A/C system. This is especially important with the receiver/drier. Additionally, when caps are removed for assembly, BE CAREFUL! Some components are shipped under pressure with dry nitrogen.Evacuate the System for 35-45 Minutes: Ensure that system components (Drier, compressor, evaporator and condenser) are at a temperature of at least 85° F. On a cool day, the components can be heated with a heat gun or by running the engine with the heater on before evacuating. Leak check and charge to specifications.
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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904144 REV C 10/09/15, PG 5 OF 25
Important Wiring Notice—Please Read
Some Vehicles May Have Had Some or All of Their Radio Interference Capacitors Removed. There Should Be a Capacitor Found At Each of the Following Locations:
1. On the positive terminal of the ignition coil.2. If there is a generator, on the armature terminal of the generator.3. If there is a generator, on the battery terminal of the voltage regulator.
Most alternators have a capacitor installed internally to eliminate what is called “whining” as the engine is revved. If whining is heard in the radio, or just to be extra cautious, a radio interference capacitor can be added to the battery terminal of the alternator.
It is also important that the battery lead is in good shape and that the ground leads are not compromised. There should be a heavy ground from the battery to the engine block, and additional grounds to the body and chassis.
If these precautions are not observed, it is possible for voltage spikes to be present on the battery leads. These spikes come from ignition systems, charging systems, and from switching some of the vehicle’s other systems on and off. Modern computer-operated equipment can be sensitive to voltage spikes on the power leads, which can cause unexpected resets, strange behavior, and/or permanent damage.
Vintage Air strives to harden our products against these types of electrical noise, but there is a point where a vehicle’s electrical system can be degraded so much that nothing can help.
Radio interference capacitors should be available at most auto and truck parts suppliers. They typically are cylindrical in shape, a little over an inch long, a little over a half inch in diameter, and they have a single lead coming from one end of the cylinder with a terminal on the end of the wire, as well as a mounting clip which is screwed into a good ground on the vehicle. The specific value of the capacitance is not too significant in comparison to ignition capacitors that are matched with the coil to reduce pitting of the points.
Care must be taken, when installing the compressor lead, not to short it to ground. The compressor lead must not be connected to a condenser fan or to any other auxiliary device. Shorting to ground or connecting to a condenser fan or any other auxiliary device may damage wiring, the compressor relay, and/or cause a malfunction.
When installing ground leads on Gen IV systems, the blower control ground and ECU ground must be connected directly to the negative battery post.
For proper system operation, the heater control valve must be connected to the ECU.
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904144 REV C 10/09/15, PG 6 OF 25
Engine Compartment Disassembly
1.2.3.4.5.6.7.
8.9.
10.11.
Remove battery and battery tray (retain).Drain radiator.Remove radiator (retain).Remove the OEM condenser and drier (discard) (See Figure 1, below).Remove the OEM A/C lines from the compressor to the evaporator (discard) (See Figure 1, below).Remove the OEM compressor and bracket (discard) (See Figure 1, below).Remove the evaporator and blower assembly (discard). NOTE: To remove the evaporator and blower assembly (under hood) and the air distribution system (under dash), the factory maunal indicates doing the following: Remove the right inner fender.Remove the OEM heater hoses, A/C hoses, and hardlines (discard) (See Figure 1, below).Remove the OEM A/C & heater wiring/vacuum harness molded grommet (See Figure 1, below).Install the 1 ¾” plug into the firewall (See Figure 1, below).Remove the passenger side grille insert.
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
Condenser Assembly and Installation1.2.
Refer to separate instructions included with the condenser kit to install the condenser.Binary switch installation (Refer to condenser instructions).
Compressor and Brackets1. Refer to separate instructions included with the bracket kit to install the compressor bracket.
Pulleys1. In most instances, the belt lengths will remain the same.
OEM A/C &Heater Wiring/
Vacuum HarnessMolded Grommet
1 ¾” Plug317102
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904144 REV C 10/09/15, PG 7 OF 25
Passenger Compartment Disassembly
1.2.3.4.5.6.7.8.9.
