Chevrolet - Vega - Parts Catalogue - 1957 - 1958

an ISO 9001:2008 Registered Company Facel Vega with Left Hand Drive Evaporator Kit with HK500 Control 589003 FV3B (1957-58) FV4 (1957-58) HK (1958-61) EX (1958) EX1 (1958-61) EX2 (1961-65) 18865 Goll St. San Antonio, TX 78266 ph: 210-654-7171 fax: 210-654-3113 903409 REV A 1/27/16, INSTRUCTIONS, EVAPORATOR KIT 589003, PG 1 OF 22 Table of Contents 1. 2. 3. 4. 5. 6. Cover Table of Contents Packing List/Parts Disclaimer Information Page Wiring Notice Engine Compartment, Condenser Assembly & Installation, Compressor & Brackets, Pulleys Figure 1 7. Passenger Compartment Figures 2, 2a & 3 8. A/C Firewall Cover Assembly Installation, Heater Cover Installation Figures 4, 5 & 5a 9. Evaporator/Cowl Front Bracket Installation, A/C Hose Routing Figures 6, 6a & 7 10. Front & Rear Evaporator Bracket Installation Figures 8, 8a & 8b 11. Heater Hardline Installation Figures 9, 10 & 10a 12. Evaporator Installation Figures 11, 11a & 11b 13. Drain Hose Installation Figures 12 & 13 14. A/C Hose, Heater Hose & Heater Control Valve Installation, A/C & Heater Hose Routing Figure 14 15. Final Steps Figures 15, 16 & 16a 16. Control Panel & Duct Hose Routing Figure 17, 17a, 17b & 18 17. Wiring Diagram 18. Gen IV Wiring Connection Instruction 19. Operation of Controls 20. Troubleshooting Information 21. Troubleshooting Information (Cont.) 22. Evaporator Kit Packing List 903409 REV A 1/27/16, INSTRUCTIONS, EVAPORATOR KIT 589003, PG 2 OF 22 2 Packing List Evaporator Kit (589003) No. Qty. Part No. 1. 2. 1 1 768005 789003 Description Facel Vega Evaporator Sub Case w/ 204 ECU Accessory Kit, 1957-65 Facel Vega w/ HK500 Control ** 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 Facel Vega Evaporator Sub Case w/ 204 ECU 768005 2 3 Accessory Kit 789003 NOTE: Images may not depict actual parts and quantities. Refer to packing list for actual parts and quantities. 903409 REV A 1/27/16, INSTRUCTIONS, EVAPORATOR KIT 589003, PG 3 OF 22 Important Notice—Please Read For Maximum System Performance, Vintage Air Recommends the Following: NOTE: Vintage Air systems are designed to operate with R134a refrigerant only. Use of any other refrigerant could damage your A/C system and/or vehicle, and possibly cause a fire, in addition to potentially voiding the warranties of the A/C system and its components. Refrigerant Capacities: Vintage Air System: 1.8 lbs. (1 lb., 12 oz.) of R134a, charged by weight with a quality charging station or scale. NOTE: Use of the proper type and amount of refrigerant is critical to system operation and performance. Other Systems: Consult manufacturer’s guidelines. Lubricant Capacities: New Vintage Air-supplied Sanden Compressor: No additional oil needed (Compressor is shipped with proper oil charge). All Other Compressors: Consult manufacturer (Some compressors are shipped dry and will need oil added). Safety Switches Your Vintage Air system is equipped with a binary pressure safety switch. A binary switch disengages the compressor clutch in cases of extreme low pressure conditions (Refrigerant Loss) or excessively high head pressure (406 PSI) to prevent compressor damage or hose rupture. A trinary switch combines Hi/Lo pressure protection with an electric fan operation signal at 254 PSI, and should be substituted for use with electric fans. Compressor safety switches are extremely important since an A/C system relies on refrigerant to circulate lubricant. Service Info: Protect Your Investment: Prior to assembly, it is critical that the compressor, evaporator, A/C hoses and fittings, hardlines, condenser and receiver/drier remained capped. Removing caps prior to assembly will allow moisture, insects and debris into the components, possibly leading to reduced performance and/or premature failure of your A/C system. This is especially important with the receiver/drier. Additionally, when caps are removed for assembly, BE CAREFUL! Some components are shipped under pressure with dry nitrogen. Evacuate the System for 35-45 Minutes: Ensure that system components (Drier, compressor, evaporator and condenser) are at a temperature of at least 85° F. On a cool day, the components can be heated with a heat gun or by running the engine with the heater on before evacuating. Leak check and charge to specifications. Bolts Passing Through Cowl and/or Firewall: To ensure a watertight seal between the passenger compartment and the vehicle exterior, for all bolts passing through the cowl and/or firewall, Vintage Air recommends coating the threads with silicone prior to installation. Heater Hose (Not Included With This Kit): Heater hose may be purchased from Vintage Air (Part# 31800-VUD) or your local parts retailer. Routing and required length will vary based on installer preference. 903409 REV A 1/27/16, INSTRUCTIONS, EVAPORATOR KIT 589003, PG 4 OF 22 4 Important Wiring Notice—Please Read Some Vehicles May Have Had Some or All of Their Radio Interference Capacitors Removed. There Should Be a Capacitor Found At Each of the Following Locations: 1. On the positive terminal of the ignition coil. 2. If there is a generator, on the armature terminal of the generator. 3. If there is a generator, on the battery terminal of the voltage regulator. Most alternators have a capacitor installed internally to eliminate what is called “whining” as the engine is revved. If whining is heard in the radio, or just to be extra cautious, a radio interference capacitor can be added to the battery terminal of the alternator. It is also important that the battery lead is in good shape and that the ground leads are not compromised. There should be a heavy ground from the battery to the engine block, and additional grounds to the body and chassis. If these precautions are not observed, it is possible for voltage spikes to be present on the battery leads. These spikes come from ignition systems, charging systems, and from switching some of the vehicle’s other systems on and off. Modern computer-operated equipment can be sensitive to voltage spikes on the power leads, which can cause unexpected resets, strange behavior, and/or permanent damage. Vintage Air strives to harden our products against these types of electrical noise, but there is a point where a vehicle’s electrical system can be degraded so much that nothing can help. Radio interference capacitors should be available at most auto and truck parts suppliers. They typically are cylindrical in shape, a little over an inch long, a little over a half inch in diameter, and they have a single lead coming from one end of the cylinder with a terminal on the end of the wire, as well as a mounting clip which is screwed into a good ground on the vehicle. The specific value of the capacitance is not too significant in comparison to ignition capacitors that are matched with the coil to reduce pitting of the points. • Care must be taken, when installing the compressor lead, not to short it to ground. The compressor lead must not be connected to a condenser fan or to any other auxiliary device. Shorting to ground or connecting to a condenser fan or any other auxiliary device may damage wiring, the compressor relay, and/or cause a malfunction. • When installing ground leads on Gen IV systems, the blower control ground and ECU ground must be connected directly to the negative battery post. 5 • For proper system operation, the heater control valve must be connected to the ECU. 903409 REV A 1/27/16, INSTRUCTIONS, EVAPORATOR KIT 589003, PG 5 OF 22 Engine Compartment 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: 1. Disconnect battery (See Figure 1, below). 2. Remove radiator cover (retain) (See Figure 1, below). 3. Drain & remove radiator (retain). 4. Remove OEM heater hoses (discard) (See Figure 1, below). 5. Remove heater blower motor assembly (discard). Heater Hoses Battery Radiator Cover Figure 1 Condenser Assembly & Installation 1. Refer to separate instructions included with the condenser kit to install the condenser. 2. Binary switch installation (Refer to condenser instructions). Compressor & Brackets 1. Refer to separate instructions included with the bracket kit to install the compressor bracket. Pulleys 1. In most instances, the belt lengths will remain the same. 903409 REV A 1/27/16, INSTRUCTIONS, EVAPORATOR KIT 589003, PG 6 OF 22 6 Passenger Compartment Perform the Following: 1. Remove the dash pad (retain) (See Figure 2, below). 2. Remove the dash (retain) (See Figure 2, below). 3. Remove the fresh air ventilation duct (discard) (See Figure 2a, below). 4. Remove the OEM heater/blower motor assembly (discard) (See Figures 2a and 3, below). OEM Fresh Air Ventilation duct OEM Blower Motor Dash Pad OEM Heater Dash Figure 2a Figure 2 OEM Heater Figure 3 7 903409 REV A 1/27/16, INSTRUCTIONS, EVAPORATOR KIT 589003, PG 7 OF 22 A/C Firewall Cover Assembly Installation 1. Install (2) 1 ¼” grommets in A/C firewall cover assembly located in fender well outside engine compartment (See Figure 4, below, and Figure 14, Page 14). 2. Apply a 1/4” bead of silicone around the back side of the A/C firewall cover assembly. 3. Install A/C firewall cover assembly on firewall under passenger side fender well using (3) 1/4-20 x 3/4” hex bolts. Secure with (3) 1/4” flat washers and (3) 1/4-20 nuts with star washers (See Figure 4, below). 4. Using the remaining hole in the firewall cover as a template, drill a 5/16” hole through the firewall (See Figure 4, below). (3) 1/4-20 x 3/4” Hex Bolts, (3) 1/4” Flat Washers and (3) 1/4-20 Nuts with Star Washers (Included in Hose Kit) Drill 5/16” Hole Through Firewall (2) 1 ¼” Grommets (Included in Hose Kit) A/C Firewall Cover Assembly 624999 (Included in Hose Kit) Figure 4 Heater Cover Installation (Original Heater Hose Routing) 1. Install heater cover gasket inside engine bay between heater cover and firewall, and secure to passenger compartment heater cover using (4) 10-32 x 1” Phillips pan head screws (See Figures 5 & 5a, below). 2. Install 1 ⅛” plug in firewall (See Figure 5, below). 1 ⅛” Plug Heater Cover Gasket Heater Cover 647028 Passenger Compartment Heater Cover with Well Nuts (4) 10-32 x 1” Phillips Pan Head Screws Figure 5 Figure 5a 903409 REV A 1/27/16, INSTRUCTIONS, EVAPORATOR KIT 589003, PG 8 OF 22 8 Evaporator/Cowl Front Bracket Installation 1. Using measurements in Figure 6, below, drill (2) 1/4” holes in cowl. 2. Install evaporator/cowl front bracket assembly to cowl using (2) 1/4-20 x 3/4” hex bolts (See Figure 6a, below). Drill 1/4” Hole 5” Drill 1/4” Hole 5/16” (2) 1/4-20 x 3/4” Hex Bolts 7 ¼” 12 ¼” Evap Figure 6 Figure 6a A/C Hose Routing 1. Route #6 and #10 A/C hoses through A/C firewall cover assembly (In fender well area, not engine compartment) (See Figure 7, below). #10 A/C Hose #6 A/C Hose Figure 7 9 903409 REV A 1/27/16, INSTRUCTIONS, EVAPORATOR KIT 589003, PG 9 OF 22 Front & Rear Evaporator Bracket Installation 1. Install (2) relays onto blower relay bracket using (2) 10-32 x 1/2” Phillips pan head screws and (2) 10-32 nuts with star washers (See Figure 8a, below). 2. On a workbench, install driver and passenger side rear evaporator brackets and blower relay bracket onto evaporator as shown in Figures 8 & 8a, below. 3. Install front mounting bracket onto evaporator using (2) 1/4-20 x 1/2” hex bolts, and tighten as shown in Figure 8b, below. Passenger Side Rear Evaporator Bracket Assembly 647025 1/4-20 x 1/2” Bolt (Located on Sub Case) Driver Side Rear Evaporator Bracket Assembly 647031 (2) Relays (2) 1/4-20 x 1/2” Bolts (Located on Sub Case) Blower Relay Bracket Figure 8 Evaporator Front Bracket 647020 1/4-20 x 1/2” Bolt (Located on Sub Case) (2) 10-32 x 1/2” Phillips Pan Head Screws and (2) 10-32 Nuts Figure 8a with Star Washers 1/4-20 x 1/2” Bolt (Located on Sub Case) 1/4-20 x 1/2” Bolt (Located on Sub Case) Figure 8b 903409 REV A 1/27/16, INSTRUCTIONS, EVAPORATOR KIT 589003, PG 10 OF 22 10 Heater Hardline Installation 1. Install (2) heater hardlines onto evaporator with properly lubricated O-rings (See Figure 9, below, and Figure 13, Page 13). Heater Hardline (Evaporator to Water Pump) Heater Hardline (Evaporator to Intake) Figure 9 A/C Hose Installation 1. Lay evaporator on passenger side floorboard, and install #6 and #10 A/C hoses onto evaporator with properly lubricated O-rings (See Figures 10 & 10a, below, and Figure 13, Page 13). NOTE: Press tape should cover all metal portions of #10 fitting. Press Tape Figure 10 11 #6 A/C Hose Figure 10a 903409 REV A 1/27/16, INSTRUCTIONS, EVAPORATOR KIT 589003, PG 11 OF 22 #10 A/C Hose Evaporator Installation 1. Lift evaporator unit up under the dashboard. Secure passenger side (left hand drive models) evaporator bracket loosely to the firewall from the passenger side fender well using a 1/4” washer and 1/4-20 nut with star washer (See Figure 11, below). 2. Secure driver side evaporator bracket loosely to the firewall from the engine compartment side of the firewall using a 1/4-20 x 3/4” hex bolt and 1/4” washer (See Figure 11a, below). 3. Using (2) 1/4-20 x 3/4” hex bolts, (2) 1/4” washers and (2) 1/4-20 nuts with star washers, secure the front evaporator mounting bracket to the evaporator/cowl front bracket (See Figure 11b, below). 4. Verify that the evaporator unit is level and square to the dash, and then tighten all mounting bolts. NOTE: Tighten the bolt on firewall first, and then tighten the front mounting bracket screws. 1/4” Washer 1/4-20 x 3/4” Hex Bolt 1/4-20 Nut with Star Washer 1/4” Washer Figure 11 Figure 11a (2) 1/4-20 x 3/4” Hex Bolts (2) 1/4” Washers Evaporator/Cowl Front Bracket Evaporator Front Bracket (2) 1/4-20 Nuts with Star Washers Figure 11b 903409 REV A 1/27/16, INSTRUCTIONS, EVAPORATOR KIT 589003, PG 12 OF 22 12 Drain Hose Installation 1. Locate evaporator drain on bottom of evaporator case. 2. In line with the drain, lightly make a mark on the firewall. Measure one inch down and drill a 5/8” hole through the firewall (See Figure 12, right). 3. Install drain hose to bottom of evaporator unit and route through firewall (See Figure 12, right). 1” Drain Hose Drain Figure 12 Lubricating O-rings Male O-ring Insert #6 O-ring #8 O-ring #10 O-ring For a proper seal of fittings: Install supplied O-rings as shown, and lubricate with supplied oil. O-ring Supplied Oil for O-rings NOTE: Standard torque specifications: #6: 11 to 13 ft-lb. #8: 15 to 20 ft-lb. #10: 21 to 27 ft-lb. 13 Female Nut O-ring Installs Over Male Insert to Swaged Lip Figure 13 Twist With This Wrench Hold With This Wrench 903409 REV A 1/27/16, INSTRUCTIONS, EVAPORATOR KIT 589003, PG 13 OF 22 A/C Hose, Heater Hose & Heater Control Valve Installation 1. Route A/C hoses as shown in Figure 14, below. 2. Route a piece of heater hose from the water pump to the top heater fitting of the heater core as shown in Figure 9, Page 11, and Figure 14, below. Secure using hose clamps. 3. Route a piece of heater hose from the intake to the bottom heater fitting of the heater core as shown in Figure 9, Page 11, and Figure 14, below. NOTE: Install heater control valve in line with intake manifold (pressure side) heater hose, and secure using hose clamps as shown in Figure 14, below. Also note proper flow direction. A/C & Heater Hose Routing NOTE: Vintage Air Systems Require (2) 5/8” Hose Nipples (Not Supplied). #10 Tite Fit 90° A/C Fitting (See Figure 5, Page 8) (See Figure 4, Page 8) #8 Tite Fit 90° A/C Fitting Heater Hose (Heater Control Valve/Intake) Tie Wrap #8 A/C Hose (Comp./Cond.) 126012 (2) #6 Adel Clamps From Heater Control Valve to Evaporator (3) #10 Adel Clamps Hose Clamps Heater #6 A/C Hose Hose (Evap./Core) 126001 #10 A/C Hose (Evap./Core) Fro Fro 126002 mE mI to W vap Ma ntake nifo ate orato r Pu ld r mp (4) 10-24 Nuts w/ Star Washers NOTE: Flow direction follows (2 Included in Hose Kit) molded arrow on valve. Figure 14 #10 A/C Hose (Comp./Core) 126013 #6 Cond./Drier Hardline #6 Drier/ 121029 Core Hardline 121030 (2) #10 Hardline Brackets 643156 (Included in Hose Kit) #10 Evap./Core Hardline 121033 (Included in Hose Kit) (2) #4 Adel Clamps 31603-VUD #8 Condenser Hardline 121032 Compressor Safety Switch (Trinary Type) Screw-on Drier (Refer to Condenser Instructions) (2) 10-24 x 3/4” Pan Head Screws (Included in Hose Kit) (2) #8 Adel Clamps 316050 (Included in Hose Kit) 903409 REV A 1/27/16, INSTRUCTIONS, EVAPORATOR KIT 589003, PG 14 OF 22 (2) 10-24 x 3/8” Pan Head Screws 14 Final Steps 1. Install duct hoses as shown in Figures 17 & 17a, Page 16. Install defrost duct as shown in Figures 17b & 17c, Page 16. 2. Route A/C wires (12 volt/grounds/trinary switch/heater valve) through 1 ¼” x 1” grommet with 1/2” ID hole as shown in Figure 15, below. 3. Install control panel assembly. 4. Plug the wiring harnesses into the ECU module on the sub case as shown in Figure 18, Page 16 (Wire according to wiring diagrams on Pages 17 and 18). 5. Reinstall dash and all previously removed items. 6. Install driver and passenger side under dash louvers between dash and padded trim (See Figures 16 & 16a, below). 7. 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. 8. Double check all fittings, brackets and belts for tightness. 9. Vintage Air recommends that all A/C systems be serviced by a certified automotive air conditioning technician. 10. Evacuate the system for a minimum of 45 minutes prior to charging, and perform a leak check prior to servicing. 11. Charge the system to the capacities stated on Page 4 of this instruction manual. 12. See Operation of Controls procedures on Page 19. 1 ¼” x 1” with 1/2” Hole Grommet 33133-VUI Wiring Harness (Heater Control Valve) Wiring Harness (12 Volt/Grounds /Trinary Switch) Figure 15 From Control Panel ECU Plug From Control Wiring Harness 232002-VUA Plug From Wiring Harness 232001-VUR Padded Trim Driver Side Under Dash Louver Figure 16 15 Passenger Side Under Dash Louver Figure 16a 903409 REV A 1/27/16, INSTRUCTIONS, EVAPORATOR KIT 589003, PG 15 OF 22 Control Panel & Duct Hose Routing Figure 17c Figure 17b Figure 17a Figure 17 Driver Side Under Dash Louver 2 ½” x 30” Driver Side Center Under Dash Louver 2 ½” x 12” Figure 17 Passenger Side Center Under Dash Louver 2 ½” x 6” Passenger Side Under Dash Louver 2 ½” x 24” Figure 17a Figure 17b Defrost Duct Assembly 496113 #6 x 3/8” Phillips Pan Head Screw 903409 REV A 1/27/16, INSTRUCTIONS, EVAPORATOR KIT 589003, PG 16 OF 22 Figure 17c 16 Wiring Diagram 232007-VUR TAN ORA BLK AC ANNUNCIATOR BACKLIGHT POS BACKLIGHT NEG GND 5V-SW WHT RED WHT/RED WHT/YEL JF8 TEMP WIPER MODE WIPER WHT/GRN FAN WIPER PRE-WIRED VIEWED FROM WIRE SIDE 232002-VUA A/C (IF USED) GEN IV ECU GEN IV WIRING DIAGRAM REV D, 5/6/2014 TEMP MODE FAN PROGRAM * DASH LAMP (IF USED) *** WIDE OPEN THROTTLE SWITCH (OPTIONAL) ** CIRCUIT BREAKER 30 AMP HEATER CONTROL VALVE • Dash Lamp Is Used Only With Type 232007-VUR Harness. • Warning: Always Mount Circuit Breaker As Close to the Battery As Possible. (NOTE: Wire Between Battery and Circuit Breaker Is Unprotected and Should Be Carefully Routed to Avoid a Short Circuit). 17 • Wide Open Throttle Switch Contacts Close Only at Full Throttle, Which Disables A/C Compressor. 903409 REV A 1/27/16, INSTRUCTIONS, EVAPORATOR KIT 589003, PG 17 OF 22 Gen IV Wiring Connection Instruction WIRING HARNESS CONTROL WIRING HARNESS RED & WHITE A/C COMPRESSOR RELAY RED BLUE RED WH IT E NOTE: MOUNT RELAY IN DESIRED LOCATION UNDER DASH Ignition Switch: VIOLET Violet 12V Ign Switch Source (Key On Accessory) Position Must Be Switched. +12V NOTE: WIRING YELLOW & ORANGE (IGNITION HOT HARNESS COMING FROM TERMINAL) HARNESS ARE NOT USED. YELLOW RUN BAT IGNITION SWITCH ORANGE TAN DASH BACK LIGHT+0-12v GRAY GRAY WIRE IS USED FOR PROGRAMING CONTROLS IF APPLICABLE RED GREEN RED GREEN FIREWALL BLACK BLUE Heater Control Valve: RED LATCH WIRING HARNESS WHITE CHASSIS GROUND NOTE: HEATER CONTROL VALVE CONNECTION AND CHASSIS GROUND MAY BE LOCATED ON EITHER SIDE OF THE FIREWALL. ENSURE CONNECTOR IS LATCHED FIRMLY. HEATER CONTROL VALVE K BLAC BLUE COMPRESSOR WHITE NOTE: CONNECT WHITE WIRES DIRECTLY TO (-) BATTERY TERMINAL WHITE RED RED CIRCUIT BREAKER 30 AMP Install With Servo Motor Facing Down, As Shown. Note Flow Direction Arrow Molded Into Valve Body, And Install Accordingly. Binary/Trinary & Compressor: Binary: Connect As Shown (Typical Compressor Wiring). Be Sure Compressor Body Is Grounded. BINARY SAFETY SWITCH BLUE Dash Light: Tan Wire Used Only With Vintage Air Supplied Control Panel With LED Back Light. RED WARNING: ALWAYS MOUNT CIRCUIT BREAKER AS CLOSE TO THE BATTERY AS POSSIBLE. (NOTE: WIRE BETWEEN BATTERY AND CIRCUIT BREAKER IS UNPROTECTED AND SHOULD BE CAREFULLY ROUTED TO AVOID A SHORT CIRCUIT). + - Trinary Switch: Connect According To Trinary Switch Wiring Diagram. Circuit Breaker/Battery: White Must Run To (-) Battery. Red May Run To (+) Battery Or Starter. Mount Circuit Breaker As Close to Battery As Possible. BATTERY 903409 REV A 1/27/16, INSTRUCTIONS, EVAPORATOR KIT 589003, PG 18 OF 22 18 Operation of Controls 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 control panel instructions for calibration procedure. Blower Speed This lever/knob controls blower speed, from OFF to HI. Mode Control This lever/knob controls the mode positions, from DASH to FLOOR to DEFROST, with a blend in between. Mode Control Temperature Control This lever/knob controls the temperature, from HOT to COLD. Blower Speed A/C Operation Blower Speed Adjust to desired speed. Mode Control Adjust to desired mode position (DASH position recommended). Temperature Control For A/C operation, adjust to coldest position to engage compressor (Adjust between HOT and COLD to reach desired temperature). Heat Operation Blower Speed Adjust to desired speed. Mode Control Adjust to desired mode position (FLOOR position recommended). Temperature Control For maximum heating, adjust to hottest position (Adjust between HOT and COLD to reach desired temperature). Defrost/De-fog Operation Blower Speed Adjust to desired speed. Temperature Control Adjust to desired temperature. Mode Control Adjust to DEFROST position for maximum defrost, or between FLOOR and DEFROST positions for a bi-level blend (Compressor is automatically engaged). 19 903409 REV A 1/27/16, INSTRUCTIONS, EVAPORATOR KIT 589003, PG 19 OF 22 Temperature Control 903409 REV A 1/27/16, INSTRUCTIONS, EVAPORATOR KIT 589003, PG 20 OF 22 Symptom Compressor will not turn off (All other functions work). 3. Compressor will not turn on (All other functions work). 2. Blower stays on high speed when ignition is on or off. 1b. Blower stays on high speed when ignition is on. 1a. 20 System is charged. System is not charged. All other functions work. No other functions work. Condition Check 2-pin connector at ECU housing. Repair or replace pot/control wiring. Replace relay. Check for faulty A/C potentiometer or associated wiring. Check for faulty A/C relay. Check continuity to ground on white control head wire. Check for 5V on red control head wire. Charge system or bypass pressure switch. Replace BSC (This will require removal of evaporator from vehicle). Check to ensure that no BSC wiring is damaged or shorted to vehicle ground. The BSC operates the blower by ground side pulse width modulation switching. The positive wire to the blower will always be hot. If the “ground” side of the blower is shorted to chassis ground, the blower will run on HI. Be sure the small, 20 GA white ground wire is connected to the battery ground post. If it is, replace the ECU. Verify continuity to chassis ground with white control head wire at various points. Verify that all pins are inserted into plug. Ensure that no pins are bent or damaged in ECU. Actions Check for disconnected or faulty thermistor. Check for faulty A/C potentiometer or associated wiring (Not applicable to 3-pot controls). System must be charged for compressor to engage. Unplug 3-wire BSC control connector from ECU. If blower stays running, BSC is either improperly wired or damaged. Unplug 3-wire BSC control connector from ECU. If blower shuts off, ECU is either improperly wired or damaged. Check for damaged ground wire (white) in control head harness. Check for damaged blower switch or potentiometer and associated wiring. Check for damaged pins or wires in control head plug. Checks Red wire at A/C pot should have approximately 5V with ignition on. White wire will have continuity to chassis ground. White/ Blue wire should vary between 0V and 5V when lever is moved up or down. Disconnected or faulty thermistor will cause compressor to be disabled. To check for proper pot function, check voltage at white/blue wire. Voltage should be between 0V and 5V, and will vary with pot lever position. Danger: Never bypass safety switch with engine running. Serious injury can result. No other part replacements should be necessary. See blower switch check procedure. Loss of ground on this wire renders control head inoperable. Notes Troubleshooting Guide Symptom 903409 REV A 1/27/16, INSTRUCTIONS, EVAPORATOR KIT 589003, PG 21 OF 22 8. When ignition is turned on, blower momentarily comes on, then shuts off. This occurs with the blower switch in the OFF position. Erratic functions of blower, mode, temp, etc. 7. Blower turns on and off rapidly. 6. Loss of mode door function. 5. System will not turn on, or runs intermittently. 4. 21 This is an indicator that the system has been reset. Be sure the red power wire is on the battery post, and not on a switched source. Also, if the system is pulled below 7V for even a split second, the system will reset. Run red power wire directly to battery. Repair or replace. Charge battery. Check for faulty battery or alternator. Battery voltage is less than 12V. Check for damaged switch or pot and associated wiring. Ensure all system grounds and power connections are clean and tight. Verify proper meter function by checking the condition of a known good battery. Check for positive power at heater valve green wire and blower red wire. Check for ground on control head white wire. Install capacitors on ignition coil and alternator. Ensure good ground at all points. Relocate coil and associated wiring away from ECU and ECU wiring. Check for burned or loose plug wires. Actions Check for at least 12V at circuit breaker. Check for damaged stepper motor or wiring. Check for obstructed or binding mode doors. Check for damaged mode switch or potentiometer and associated wiring. Verify battery voltage is greater than 10 volts and less than 16. Verify connections on power lead, ignition lead, and both white ground wires. Noise interference from either ignition or alternator. Checks Battery voltage is at least 12V. Partial function of mode doors. No mode change at all. Will not turn on under any conditions. Works when engine is not running; shuts off when engine is started (Typically early Gen IV, but possible on all versions). Condition System shuts off blower at 10V. Poor connections or weak battery can cause shutdown at up to 11V. Typically caused by evaporator housing installed in a bind in the vehicle. Be sure all mounting locations line up and don’t have to be forced into position. Ignition noise (radiated or conducted) will cause the system to shut down due to high voltage spikes. If this is suspected, check with a quality oscilloscope. Spikes greater than 16V will shut down the ECU. Install a radio capacitor at the positive post of the ignition coil (See radio capacitor installation bulletin). A faulty alternator or worn out battery can also result in this condition. Notes Troubleshooting Guide (Cont.) Packing List Evaporator Kit (589003) No. Qty. Part No. 1. 2. 1 1 768005 789003 Description Facel Vega Evaporator Sub Case w/ 204 ECU Accessory Kit, 1957-65 Facel Vega w/ HK500 Control Checked By: Packed By: Date: 1 Facel Vega Evaporator Sub Case w/ 204 ECU 768005 2 Accessory Kit 789003 NOTE: Images may not depict actual parts and quantities. Refer to packing list for actual parts and quantities. 903409 REV A 1/27/16, INSTRUCTIONS, EVAPORATOR KIT 589003, PG 22 OF 22