an ISO 9001:2008 Registered Company
1961-62 Chevrolet Impala with Factory AirEvaporator Kit
(564062)
18865 Goll St. San Antonio, TX 78266 Phone: 210-654-7171
Fax: 210-654-3113www.vintageair.com
904062 REV E 11/04/15, PG 1 OF 26
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904062 REV E 11/04/15, PG 2 OF 26
Thank you for purchasing this evaporator kit from Vintage Air. When installing these components as part of a complete SureFit™ system, Vintage Air recommends working from front to back on the vehicle, installing the condenser kit, hose kit, and compressor first, followed by the wiring, evaporator, and finally the control panel.
Cover..................................................................................................................................Table of Contents.................................................................................................................Packing List/Parts Disclaimer..................................................................................................Information Page..................................................................................................................Wiring Notice.......................................................................................................................Engine Compartment Disassembly, Condenser Assembly and Installation, Compressor and Brackets, Pulleys..................................................................................................................Passenger Compartment Disassembly..................................................................................... Defrost Duct Installation.......................................................................................................Speaker Mounting, Evaporator Installation............................................................................... Evaporator Installation (Cont.)............................................................................................. Firewall Cover Installation................................................................................................... Drain Hose Installation, Driver Side Under Dash Louver Mounting Holes, Passenger Side Under Dash Louver Mounting Holes................................................................................................ Driver Side Under Dash Louver Installation, Center/Passenger Side Under Dash Louver Installation........................................................................................................................Lubricating O-rings, A/C Hose Installation..............................................................................Heater Hose & Heater Control Valve Installation.....................................................................A/C & Heater Hose Routing..................................................................................................Final Steps........................................................................................................................ Control Panel & Duct Hose Routing....................................................................................... Evaporator Hardline Installation...........................................................................................Wiring Diagram..................................................................................................................Gen IV Wiring Connection Instruction...................................................................................Operation of Controls..........................................................................................................Troubleshooting Guide.........................................................................................................Troubleshooting Guide (Cont.)..............................................................................................Templates: Driver Side Under Dash Louver Bezel & Defrost Duct Mounting.................................Packing List.......................................................................................................................
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Table of Contents
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904062 REV E 11/04/15, PG 3 OF 26
Packing List: Evaporator Kit (564062)
No. 1.2.
Qty.11
Part No.744004-VUE784062
DescriptionGen 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.
NOTE: Images may not depict actual parts and quantities. Refer to packing list for actual parts and quantities.
1
2
Gen IV Evaporator Sub Case
744004-VUE
Accessory Kit784062
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904062 REV E 11/04/15, PG 4 OF 26
Important Notice—Please ReadFor Maximum System Performance, Vintage Air Recommends the Following:
New Vintage Air-supplied Sanden Compressor: No additional oil needed (Compressor is shipped with proper oil charge).All Other Compressors: Consult manufacturer (Some compressors are shipped dry and will need oil added).
NOTE: Vintage Air systems are designed to operate with R134a refrigerant only. Use of any other refrigerant could damage your A/C system and/or vehicle, and possibly cause a fire, in addition to potentially voiding the warranties of the A/C system and its components.
Refrigerant Capacities:Vintage Air System: 1.8 lbs. (1 lb., 12 oz.) of R134a, charged by weight with a quality charging station or scale. NOTE: Use of the proper type and amount of refrigerant is critical to system operation and performance.Other Systems: Consult manufacturer’s guidelines.
Lubricant Capacities:
Safety Switches
Service Info:Protect Your Investment: Prior to assembly, it is critical that the compressor, evaporator, A/C hoses and fittings, hardlines, condenser and receiver/drier remained capped. Removing caps prior to assembly will allow moisture, insects and debris into the components, possibly leading to reduced performance and/or premature failure of your A/C system. This is especially important with the receiver/drier. Additionally, when caps are removed for assembly, BE CAREFUL! Some components are shipped under pressure with dry nitrogen.Evacuate the System for 35-45 Minutes: Ensure that system components (Drier, compressor, evaporator and condenser) are at a temperature of at least 85° F. On a cool day, the components can be heated with a heat gun or by running the engine with the heater on before evacuating. Leak check and charge to specifications.
Your Vintage Air system is equipped with a binary pressure safety switch. A binary switch disengages the compressor clutch in cases of extreme low pressure conditions (Refrigerant Loss) or excessively high head pressure (406 PSI) to prevent compressor damage or hose rupture. A trinary switch combines Hi/Lo pressure protection with an electric fan operation signal at 254 PSI, and should be substituted for use with electric fans. Compressor safety switches are extremely important since an A/C system relies on refrigerant to circulate lubricant.
Bolts Passing Through Cowl and/or Firewall:To ensure a watertight seal between the passenger compartment and the vehicle exterior, for all bolts passing through the cowl and/or firewall, Vintage Air recommends coating the threads with silicone prior to installation.
Heater Hose (Not Included With This Kit):Heater hose may be purchased from Vintage Air (Part# 31800-VUD) or your local parts retailer. Routing and required length will vary based on installer preference.
