Chevrolet - Vinetageair - Workshop Manual - 1955 - 1956

an ISO 9001:2015 Registered Company 1955-56 Chevrolet Full-Size Evaporator Kit (56155-PCZ) 18865 Goll St. San Antonio, TX 78266 Phone: 800-862-6658 Sales: [email protected] Tech Support: [email protected] www.vintageair.com 906155-PCZ REV H 05/05/21, PG 1 OF 27 www.vintageair.com Table of Contents Cover.................................................................................................................................. 1 Table of Contents................................................................................................................. 2 Packing List/Parts Disclaimer.................................................................................................. 3 Information Page................................................................................................................. 4 Wiring Notice....................................................................................................................... 5 Engine Compartment Disassembly, Passenger Compartment Disassembly.................................... 6 Condenser Assembly Installation, Core Support Modification...................................................... 7 Compressor and Brackets, Pulleys, Defrost Duct Installation, Control Panel Conversion.................. 8 Evaporator Installation.......................................................................................................... 9 Evaporator Installation (Cont.)............................................................................................. 10 Evaporator Installation (Final)............................................................................................. 11 Under Dash Louver Installation, Drain Hose Installation........................................................... 12 Lubricating O-rings, Heater Control Valve Installation.............................................................. 13 A/C Hardline and Hose Installation, Liquid Line and Binary Switch Installation............................ 14 A/C and Heater Hose Routing............................................................................................... 15 Firewall Cover Installation................................................................................................... 16 Wiring Installation. ............................................................................................................ 17 Duct Hose Routing............................................................................................................. 18 Glove Box Installation, Final Steps........................................................................................ 19 Evaporator Hardline Installation........................................................................................... 20 Wiring Diagram.................................................................................................................. 21 Gen IV Wiring Connection Instruction................................................................................... 22 Operation of Controls......................................................................................................... 23 Troubleshooting Guide........................................................................................................ 24 Troubleshooting Guide (Cont.)............................................................................................. 25 Core Support Modification Template..................................................................................... 26 Packing List....................................................................................................................... 27 2 906155-PCZ REV H 05/05/21, PG 2 OF 27 Packing List: Evaporator Kit (56155-PCZ) www.vintageair.com No. 1. 2. Qty. 1 1 Part No. 760155-VCE 78255-PCN Description Gen IV Evaporator Sub Case Accessory Kit ** Before beginning installation, open all packages and check contents of shipment. Please report any shortages directly to Vintage Air within 15 days. After 15 days, Vintage Air will not be responsible for missing or damaged items. 1 Gen IV Evaporator Sub Case 760155-VCE 2 Driver Side Accessory Kit 78255-PCN Passenger Side NOTE: Images may not depict actual parts and quantities. Refer to packing list for actual parts and quantities. 3 906155-PCZ REV H 05/05/21, PG 3 OF 27 www.vintageair.com 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. (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: 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 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. 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. 4 906155-PCZ REV H 05/05/21, PG 4 OF 27 www.vintageair.com 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. 5 906155-PCZ REV H 05/05/21, PG 5 OF 27 www.vintageair.com Engine Compartment Disassembly 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. 2. Remove battery and battery tray. 3. Remove air cleaner. 4. Drain radiator. 5. Disconnect heater hoses. Passenger Compartment Disassembly Perform the Following: 1. Remove the OEM heater assembly by removing the control cables, along with (2) 7/16” nuts on the firewall and (1) under the dash (discard). 2. Remove the heater blower (discard) (See Figure 1, below). 3. Remove the butterfly duct above the kick panel vent, as well as the panel flange (discard). Install the new vent cover as shown in Figure 2, below. 4. Remove the glove box door (retain). 5. Remove the glove box (discard). 6. Remove the original defrost duct from the heater to the windshield (discard). 7. Remove the ash tray (retain). 8. Remove the ash tray slider assembly (retain). 9. Remove the vent and cables from the dash (retain) (See Figure 1, below). 10. Remove the control panel (retain). 11. Remove the passenger side speaker grille (retain) (See Figure 1, below). 6 OEM Screws 11 Figure 2 5 2 8 7 4 Figure 1 6 1 3 906155-PCZ REV H 05/05/21, PG 6 OF 27 Condenser Assembly Installation www.vintageair.com 1. Loosen the (6) bolts that secure the radiator to the core support. 2. Slide the condenser assembly into position. The condenser brackets will be held between the radiator and the core support. Secure with the (6) radiator bolts (See Figures 3 & 3b, below). Holding the condenser in position, tighten the (6) radiator bolts. Core Support Modification 1. Locate the core support modification template on Page 26, and align the template on the passenger side of the core support panel. Using the template, mark holes and cut a 1 ¼” hole using a hole saw. Drill a 5/16” hole in the noted location (See Figure 3a, below). 2. Install the #6 and #8 condenser hardlines through the 1 ¼” hole. Lubricate a #6 and #8 O-ring as shown in Figure 9, Page 13, and connect the #6 and #8 condenser hardlines to the condenser. 3. Locate the split grommet and install as shown in Figure 3b, below. 4. Install the drier loosely as shown in Figure 3b, below. NOTE: Refrigerant flow follows the arrow on the drier. OEM Radiator Side of Core Support Vintage Air Condenser Hole in Core Support NOTE: #8 (Larger) Fitting is at Top of Radiator. 1/4” Nut with Flat Washer CORE SUPPORT TEMPLATE #8 Condenser Hardline 35018-VCG Drier #6 Condenser Hardline 35017-VCG 5/16” Bolts 1 ¼” 1/4” x 1” Bolt 5/16” Split Grommet Figure 3a Mount Drier to Inside of Core Support Through 5/16” Hole Figure 3b Install (8) #6 x 3/8” Pan Head Screws Figure 3 7 906155-PCZ REV H 05/05/21, PG 7 OF 27 Compressor and Brackets www.vintageair.com 1. Refer to separate instructions included with the bracket kit to install the compressor bracket. Defrost Duct Installation 1. Install the defrost ducts with 2” duct hose: 10” (passenger side) and 24” (driver side) (See Figure 4, below, and Figure 13, Page 18). 2. Install the defrost ducts (See Figures 4 & 4a, below). NOTE: The rounded side of the defrost ducts face the passenger compartment. Defrost Hole #8 x 1/2” Pan Head Screw (For 1956 Models using Existing Holes) #8 x 1/2” Pan Head Screw (For 1955 Models using Existing Holes) Seat Bracket in Defrost Hole Defrost Duct (Rounded Side Out) Figure 4a Figure 4 Control Panel Conversion 1. Locate the control panel conversion kit. Refer to the instructions supplied with the conversion kit to assemble the control panel. 8 906155-PCZ REV H 05/05/21, PG 8 OF 27 Evaporator Installation www.vintageair.com NOTE: For proper system operation, Vintage Air recommends using heat-blocking insulation in the area around the evaporator unit (firewall, inner cowl and kick panel). Due to the tight clearance for the evaporator unit between the firewall and dash, Vintage Air recommends an insulation thickness of no more than 1/4”. 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. 1. On a workbench, remove the center louver plenum assembly from the evaporator unit by removing (2) 10-32 x 1/2” screws (See Photos 1 & 2, below). 2. Remove the defrost plenum by removing (2) 10-32 x 1/2” screws (See Photo 3, below). 3. Install the evaporator rear brackets and the evaporator hardlines with properly lubricated O-rings (See Figure 15, Page 20, and Figure 9, Page 13). 4. Attach a 48” length of 2 ½” duct hose to the lower adapter on the center louver plenum assembly, and route the hose under the dash to the left side of the emergency brake (See Photos 4 & 5, below). 5. Attach a 48” length of 2 ½” duct hose to the upper adapter on the center louver plenum assembly, and route the hose under the dash to the right (See Photos 4 & 6, below). Center Louver Plenum Assembly Remove 10-32 x 1/2” Screw Remove (2) 10-32 x 1/2” Screws Defrost Plenum Remove 10-32 x 1/2” Screw Center Louver Plenum Assembly Photo 1 Photo 2 Route Hose Under Dash to the Left Attach a 48” Length of 2 ½” Duct Hose to Upper Adapter on Center Louver Plenum Assembly Attach a 48” Length of 2 ½” Duct Hose to Lower Adapter on Center Louver Plenum Assembly Photo 4 Driver Side Kick Panel 9 Photo 5 Photo 3 Route Hose Under Dash to the Right Emergency Brake Passenger Side Kick Panel Photo 6 906155-PCZ REV H 05/05/21, PG 9 OF 27 www.vintageair.com Evaporator Installation (Cont.) 6. Lift the evaporator unit up and under the dashboard (See Figure 5 & Figure 5a, below). Secure loosely to the firewall from the engine compartment side with (2) 1/4-20 x 1” bolts and washers (See Figure 6, Page 11, and Figure 15, Page 20). 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 flat portions of the case around the drain. 7. Install the front mounting bracket to the evaporator unit using a 1/4-20 button head bolt, and tighten as shown in Figure 6, Page 11. Loosely attach the front mounting bracket to the dash with a 1/4-20 x 1” bolt, washer and nut (See Figure 6, Page 11). 8. Reinstall the center A/C plenum to the evaporator with (2) 10-32 x 1/2” screws (See Figure 6, Page 11). 9. Attach the defrost hoses onto the previously removed defrost plenum, and install the plenum onto the evaporator unit using (2) 10-32 x 1/2” screws 10. Loosely secure the center plenum to the dash with the center plenum mounting bracket using a 1/4-20 x 1” bolt and washer (See Figure 6, Page 11). 11. Verify that the evaporator unit is level and square to the dash, then tighten all mounting bolts. NOTE: Tighten the (2) bolts on the firewall first. Then tighten the front mounting bracket bolt and nut. Tighten the center plenum mounting bolt last. Figure 5 Figure 5a NOTE: Install the evaporator unit from the passenger side floorboard. Rotate the evaporator unit so the lines pass through the opening in the firewall. Lift into place. NOTE: Once in place, secure the evaporator unit to the firewall. 10 906155-PCZ REV H 05/05/21, PG 10 OF 27 www.vintageair.com 1/4-20 x 1” Bolt & Washer Evaporator Installation (Final) Firewall A/C & Heat Blend Door ECU Module 1/4-20 Nut Defrost Door Front Mounting Bracket Dash/Floor Door To Dash To Evaporator 1/4-20 x 1” Bolt 1/4-20 x 1/2” Button Head Screw Washer Bottom Lip of Dash 1/4-20 x 1” Bolt & Washer Center Plenum Mounting Bracket Center A/C Plenum Center A/C Plenum Dash 10-32 x 1/2” Screw Figure 6 Side View 10-32 x 1/2” Screw 11 906155-PCZ REV H 05/05/21, PG 11 OF 27 Under Dash Louver Installation www.vintageair.com 1. Install the driver and passenger side under dash louvers with the flange facing the dash and kick panel as shown in Figure 8, below. Tuck the kick panel side of the louver flange behind the kick panel windlace retainer, and slide the louver up until the flange is seated against the dash. Secure the louver to the kick panel with (2) #8 x 1/2” pan head screws (See Figure 7, below). NOTE: In most cases, the louvers will fit as described. However, due to dash and kick panel variances, the presence of aftermarket components or modifications, etc., it may be necessary to trim the louver flange and/or slightly move the parking brake lever for proper fit. Dash Windlace Retainer Windlace Retainer Flange NOTE: Install louvers with flange facing the dash and kick panel. (2) #8 x 1/2” Pan Head Screws Figure 7 Drain Hose Installation 1. 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 8, below). NOTE: See Figure 12, Page 16, for the rough location of the drain hole. 2. Install the drain hose onto the bottom of the evaporator unit, and route through the firewall (See Figure 8, below, and Figure 12, Page 16). Drain Hose 1” Figure 8 Drain 12 906155-PCZ REV H 05/05/21, PG 12 OF 27 Lubricating O-rings www.vintageair.com Male O-ring Insert Female Nut #6 O-ring #8 O-ring For a proper seal of fittings: Install supplied O-rings as shown and lubricate with supplied oil. Figure 9 Figure ## O-ring #10 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. O-ring Installs Over Male Insert to Swaged Lip Twist With This Wrench Hold With This Wrench Heater Control Valve Installation 1. Install the heater control valve in line with the intake manifold (pressure side) heater hose (See Figure 10, below). ECU Module #10 Suction Hose Heater Hoses From Heater Core to Water Pump From Heater Control Valve to Heater Core From Intake Manifold to Heater Control Valve #6 Hardline Figure 10 13 Hose Clamps NOTE: Flow Direction Follows Molded Arrow on Valve. 906155-PCZ REV H 05/05/21, PG 13 OF 27 www.vintageair.com A/C Hardline and Hose Installation Standard Hose Kit: 1. Locate the (2) compressor hardlines (See Figure 11, Page 15). 2. Locate the #8 compressor hardline. Lubricate (1) #8 O-ring (See Figure 9, Page 13), and connect the #8 compressor hardline to the #8 discharge port on the compressor. Tighten the connection (See Figure 9, Page 13, and Figure 11, Page 15). 3. Locate the #10 compressor hardline. Lubricate (1) #10 O-ring (See Figure 9, Page 13), and connect the #10 compressor hardline to the #10 suction port on the compressor. Tighten the connection (See Figure 9, Page 13, and Figure 11, Page 15). 4. Secure the (2) compressor hardlines to the compressor using the supplied clamp (See Figure 11a, Page 15). 5. Locate the #8 A/C hose. The hose will connect the #8 compressor hardline and the #8 hardline from the condenser. Lubricate (2) #8 O-rings (See Figure 9, Page 13) and install (1) onto each end of the #8 A/C hose. Route the #8 A/C hose as shown in Figure 11, Page 15, and tighten (See Figure 9, Page 13). NOTE: The 90° hose fitting connects to the #8 condenser hardline. 6. Install the firewall cover (See Figure 12, Page 16). 7. Lubricate (1) #6 O-ring (See Figure 9, Page 13). Install the #6 liquid line and tighten (See Figure 9, Page 13, and Figure 11b, Page 15). 8. Locate the #10 A/C hose. The hose will connect the #10 compressor hardline and the #10 hardline from the evaporator. Lubricate (2) #10 O-rings (See Figure 9, Page 13) and install (1) onto each end of the #10 A/C hose. Route the #10 A/C hose as shown in Figure 11, Page 15 and tighten (See Figure 9, Page 13). NOTE: The 90° hose fitting connects to the #10 compressor hardline. 9. Install the heater hoses onto the heater lines, and route as shown in Figures 11 and 11b, Page 15. Secure with hose clamps. NOTE: This kit does not contain heater hose. The 5/8” heater hose may be purchased from Vintage Air or a local parts retailer. Modified Hose Kit: 1. Refer to separate instructions included with modified hose kit. Liquid Line and Binary Switch Installation 1. Install the #6 liquid line onto the drier with a lubricated #6 O-ring (See Figure 9, Page 13) and tighten (See Figure 9, Page 13, and Figure 11, Page 15). 2. Install the binary switch onto the #6 liquid line (See Figure 11, Page 15). 3. Secure the #6 liquid line to the fender using the supplied adel clamp (See Figure 11, Page 15). 14 906155-PCZ REV H 05/05/21, PG 14 OF 27 A/C and Heater Hose Routing www.vintageair.com ECU Module Evaporator Sub Case NOTE: Compressor hardlines are included with standard hose kit only. Press Tape #8 Compressor Hardline 35038-VUG-A Expansion Valve Heater Hoses #10 Compressor Hardline 35037-VUG-A Firewall Cover Heater Control Valve #10 Suction Hose Binary Switch Installation Adel Clamp #8 Condenser Hardline 35018-VCG #8 Discharge Hose Binary Switch Figure 11 #6 Hardline NOTE: Modified hose kits include (2) 135° compressor fittings (Refer to instructions included with modified hose kit). #6 Hardline From Drier to Expansion Valve 09154-PFL Split Rubber Grommet in Core Support hole #6 Hardline 35017-VCG ECU Module Firewall Cover #10 Suction Line (Insulated) Figure 11b Hardline Clamp (Standard Hose Kit Only) Figure 11a #10 Suction Hose O-rings Heater Hoses #6 Hardline 15 906155-PCZ REV H 05/05/21, PG 15 OF 27 Firewall Cover Installation www.vintageair.com 1. Pass lines through the firewall cover and secure with (2) 7/16” panel retainers (See Figure 12, below). Passenger Side Evaporator Mounting Hole Driver Side Evaporator Bracket Mounting Hole 1/4-20 x 1” Bolt & Washer 1/4-20 x 1” Bolt & Washer (2) 7/16” Panel Retainers Drain Hole Figure 12 16 906155-PCZ REV H 05/05/21, PG 16 OF 27 Wiring Installation www.vintageair.com 1. Apply (2) strips of Velcro to the ECU, and cut the tie wraps holding the ECU wiring together (See Photos 1 & 2, below). 2. Plug the main wiring harness black connector into the ECU module (See Photo 3, below). 3. Reinstall the control panel into the dash. 4. Plug the control panel connector into the ECU module (See Photo 4, below). 5. Apply (2) strips of Velcro, and mount the ECU to the right of the radio on the inner dash. NOTE: Make sure the area is clean and free of debris before applying the Velcro (See Photo 5, below). Apply (2) Strips of Velcro to ECU Cut Tie Wraps Photo 1 Photo 2 ECU Module Plug Main Wiring Harness Connector into ECU Module Main Wiring Harness Plug Control Panel Wiring Connector into ECU Module Photo 3 Photo 4 Mount ECU to Right of Radio Inner Dash View Photo 5 17 906155-PCZ REV H 05/05/21, PG 17 OF 27 Duct Hose Routing www.vintageair.com 1. Install the duct hoses as shown in Figure 13, below. Plug From Control Panel Wiring Harness 232002-VUA ECU Module Passenger Side Louver 2 ½” x 42” Plug From Wiring Harness 232600-VUA Passenger Side Defrost Duct 2” x 10” Driver Side Defrost Duct 2” x 24” Driver Side Louver 2 ½” x 48” Figure 13 18 906155-PCZ REV H 05/05/21, PG 18 OF 27 Glove Box Installation www.vintageair.com 1. Install the glove box bottom and glove box door. Secure to the dash with (3) OEM screws (See Figure 14, below). 2. With the glove box bottom and door in place, install the glove box top as shown in Figure 14, below. Using (3) #6 x 3/8” pan head screws, attach the glove box top to the glove box bottom as shown in Figure 14, below. 3. Secure the glove box top to the dash using (2) OEM screws (See Figure 14, below). Glove Box Door (3) OEM Screws Plastic Glove Box Bottom Glove Box Hinge (2) OEM Screws Glove Box Top Figure 14 (3) #6 x 3/8” Pan Head Screws Final Steps 1. Reinstall all previously removed items. 2. 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. 3. Double check all fittings, brackets and belts for tightness. 4. Vintage Air recommends that all A/C systems be serviced by a licensed automotive A/C technician. 5. Evacuate the system for a minimum of 45 minutes prior to charging, and perform a leak check prior to servicing. 6. Charge the system to the capacities stated on Page 4 of this instruction manual. 19 906155-PCZ REV H 05/05/21, PG 19 OF 27 www.vintageair.com Press Tape #10 Suction Line 09151-PCS NOTE: Wrap the #10 fitting connections with press tape. 20 906155-PCZ REV H 05/05/21, PG 20 OF 27 Figure 15 Heater Line (Evaporator to Intake) 09152-PCH #6 O-ring 33857-VUF #10 O-ring 33859-VUF Heater Line (Evaporator to Water Pump) 09153-PCH Evaporator Passenger Side Rear Bracket 64355-PCB ECU Module #6 Hardline 09150-PCL 1/4-20 x 1/2” Bolt (Located on Sub Case) 1/4-20 x 1/2” Bolt (Located on Sub Case) #10 O-ring 33859-VUF Evaporator Driver Side Rear Bracket 64354-PCB Evaporator Hardline Installation Wiring Diagram www.vintageair.com 232007-VUR TAN ORA BLK WHT JF8 RED WHT/RED WHT/YEL WHT/GRN AC ANNUNCIATOR BACKLIGHT POS BACKLIGHT NEG GND 5V-SW TEMP WIPER MODE WIPER FAN WIPER PRE-WIRED VIEWED FROM WIRE SIDE 232002-VUA A/C (IF USED) GEN IV ECU GEN IV WIRING DIAGRAM REV E, 10/6/2017 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). *** Wide open throttle switch contacts close only at full throttle, which disables A/C compressor. 21 906155-PCZ REV H 05/05/21, PG 21 OF 27 Gen IV Wiring Connection Instruction www.vintageair.com WIRING HARNESS CONTROL WIRING HARNESS RED & WHITE A/C COMPRESSOR RELAY RED BLUE NOTE: MOUNT RELAY IN DESIRED LOCATION UNDER DASH RED WH IT E Ignition Switch: VIOLET Violet 12V ignition 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: When using a Vintage Air-supplied control panel, connect the tan wire from the Gen IV evaporator wiring harness to the factory dash lights to enable panel backlighting. Circuit Breaker/Battery: White must run to (-) battery. Red may run to (+) battery or starter. Mount circuit breaker as close to battery as possible. 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. - BATTERY 22 906155-PCZ REV H 05/05/21, PG 22 OF 27 Operation of Controls www.vintageair.com 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. 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. Temperature Control OFF FAN HI DASH FLOOR DEF C O L D H E A T OFF FAN HI DASH FLOOR DEF C O L D H E A T OFF FAN HI DASH FLOOR DEF C O L D H E A T OFF FAN HI DASH FLOOR DEF C O L D Blower Speed H E A T Mode Control Adjust to DEFROST position for maximum defrost, or between FLOOR and DEFROST positions for a bi-level blend (Compressor is automatically engaged). 23 906155-PCZ REV H 05/05/21, PG 23 OF 27 24 906155-PCZ REV H 05/05/21, PG 24 OF 27 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. System is charged. System is not charged. All other functions work. No other functions work. Condition www.vintageair.com Repair or replace pot/control wiring. Replace relay. Check for faulty A/C relay. Check 2-pin connector at ECU housing. 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 faulty A/C potentiometer or associated wiring. 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 25 906155-PCZ REV H 05/05/21, PG 25 OF 27 Symptom 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. 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 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.) 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 www.vintageair.com 1” 26 3 9/16” Fold Page at This Line and Position at Edge of Core Support (Removable Panel) 2 5/16” Core Support Modification Template 1 ¼” Diameter NOTE: Due to printing variances, measure the line below before using this template. If template is scaled properly, the line should measure 6 inches. www.vintageair.com 3 ¼” 2 ⅜” 2 ⅛” 1/2” Locate Existing Holes 5/16” Diameter 906155-PCZ REV H 05/05/21, PG 26 OF 27 www.vintageair.com Part No. No. Qty. 760155-VCE 1. 1 78255-PCN 2. 1 Packing List: Evaporator Kit (56155-PCZ) Description Gen IV Evaporator Sub Case Accessory Kit Checked By: Packed By: Date: 1 Gen IV Evaporator Sub Case 760155-VCE 2 Driver Side Accessory Kit 78255-PCN Passenger Side NOTE: Images may not depict actual parts and quantities. Refer to packing list for actual parts and quantities. 27 906155-PCZ REV H 05/05/21, PG 27 OF 27