an ISO 9001:2015 Registered Company
1961-62 Chevrolet Impala
without Factory Air
Evaporator Kit
(561062)
18865 Goll St. San Antonio, TX 78266
Phone: 800-862-6658
Sales:
[email protected]
Tech Support:
[email protected]
www.vintageair.com
903062 REV H 08/12/19, PG 1 OF 26
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, Condenser Assembly and Installation, Compressor and
Brackets, Pulleys.................................................................................................................. 6
Passenger Compartment Disassembly..................................................................................... 7
Defrost Duct Installation....................................................................................................... 8
Speaker Mounting, Evaporator Installation............................................................................... 9
Fresh Air Cap Installation, Firewall Cover Installation.............................................................. 10
Evaporator Installation (Cont.)............................................................................................. 11
Drain Hose Installation, Driver Side Under Dash Louver Mounting Holes, Passenger Side Under
Dash Louver Mounting Holes ............................................................................................... 12
Driver Side Under Dash Louver Installation, Center/Passenger Side Under Dash Louver
Installation........................................................................................................................ 13
Lubricating O-rings, A/C Hose Installation.............................................................................. 14
Heater Hose & Heater Control Valve Installation..................................................................... 15
A/C & Heater Hose Routing.................................................................................................. 16
Final Steps........................................................................................................................ 17
Control Panel & Duct Hose Routing....................................................................................... 18
Evaporator Hardline Installation........................................................................................... 19
Wiring Diagram.................................................................................................................. 20
Gen IV Wiring Connection Instruction................................................................................... 21
Operation of Controls.......................................................................................................... 22
Troubleshooting Guide......................................................................................................... 23
Troubleshooting Guide (Cont.).............................................................................................. 24
Templates: Driver Side Under Dash Louver Bezel & Defrost Duct Mounting................................. 25
Packing List....................................................................................................................... 26
2
903062 REV H 08/12/19, PG 2 OF 26
Packing List:
Evaporator Kit (561062)
www.vintageair.com
No.
1.
2.
Qty.
1
1
Part No.
744044-VUE
784061
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
744044-VUE
2
Accessory Kit
784061
NOTE: Images may not depict actual parts and quantities.
Refer to packing list for actual parts and quantities.
3
903062 REV H 08/12/19, PG 3 OF 26
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 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.
4
903062 REV H 08/12/19, PG 4 OF 26
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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
903062 REV H 08/12/19, PG 5 OF 26
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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 (retain).
3. Drain radiator.
4. Remove passenger side hood hinge (retain) (See Figure 1a, below).
5. Remove OEM blower assembly (discard) (See Figure 1, below).
Hood
Hinge
OEM
Heater/Blower
Assembly
Figure 1a
Figure 1
Condenser Assembly and Installation
1. Refer to separate instructions included with the condenser kit to install the condenser.
2. Binary switch installation (Refer to condenser instructions).
Compressor and 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
903062 REV H 08/12/19, PG 6 OF 26
Passenger Compartment
Disassembly
www.vintageair.com
Perform the Following:
1. Remove the OEM control panel assembly (retain) (See Figure 2, below).
2. Remove the OEM heater assembly (discard) (See Figure 2, below).
3. Remove the glove box (discard) (See Figure 2, below).
4. Remove the radio and speaker (retain) (See Figure 2, below).
5. Remove the OEM defrost duct assembly (discard) (See Figures 2 & 3, below).
6. Remove the (3) spot welds on the defrost duct with a chisel or die grinder (See Figure 3, below).
Speaker
OEM
Defrost Duct
Radio
OEM
Control Panel
Glove
Box
OEM Heater
Plenum
Figure 2
Dash
Support
Dash
Support
Inner
Cowl
Use a Chisel or
Die Grinder to
Break Spot Welds
Defrost
Duct
Figure 3
7
903062 REV H 08/12/19, PG 7 OF 26
Defrost Duct Installation
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1. Cut out the defrost duct mounting template on Page 25.
2. Place the template onto the inner cowl. Once aligned, tape the template into place (See Figure 4, below).
3. Using a center punch or scribe, mark the (2) mounting holes on the inner cowl (See Figure 4, below).
4. Once the holes are marked, remove the template and drill (2) 1/8” holes into the inner cowl.
5. Install a J-nut onto the end of the speaker bracket as shown in Figure 4a, below.
6. Place the defrost duct under the dash, and align it with the OEM defrost opening in the dash and the mounting
holes in the inner cowl.
7. Once the defrost duct and speaker bracket are aligned, secure the defrost duct and the speaker bracket to the
inner cowl using (2) #10 x 1/2” sheet metal screws (See Figure 4a, below).
Tape
Dash Support
Brace
Mark
Mounting
Holes
Inner
Cowl
Template
View Shown Through Glove
Box Opening in Dash.
Figure 4
J-nut
Defrost
Duct
Figure 4a
8
(2) #10 x 1/2”
Sheet Metal
Screws
903062 REV H 08/12/19, PG 8 OF 26
Speaker Mounting
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1. Using a #10 x 1/2” sheet metal screw, secure the speaker bracket to the bracket on the defrost duct (See
Figure 5, below).
Speaker
Bracket
#10 x 1/2”
Sheet Metal
Screw
Figure 5
Evaporator Installation
1. On a workbench, install the evaporator front and rear mounting brackets onto the evaporator using (6) 1/4-20
x 1/2” hex bolts, and tighten as shown in Figures 6 & 6a, below.
2. Install the hardlines with properly lubricated O-rings (See Figure 15, Page 14, and Figure 21, Page 19).
1/4-20 x 1/2”
Hex Bolt
Front Evaporator
Bracket
643062
1/4-20 x 1/2”
Hex Bolt
Figure 6
Driver Side Rear
Evaporator Bracket
643064
(2) 1/4-20 x 1/2”
Hex Bolts
Figure 6a
Passenger Side Rear
Evaporator Bracket
643063
(2) 1/4-20 x 1/2”
Hex Bolts
9
1/4-20 x 1 ½”
Coarse Bolt
with Flat Washer
1/4” Push Nut
Bolt Retainer
3/4” Nylon
Spacer
903062 REV H 08/12/19, PG 9 OF 26
Fresh Air Cap Installation
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1. Apply a 1/4” bead of silicone around the mating surface of the fresh air cap as shown in Figure 7, below.
2. Attach the fresh air cap to the firewall using a 1/4-20 x 1” bolt and washer (See Figure 7, below).
1/4-20 x 1”
Bolt and
Washer
Fresh Air
Cap
Silicone
Mating Surface
of Fresh Air Cap
Figure 7
Firewall Cover Installation
1. Apply a 1/4” bead of silicone around the mating surface of the firewall cover, and secure it to the firewall using
(5) 1/4-20 x 1/2” bolts, (10) flat washers and (5) nuts as shown in Figure 8, below.
Passenger Compartment
View
Figure 8
Mating Surface
of Firewall
Cover
10
Silicone
903062 REV H 08/12/19, PG 10 OF 26
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Evaporator Installation (Cont.)
NOTE: Before the installation of the evaporator unit, there may be firewall insulation retainers located
on the firewall that will interfere with the installation of the evaporator brackets (See Figure 7,
below).
1. Remove the #6 grommet (See Figure 9, below).
2. Lift the evaporator unit up under the dashboard, and secure loosely to the firewall from the engine
compartment side using (2) 1/4-20 nuts and washers (See Figure 9, below).
3. Using a 1/4-20 x 1 ¼” pan head screw with a 1/4” flat washer, secure the front evaporator mounting bracket
to the dash (See Figures 9 & 9a, 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 the firewall first. Then tighten the front mounting bracket screws.
5. Once the evaporator is installed, install a #6 grommet over the #6 hardline from the engine compartment.
#6 Grommet
33145-VUI
Remove Firewall Insulation
Retainer If Equipped
Rear
Evaporator
Bracket
1/4-20 Nut
and Flat Washer
1/4-20 Nut
and Flat Washer
Figure 9
Bracket
Dash
Rear
Evaporator
Bracket
Evaporator
Figure 9a
11
1/4-20
Well Nut
1/4”
Flat washer
1/4-20 x 1 ¼”
Pan Head
Screw
903062 REV H 08/12/19, PG 11 OF 26
Drain Hose Installation
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1. Locate the evaporator drain on the bottom of the evaporator case.
2. In line with the drain, lightly make a mark on firewall. Then, measure 1” down and drill a 5/8” hole through
the firewall (See Figure 10, below).
3. Install the drain hose onto the evaporator drain on the bottom of the unit, and route it through the firewall.
1”
Figure 10
Drain
Hose
Driver Side
Under Dash Louver Mounting Holes
1. Cut out the template provided on Page 25. Place the template under the dash on the driver side by aligning
the left side of the template against the edge of the dash as shown in Figure 11, below. Make sure the OEM
holes line up with the holes on the template as shown in Figure 11, below.
2. Once the template is aligned correctly and taped into place, mark the mounting holes on the dash. Once the
holes are marked in the correct location, drill (2) 3/16” holes into the dash for the driver side louver bezel
(See Figure 11, below).
Drill (2) 3/16”
Holes
Figure 11
Passenger Side
Under Dash Louver Mounting Holes
1. Using the (2) OEM dimples under the dash, drill (2) 3/16” holes in the dash as shown in Figure 12, below.
Figure 12
Drill (2) 3/16”
Holes
12
903062 REV H 08/12/19, PG 12 OF 26
Driver Side
Under Dash Louver Installation
www.vintageair.com
1. Place the louver bezel under the dash, and align it with the 3/16” holes in the dash.
2. Secure the louver bezel under the dash using (2) 10-24 x 3/8” pan head screws and (2) 10-24 nuts with star
washers (See Figure 13, below).
3. Install the louver into the under dash bezel as shown in Figure 13a, below.
(2) 10-24 x 3/8”
Pan Head Screws
and (2) Nuts with
Star Washers
Louver
Figure 13a
Figure 13
Center/Passenger Side
Under Dash Louver Installation
1. Place the louver bezel under the dash, and align it with the OEM holes in the dash.
2. Secure the louver bezel under the dash using (3) 10-24 x 3/8” pan head screws and (3) 10-24 nuts with star
washers (See Figure 14, below).
3. Install the louvers into the under dash bezel as shown in Figure 14a, below.
(3) Louvers
Figure 14
Figure 14a
(3) 10-24 x 3/8”
Pan Head Screws
and (3) Nuts with
Star Washers
Final Assembly
13
903062 REV H 08/12/19, PG 13 OF 26
Lubricating O-rings
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Male
O-ring Insert
Female Nut
#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.
O-ring Installs
Over Male Insert
to Swaged Lip
Figure 15
Figure ##
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 15, above) and connect the 135°
female fitting with 134a service port to the #8 discharge port on the compressor. Then route the straight
female fitting to the #8 condenser hardline coming through the core support (See Figure 17, Page 16).
Tighten each fitting connection as shown in Figure 15, above.
2. Locate the #10 compressor A/C hose. Lubricate (2) #10 O-rings (See Figure 15, above) and connect the #10
135° female fitting with 134a service port to the #10 suction port on the compressor. Then route the 45°
female fitting to the #10 evaporator hardline coming through the firewall (See Figure 17, Page 16). Tighten
each fitting connection as shown in Figure 15, above. NOTE: Wrap the #10 fitting connections with
press tape (See Figure 16, Page 15).
3. Locate the #6 evaporator/core hardline. Lubricate (2) #6 O-rings (See Figure 15, above) and connect the
hardline to the #6 hardline coming through the core support from the drier. Then attach the other end of the
hardline with lubricated O-ring to the #6 evaporator hardline coming through the firewall (See Figure 17,
Page 16). Tighten each fitting connection as shown in Figure 15, above.
4. Use a #2 and a #10 Adel clamp to secure the #6 evaporator/core hardline and the 5/8” heater hose to the
inner fenderwell as shown in Figure 17, Page 16. Secure the Adel clamps to the inner fender using
(2) 10-32 x 1/2” pan head screws with nuts.
Modified Hose Kit:
1. Refer to separate instructions included with modified hose kit.
14
903062 REV H 08/12/19, PG 14 OF 26
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Heater Hose
& Heater Control Valve Installation
NOTE: Vintage Air systems use 5/8” heater connections. On engines equipped with 3/4” hose nipples,
these will need to be removed and replaced with 5/8” nipples (not supplied). For water pumps with a
cast-in 3/4” heater outlet, a 3/4” x 5/8” reducer fitting (not supplied) will need to be installed in the
heater hose.
1. Route the heater hose from the water pump to the heater line coming through the firewall as shown in Figure
16, below. Secure using hose clamps.
2. Route the heater hose from the intake to the heater line coming through the firewall as shown in Figure 16,
below. NOTE: Install the heater control valve in line with the intake manifold (pressure side) heater
hose, and secure using hose clamps. Also note proper flow direction.
ECU
Module
NOTE: Flow Direction Follows
Molded Arrow on Valve.
Press
Tape
From Heater
Control Valve
Heater
Hose
#10 Suction Line
(Insulated)
091671
Expansion
Valve
From
Intake
#6 O-ring
Heater Control
Valve
#6 Hardline
091078
5/8” Heater Line
(Intake)
091661
#10 O-ring
5/8” Heater Line
(Water Pump)
091661
#10 Suction
Hose
096059
#6 Hardline
091061
To Water
Pump
Figure 16
Press
Tape
15
903062 REV H 08/12/19, PG 15 OF 26
16
#10 Adel
Clamp
31601-VUD
Heater
Hose
O-rings
#2 Adel
Clamp
31600-VUD
Inner
Fender
10-32 x 1/2”
Pan Head Screw
and Nut
10-32 x 1/2”
Pan Head
Screw
#6 Drier/Condenser
Hardline
35117-VCG
#8 A/C Discharge Hose
(Compressor/Condenser)
096062
10-32 Nut with
Star Washer
Figure 17
Inner
Fender
#6 Drier/Core
Hardline
091063
#8 Condenser
Hardline
091064
#10 A/C Suction Hose
(Compressor/Evaporator)
096059
Heater Control
Valve
Evaporator
Sub Case
#6 Evaporator/Core
Hardline
091061
ECU
Module
#6 Evaporator/Core
Hardline
091061
10-32 x 1/2”
Pan Head Screw
and Nut
Firewall
Cover
627003
Expansion
Valve
#10 Suction Line
(Insulated)
091671
Press
Tape
www.vintageair.com
NOTE: Vintage Air Systems use 5/8” heater connections. On
engines equipped with 3/4” hose nipples, these will need to
be removed and replaced with 5/8” nipples (not supplied). For
water pumps with a cast-in 3/4” heater outlet, a 3/4” x 5/8”
reducer fitting (not supplied) will need to be installed in the
heater hose.
Compressor
Safety Switch
(Binary Type
Screw on Drier)
(Refer to
Condenser
Instruction)
A/C & Heater Hose Routing
903062 REV H 08/12/19, PG 16 OF 26
Final Steps
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1. Install duct hoses as shown in Figure 20, Page 18.
2. Route A/C wires (12 volt/grounds/binary switch/heater control valve) through 3/8” grommet as shown in
Figure 19, below).
3. Install 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 20, Page 18. Wire
according to wiring diagrams on Pages 20 & 21.
5. Install supplied glove box, and secure using (3) OEM screws through the OEM holes as shown in Figure 18,
below.
6. Reinstall glove box door.
7. Reinstall all previously removed items.
8. 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.
9. Double check all fittings, brackets and belts for tightness.
10. Vintage Air recommends that all A/C systems be serviced by a licensed automotive A/C technician.
11. Evacuate the system for a minimum of 45 minutes prior to charging, and perform a leak check prior to
servicing.
12. Charge the system to the capacities stated on Page 4 of this instruction manual.
13. See Operation of Controls procedures on Page 22.
Grommet
33144-VUI
(3) OEM
Screws
Figure 19
Figure 18
17
903062 REV H 08/12/19, PG 17 OF 26
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Control Panel & Duct Hose Routing
Passenger Side
Louver
2 ½” x 38”
Plug From
Control
Wiring
Harness
232002-VUA
Driver Side
Defrost Duct
2” x 15”
Plug From
Wiring
Harness
232600-VUA
Driver Side
Louver
2 ½” x 36”
Passenger Side
Defrost Duct
2” x 15”
Driver Side
Center Louver
2 ½” x 12”
Passenger Side
Louver
Passenger Side
Center Louver
2 ½” x 12”
Driver Side
Louver
Figure 20
Passenger Side
Center Louver
Driver Side
Center Louver
18
903062 REV H 08/12/19, PG 18 OF 26
19
903062 REV H 08/12/19, PG 19 OF 26
#10 Suction
Line
091671
Press Tape
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Heater Line
(Evaporator
to Intake)
091661
#6 O-ring
33857-VUF
Heater Line
(Evaporator to
Water Pump)
091661
#10 O-ring
33859-VUF
ECU
Module
#6 Hardline
091078
Figure 21
(2) #10 O-rings
33859-VUF
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.
20
903062 REV H 08/12/19, PG 20 OF 26
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 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:
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
21
903062 REV H 08/12/19, PG 21 OF 26
Operation of Controls
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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.
Temperature Control
This lever/knob controls
the temperature,
from HOT to COLD.
NOTE: Original
blower switch
will not be used.
Blower
Speed
Temperature
Control
Mode
Control
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).
22
903062 REV H 08/12/19, PG 22 OF 26
23
903062 REV H 08/12/19, PG 23 OF 26
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
24
903062 REV H 08/12/19, PG 24 OF 26
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
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
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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.)
25
Cut Along Dotted Line
3.375”
Cut Along Dotted Line
Drill 3/16”
Defrost Duct Mounting Template
Driver Side Under Dash
Louver Template
Drill 3/16”
Align This Edge Against
Dash Brace
Cut Along Dotted Line
www.vintageair.com
Templates:
Driver Side Under Dash Louver Bezel
& Defrost Duct Mounting
903062 REV H 08/12/19, PG 25 OF 26
www.vintageair.com
Part No.
No.
Qty.
744004-VUE
1.
1
784061
2.
1
Packing List:
Evaporator Kit (561062)
Description
Gen IV Evaporator Sub Case
Accessory Kit
Checked By:
Packed By:
Date:
1
Gen IV Evaporator
Sub Case
744004-VUE
2
Accessory Kit
784061
NOTE: Images may not depict actual parts and quantities.
Refer to packing list for actual parts and quantities.
26
903062 REV H 08/12/19, PG 26 OF 26