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904062 REV E 11/04/15, PG 5 OF 26
Important Wiring Notice—Please Read
Some Vehicles May Have Had Some or All of Their Radio Interference Capacitors Removed. There Should Be a Capacitor Found At Each of the Following Locations:
1. On the positive terminal of the ignition coil.2. If there is a generator, on the armature terminal of the generator.3. If there is a generator, on the battery terminal of the voltage regulator.
Most alternators have a capacitor installed internally to eliminate what is called “whining” as the engine is revved. If whining is heard in the radio, or just to be extra cautious, a radio interference capacitor can be added to the battery terminal of the alternator.
It is also important that the battery lead is in good shape and that the ground leads are not compromised. There should be a heavy ground from the battery to the engine block, and additional grounds to the body and chassis.
If these precautions are not observed, it is possible for voltage spikes to be present on the battery leads. These spikes come from ignition systems, charging systems, and from switching some of the vehicle’s other systems on and off. Modern computer-operated equipment can be sensitive to voltage spikes on the power leads, which can cause unexpected resets, strange behavior, and/or permanent damage.
Vintage Air strives to harden our products against these types of electrical noise, but there is a point where a vehicle’s electrical system can be degraded so much that nothing can help.
Radio interference capacitors should be available at most auto and truck parts suppliers. They typically are cylindrical in shape, a little over an inch long, a little over a half inch in diameter, and they have a single lead coming from one end of the cylinder with a terminal on the end of the wire, as well as a mounting clip which is screwed into a good ground on the vehicle. The specific value of the capacitance is not too significant in comparison to ignition capacitors that are matched with the coil to reduce pitting of the points.
Care must be taken, when installing the compressor lead, not to short it to ground. The compressor lead must not be connected to a condenser fan or to any other auxiliary device. Shorting to ground or connecting to a condenser fan or any other auxiliary device may damage wiring, the compressor relay, and/or cause a malfunction.
When installing ground leads on Gen IV systems, the blower control ground and ECU ground must be connected directly to the negative battery post.
For proper system operation, the heater control valve must be connected to the ECU.
•
•
•
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904062 REV E 11/04/15, PG 6 OF 26
Engine Compartment Disassembly
1.2.3.4.5.6.7.8.9.
Disconnect battery.Remove battery.Drain radiator.Evacuate the A/C system if necessary.Remove the OEM condenser and drier (discard) (See Figure 1, below).Remove the OEM A/C lines from the compressor to the evaporator (discard) (See Figure 1, below).Remove the OEM A/C compressor and compressor bracket (discard) (See Figure 1, below).Remove the OEM blower assembly (discard) (See Figure 1, below).To remove the OEM evaporator assembly, the factory manual indicates doing the following: Remove the right fender and skirt.
NOTE: Before starting the installation, check the function of the vehicle (horn, lights, etc.) for proper operation, and study the instructions, illustrations, & diagrams.Perform the Following:
Figure 1
Condenser Assembly and Installation1.2.
Refer to separate instructions included with the condenser kit to install the condenser.Binary switch installation (Refer to condenser instructions).
Compressor and Brackets1. Refer to separate instructions included with the bracket kit to install the compressor bracket.
Pulleys1. In most instances, the belt lengths will remain the same.
OEMHeater/Blower
AssemblyOEM
EvaporatorAssembly
OEM A/CLine
OEMCompressor
Fender
OEMDrier
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904062 REV E 11/04/15, PG 7 OF 26
Passenger Compartment Disassembly
1.2.3.4.5.6.7.8.9.
Remove the passenger side OEM A/C duct assembly (See Figure 2, below).Remove the driver side OEM A/C duct and louver (See Figure 2, below).Remove the OEM center louver assembly (See Figure 2, below).Remove the OEM control panel assembly (See Figure 2, below).Remove the OEM heater assembly (See Figure 2, below).Remove the glove box (discard).Remove the radio and speaker (retain) (See Figure 2, below).Remove the OEM defrost duct assembly (discard) (See Figure 3, below).Remove the (3) spot welds on the defrost duct using a chisel or die grinder (See Figure 3, below).
Perform the Following:
Figure 3
Figure 2
Speaker Radio
OEMA/C Duct
Hose
OEMDriver Side
Louver AssemblyGlove Box
OEM Control Panel
OEMCenter Louver
Assembly
OEMPassenger Side
Louver Assembly
OEMHeater Plenum
OEMDefrost Duct
DashSupport
DashSupport
Defrost Duct
InnerCowlUse a Chisel or
Die Grinder toBreak Spot Welds
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904062 REV E 11/04/15, PG 8 OF 26
Defrost Duct Installation1.2.3.4.5.6.
7.
Cut out the defrost duct mounting template on Page 25.Place the template onto the inner cowl. Once aligned, tape the template into place (See Figure 4, below).Using a center punch or scribe, mark the (2) mounting holes on the inner cowl (See Figure 4, below).Once the holes are marked, remove the template and drill (2) 1/8” holes into the inner cowl.Install a J-nut onto the end of the speaker bracket as shown in Figure 4a, below.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.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).
Figure 4a
Figure 4
Tape
MarkMounting
Holes
Inner CowlTemplate
Dash SupportBrace
J-nut
DefrostDuct
(2) #10 x 1/2” Sheet Metal
Screws
View Shown Through GloveBox Opening in Dash.
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904062 REV E 11/04/15, PG 9 OF 26
Evaporator Installation
Speaker Mounting
1.
2.
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.Install the hardlines with properly lubricated O-rings (See Figure 14, Page 14, and Figure 20, Page 19).
Using a #10 x 1/2” sheet metal screw, secure the speaker bracket to the bracket on the defrost duct (See Figure 5, below).
Figure 6
Figure 6a
Figure 5SpeakerBracket
#10 x 1/2”Sheet Metal
Screw
1/4-20 x 1/2”Hex Bolt
1/4-20 x 1/2”Hex Bolt
Front EvaporatorBracket 643062
Driver Side RearEvaporator Bracket
643064
Passenger Side RearEvaporator Bracket
643063
(2) 1/4-20 x 1/2”Hex Bolts
(2) 1/4-20 x 1/2”Hex Bolts
1/4-20 x 1 ½”Coarse Bolt
with Flat Washer
1/4” Push NutBolt Retainer
3/4” NylonSpacer
10
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904062 REV E 11/04/15, PG 10 OF 26
Figure 7
Evaporator Installation (Cont.)1.
2.
3.
Lift the evaporator unit up under the dashboard, and secure loosely to the firewall from the enginecompartment side using (2) 1/4-20 nuts and washers (See Figure 7, below).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 7 & 7a, below).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.
1/4-20 Nut andFlat Washer
1/4-20 Nut andFlat Washer
Rear Evaporator
Bracket
Rear Evaporator
Bracket
Figure 7a
Bracket
Dash
1/4-20Well Nut
1/4” Flat washer
1/4-20 x 1 ¼”Pan Head
Screw
Evaporator
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904062 REV E 11/04/15, PG 11 OF 26
Figure 8
Firewall Cover Installation1.2.
3.
4.
5.6.7.8.
Apply a 1/4” bead of silicone around the mating surface of the A/C block-off plate as shown in Figure 8, below.Install the A/C block-off plate onto the firewall using (9) #14 x 3/4” sheet metal screws as shown in Figure 8, below.Apply a 1/4” bead of silicone around the mating surface of the heater/blower cover as shown in Figure 8, below.Install the heater/blower cover onto the firewall using (5) #14 x 3/4” sheet metal screws as shown in Figure 8, below.Drill (2) 1/8” holes into the firewall using the heater/blower cover as a template (See Figure 8, below).Use the remaining (2) #14 x 3/4” sheet metal screws to finish securing the heater/blower cover to the firewall.Apply a 1/4” bead of silicone around the mating surface of the firewall cover as shown in Figure 8, below.Pass lines through the firewall cover, and secure the cover to the firewall using (5) 7/16” panel retainers (See Figure 8, below).
Heater/BlowerCover
627063
A/C Block-Off Plate
627064
(5) 7/16”Panel RetainersFirewall
Cover627062
(7) #14 x 3/4”Sheet Metal
Screws
(9) #14 x 3/4”Sheet Metal
Screws
Drill (2) 1/8” Holes
Mating Surfaceof Firewall
Cover
Mating Surfaceof A/C Block-Off
Plate
Retainers
Silicone
Silicone
Silicone
Mating Surfaceof Heater/Blower
Cover
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904062 REV E 11/04/15, PG 12 OF 26
Figure 9
Figure 10
Figure 11
Drain Hose Installation
Driver Side Under Dash Louver Mounting Holes
Passenger Side Under Dash Louver Mounting Holes
1.2.
3.
1.
2.
1.
Locate the evaporator drain on the bottom of the evaporator case.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 9, below).Install the drain hose onto the evaporator drain on the bottom of the unit, and route it through the firewall.
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 10, below. Make sure the OEM holes line up with the holes on the template as shown in Figure 10, below.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 10, below).
Using the (2) OEM dimples under the dash, drill (2) 3/16” holes in the dash as shown in Figure 11, below.
1” DrainHose
Drill (2) 3/16”Holes
Drill (2) 3/16”Holes
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904062 REV E 11/04/15, PG 13 OF 26
Figure 13b
Figure 13
Figure 13a
Figure 12Figure 12a
Driver Side Under Dash Louver Installation
1.2.
3.
Place the louver bezel under the dash, and align it with the 3/16” holes in the dash.Secure the louver bezel under the dash using (2) 10-32 x 1/2” pan head screws and (2) 10-32 nuts with star washers (See Figure 12, below).Install the louver into the under dash bezel as shown in Figure 12a, below.
Center/Passenger Side Under Dash Louver Installation
1.2.
3.
4.5.
Place the louver bezel under the dash, and align it with the OEM holes in the dash.Secure the louver bezel under the dash using (2) 10-32 x 1/2” pan head screws and (2) 10-32 nuts with star washers (See Figure 13, below).Install the center louver hose adapter onto the OEM center louver housing using (2) #8 x 1/2” pan headscrews and (2) 3/16” washers as shown in Figure 13a, below.Install the OEM center louver housing under the dash using (2) OEM screws as shown in Figure 13b, below. Install the OEM louver into the passenger side under dash bezel as shown in Figure 13b, below.
(2) 10-32 x 1/2”Pan Head Screwsand (2) Nuts with
Star Washers
(2) 10-32 x 1/2”Pan Head Screwsand (2) Nuts with
Star Washers
Driver Side Louver Bezel
Assembly494164
OEMLouver
OEMLouverHousing
OEMLouverHousing
OEMLouver
Passenger SideLouver Assembly (2) 3/16”
Flat Washers
(2) #8 x 1/2”Pan Head Screws
Center LouverHose Adapter
Assembly
(2) OEMScrews
Final Assembly
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904062 REV E 11/04/15, PG 14 OF 26
Figure ##
O-ring Installs Over Male Insert to Swaged Lip
O-ring#6 O-ring
#8 O-ring #10 O-ring
O-ring
Supplied Oil for O-rings
Male Insert
Female Nut
Hold With This Wrench
Twist With This Wrench
Lubricating O-rings For a proper seal of fittings: Install supplied O-rings as shown, and lubricate with supplied oil.
NOTE: Standard torque specifications:#6: 11 to 13 ft-lb.#8: 15 to 20 ft-lb.
#10: 21 to 27 ft-lb.
Figure 14
A/C Hose Installation
1.
2.
3.
4.
Locate the #8 compressor A/C hose. Lubricate (2) #8 O-rings (See Figure 14, 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 16, Page 16). Tighten each fitting connection as shown in Figure 14, above.Locate the #10 compressor A/C hose. Lubricate (2) #10 O-rings (See Figure 14, above) and connect the #10 135° female fitting with 134a service port to the #10 suction port on the compressor. Then route the 45° female fitting to the #10 evaporator hardline coming through the firewall (See Figure 16, Page 16). Tighten each fitting connection as shown in Figure 14, above. NOTE: Wrap the #10 fitting connections with press tape (See Figure 15, Page 15).Locate the #6 evaporator/core hardline. Lubricate (2) #6 O-rings (See Figure 14, 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 16, Page 16). Tighten each fitting connection as shown in Figure 14, above.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 16, Page 16. Secure the Adel clamps to the inner fender using (2) 10-32 x 1/2” pan head screws with nuts.
Standard Hose Kit:
1. Refer to separate instructions included with modified hose kit.Modified Hose Kit:
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904062 REV E 11/04/15, PG 15 OF 26
Figure 15
Heater Hose & Heater Control Valve Installation
1.
2.
Route the heater hose from the water pump to the heater line coming through the firewall as shown in Figure 15, below. Secure using hose clamps.Route the heater hose from the intake to the heater line coming through the firewall as shown in Figure 15, 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.
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.
ECUModule
Press Tape
#10 Suction Line (Insulated)09151-PCS
ExpansionValve
#6 Hardline091067
5/8” Heater Line(Intake)091065
5/8” Heater Line(Water Pump)
091066#10 O-ring #6 O-ring
#10 SuctionHose
096063
#6 Hardline091062
HeaterHose
From Heater Control Valve
FromIntake
Heater ControlValve
Press Tape
NOTE: Flow Direction FollowsMolded Arrow on Valve.
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16 904062 REV E 11/04/15, PG 16 OF 26
Fig
ure
16
A/C & Heater Hose Routing
ECU
Mod
ule
Pres
s Ta
pe
#10
Suc
tion
Line
(I
nsul
ated
)09
151-
PCS
NO
TE:
Vin
tag
e A
ir S
yste
ms
use
5/
8”
hea
ter
con
nec
tion
s. O
n
eng
ines
eq
uip
ped
wit
h 3
/4
” h
ose
nip
ple
s, t
hes
e w
ill n
eed
to
be
rem
oved
an
d r
epla
ced
wit
h 5
/8
” n
ipp
les
(not
su
pp
lied
). F
or
wat
er p
um
ps
wit
h a
cas
t-in
3/
4”
hea
ter
outl
et,
a 3
/4
” x
5/
8”
red
uce
r fi
ttin
g (
not
su
pp
lied
) w
ill n
eed
to
be
inst
alle
d in
th
e h
eate
r h
ose.
Evap
orat
orSub
Cas
e
Expa
nsio
nVa
lve
Fire
wal
lCov
er62
7062
O-r
ings
Hea
ter
Con
trol
Valv
e#
6 Ev
apor
ator
/Cor
eH
ardl
ine
0910
6210
-32
x 1/
2”Pa
n H
ead
Scr
ew
and
Nut
10-3
2 x
1/2”
Pan
Hea
d Scr
ew
and
Nut
Hea
ter
Hos
e
#10
Ade
lCla
mp
3160
1-VU
D
#2
Ade
lCla
mp
3160
0-VU
D
Inne
rFe
nder
Inne
rFe
nder
#8
Con
dens
erH
ardl
ine
0910
64
#6
Drier
/Cor
eH
ardl
ine
0910
63 10-3
2 N
ut w
ith
Sta
r W
ashe
r 10-3
2 x
1/2”
Pan
Hea
d Scr
ew#
6 D
rier
/Con
dens
erH
ardl
ine
3511
7-VCG
Com
pres
sor
Saf
ety
Switc
h (B
inar
y Ty
peScr
ew o
n D
rier
)(R
efer
to
Con
dens
erIn
stru
ctio
n)
#8
A/C
Dis
char
ge H
ose
(Com
pres
sor/
Con
dens
er)
0960
62
#10
A/C
Suc
tion
Hos
e(C
ompr
esso
r/Ev
apor
ator
)09
6063
Inne
rFe
nder
#6
Evap
orat
or/C
ore
Har
dlin
e09
1062
17
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904062 REV E 11/04/15, PG 17 OF 26
Figure 17 Figure 18
Final Steps1.2.
3.4.
5.
6.7.8.
9.10.11.
12.13.
Install duct hoses as shown in Figure 19, Page 18.Route A/C wires (12 volt/grounds/binary switch/heater control valve) through 3/8” grommet as shown in Figure 18, below.Install control panel assembly. Refer to control panel instructions.Plug the wiring harnesses into the ECU module on the sub case as shown in Figure 19, Page 18. Wire according to wiring diagrams on Pages 20 & 21.Install supplied glove box, and secure using (3) OEM screws through the OEM holes as shown in Figure 17, below.Reinstall glove box door.Reinstall all previously removed items.Fill radiator with at least a 50/50 mixture of approved antifreeze and distilled water. It is the owner’s responsibility to keep the freeze protection at the proper level for the climate in which the vehicle is operated. Failure to follow antifreeze recommendations will cause heater core to corrode prematurely and possibly burst in A/C mode and/or freezing weather, voiding your warranty.Double check all fittings, brackets and belts for tightness.Vintage Air recommends that all A/C systems be serviced by a licensed automotive A/C technician.Evacuate the system for a minimum of 45 minutes prior to charging, and perform a leak check prior to servicing.Charge the system to the capacities stated on Page 4 of this instruction manual.See Operation of Controls procedures on Page 22.
Grommet33144-VUI
FirewallCover
627062
(3) OEMScrews
18
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904062 REV E 11/04/15, PG 18 OF 26
Figure 19
Control Panel & Duct Hose Routing
Driver SideCenter Louver
Driver SideLouver
Passenger SideCenter Louver
Passenger SideLouver
Driver SideLouver
2 ½” x 36”
Driver SideCenter Louver
2 ½” x 12”
Passenger SideCenter Louver
2 ½” x 12”
Passenger SideDefrost Duct
2” x 15”
Plug FromWiring
Harness232001-VUR
Passenger SideLouver
2 ½” x 38”
Plug FromControlWiring
Harness232002-VUA
Driver SideDefrost Duct
2” x 15”
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19 904062 REV E 11/04/15, PG 19 OF 26
Fig
ure
20
Evap
orat
or H
ard
line
Inst
alla
tion
ECU
Mod
ule
#10
O-r
ing
3385
9-VU
F
Pres
s Ta
pe
#10
Suc
tion
Line
0915
1-PC
S
#6
O-r
ing
3385
7-VU
F
Hea
ter
Line
(Eva
pora
tor
to I
ntak
e)09
1065
Hea
ter
Line
(Eva
pora
tor
to
Wat
er P
ump)
0910
66#
6 H
ardl
ine
0910
67
(2)
#10
O-r
ings
3385
9-VU
F
20
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904062 REV E 11/04/15, PG 20 OF 26
WHT/GRN
WHT/YELWHT/RED
RED
WHTBACKLIGHT NEG
FAN WIPER
MODE WIPER
TEMP WIPER
5V-SW
GND
BACKLIGHT POS
AC ANNUNCIATOR
PRE-WIRED
GEN IV WIRING DIAGRAMREV D, 5/6/2014
GEN IV ECU
PROGRAM
Wiring Diagram
TEMP
MODE
FAN
A/C(IF USED)
232007-VUR
232002-VUA
** CIRCUITBREAKER30 AMP
*** WIDE OPENTHROTTLESWITCH
(OPTIONAL)
* DASH LAMP(IF USED)
Dash Lamp Is Used Only With Type 232007-VUR Harness.Warning: Always Mount Circuit Breaker As Close to the Battery As Possible. (NOTE: Wire BetweenBattery and Circuit Breaker Is Unprotected and Should Be Carefully Routed to Avoid a ShortCircuit).Wide Open Throttle Switch Contacts Close Only at Full Throttle, Which Disables A/C Compressor.