Remove the glove box door (retain).Remove the glove box (discard) (See Figure 2, below).Disconnect all wires and cables from the control panel and radio.Remove the radio and control panel (retain).Remove all hoses and ducting from the OEM louvers (See Figure 2, below).Remove the OEM under dash louver assembly and the (2) louvers in the dash (retain) (See Figure 2, below).Remove the OEM defrost duct assembly by straightening the (4) metal tabs (See Figure 2, below).Remove the OEM A/C & heater assembly (discard) (See Figure 2, below).Remove the passenger side kick panel/fresh air door assembly as shown in Figure 2a, below.
Perform the Following:
Figure 2
Figure 2a
MetalTabs
Defrost DuctAssembly
Under DashLouver Assembly
OEM A/C &Heater Assembly
A/C & HeaterAssembly &
Related Ducting
Passenger SideKick Panel
Fresh AirDoor Assembly
Glove Box &Glove Box Door
ControlPanel
Radio
MetalTabs
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904144 REV C 10/09/15, PG 8 OF 25
Defrost Duct Installation1. Install the defrost ducts under the dash and align them with the OEM openings. Install the passenger side
defrost duct to the cowl using a #10 x 1/2” sheet metal screw (See Figure 3, below). NOTE: The driver side defrost duct installs behind the steering column brace, and is secured using the steering column OEM bolt as shown in Figure 3, below.
Figure 3
Figure 4
Hose Adapter Installation1.2.
Install (2) S-clips onto the driver and passenger side hose adapters as shown in Figure 4, below.Install the driver and passenger side hose adapters onto the OEM louvers (See Figure 4, below).
Passenger SideDriver Side
Install (2)S-clips
Install (2)S-clips
Steering ColumnBrace
OEM DefrostDuct Opening
#10 x 1/2”Sheet Metal Screw
Passenger SideDefrost Duct
Assembly496087
Driver SideDefrost Duct
Assembly496086
Driver SideHose Adapter
496083
Passenger SideHose Adapter
496082
OEMBolt
DefrostDuct Defrost
DuctCowlCowl
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904144 REV C 10/09/15, PG 9 OF 25
Center Louver Installation1.2.3.
Modify the OEM center louver assembly as shown in Figure 5, below.Install (2) S-clips onto the center louver hose adapter (See Figure 5a, below).Install the center louver hose adapter onto the OEM center louver assembly as shown in Figure 5a, below.
Figure 5
Figure 5a
Cut & RemoveShaded Portion
Center LouverHose Adapter
496081
4”
OEM CenterLouver Assembly
Install (2)S-clipsOEM Center
Louver Assembly
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904144 REV C 10/09/15, PG 10 OF 25
Figure 6
Figure 7
Figure 7a
Figure 7b
Fresh Air Cap Installation
Kick Panel Fresh Air Cap Installation
1.2.3.
4.5.6.
1.2.
3.
Install (4) grommets into the fresh air cap (See Figure 6, below).Apply a 1/4” bead of silicone around the mating surface of the fresh air cap as shown in Figure 6, below.Attach the fresh air cap to the firewall using the fresh air cap bracket, a 1/4-20 x 1 ½” bolt, and a washer (See Figure 6, below). NOTE: The fresh air cap installs on the engine side of the firewall.Install a 7/8” plug and a 3/8” grommet into the firewall (See Figure 6, below).Install (2) 1/2” plugs into the firewall as shown in Figure 6, below.Enlarge (2) OEM holes to 5/16” as shown in Figure 6, below.
Install (4) grommets into the kick panel fresh air cap (See Figure 7a, below).Place the kick panel into position in the passenger compartment. Route the A/C and heater hoses through the fresh air cap, the kick panel, and the kick panel fresh air cap as shown in Figures 12 & 12b, below.Apply a 1/4” bead of silicone around the mating surface of the kick panel fresh air cap, and secure using (5) OEM screws as shown in Figures 7a & 7b, below.
Fresh Air CapMating Surface
Kick PanelFresh Air Cap
Mating Surface
EngineCompartment
Side ofFirewall
Fresh Air CapBracket
64164-VCB
1/2” Plug31102-GUR
Enlarge Holeto 5/16”
OEMHoles
7/8” Plug33142-VUI
Grommet33145-VUI
EnlargeHole to 5/16”
1/2” Plug31102-GUR
#10 A/CHose
#10 A/CHose
(5) OEMScrews
#6 A/CHose #6 A/C
Hose(2) HeaterHoses
(2) HeaterHoses
Fresh AirCap
Silicone
Silicone
(4) Grommets33137-VUI
(4) Grommets33137-VUI
1/4-20 x 1 ½”Bolt & Washer
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904144 REV C 10/09/15, PG 11 OF 25
Figure 8
Firewall Cover Installation1.2.
Apply a 1/4” bead of silicone around the mating surface of the firewall cover (See Figure 8, below).From the passenger compartment, install the firewall cover onto the firewall. From the engine compartment, secure the firewall cover to the firewall using (2) 1/4-20 x 1” bolts and (2) 1/4” flat washers (See Figure 8, below). NOTE: For a finished appearance and a watertight seal, Vintage Air recommends applying a smooth bead of automotive seam sealer in the engine compartment to the joint between the firewall cover and the firewall.
Firewall CoverMating Surface
(2) 1/4-20 x 1”Bolts (2) 1/4”
Flat Washers
FirewallCover
644106
Silicone
Evaporator Installation
1.
2.
3.
4.
5.
6.7.
8.
9.
On a workbench, install (2) heater fittings (See Figure 9, Page 12) with properly lubricated O-rings (See Figure 14, Page 14).Install the evaporator front and rear mounting brackets using (6) 1/4-20 x 1/2” bolts (supplied on the evaporator sub case) (See Figure 10, Page 12, and Figure 12, Page 13).Place the evaporator unit under the dashboard by the passenger side kick panel, and install the heater hoses and #6 A/C hose (See Figure 11, Page 13). Use (2) hose clamps on the heater hoses.Lift the evaporator sub case up under the dashboard. Secure loosely to the firewall using (2) 1/4-20 x 1 ¼” hex bolts and (2) 1/4” flat washers (See Figure 12, Page 13). NOTE: When lifting up the evaporator sub case, be careful to prevent damage to the drain outlet located at the bottom of the unit. Feed the hoses into or out of the kick panel fresh air cap as needed while lifting the evaporator sub case into position.Install the #10 A/C hose onto the evaporator (See Figure 11, Page 13) with properly lubricated O-rings (See Figure 14, Page 14).Install press tape all around the #10 A/C hose fitting as shown in Figure 11, Page 13.Using the front mounting bracket as a template, mark and drill (2) 3/16” holes on the inner cowl (See Figure 12, Page 13). NOTE: To ensure proper drainage, it is very important that the evaporator is level, both left-right and fore-aft. Prior to drilling, check for level on the flat portions of the case around the drain.Loosely attach the front mounting bracket to the inner cowl using (2) #14 x 3/4” sheet metal screws (See Figure 12, Page 13).Verify that the evaporator unit is level and square to the dash. Then, tighten all mounting bolts. NOTE: Tighten the bolts on the firewall first. Then tighten the front mounting bracket sheet metal 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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904144 REV C 10/09/15, PG 12 OF 25
Evaporator Installation (Cont.)
Figure 9
Figure 10
(2) HeaterFittings
MountingHolesRear
EvaporatorBracket Assembly
644104
(2) 1/4-20 x 1/2”Hex Bolts
(Located onSub Case)
(2) 1/4-20 x 1/2”Hex Bolts
(Located onSub Case)
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904144 REV C 10/09/15, PG 13 OF 25
Evaporator Installation (Final)
Figure 11
Figure 12
Kick PanelFresh Air
Cap
(2) #14 x 3/4”Sheet Metal Screws
Drill (2)3/16” Holes
#10 A/CHose
PressTape
#6 A/CHose
(2) HeaterHoses
HoseClamps
(2) 1/4-20 x 1 ¼”Hex Bolts
(2) 1/4”Flat Washers 1/4-20 x 1/2”
Hex Bolt(Located onSub Case)
1/4-20 x 1/2”Hex Bolt
(Located onSub Case)
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904144 REV C 10/09/15, PG 14 OF 25
Drain Hose Installation1.2.
3.
Locate the evaporator drain on the bottom of the evaporator case.In line with the drain, lightly make a mark on the firewall. Measure 1” down and 2 ½” to the left and drill a 5/8” hole through the firewall (See Figure 13, below).Attach the drain hose to the outlet on the bottom of the evaporator unit, and route it through the firewall (See Figure 13, below).
A/C Hose Installation
1.
2.
3.
Locate the #8 compressor A/C hose. Lubricate (2) #8 O-rings (See Figure 14, above) and connect the 90° female fitting with 134a service port to the #8 discharge port on the compressor. Then route the 90° female fitting to the #8 condenser/compressor hardline coming through the core support (See Figure 15, Page 15). Tighten each fitting connection as shown in Figure 14, above.Locate the #10 compressor A/C hose. Lubricate (2) #10 O-rings (See Figure 14, above) and connect the #10 135° female fitting with 134a service port to the #10 suction port on the compressor. Then route the 90° female fitting to the #10 fitting on the evaporator (See Figure 11, Page 13, and Figure 15, Page 15). Tighten each fitting connection as shown in Figure 14, above.Locate the #6 evaporator A/C hose. Lubricate (2) #6 O-rings (See Figure 14, above) and connect the 90° female fitting to the #6 drier/core hardline coming through the core support from the drier. Then route the 90° female fitting to the #6 fitting on the evaporator (See Figure 11, Page 13, and Figure 15, Page 15). Tighten each fitting connection as shown in Figure 14, above.
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 14
Figure 13
EvaporatorCase
DrainHose
Drain
2 ½”1”
1”2 ½”
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904144 REV C 10/09/15, PG 15 OF 25
Heater Hose & Heater Control Valve Installation
1.
2.
Route a piece of heater hose from the water pump to the top heater fitting of the heater core as shown in Figure 11, Page 13, and Figure 15, below. Secure using hose clamps. NOTE: OEM water pump outlet is 3/4”. A 3/4” x 5/8” reducer fitting is required (not supplied).Route a piece of heater hose from the intake to the bottom heater fitting of the heater core as shown in Figure 11, Page 13, and Figure 15, below. NOTE: Install the heater control valve in line with the intake manifold (pressure side) heater hose, and secure using hose clamps as shown in Figure 15, below. Also note proper flow direction.
A/
C a
nd
Hea
ter
Hos
e R
outi
ng
Fig
ure
15#
8 Con
dens
er/
Com
pres
sor
Har
dlin
e09
1179
#10
Suc
tion
Hos
e09
6076
#8
Dis
char
geH
ose
0960
69
Hea
ter
Hos
e(I
ntak
e M
anifo
ldto
Hea
ter
Con
trol
Valv
e)
Com
pres
sor
Saf
ety
Switc
h(B
inar
y Ty
pe)
Scr
ew o
n D
rier
(Ref
er t
o Con
dens
erIn
stru
ctio
ns)
#6
Drier
/Cor
eH
ardl
ine
0911
80
#6
Hos
e09
6066
Hos
eCla
mps
From
Int
ake
Man
ifold
From
Eva
pora
tor
to W
ater
Pum
p
From
Hea
ter
Con
trol
Val
veto
Eva
pora
tor
Hea
ter
Hos
es
NO
TE:
OEM
Wat
er P
um
p O
utl
et is
3/
4”.
A 3
/4
” x
5/
8”
Red
uce
r Fi
ttin
g is
Req
uir
ed (
Not
Su
pp
lied
).
NO
TE:
Flow
Dir
ecti
on F
ollo
ws
Mol
ded
Arr
ow o
n V
alve
.
(4)
Tie
Wra
p
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904144 REV C 10/09/15, PG 16 OF 25
Passenger Side Under Dash Louver Hose Adapter Installation
1.2.
3.
Cut and remove the OEM passenger side under dash louver hose adapter as shown in Figure 16, below.Install the supplied foam around the OEM passenger side under dash louver hose adapter as shown in Figure 16a, below.Install the hose adapter onto the OEM passenger side under dash louver using (2) #8 x 1/2” pan head screws as shown in Figure 16b, below.
Figure 16
Figure 16a
Figure 16b
3/4”
Cut &Remove
Cut Foam3/8” x 5” Long
and Install
(2) #8 x 1/2”Pan Head Screws
Passenger SideUnder Dash Louver
Hose Adapter496084
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904144 REV C 10/09/15, PG 17 OF 25
Driver Side Under Dash Louver Hose Adapter Installation
1.
2.
Install the supplied foam around the OEM driver side under dash louver hose adapter as shown in Figure 17, below.Install the hose adapter onto the OEM driver side under dash louver using (2) #8 x 1/2” pan head screws as shown in Figure 17a, below.
Figure 17
Figure 17a
(2) #8 x 1/2”Pan Head Screws
Driver SideUnder Dash Louver
Hose Adapter496085
Cut Foam3/8” x 9 ½” Long
and Install
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904144 REV C 10/09/15, PG 18 OF 25
Figure 18 Figure 19
Figure 20
Final Steps1.2.
3.4.
5.6.7.8.
9.10.11.
12.13.
Install duct hoses as shown in Figure 21, Page 19.Route A/C wires (12-volt/grounds/binary switch/heater control valve) through 3/8” grommet as shown in Figure 18, below.Install control panel assembly. Refer to control panel instructions.Plug the wiring harnesses into the ECU module on the sub case as shown in Figure 21, Page 19. Wire according to the wiring diagrams on Pages 20 and 21.Refer to the instruction below and install the glove box.Modify the passenger side kick panel as shown in Figure 19, below.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 22.
Glove Box Installation1.2.3.
Install (2) U-nuts on the glove box top and bottom (See Figure 20, below).Install the glove box bottom into the glove box compartment using the OEM screws (See Figure 20, below).Install the glove box top using (4) S-clips and OEM screws (See Figure 20, below).
Cut & Remove5”
Cut & Remove1”
3/8” Grommet33145-VUI
Glove Box Top496077
OEMScrews
(4) S-clips
(2) U-nuts
Glove Box Bottom496078
Passenger Side Kick Panel
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904144 REV C 10/09/15, PG 19 OF 25
Figure 21
Figure 21a
Control Panel & Duct Hose Routing1.2.
Route the passenger side duct hose as shown in Figure 21a, below.Tie wrap the duct hose to the dash brace for glove box clearance (See Figure 21a, below).
Passenger SideDefrost Duct
2” x 13”
FromControls
Glove BoxArm
DashBraceTie
Wrap
Passenger SideCenter LouverUnder Dash
2” x 21”
Driver SideCenter LouverUnder Dash
2” x 26”
Driver SideDefrost Duct
2” x 30”
Center LouverPassenger Side
2 ½” x 16”
Passenger SideLouver
2 ½” x 66”
Driver SideLouver
2 ½” x 42”
Center LouverDriver Side2 ½” x 20”
Plug From Control Panel
Harness232007-VUR
Plug From Wiring
Harness232001-VUR
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904144 REV C 10/09/15, PG 20 OF 25
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 D, 5/6/2014
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
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904144 REV C 10/09/15, PG 21 OF 25
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 Ign Switch Source (Key On Accessory) Position Must Be Switched.
Tan Wire Used Only With Vintage Air Supplied Control Panel With LED Back Light.
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.
22
www.vintageair.com
904144 REV C 10/09/15, PG 22 OF 25
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
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.
Blower Speed
Blower Speed
This lever/knob controlsblower speed, from
OFF to HI.
This lever/knob controls the mode positions,from DASH to FLOORto DEFROST, with a blend in between.
This lever/knob controlsthe temperature,
from HOT to COLD.
Blower Speed
Mode Control
Temperature Control
TemperatureControl
Mode 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).
A/C Light
NOTE: A/C operation toggles on & off when temperature control is moved to the HOT or COLD ends of travel. A/C operation is indicated by the blue A/C light.
OFF FAN HI
DEFAC
COLDHOT
DASH FLR
AIR CONDITIONING
OFF FAN HI
DEFAC
COLDHOT
DASH FLR
AIR CONDITIONING
OFF FAN HI
DEF
AC
COLDHOT
DASH FLR
AIR CONDITIONING
OFF FAN HI
DEF
AC
COLDHOT
DASH FLR
AIR CONDITIONING
Blower Speed
ww
w.v
inta
gea
ir.c
om
23 904144 REV C 10/09/15, PG 23 OF 25
Sym
pto
m
C
on
dit
ion
C
heck
s
Act
ion
s
N
ote
s
Blo
wer
sta
ys o
n
hig
h s
pee
d w
hen
ig
nitio
n is
on.
1a.
No o
ther
funct
ions
work
.
Chec
k fo
r dam
aged
pin
s or
wires
in c
ontr
ol hea
d p
lug.
Ver
ify
that
all
pin
s ar
e in
sert
ed into
plu
g.
Ensu
re t
hat
no
pin
s ar
e ben
t or
dam
aged
in E
CU
.
Chec
k fo
r dam
aged
gro
und
wire
(white)
in c
ontr
ol hea
d
har
nes
s.
Ver
ify
continuity
to c
has
sis
gro
und w
ith w
hite
contr
ol
hea
d w
ire
at v
ario
us
poin
ts.
Loss
of gro
und o
n t
his
wire
render
s co
ntr
ol hea
d
inoper
able
.
All
oth
er f
unct
ions
work
.Chec
k fo
r dam
aged
blo
wer
sw
itch
or
pote
ntiom
eter
and
asso
ciat
ed w
irin
g.
Blo
wer
sta
ys o
n
hig
h s
pee
d w
hen
ig
nitio
n is
on o
r off.
Unplu
g 3
-wire
BSC c
ontr
ol
connec
tor
from
ECU
. If
blo
wer
sh
uts
off,
ECU
is
eith
er
impro
per
ly w
ired
or
dam
aged
.
Be
sure
the
smal
l, 2
0 G
A w
hite
gro
und w
ire
is c
onnec
ted
to t
he
bat
tery
gro
und p
ost
. If
it
is,
repla
ce t
he
ECU
.
Unplu
g 3
-wire
BSC c
ontr
ol
connec
tor
from
ECU
. If
blo
wer
st
ays
runnin
g,
BSC is
eith
er
impro
per
ly w
ired
or
dam
aged
.
Chec
k to
ensu
re t
hat
no B
SC w
irin
g is
dam
aged
or
short
ed t
o v
ehic
le g
round.
The
BSC o
per
ates
the
blo
wer
by
gro
und s
ide
puls
e w
idth
modula
tion s
witch
ing.
The
posi
tive
wire
to t
he
blo
wer
will
alw
ays
be
hot.
If th
e “g
round”
side
of
the
blo
wer
is
short
ed t
o c
has
sis
gro
und,
the
blo
wer
will
run o
n H
I.
Rep
lace
BSC (
This
will
req
uire
rem
oval
of ev
apora
tor
from
veh
icle
).N
o o
ther
par
t re
pla
cem
ents
sh
ould
be
nec
essa
ry.
Com
pre
ssor
will
not
turn
on
(All
oth
er funct
ions
work
).
2.
Sys
tem
is
not
char
ged
.Sys
tem
must
be
char
ged
for
com
pre
ssor
to e
ngag
e.Char
ge
syst
em o
r byp
ass
pre
ssure
sw
itch
.
Dan
ger:
Never
byp
ass
sa
fety
sw
itch
wit
h
en
gin
e r
un
nin
g.
Seri
ou
s in
jury
can
resu
lt.
Sys
tem
is
char
ged
.
1b
.
Tro
ub
lesh
oo
tin
g G
uid
e
Chec
k fo
r fa
ulty
A/C
pote
ntiom
eter
or
asso
ciat
ed
wirin
g (
Not
applic
able
to 3
-pot
contr
ols
).
Chec
k fo
r dis
connec
ted o
r fa
ulty
ther
mis
tor.
Chec
k co
ntinuity
to g
round o
n w
hite
contr
ol hea
d w
ire.
Chec
k fo
r 5V o
n r
ed c
ontr
ol hea
d w
ire.
Chec
k 2-p
in c
onnec
tor
at E
CU
housi
ng.
To c
hec
k fo
r pro
per
pot
funct
ion,
chec
k vo
ltag
e at
w
hite/
blu
e w
ire.
Voltag
e sh
ould
be
bet
wee
n 0
V a
nd
5V,
and w
ill v
ary
with p
ot
leve
r posi
tion.
Dis
connec
ted o
r fa
ulty
ther
mis
tor
will
cau
se
com
pre
ssor
to b
e dis
able
d.
Red
wire
at A
/C p
ot
should
hav
e ap
pro
xim
atel
y 5V
with ignitio
n o
n.
White
wire
will
hav
e co
ntinuity
to
chas
sis
gro
und.
White/
Blu
e w
ire
should
var
y bet
wee
n 0
V a
nd 5
V w
hen
le
ver
is m
oved
up o
r dow
n.
3. Com
pre
ssor
will
not
turn
off
(A
ll oth
er funct
ions
work
).
Chec
k fo
r fa
ulty
A/C
pote
ntiom
eter
or
asso
ciat
ed
wirin
g.
Chec
k fo
r fa
ulty
A/C
rel
ay.
Rep
air
or
repla
ce p
ot/
contr
ol w
irin
g.
Rep
lace
rel
ay.
See
blo
wer
sw
itch
chec
k pro
cedure
.
ww
w.v
inta
gea
ir.c
om
24 904144 REV C 10/09/15, PG 24 OF 25
Sym
pto
m
C
on
dit
ion
Ch
eck
s
Act
ion
s
N
ote
s
Sys
tem
will
not
turn
on,
or
runs
inte
rmitte
ntly.
4.
Work
s w
hen
engin
e is
not
runnin
g;
shuts
off w
hen
en
gin
e is
sta
rted
(T
ypic
ally
ear
ly G
en I
V,
but
poss
ible
on a
ll ve
rsio
ns)
.
Nois
e in
terf
eren
ce f
rom
either
ig
nitio
n o
r al
tern
ator.
Inst
all ca
pac
itors
on ignitio
n c
oil
and a
lter
nat
or. E
nsu
re
good g
round a
t al
l poin
ts.
Rel
oca
te c
oil
and a
ssoci
ated
w
irin
g a
way
fro
m E
CU
and E
CU
wirin
g.
Chec
k fo
r burn
edor
loose
plu
g w
ires
.
Ver
ify
connec
tions
on p
ow
er
lead
, ig
nitio
n lea
d,
and b
oth
white
gro
und w
ires
.
Ver
ify
pro
per
met
er f
unct
ion b
y ch
ecki
ng t
he
conditio
n o
f a
know
n g
ood b
atte
ry.
Ignitio
n n
ois
e (r
adia
ted o
rco
nduct
ed)
will
cau
se t
he
syst
em t
o s
hut
dow
n d
ue
tohig
h v
oltag
e sp
ikes
. If
this
is s
usp
ecte
d,
chec
k w
ith a
qual
ity
osc
illosc
ope.
Spik
esgre
ater
than
16V w
ill s
hut
dow
n t
he
ECU
. In
stal
l a
radio
cap
acitor
at t
he
posi
tive
post
of th
e ig
nitio
nco
il (S
ee r
adio
cap
acitor
inst
alla
tion b
ulle
tin).
A
faulty
alte
rnat
or
or
worn
out
bat
tery
can
als
o r
esult
in t
his
conditio
n.
Will
not
turn
on u
nder
an
y co
nditio
ns.
Ver
ify
bat
tery
voltag
e is
gre
ater
than
10 v
olts
and les
sth
an 1
6.
Loss
of m
ode
door
funct
ion.
No m
ode
chan
ge
at a
ll.Chec
k fo
r dam
aged
mode
switch
or
pote
ntiom
eter
and
asso
ciat
ed w
irin
g.
Part
ial fu
nct
ion o
f m
ode
doors
.
Typic
ally
cau
sed b
y ev
apora
tor
housi
ng
inst
alle
d in a
bin
d in t
he
vehic
le.
Be
sure
all
mounting loca
tions
line
up
and d
on’t h
ave
to b
e fo
rced
in
to p
osi
tion.
Blo
wer
turn
s on
and o
ff r
apid
ly.
6.
Bat
tery
voltag
e is
at
leas
t 12V.
Chec
k fo
r at
lea
st 1
2V a
t ci
rcuit b
reak
er.
Ensu
re a
ll sy
stem
gro
unds
and p
ow
er c
onnec
tions
are
clea
n a
nd t
ight.
Bat
tery
voltag
e is
les
s th
an 1
2V.
5.
Tro
ub
lesh
oo
tin
g G
uid
e (
Co
nt.
)
Chec
k fo
r fa
ulty
bat
tery
or
alte
rnat
or.
Char
ge
bat
tery
.
Sys
tem
shuts
off b
low
er a
t 10V.
Poor
connec
tions
or
wea
k bat
tery
can
cau
se
shutd
ow
n a
t up t
o 1
1V.
7. When
ignitio
n is
turn
ed o
n,
blo
wer
m
om
enta
rily
co
mes
on,
then
sh
uts
off.
This
occ
urs
with t
he
blo
wer
sw
itch
in
the
OFF
posi
tion.
This
is
an indic
ator
that
the
syst
em h
as b
een r
eset
. Be
sure
the
red p
ow
er w
ire
is o
nth
e bat
tery
post
, an
d n
ot
on a
sw
itch
ed s
ourc
e. A
lso,
if
the
syst
em is
pulle
d b
elow
7V f
or
even
a s
plit
sec
ond,
the
syst
em w
ill r
eset
.
Run r
ed p
ow
er w
ire
direc
tly
to b
atte
ry.
Chec
k fo
r posi
tive
pow
er a
t hea
ter
valv
e gre
en w
ire
and
blo
wer
red
wire.
Chec
k fo
r gro
und o
n c
ontr
ol hea
d w
hite
wire.
Chec
k fo
r obst
ruct
ed o
r bin
din
g m
ode
doors
.
Chec
k fo
r dam
aged
ste
pper
m
oto
r or
wirin
g.
Err
atic
funct
ions
of
blo
wer
, m
ode,
te
mp,
etc.
Chec
k fo
r dam
aged
sw
itch
or
pot
and a
ssoci
ated
wirin
g.
Rep
air
or
repla
ce.
8.
25
www.vintageair.com
904144 REV C 10/09/15, PG 25 OF 25
OFF
DASH
HOT
AC
FAN HI
DEF
FLRCOLD
Packing List: Evaporator Kit (564171)
No. 1.2.
Qty.11
Part No.762171784156
DescriptionGen IV 6-Vent Evaporator Sub Case with 204 ECUAccessory Kit
NOTE: Images may not depict actual parts and quantities. Refer to packing list for actual parts and quantities.
1
2
Gen IV 6-Vent Evaporator Sub Case
w/ 204 ECU762171
Accessory Kit784156
Checked By:Packed By:
Date: