Chevrolet - Vintage - Workshop Manual - 1959 - 1960

an ISO 9001:2008 Registered Company 1959-60 Chevrolet Full-Size/El Camino with 4-Lever Controls 561056 18865 Goll St. San Antonio, TX 78266 ph: 210-654-7171 fax: 210-654-3113 901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT PG 1 OF 23 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 8. Defrost Duct Installation, Fresh Air Cap Installation Figures 3 & 4 9. Kick Panel Fresh Air Plate Installation Figures 5, 5a, 5b & 5c 10. Firewall Cover Installation, Evaporator Bracket and Heater Hose Fitting Installation Figures 6 & 7 11. Evaporator Bracket and Heater Hose Fitting Installation (Cont.) Figure 8 12. Evaporator Installation Figures 9 & 9a 13. Drain Hose Installation, Lubricating O-rings, A/C Hose Installation Figures 10 & 11 14. Heater Hose & Heater Control Valve Installation Figure 12 15. Driver Side Under Dash Louver Installation, Center/Passenger Side Under Dash Louver Installation Figures 13, 13a, 14 & 14a 16. Final Steps Figures 15 & 16 17. Control Panel & Duct Hose Routing Figure 17 18. Wiring Diagram 19. Gen IV Wiring Connection Instruction 20. Operation of Controls 21. Troubleshooting Information 22. Troubleshooting Information (Cont.) 23. Evaporator Kit Packing List 2 901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT PG 2 OF 23 Packing List Evaporator Kit (561056) No. 1. 2. Qty. 1 1 Part No. Description 744004-VUE 781160 Gen IV 4-Vent Evaporator Sub Case w/ 204 ECU Accessory Kit 59-60 Chevrolet Full-Size/El Camino w/ 4-Lever Controls ** 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 4-Vent Evaporator Sub Case w/ 204 ECU 744004-VUE 2 3 Accessory Kit 781160 NOTE: Images may not depict actual parts and quantities. Refer to packing list for actual parts and quantities. 901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT PG 3 OF 23 Important Notice—Please Read For Maximum System Performance, Vintage Air Recommends the Following: 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. 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. 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: Attention: The following system components are capped: Compressor, evaporator, condenser & drier. Caps may be under pressure with dry nitrogen. Be careful removing caps. Do not remove caps prior to installation. Removing caps prior to installation will cause components to collect moisture and lead to premature failure and reduced performance. Evacuate the system for 35-45 minutes with system components (Drier, compressor, evaporator and condenser) at a temperature of at least 85° F. On a cool day, the components can be heated with a heat gun OR by running the engine with the heater on before evacuating. Leak check and charge to specifications. Vintage Air Systems Are Designed to Operate With R134a Refrigerant Only! Use of Any Other Refrigerants Is a Fire Hazard and Could Damage Either Your Air Conditioning System or Your Vehicle. Use of Any Other Refrigerants Will Void All Warranties of the Air Conditioning System and Components. Use of the Proper Type and Amount of Refrigerant Is Critical to Proper System Operation. Vintage Air Recommends Our Systems Be Charged By Weight With a Quality Charging Station or Scale. Refrigerant Capacity for Vintage Air Systems: (For other systems, consult manufacturer’s guidelines) R134a System Charge with 1.8 lbs. (1 lb., 12 oz.) of refrigerant. 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). 901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT PG 4 OF 23 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. • For proper system operation, the heater control valve must be connected to the ECU. 5 901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT PG 5 OF 23 Engine Compartment Before starting the installation, check the function of the vehicle (horn, lights, etc.) for proper operation. Study the instructions, illustrations & diagrams. Perform the Following: 1. Remove battery and battery tray (retain) (See Figure 1, below). 2. Drain radiator. 3. Remove heater blower motor assembly (discard) (See Figure 1, below). 4. Remove OEM heater hoses (discard) (See Figure 1, below). 5. Remove OEM heater wiring. OEM Blower Motor Assembly Battery & Battery Tray Radiator 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. 6 901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT PG 6 OF 23 Passenger Compartment Perform the Following: 1. Remove glove box door (retain) and glove box (discard) (See Figure 2, below). 2. Disconnect all wires and cables from OEM control panel. 3. Remove OEM control panel (retain) (See Figure 2, below). 4. Remove OEM heater assembly (discard) (See Figure 2a, below). 5. Remove OEM duct hose from defrost ducts (discard) (See Figure 2a, below). 6. Remove passenger side OEM kick panel fresh air grille and door (discard) (See Figure 2a, below). Glove Box Door & Glove Box OEM Control Panel Figure 2 Defrost Duct Hose OEM Heater Passenger Side Kick Panel Fresh Air Grille & Door Figure 2a 7 901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT PG 7 OF 23 Defrost Duct Installation 1. Install (2) S-clips onto driver and passenger side defrost duct hose adapters (See Figure 3, below). 2. Attach hose adapters to driver and passenger side OEM defrost ducts as shown in Figure 3, below. Passenger Side OEM Defrost Duct Hose Adapters Driver Side OEM Defrost Duct Figure 3 Fresh Air Cap Installation 1. Install (4) grommets in fresh air cap (See Figure 4, below). 2. Apply a 1/4” bead of silicone around the back side of the fresh air cap as shown in Figure 4, below. 3. Attach fresh air cap to firewall using a 1/4-20 X 1 ½” bolt and washer (See Figure 4, below). NOTE: Fresh air cap installs on engine side of firewall. (4) Grommets 33137-VUI Fresh Air Cap 1/4-20 X 1 ½” Bolt w/ Washer Silicone Engine Compartment Firewall Back Side of Fresh Air Cap Figure 4 8 901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT PG 8 OF 23 Kick Panel Fresh Air Plate Installation 1. Install (4) grommets in kick panel plate (See Figure 5a, below). Silicone 2. Route A/C and heater hoses through fresh air cap and kick panel plate as shown in Figures 5 and 5b, below. 3. Apply a 1/4” bead of silicone around the back side of the kick panel plate as shown in Figure 5a, below. 4. Secure kick panel plate to kick panel using (6) OEM screws as shown in Figure 5b, below. 5. Reinstall kick panel (See Figure 5c, below). 6. Secure kick panel fresh air cap to kick panel using (4) #8 x 1 ¼” Phillips pan head screws with washers as shown in Figure 5c, below. Back Side of Kick Panel Plate #10 A/C Hose (2) Heater Hoses #6 A/C Hose Figure 5 (6) OEM Screws Kick Panel Plate 642050 Figure 5b Kick Panel (4) #8 x 1 ¼” Phillips Pan Head Screws w/ Washers Kick Panel Fresh Air Cap 626684 Figure 5c 9 901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT PG 9 OF 23 (4) Grommets 33137-VUI Figure 5a Firewall Cover Installation 1. Apply a 1/4” bead of silicone around the back side of the firewall cover as shown in Figure 6, below. 2. From inside the car, install firewall cover onto firewall as shown in Figure 6, below. From the engine compartment, secure firewall cover to firewall using (4) 1/4-20 x 1” hex bolts and (4) flat washers (See Figure 6, below). Engine Compartment Side of Firewall Silicone (4) 1/4-20 x 1” Hex Bolts Back Side of Firewall Cover Firewall Cover 648235 View Shown From Inside Car, Through Dash (4) Flat Washers Figure 6 Evaporator Bracket and Heater Hose Fitting Installation 1. On a workbench, install evaporator rear bracket and heater hose fittings with properly lubricated O-rings (See Figure 8, Page 11, and Figure 11, Page 13). 2. Install front mounting bracket onto evaporator using (2) 1/4-20 x 1/2” hex bolts and tighten as shown in Figure 7, below. Front Evaporator Bracket 643089 (2) 1/4-20 X 1/2” Hex Bolts Figure 7 10 901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT PG 10 OF 23 Evaporator Bracket and Heater Hose Fitting Installation (Cont.) ECU Module (2) 1/4-20 x 1/2” Hex Bolts Hold With This Wrench (2) 1/4-20 x 1/2” Hex Bolts Rear Evaporator Bracket 643090 Twist With This Wrench Lubricate O-ring (See Figure 11, Page 13) Figure 8 (2) Heater Fittings 121004 (2) #10 O-rings 11 901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT PG 11 OF 23 Evaporator Installation 1. Install A/C & heater hoses as shown in Figure 9a, below. 2. Lift evaporator unit up under the dashboard. Secure loosely to the firewall using (2) 1/4-20 x 1” hex bolts and (2) flat washers (See Figure 9, below). 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. 3. Using front evaporator bracket as a guide, mark and drill (2) 3/16” holes in cowl (See Figure 9, below). 4. Using (2) #14 x 3/4” sheet metal screws, secure the front evaporator mounting bracket to the inner cowl (See Figure 9, below). 5. Verify that evaporator unit is level and square to the dash; then tighten all mounting bolts. NOTE: Tighten the bolt on the firewall first. Then tighten the front mounting bracket. NOTE: After installing #10 suction line, wrap all exposed metal (fittings & tube) with supplied press tape. Press Tape (2) #14 x 3/4” Sheet Metal Screws Drill (2) 3/16” Holes #10 A/C Hose #6 A/C Hose Heater Hose (To Water Pump) Heater Hose (To Heater Control Valve, Then to Manifold) Hose Clamps Figure 9a Inner Cowl (2) 1/4-20 X 1” Hex Bolts (2) 1/4” Flat Washers View Shown From Inside Car, Through Dash Figure 9 12 901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT PG 12 OF 23 Drain Hose Installation 1. Drill a 5/8” hole in firewall using the measurements in Figure 10, below. 2. Install drain hose to bottom of evaporator unit and route through firewall (See Figure 10a, below). 2 ½” Figure 10 4 ½” Male O-ring Insert Drill 5/8” Hole Female Nut #6 O-ring #8 O-ring Drain Hose Drain Figure 10a Lubricating O-rings For a proper seal of fittings: Install supplied O-rings as shown, and lubricate with supplied oil. O-ring #10 O-ring Supplied Oil for O-rings O-ring Installs Over Male Insert to Swaged Lip NOTE: Standard torque specifications: #6: 11 to 13 ft-lb. #8: 15 to 20 ft-lb. #10: 21 to 27 ft-lb. Figure 11 Twist With This Wrench Hold With This Wrench A/C Hose Installation Standard Hose Kit: 1. Locate the #8 compressor A/C hose. Lubricate (2) #8 O-rings (See Figure 11, above) and connect the 135° female fitting with 134a service port to the #8 discharge port on the compressor. Route the 45° female fitting to the #8 condenser hardline (See Figure 12, Page 14). Tighten each fitting connection as shown in Figure 11, above. 2. Locate the #10 compressor A/C hose. Lubricate (2) #10 O-rings (See Figure 11, above) and connect the #10 135° female fitting with 134a service port to the #10 suction port on the compressor. Route the 90° female fitting to the #10 fitting on evaporator (See Figure 9a, Page 12, and Figure 12, Page 14). Tighten each fitting connection as shown in Figure 11, above. Install #10 adel clamp on #10 A/C hose, and secure to passenger side fender well using a 10/32 x 1/2” Phillips pan head screw and a 10/32 nut with star washer (See Figure 12, Page 14). 3. Locate the #6 evaporator A/C hose. Lubricate (2) #6 O-rings (See Figure 11, above) and connect the straight female fitting to the drier. Route the 90° female fitting to the #6 fitting on evaporator (See Figure 9a, Page 12, and Figure 12, Page 14). Tighten each fitting connection as shown in Figure 11, above. Install #6 adel clamp on #6 A/C hose, and secure to passenger side fender well using a 10/32 x 1/2” Phillips pan head screw and 10/32 nut with star washer (See Figure 12, Page 14). Modified A/C Hose Kit: 1. Refer to separate instructions included with modified hose kit. 13 901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT PG 13 OF 23 Heater Hose & Heater Control Valve Installation 1. Route a piece of heater hose from the water pump to the top heater fitting of the heater core as shown in Figure 9a, Page 12, and Figure 12, below. Secure using hose clamps. Figure 12 #8 Discharge Hose 096086 Compressor Safety Switch NOTE: Flow direction follows #6 Drier/ (Binary Type) molded arrow on valve. Condenser Hardline Screw-on Drier 091181 (Refer to Condenser Instructions) Fro m to W Evap ate orato r Pu r mp Fro m Ma Intake nifo ld #6 Adel Clamp Hose Clamps Heater Hose From Heater Control Valve to Evaporator #10 Adel Clamp #10 Suction Hose 096087 #6 Hose 096085 #8 Condenser/ Compressor Hardline 091182 Tie Wrap Heater Hose (Heater Cntrl Valve/Intake) Enlarge OEM Hole to 5/8” NOTE: Vintage Air Systems Require (2) 5/8” Hose Nipples (Not Supplied) A/C & Heater Hose Routing 2. Route a piece of heater hose from the intake to the bottom heater fitting of the heater core as shown in Figure 9a, Page 12, and Figure 12, below. NOTE: Install heater control valve in line with intake manifold (pressure side) heater hose, and secure using hose clamps as shown in Figure 12, below. Also note proper flow direction. 901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT PG 14 OF 23 14 Driver Side Under Dash Louver Installation 1. Place driver side louver housing under dash. Mark and drill (2) 5/32” holes in dash as shown in Figure 13, below. 2. Secure louver housing under dash using (2) #10 x 1/2” sheet metal screws as shown in Figure 13, below. 3. Install louver into housing as shown in Figure 13a, below. Driver Side Under Dash Louver Housing 626683 (2) #10 x 1/2” Sheet Metal Screws Figure 13 Ball Louver 49053-VUL Figure 13a Center/Passenger Side Under Dash Louver Installation 1. Place louver housing under dash. Align center louvers with center of radio; then mark and drill (3) 5/32” holes in dash as shown in Figure 14, below. 2. Secure louver housing under dash using (3) #10 x 1/2” sheet metal screws as shown in Figure 14, below. 3. Install louvers into housing as shown in Figure 14a, below. Center/Passenger Side Under Dash Louver Housing 626682 Figure 14 (3) #10 x 1/2” Sheet Metal Screws (2) Louvers 49057-VUL 15 Figure 14a Ball Louver 49053-VUL 901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT PG 15 OF 23 Final Steps 1. Install duct hoses as shown in Figure 17, Page 17. 2. Route A/C wires (12 volt/grounds/binary switch/heater valve) through 3/8” grommet as shown in Figure 15, below. 3. Reinstall OEM control panel assembly. Refer to control panel instructions. 4. Plug the wiring harnesses into the ECU module on the sub case as shown in Figure 17, Page 17 (Wire according to wiring diagrams on Pages 18 and 19). 5. Install (4) S-clips on glove box bottom (See Figure 16, below). 6. Install (4) #8 U-nuts on glove box bottom (See Figure 16, below). 7. The glove box is a two piece assembly. Install bottom piece first, and then the top. Secure assembly using OEM screws. 8. Install glove box door using OEM screws. 9. Reinstall all previously removed items. 10. 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. 11. Double check all fittings, brackets and belts for tightness. 12. Vintage Air recommends that all A/C systems be serviced by a certified automotive air conditioning technician. 13. Evacuate the system for a minimum of 45 minutes prior to charging, and perform a leak check prior to servicing. 14. Charge the system to the capacities stated on Page 4 of this instruction manual. 15. See Operation of Controls procedures on Page 20. Wiring Harness (Heater Control Valve) Grommet 33144-VUI Glove Box Top 62384-VCI (4) S-clips Wiring Harness (12 Volt/Grounds/Binary Switch) Figure 15 Glove Box Bottom 62385-VCI (4) #8 U-nuts Figure 16 16 901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT PG 16 OF 23 Control Panel & Duct Hose Routing From Control Panel Passenger Side Defrost Duct 2” x 12” Driver Side Defrost Duct 2” x 24” Plug From Control Wiring Harness 232002-VUA Plug From Wiring Harness 232001-VUR Passenger Side Louver 2 ½” x 48” Figure 17 Driver Side Louver 2 ½” x 38” Driver Side Center Louver 2 ½” x 15” Passenger Side Center Louver 2 ½” x 15” 17 901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT PG 17 OF 23 Wiring Diagram 232007-VUR TAN ORA BLK WHT RED WHT/RED WHT/YEL JF8 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 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). • Wide Open Throttle Switch Contacts Close Only at Full Throttle, Which Disables A/C Compressor. 901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT PG 18 OF 23 18 Gen IV Wiring Connection Instruction 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 +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 BLACK BLUE Heater Control Valve: RED WHITE LATCH CHASSIS GROUND WIRING HARNESS 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 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). 19 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 CIRCUIT BREAKER 30 AMP Dash Light: Tan Wire Used Only With Vintage Air Supplied Control Panel With LED Back Light. RED GREEN FIREWALL BLUE Violet 12V Ign Switch Source (Key On Accessory) Position Must Be Switched. + - 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 901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT PG 19 OF 23 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. Not Used AIR Blower Speed DEF HEAT DEF HEAT Temperature Control FAN 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). AIR FAN AIR FAN 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). DEF HEAT Defrost/De-fog Operation Blower Speed Adjust to desired speed. Temperature Control Adjust to desired temperature. AIR HEAT FAN Mode Control Adjust to DEFROST position for maximum defrost, or between FLOOR and DEFROST positions for a bi-level blend (Compressor is automatically engaged). DEF 20 901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT PG 20 OF 23 901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT PG 21 OF 23 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. Symptom 21 System is charged. System is not charged. All other functions work. No other functions work. Condition 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 901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT PG 22 OF 23 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. 22 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 (561056) No. Qty. 1. 2. 1 1 Part No. Description 744004-VUE 781160 Gen IV 4-Vent Evaporator Sub Case w/ 204 ECU Accessory Kit 59-60 Chevrolet Full-Size/El Camino w/ 4-Lever Controls Checked By: Packed By: Date: 1 Gen IV 4-Vent Evaporator Sub Case w/ 204 ECU 744004-VUE 2 Accessory Kit 781160 NOTE: Images may not depict actual parts and quantities. Refer to packing list for actual parts and quantities. 901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT PG 23 OF 23