JF8
BLK
ORA
TAN
VIEWED FROM WIRE SIDE
••
•
HEATERCONTROL VALVE
21
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904062 REV E 11/04/15, PG 21 OF 26
RED
CIRCUIT BREAKER30 AMP
+
+
-
BLACK
REDWHITE
RED
CHASSIS GROUND
A/CCOMPRESSOR
RELAY
Ignition Switch:
Dash Light:
NOTE: MOUNT RELAYIN DESIRED LOCATION
UNDER DASH
GREEN
FIREWALL
BLUE
BLUE
RED &
WHITE
VIOLET
(IGNITION HOTTERMINAL)
IGNITION SWITCH
DASH BACK LIGHT+0-12vTAN
GRAY
BLUE
WHITE
WHITE
REDRED
WHITE
COMPRESSOR
BATTERY
NOTE: CONNECT WHITEWIRES DIRECTLY TO
(-) BATTERY TERMINAL
BATRUN
12V
RED GREEN
RED
RED
BLUE
LATCH
BLACK
BINARYSAFETYSWITCH
YELLOW
ORANGE
WIRING HARNESS
Violet 12V Ign Switch Source (Key On Accessory) Position Must Be Switched.
Tan Wire Used Only With Vintage Air Supplied Control Panel With LED Back Light.
Binary: Connect As Shown (Typical Compressor Wiring). Be Sure Compressor Body Is Grounded.
Trinary Switch: Connect According To Trinary Switch Wiring Diagram.
Install With Servo Motor Facing Down, As Shown. Note Flow Direction Arrow Molded Into Valve Body, And Install Accordingly.
White Must Run To (-) Battery. Red May Run To (+) Battery Or Starter. Mount Circuit Breaker As Close to Battery As Possible.
Heater Control Valve:
Binary/Trinary & Compressor:
Circuit Breaker/Battery:
CONTROL WIRING HARNESS
NOTE: YELLOW & ORANGE
COMING FROM HARNESS ARE NOT
USED.
WIRING HARNESS
GRAY WIRE IS USED FOR PROGRAMING CONTROLS
IF APPLICABLE
WIRING HARNESS
Gen IV Wiring Connection Instruction
HEATERCONTROL VALVE
WARNING: ALWAYS MOUNT CIRCUIT BREAKER
AS CLOSE TO THE BATTERY AS POSSIBLE. (NOTE: WIRE BETWEEN BATTERY AND CIRCUIT BREAKER IS UNPROTECTED
AND SHOULD BE CAREFULLY ROUTED TO AVOID A SHORT CIRCUIT).
NOTE: HEATER CONTROL VALVE CONNECTION AND CHASSIS GROUND MAY BE LOCATED ON EITHER SIDE OF THE FIREWALL. ENSURECONNECTOR IS LATCHED
FIRMLY.
22
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904062 REV E 11/04/15, PG 22 OF 26
Operation of Controls
Adjust to desiredspeed.
Blower SpeedAdjust to desired
speed.
Adjust to desiredmode position (DASH position recommended).
Adjust to desiredspeed.
Adjust to DEFROST position for maximum defrost, or between FLOOR and DEFROST positions for a bi-level
blend (Compressor is automatically engaged).
Adjust to desired temperature.
For A/C operation, adjust tocoldest position to engage
compressor (Adjust between HOT and COLD to reachdesired temperature).
A/C Operation
Heat Operation
Defrost/De-fog Operation
On Gen IV systems with three lever/knob controls, the temperature control toggles between heat and A/C operations. To activate A/C, move the temperature lever/knob all the way to cold and then back it off to the desired vent temperature. For heat operation, move the temperature lever/knob all the way to hot and then adjust to the desired vent temperature. The blower will momentarily change speed, each time you toggle between operations, to indicate the change. NOTE: For proper control panel function, refer to control panel instructions for calibration procedure.
Blower Speed
Blower Speed
This lever/knob controlsblower speed, from
OFF to HI.
This lever/knob controls the mode positions,from DASH to FLOORto DEFROST, with a blend in between.
This lever/knob controlsthe temperature,
from HOT to COLD.
Blower Speed
Mode Control
Temperature Control
Blower Speed
TemperatureControl
Temperature Control
Temperature Control
Temperature Control
Mode Control
Mode Control
Mode Control
For maximum heating, adjust to hottest position (Adjust between HOT and COLD to reach desired temperature).Adjust to desired
mode position(FLOOR position recommended).
ModeControl
NOTE: Original blower switch will not be used.
ww
w.v
inta
gea
ir.c
om
23 904062 REV E 11/04/15, PG 23 OF 26
Sym
pto
m
C
on
dit
ion
C
heck
s
Act
ion
s
N
ote
s
Blo
wer
sta
ys o
n
hig
h s
pee
d w
hen
ig
nitio
n is
on.
1a.
No o
ther
funct
ions
work
.
Chec
k fo
r dam
aged
pin
s or
wires
in c
ontr
ol hea
d p
lug.
Ver
ify
that
all
pin
s ar
e in
sert
ed into
plu
g.
Ensu
re t
hat
no
pin
s ar
e ben
t or
dam
aged
in E
CU
.
Chec
k fo
r dam
aged
gro
und
wire
(white)
in c
ontr
ol hea
d
har
nes
s.
Ver
ify
continuity
to c
has
sis
gro
und w
ith w
hite
contr
ol
hea
d w
ire
at v
ario
us
poin
ts.
Loss
of gro
und o
n t
his
wire
render
s co
ntr
ol hea
d
inoper
able
.
All
oth
er f
unct
ions
work
.Chec
k fo
r dam
aged
blo
wer
sw
itch
or
pote
ntiom
eter
and
asso
ciat
ed w
irin
g.
Blo
wer
sta
ys o
n
hig
h s
pee
d w
hen
ig
nitio
n is
on o
r off.
Unplu
g 3
-wire
BSC c
ontr
ol
connec
tor
from
ECU
. If
blo
wer
sh
uts
off,
ECU
is
eith
er
impro
per
ly w
ired
or
dam
aged
.
Be
sure
the
smal
l, 2
0 G
A w
hite
gro
und w
ire
is c
onnec
ted
to t
he
bat
tery
gro
und p
ost
. If
it
is,
repla
ce t
he
ECU
.
Unplu
g 3
-wire
BSC c
ontr
ol
connec
tor
from
ECU
. If
blo
wer
st
ays
runnin
g,
BSC is
eith
er
impro
per
ly w
ired
or
dam
aged
.
Chec
k to
ensu
re t
hat
no B
SC w
irin
g is
dam
aged
or
short
ed t
o v
ehic
le g
round.
The
BSC o
per
ates
the
blo
wer
by
gro
und s
ide
puls
e w
idth
modula
tion s
witch
ing.
The
posi
tive
wire
to t
he
blo
wer
will
alw
ays
be
hot.
If th
e “g
round”
side
of
the
blo
wer
is
short
ed t
o c
has
sis
gro
und,
the
blo
wer
will
run o
n H
I.
Rep
lace
BSC (
This
will
req
uire
rem
oval
of ev
apora
tor
from
veh
icle
).N
o o
ther
par
t re
pla
cem
ents
sh
ould
be
nec
essa
ry.
Com
pre
ssor
will
not
turn
on
(All
oth
er funct
ions
work
).
2.
Sys
tem
is
not
char
ged
.Sys
tem
must
be
char
ged
for
com
pre
ssor
to e
ngag
e.Char
ge
syst
em o
r byp
ass
pre
ssure
sw
itch
.
Dan
ger:
Never
byp
ass
sa
fety
sw
itch
wit
h
en
gin
e r
un
nin
g.
Seri
ou
s in
jury
can
resu
lt.
Sys
tem
is
char
ged
.
1b
.
Tro
ub
lesh
oo
tin
g G
uid
e
Chec
k fo
r fa
ulty
A/C
pote
ntiom
eter
or
asso
ciat
ed
wirin
g (
Not
applic
able
to 3
-pot
contr
ols
).
Chec
k fo
r dis
connec
ted o
r fa
ulty
ther
mis
tor.
Chec
k co
ntinuity
to g
round o
n w
hite
contr
ol hea
d w
ire.
Chec
k fo
r 5V o
n r
ed c
ontr
ol hea
d w
ire.
Chec
k 2-p
in c
onnec
tor
at E
CU
housi
ng.
To c
hec
k fo
r pro
per
pot
funct
ion,
chec
k vo
ltag
e at
w
hite/
blu
e w
ire.
Voltag
e sh
ould
be
bet
wee
n 0
V a
nd
5V,
and w
ill v
ary
with p
ot
leve
r posi
tion.
Dis
connec
ted o
r fa
ulty
ther
mis
tor
will
cau
se
com
pre
ssor
to b
e dis
able
d.
Red
wire
at A
/C p
ot
should
hav
e ap
pro
xim
atel
y 5V
with ignitio
n o
n.
White
wire
will
hav
e co
ntinuity
to
chas
sis
gro
und.
White/
Blu
e w
ire
should
var
y bet
wee
n 0
V a
nd 5
V w
hen
le
ver
is m
oved
up o
r dow
n.
3. Com
pre
ssor
will
not
turn
off
(A
ll oth
er funct
ions
work
).
Chec
k fo
r fa
ulty
A/C
pote
ntiom
eter
or
asso
ciat
ed
wirin
g.
Chec
k fo
r fa
ulty
A/C
rel
ay.
Rep
air
or
repla
ce p
ot/
contr
ol w
irin
g.
Rep
lace
rel
ay.
See
blo
wer
sw
itch
chec
k pro
cedure
.
ww
w.v
inta
gea
ir.c
om
24 904062 REV E 11/04/15, PG 24 OF 26
Sym
pto
m
C
on
dit
ion
Ch
eck
s
Act
ion
s
N
ote
s
Sys
tem
will
not
turn
on,
or
runs
inte
rmitte
ntly.
4.
Work
s w
hen
engin
e is
not
runnin
g;
shuts
off w
hen
en
gin
e is
sta
rted
(T
ypic
ally
ear
ly G
en I
V,
but
poss
ible
on a
ll ve
rsio
ns)
.
Nois
e in
terf
eren
ce f
rom
either
ig
nitio
n o
r al
tern
ator.
Inst
all ca
pac
itors
on ignitio
n c
oil
and a
lter
nat
or. E
nsu
re
good g
round a
t al
l poin
ts.
Rel
oca
te c
oil
and a
ssoci
ated
w
irin
g a
way
fro
m E
CU
and E
CU
wirin
g.
Chec
k fo
r burn
edor
loose
plu
g w
ires
.
Ver
ify
connec
tions
on p
ow
er
lead
, ig
nitio
n lea
d,
and b
oth
white
gro
und w
ires
.
Ver
ify
pro
per
met
er f
unct
ion b
y ch
ecki
ng t
he
conditio
n o
f a
know
n g
ood b
atte
ry.
Ignitio
n n
ois
e (r
adia
ted o
rco
nduct
ed)
will
cau
se t
he
syst
em t
o s
hut
dow
n d
ue
tohig
h v
oltag
e sp
ikes
. If
this
is s
usp
ecte
d,
chec
k w
ith a
qual
ity
osc
illosc
ope.
Spik
esgre
ater
than
16V w
ill s
hut
dow
n t
he
ECU
. In
stal
l a
radio
cap
acitor
at t
he
posi
tive
post
of th
e ig
nitio
nco
il (S
ee r
adio
cap
acitor
inst
alla
tion b
ulle
tin).
A
faulty
alte
rnat
or
or
worn
out
bat
tery
can
als
o r
esult
in t
his
conditio
n.
Will
not
turn
on u
nder
an
y co
nditio
ns.
Ver
ify
bat
tery
voltag
e is
gre
ater
than
10 v
olts
and les
sth
an 1
6.
Loss
of m
ode
door
funct
ion.
No m
ode
chan
ge
at a
ll.Chec
k fo
r dam
aged
mode
switch
or
pote
ntiom
eter
and
asso
ciat
ed w
irin
g.
Part
ial fu
nct
ion o
f m
ode
doors
.
Typic
ally
cau
sed b
y ev
apora
tor
housi
ng
inst
alle
d in a
bin
d in t
he
vehic
le.
Be
sure
all
mounting loca
tions
line
up
and d
on’t h
ave
to b
e fo
rced
in
to p
osi
tion.
Blo
wer
turn
s on
and o
ff r
apid
ly.
6.
Bat
tery
voltag
e is
at
leas
t 12V.
Chec
k fo
r at
lea
st 1
2V a
t ci
rcuit b
reak
er.
Ensu
re a
ll sy
stem
gro
unds
and p
ow
er c
onnec
tions
are
clea
n a
nd t
ight.
Bat
tery
voltag
e is
les
s th
an 1
2V.
5.
Tro
ub
lesh
oo
tin
g G
uid
e (
Co
nt.
)
Chec
k fo
r fa
ulty
bat
tery
or
alte
rnat
or.
Char
ge
bat
tery
.
Sys
tem
shuts
off b
low
er a
t 10V.
Poor
connec
tions
or
wea
k bat
tery
can
cau
se
shutd
ow
n a
t up t
o 1
1V.
7. When
ignitio
n is
turn
ed o
n,
blo
wer
m
om
enta
rily
co
mes
on,
then
sh
uts
off.
This
occ
urs
with t
he
blo
wer
sw
itch
in
the
OFF
posi
tion.
This
is
an indic
ator
that
the
syst
em h
as b
een r
eset
. Be
sure
the
red p
ow
er w
ire
is o
nth
e bat
tery
post
, an
d n
ot
on a
sw
itch
ed s
ourc
e. A
lso,
if
the
syst
em is
pulle
d b
elow
7V f
or
even
a s
plit
sec
ond,
the
syst
em w
ill r
eset
.
Run r
ed p
ow
er w
ire
direc
tly
to b
atte
ry.
Chec
k fo
r posi
tive
pow
er a
t hea
ter
valv
e gre
en w
ire
and
blo
wer
red
wire.
Chec
k fo
r gro
und o
n c
ontr
ol hea
d w
hite
wire.
Chec
k fo
r obst
ruct
ed o
r bin
din
g m
ode
doors
.
Chec
k fo
r dam
aged
ste
pper
m
oto
r or
wirin
g.
Err
atic
funct
ions
of
blo
wer
, m
ode,
te
mp,
etc.
Chec
k fo
r dam
aged
sw
itch
or
pot
and a
ssoci
ated
wirin
g.
Rep
air
or
repla
ce.
8.
25
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904062 REV E 11/04/15, PG 25 OF 26
Templates: Driver Side Under Dash Louver Bezel
& Defrost Duct Mounting
Drill 3/16”
Drill 3/16”
Cut
Alo
ng D
otte
d Li
ne
Dri
ver
Sid
e U
nd
er D
ash
Lou
ver
Tem
pla
te
3.375”
Defrost D
uct M
oun
ting
Temp
late
Align This Edge AgainstDash Brace
Cut A
long Dotted Line
Cut
Alo
ng D
otte
d Li
ne
26
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904062 REV E 11/04/15, PG 26 OF 26
Packing List: Evaporator Kit (564062)
No. 1.2.
Qty.11
Part No.744004-VUE784062
DescriptionGen IV Evaporator Sub CaseAccessory Kit
NOTE: Images may not depict actual parts and quantities. Refer to packing list for actual parts and quantities.
1
2
Gen IV Evaporator Sub Case
744004-VUE
Accessory Kit784062
Checked By:Packed By:
Date: