1963 CHEVY IMPALA WITHOUT FACTORY AIR
561063
903063 REV C 7/7/14 1963 IMPALA w/o EVAP INST PG 1 OF 25
an ISO 9001:2008 Registered Company
2903063 REV C 7/7/14, 1963 IMPALA w/o EVAP INST PG 2 OF 25
PAGES
Table of Contents
1. COVER 2. TABLE OF CONTENTS 3. PACKING LIST / PARTS DISCLAIMER 4. INFORMATION PAGE 5. WIRING NOTICE 6. ENGINE COMPARTMENT FIGURE 1 7. CONDENSER ASSEMBLY, COMPRESSOR & BRACKET, PULLEYS, & PASSENGER COMPARTMENT FIGURES 2, 2a & 3 8. DEFROST DUCT INSTALLATION & FRESH AIR COVER INSTALLATION FIGURES 4 & 5 9. KICK PANEL INSTALLATION & FIGURES 6, 6a, 7 & 7a10.
& 8a 11. FIGURE 9 & 9a12. FIREWALL CAP INSTALLATION & DRAIN HOSE INSTALLATION FIGURES 10,10a & 1113.
FIGURES 12,12a & 13 & 13a 14. LUBRICATING O-RINGS, A/C HOSE INSTALLATION, & MODIFIED A/C HOSE KIT FIGURE 1415. HEATER HOSE & HEATER CONTROL VALVE INSTALLATION FIGURE 1516. AC & HEATER HOSE ROUTING FIGURE 16 17. FINAL STEPS & GLOVE BOX INSTALLATION FIGURES 17,18 & 18a18.
20. WIRING DIAGRAM21. GEN IV WIRING CONNECTION INSTRUCTIONS22. OPERATION OF CONTROLS23. TROUBLE SHOOTING INFORMATION24. 25. EVAPORATOR KIT PACKING LIST
19. EVAPORATOR HARDLINE INSTALLATION FIGURE 20
TROUBLE SHOOTING INFORMATION CONT.
FIREWALL COVER INSTALLATION
EVAPORATOR INSTALLATION FIGURES 8
EVAPORATOR INSTALLATION CONT.
DRIVER SIDE UNDER DASH LOUVER INSTALLATION & CENTER/ PASSENGER SIDE UNDER DASH LOUVER INSTALLATION
CONTROL PANEL & DUCT HOSE ROUTING FIGURE 19
3903063 REV C 7/7/14 1963 IMPALA w/o EVAP INST PG 3 OF 25
** 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.
EVAPORATOR KIT PACKING LISTEVAPORATOR KIT
561063No. QTY. PART No. DESCRIPTION
1.2.
11 784063
744004-VUE
1
ACCESSORY KIT784063
2
GEN IV 4 VENTAP. SUB CASE
EV
744004-VUE
GEN IV 4 VENT EVAP. SUB CASE 1963 IMPALA w/o AC ACC. KIT
NOTE: IMAGES MAY NOT DEPICT ACTUAL PARTS AND QUANTITIES.REFER TO PACKING LIST FOR ACTUAL PARTS AND QUANTITIES.
4903063 REV C 7/7/14, 1963 IMPALA w/o EVAP INST PG 4 OF 25
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.
5903063 REV C 7/7/14 1963 IMPALA w/o EVAP INST PG 5 OF 25
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.
•
•
•
6903063 REV C 7/7/14, 1963 IMPALA w/o EVAP INST PG 6 OF 25
INSTALLATION INSTRUCTIONS FOR 1963 IMPALA w/o AC
ENGINE COMPARTMENT
BEFORE STARTING THE AIR CONDITIONER INSTALLATION, CHECK FOR PROPER OPERATION OF ALL COMPONENTS (RADIO,LIGHTS, WIPERS, ETC.). STUDY THE INSTRUCTIONS, ILLUSTRATIONS AND DIAGRAMS. FOR EASE OF INSTALLATION
CHECK OFF ( ) EACH PROCEDURE PRIOR TO MOVING ON TO THE NEXT STEP.
FIGURE 1
DISCONNECT BATTERY AND REMOVEDRAIN RADIATORREMOVE O.E.M. HEATER/ BLOWER ASSEMBLY (DISCARD) SEE FIGURE 1 TO REMOVE OEM HEATER/ BLOWER ASSEMBLY. THE FACTORY MANUAL INDICATES DOING THE FOLLOWING, .
REMOVE RIGHT INNER FENDER
O.E.M. HEATER/BLOWER
ASSEMBLY
RIGHT INNERFENDER
7903063 REV C 7/7/14 1963 IMPALA w/o EVAP INST PG 7 OF 25
O.E.M.HEATER
ASSEMBLY
O.E.M.DEF DUCTASSEMBLY
RADIO
INSTRUMENT PANEL
GLOVE BOX
DOOR
SPEAKER
O.E.M.CONTROL PANEL
REMOVE INSTRUMENT PANEL, SEE FIGURE 2 BELOW.REMOVE THE OEM CONTROL PANEL ASM. SEE FIGURE 2 BELOWREMOVE GLOVE BOX DOOR
DEFROSTREMOVE O.E.M HEATER ASSM BLY SEE FIGURE 2a BELOW.REMOVE O.E.M DUCT ASSEMBLY, SEE FIGURE 2a & 3 BELOW.(REMOVE SPOT WELDS ON DEF DUCT BY CHISEL OR DIE GRINDER. SEE FIGURE 3 BELOW.)
REMOVE GLOVE BOX (DISCARD)REMOVE RADIO,SPEAKER (RETAIN)
E
PASSENGER COMPARTMENT
CONDENSER ASSEMBLY & INSTALLATION
REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH THE CONDENSER KIT TO INSTALL THE CONDENSER.BINARY SWITCH INSTALLATION (REFER TO CONDENSER INSTRUCTIONS)
REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH THE BRACKET KIT TO INSTALL THE COMPRESSOR BRACKET.
IN MOST INSTANCES THE BELT LENGTHS WILL REMAIN THE SAME.
COMPRESSOR & BRACKETS
PULLEYS
FIGURE 2
FIGURE 2aFIGURE 3
USE A CHISEL ORDIE GRINDER TO
BREAK SPOT-WELDS
DEFROST DUCT
ASSEMBLY
INNER COWL
DASH SUPPORT
8903063 REV C 7/7/14, 1963 IMPALA w/o EVAP INST PG 8 OF 25
DEFROST DUCT
INSTALLATION
FIGURE 4
(2) #10 X 1/2” SHEET METAL
SCREWS
1/4-20 x 1”BOLT w/ WASHER
FRESH AIR COVER INSTALLATIONAPPLY A 1/4“ BEAD OF SILICONE AROUND THE BACK SIDE OF THE FRESH AIR CAP AS SHOWN IN FIGURE 5, BELOW.
ATTACH FRESH AIR CAP TO FIREWALL USING A 1/4-20 x 1" BOLT AND WASHER, SEE FIGURE 5, BELOW.
SILICONE OEM HEATER HOLES
BACK SIDEOF FRESH AIR
CAP
FRESH AIRCAP
FIGURE 5
PLACE DEFROST DUCT UNDER DASH, ALIGN WITH O.E.M. DEFROST OPENING IN DASH. DRILL (2) 1/8 HOLES IN COWL USING DEFROST DUCT HOLE AS TEMPLATE. SECURE USING (2) #10 x 1/2 SHEET METAL SCREWS AS SHOWN BELOW IN FIGURE 4.
9903063 REV C 7/7/14 1963 IMPALA w/o EVAP INST PG 9 OF 25
FIGURE 7
FIREWALL COVER INSTALLATION
APPLY A 1/4” BEAD OF SILICONE AROUND THE FIREWALL COVER AS SHOWN IN FIGURE 7a.
FROM INSIDE THE CAR, INSTALL FIREWALL COVER ON FIREWALL SEE FIGURE 7. FROM THE ENGINE COMPARTMENT SECURE FIREWALL COVER TO FIREWALLUSING (3) 1/4-20 x 1” HEX BOLTS WITH WASHERS AND 1/4-20 COARSE NUT w/ STARWASHER. SEE FIGURE 7.
INSTALL GROMMET ON FIREWALL COVER AS SHOWN IN FIGURE 7.
(3) 1/4-20 COARSE NUT w/ STARWASHER
(3) 1/4-20 x 1” HEX BOLTS
w/ FLAT WASHERS
VIEW SHOWN FROM INSIDE CAR.
33144-VUIGROMMET
7/8 OD x 3/8 ID
ENGINE SIDEOF FIREWALL
COVER
FIGURE 7a
SILICONE
643166FIREWALLCOVER
KICK PANEL INSTALLATION
REMOVE THE PASSENGER SIDE KICK PANEL BY REMOVING THE (2) #10 x 1” PH PAN HEAD SCREWS, DISCONNECT THE FRESH AIR CABLE FROM DOOR AND DISCARD CABLE ASSEMBLY. CLOSE FRESH AIR DOOR ASSEMBLY IN KICK PANEL AND SEAL DOOR w/ 1/4” BEAD OF SILICONE AROUND DOOR AS SHOWN IN FIGURE 6.
INSTALL PASSENGER SIDE KICK PANEL USING THE (2) OEM SCREWS AS SHOWN IN FIGURE 6a.
#10 x 1” PHPAN HEADSCREWS
PASSENGER SIDEKICK PANEL
FRESH AIR DOOR
1/4” BEADOF
SILICONE
FIGURE 6 FIGURE 6a
10903063 REV C 7/7/14, 1963 IMPALA w/o EVAP INST PG 10 OF 25
INSTALL (2) 1/4-20 x 1” HEX BOLT AND 1/4” PUSH-ON NUT ON EVAP REAR BRKT AS SHOWN IN FIGURE 8a BELOW. INSTALL EVAPORATOR FRONT & REAR MOUNTING BRACKETS ON EVAPORATOR USING (6)1/4-20 x 1/2” HEX BOLTS AND TIGHTEN AS SHOWN IN FIGURE 8 & 8a BELOW. INSTALL (2) A/C HARDLINES WITH PROPERLY
ON A WORK BENCH INSTALL (2) HEATER LINE WITH PROPERLY LUBRICATED O-RINGS. (SEE FIGURE 13 PAGE 14, AND FIGURE 19 PAGE 19.)
LUBRICATED O-RINGS. (SEE FIGURE 13 PAGE 14, AND FIGURE 19 PAGE 19.)
EVAPORATOR INSTALLATION
FIGURE 8
FIGURE 8a
EVAP FRONTBRKT
643163
(2) 18290-VUB1/4-20 x 1”HEX BOLT
189125-MUR1/4” PUSH NUTBOLT RETAINER
18287-VUB(2)1/4-20 x ½”
HEX BOLT
18287-VUB(2) 1/4-20 x ½”
HEX BOLT
18287-VUB(2) 1/4-20 x ½”
HEX BOLT
EVAP REARBRKT
643164
11903063 REV C 7/7/14 1963 IMPALA w/o EVAP INST PG 11 OF 25
FIGURE 9
EVAPORATOR INSTALLATION CONT.
LIFT EVAPORATOR UNIT UP UNDER THE DASHBOARD SEE FIGURE . SECURE 9 LOOSELY TO THE FIREWALL FROM THE ENGINE COMPARTMENT SIDE USING (2) 1/4-20 NUTS w/ STAR WASHER AND FLAT WASHERS, SEE FIGURE 9. USING OEM SCREW SECURE THE FRONT EVAPORATOR MOUNTING BRACKET TO OEM SPEAKER MOUNTING BRKT. SEE FIGURE 9 AND 9a.
VERIFY THAT EVAPORATOR UNIT IS LEVEL AND SQUARE TO THE DASH, THEN TIGHTEN ALL MOUNTING BOLTS.(NOTE: TIGHTEN THE BOLT ON FIREWALL FIRST, THEN THE FRONT MOUNTING BRACKET SCREWS.)
FIGURE 9a
EVAPORATORBRACKET
MOUNTING HOLES
OEMFASTENER
SPEAKERBRKT OEM
SCREW
EVAP FRONTBRKT
12903063 REV C 7/7/14, 1963 IMPALA w/o EVAP INST PG 12 OF 25
DRAINHOSE
EVAPORATORCASE
1”
1”2 1/2”
FIREWALL CAP INSTALLATION INSTALL GROMMETS ON FIREWALL CAP AS SHOWN IN FIGURE 10 BELOW.
PASS LINES THROUGH FIREWALL CAP, AND SECURE WITH (3) #10 x 1/2 SHEET METAL SCREWS. SEE FIGURE 10 BELOW.
APPLY A 1/4“ BEAD OF SILICONE AROUND THE BACK SIDE OF THE FIREWALL CAP AS SHOWN IN FIGURE 10a BELOW.
FIGURE 10
FIGURE 10a
IN-LINE WITH DRAIN, LIGHTLY MAKE A MARK ON THE FIREWALL MEASURE 1” DOWN AND 2 1/2” TO THE LEFT AND DRILL A 5/8” HOLE THROUGH THE FIREWALL. SEE FIGURE 11 BELOW.
INSTALL DRAIN HOSE TO BOTTOM OF EVAPORATOR UNIT AND ROUTE THROUGH FIREWALL. SEE FIGURE 11 BELOW.
LOCATE EVAPORATOR DRAIN ON BOTTOM OF EVAPORATOR CASE.
DRAIN HOSE INSTALLATION
FIGURE 11
SILICONE
643167FIREWALL
CAP
33137-VUI
33135-VUI
(3) 18247-VUB#10 x 1/2
SHEET METALSCREWS
13903063 REV C 7/7/14 1963 IMPALA w/o EVAP INST PG 13 OF 25
(3) LOUVERS 49157-VUL
CENTER/PASSENGER SIDE UNDER DASH LOUVER INSTALLATION
(3) 10/32 x 1/2”PAN HEAD SCREWS
w/ NUT w/STAR WASHER
OEMHOLE
PLACE LOUVER BEZEL UNDER DASH AND ALIGN WITH O.E.M. HOLE IN PASSENGER SIDE DASH SEE FIGURE 13 BELOW. ALIGN LOUVER BEZEL UNDER DASH AND USE LOUVER BEZEL HOUSING AS YOUR GUIDETO MARK AND DRILL (2) 3/16 HOLES UNDER DASH.SECURE LOUVER BEZEL UNDER DASH USING (3) 10/32 x 1/2” PAN HEAD SCREW w/ 10/32 NUTS w/ STAR WASHERSEE FIGURE 13 BELOW.INSTALL LOUVER IN UNDER DASH BEZEL AS SHOWN IN FIGURE 13a BELOW.
FIGURE 13
DRIVER SIDE UNDER DASH LOUVER INSTALLATION
PLACE LOUVER BEZEL UNDER DASH AND ALIGN TO DASH.
SECURE LOUVER BEZEL UNDER DASH USING (2) 10/32 x 1/2” PAN HEAD SCREW w/ 10/32 NUT w/ STAR WASHER
INSTALL LOUVER IN UNDER DASH BEZEL AS SHOWN IN FIGURE 12a BELOW.
ALIGN LOUVER BEZEL UNDER DASH AND USE LOUVER BEZEL HOUSING AS YOUR GUIDETO MARK AND DRILL (2) 3/16 HOLES UNDER DASH.
SEE FIGURE 12 BELOW.
FIGURE 12a
FIGURE 12
(2) 10/32 x 1/2PAN
HEAD SCREWSw/NUT w/ STAR WASHER
49157-VUL LOUVERS
FINAL ASSEMBLY
FIGURE 13a
14903063 REV C 7/7/14, 1963 IMPALA w/o EVAP INST PG 14 OF 25
LOCATE THE #8 COMPRESSOR A/C HOSE. LUBRICATE (2) #8 O-RINGS (SEE FIGURE 14, ABOVE) AND CONNECTTHE 135° FEMALE FITTING w/134a SERVICE PORT TO THE #8 DISCHARGE PORT ON THE COMPRESSOR.ROUTE THE STRAIGHT FEMALE FITTING TO THE #8 CONDENSER HARDLINE COMING THROUGH 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 w/134a SERVICE PORT TO THE #10 SUCTION PORT ON THE COMPRESSOR. 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 14 ABOVE.
LOCATE THE #6 EVAP/CORE HARDLINE AND LUBRICATE (2) #6 O-RINGS (SEE FIGURE 14 , ABOVE) AND CONNECT THE HARDLINE TO THE #6 HARDLINE COMING THROUGH THE CORE SUPPORT FROM DRIER. 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 & #10 ADEL CLAMP TO SECURE THE #6 EVAP/ CORE HARDLINE AND THE 5/8” HEATER HOSE TO THEINNER FENDERWELL AS SHOWN IN FIGURE 16, PAGE 16. SECURE THE ADEL CLAMP TO THE INNER FENDER USING(2)10-32 x ½” PH PAN HEAD SCREWS w/ NUTS.
(NOTE: WRAP THE #10 FITTING CONNECTIONS WITH PRESS TAPE. SEE FIGURE 15, PAGE 15.
A/C HOSE INSTALLATIONSTANDARD HOSE KIT
REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH MODIFIED HOSE KIT.
MODIFIED A/C HOSE KIT
LUBRICATING O-RINGS
#6 O-RING
#8 O-RING #10 O-RING
HOLD WITHTHIS WRENCH
FOR A PROPER SEAL OF FITTINGS:INSTALL SUPPLIED O-RINGS AS SHOWNAND LUBRICATE WITH SUPPLIED OIL.
O-RING
SUPPLIED OIL FOR O-RINGS O-RING, INSTALLS
OVER MALE INSERTTO SWAGED LIP
MALEINSERT
FEMALENUT
O-RING
TWIST WITHTHIS WRENCH
FIGURE 14
15903063 REV C 7/7/14 1963 IMPALA w/o EVAP INST PG 15 OF 25
ROUTE A PIECE OF HEATER HOSE FROM THE WATER PUMP TO THE HEATER LINE COMING THROUGH THE FIREWALLAS SHOWN IN FIGURE 15 . SECURE USING HOSE CLAMPS.
INSTALL HEATER CONTROL VALVE IN-LINE WITH INTAKE MANIFOLD (PRESSURE SIDE) HEATER HOSE, SECURE USING HOSE CLAMPS AS SHOWN IN FIGUREBELOW.
, BELOW
ROUTE A PIECE OF HEATER HOSE FROM THE INTAKE TO THE HEATER LINE COMING THROUGH THE FIREWALLAS SHOWN IN FIGURE 15, BELOW. NOTE:
15, NOTE PROPER FLOW DIRECTION.
HEATER HOSE & HEATER CONTROL VALVE INSTALLATIONNOTE: VINTAGE AIR SYSTEMS REQUIRE (2) 5/8 HOSE NIPPLES (NOT SUPPLIED). ONE ONE FOR THE WATER PUMP (SUCTION) - IF REQUIRED REMOVE EXISTING HOSE NIPPLE OR NIPPLES AND INSTALL NEW 5/8 HOSE NIPPLES IN INTAKE AND WATER PUMP.
FOR THE INTAKE (PRESSURE) AND
ECUMODULE
PRESSTAPE
#10 SUCTIONLINE (INSULATED)
091671EXPANSION
VALVE
O-RING
HEATERHOSE
PRESS TAPE
FROM HEATER CONTROL VALVE
NOTE: FLOW DIRECTION FOLLOWS MOLDED ARROW ON VALVE.
FROM INTAKE
FIGURE 15
#10 SUCTIONHOSE
096059
#6 LIQUIDLINE
091061TO
WATER PUMP
16903063 REV C 7/7/14 1963 IMPALA w/o EVAP INST PG 16 OF 25
HEA
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461171
HEA
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#6
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#10 A
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31601-V
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#2 A
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31600-V
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10-3
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w/
NU
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10-3
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643166
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17903063 REV C 7/7/14 1963 IMPALA w/o EVAP INST PG 17 OF 25
FINAL STEPSINSTALL DUCT HOSES AS SHOWN IN FIGURE 19, PAGE 18.ROUTE A/C WIRES THROUGH 3/8” GROMMET AS SHOWN ON FIGURE 16 ( 12 VOLT/ GROUND/ BINARY SWITCH/ HEATER VALVE)
PLUG THE CONTROL PANEL HARNESS INTO THE ECU MODULE ON SUB CASE AS SHOWN IN PAGE 18.
REINSTALL ALL PREVIOUSLY REMOVED ITEMS (BATTERY RADIO, SPEAKER, INSTRUMENT PANEL).FILL RADIATOR WITH AT LEAST A 50/50 MIXTURE OF APPROVED ANTIFREEZE AND DISTILLED WATER.IT IS THE OWNERS 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 CORRODEPREMATURELY AND POSSIBLY BURST IN AC MODE AND/OR FREEZING WEATHER, VOIDING YOUR WARRANTY.DOUBLE CHECK ALL FITTINGS, BRACKETS AND BELTS FOR TIGHTNESS.VINTAGE AIR RECOMMENDS THAT ALL AC SYSTEMS BE SERVICED BY A CERTIFIED AUTOMOTIVE AIR CONDITIONINGTECHNICIAN.EVACUATE THE SYSTEM FOR A MINIMUM OF 45 MINUTES PRIOR TO CHARGING AND LEAK CHECK PRIOR TO SERVICING.
CHARGE THE SYSTEM TO THE CAPACITIES STATED ON THE INFORMATION PAGE (PAGE 4) OF THIS INSTRUCTION MANUAL.
INSTALL CONTROL PANEL ASM.
PLUG THE WIRING HARNESS INTO THE ECU MODULE ON SUB CASE AS SHOWN IN FIGURE 19, PAGE 18. (WIRE ACCORDING TO WIRING DIAGRAM ON PAGE 20 & 21.)
CONTROL PANEL MUST BE CALIBRATED. (REFER TO CONTROL PANEL INSTRUCTIONS FOR CALIBRATION PROCEDURES.GLOVE BOX INSTALLATION ( SEE FIGURE 18)NOTE:
GLOVE BOX INSTALLATIONTHE NEW GLOVE BOX IS MADE IN TWO (2) PIECES FOR EASY INSTALLATION.INSERT BOTTOM HALF OF NEW GLOVE BOX, INTO GLOVE BOX OPENING AND POSITION IN PLACE.INSERT TOP HALF OF GLOVE BOX AND FASTEN TO BOTTOM HALF USING (4) #6 x 3/8" BLACK PAN HEAD PHILLIPS SCREWS (SEE FIGURE 18, BELOW).INSTALL GLOVE BOX DOOR USING (3) OEM SCREWS THROUGH THE TINNERMAN NUTS.INSTALL GLOVE BOX USING (2) OEM SCREWS SEE FIGURE 18a.
GLOVE BOX TOP
624163
(4)#6 x 3/8PH PAN HEAD
SCREWS
FIGURE 18
FIGURE 18a
OEM SCREWS
OEM SCREWS
TINNERMAN NUTS
GLOVE BOX BOTTOM624164
FIREWALLCOVER
3/8” GROMMET
FIGURE 17
WIRING HARNESS(12 VOLT/GROUNDS/BINARY SWITCH)
WIRING HARNESS(HEATER CONTROL VALVE)
18903063 REV C 7/7/14, 1963 IMPALA w/o EVAP INST PG 18 OF 25
CONTROL PANEL & DUCT HOSE ROUTING
DRIVER SIDEDEF. DUCT2” x 15”
DRIVER SIDE LOUVER
2 ½” x 38”
CENTER
DRIVER SIDE2 ½” x 12”
LOUVER
PASS. SIDEDEF. DUCT2” x 15”
PASSENGER
SIDE LOUVER2 ½” x 38”
FIGURE 19
CENTER
PASS. SIDE2 ½” x 16”
LOUVER
PLUGFROM
CONTROLWIRING
HARNESS232002-VUA
PLUGFROM
WIRINGHARNESS
232001-VUR
DRIVER SIDE
LOUVER
PASSENGER
SIDELOUVER
CENTER
DRIVER SIDELOUVER
CENTER
PASSENGER SIDE
LOUVER
19903063 REV C 7/7/14 1963 IMPALA w/o EVAP INST PG 19 OF 25
ECU
MO
DU
LE
PR
ESS
TAPE
#1
0 O
-RIN
G(3
38
59
-VU
F)
#6
O-R
ING
(33857-V
UF)
HEA
TER
LIN
E(E
VA
P TO
INTA
KE)
091661
#6 L
IQU
ID L
INE
091078
HEA
TER
LIN
E(E
VA
P TO
WA
TER
PUM
P)091661
#10 S
UC
TIO
N L
INE
(091671)
#1
0 O
-RIN
G3
38
59
-VU
F
EVA
PO
RA
TOR
HA
RD
LIN
E IN
STA
LLA
TIO
N
FIG
UR
E 2
0
20903063 REV C 7/7/14, 1963 IMPALA w/o EVAP INST PG 20 OF 25
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
21903063 REV C 7/7/14 1963 IMPALA w/o EVAP INST PG 21 OF 25
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.
22903063 REV C 7/7/14, 1963 IMPALA w/o EVAP INST PG 22 OF 25
OPERATION OF CONTROLS
NOTE: WHEN BATTERY POWER IS FIRST CONNECTED TO THE ECU, THE COMPUTER GOES THROUGH AN INITIALIZATION SEQUENCE. THIS INITIALIZATION MAY TAKE UP TO 30 SECONDS. DURING INITIALIZATION THE BLOWER WILL NOT OPERATE, BUT THE DOORS INSIDE THE UNIT WILL BE OPERATING. A LOW BATTERY OR DISCONNECTING THE BATTERY MAY ALSO TRIGGER A RE-INITIALIZATION. DURING START UP, A LOW BATTERY MAY DROP BELOW 7 VOLTS, TRIGGERING RE-INITIALIZATION.
BLOWER SPEEDSLIDE THE FAN LEVER
UP OR DOWNTO SELECT DESIRE
FAN SPEED(SLIDE LEVER ALL THE WAY
DOWN FOR MAXIMUMFAN SPEED)
BLOWER SPEEDSLIDE THE FAN LEVER
UP OR DOWN TO SELECT DESIRE FAN
SPEED (SLIDE LEVER ALL THE WAY DOWN FOR MAXIMUM
FAN SPEED)
BLOWER SPEEDSLIDE THE FAN LEVER
UP OR DOWN TO SELECT DESIRE FAN
SPEED (SLIDE LEVER ALL THE WAY DOWN FOR MAXIMUM
FAN SPEED)
BLOWER SPEEDTHIS LEVER CONTROLS
THE BLOWER SPEED,FROM OFF TO HI
DEFROST MODEHEAT MODE
MODELEVER
THERMOSTATLEVER
SYSTEM OFFA/C MODE
BLOWER SPEED
NOTE: ORIGINAL BLOWER SWITCH WILL NOT BE USED.
THERMOSTAT LEVERIN A/C MODE SLIDE THETEMP LEVER ALL THE WAY
UP TO ENGAGE COMPRESSOR FOR
MAXIMUM COOLING.(SLIDE LEVER UP OR DOWN TO
ADJUST DESIRED TEMPERATURE)
THERMOSTAT LEVERIN HEAT MODE SLIDE THETEMP LEVER ALL THE WAY
DOWN FOR MAXIMUM HEATING.(SLIDE LEVER UP OR DOWN TO
ADJUST DESIRED TEMPERATURE)
THERMOSTAT LEVERIN DEF MODE SLIDE THETEMP LEVER ALL THE WAY
UP TO
(SLIDE LEVER UP OR DOWN TO ADJUST DESIRED TEMPERATURE)
ENGAGE COMPRESSOR FOR MAXIMUM COOLING.
THERMOSTAT LEVERTHIS LEVER CONTROLS
THE TEMPERATUREFROM HOT TO COLD
MODE LEVERSLIDE THE MODE LEVER ALL THE
WAY UP FOR DASH MODE
MODE LEVERSLIDE THE MODE LEVER
TO THE CENTER FOR FLOOR MODE
(SLIDE LEVER UP OR DOWN TO BLEND BETWEEN DESIRED
MODE POSITIONS)
MODE LEVERSLIDE THE MODE LEVER
ALL THE WAY DOWN FOR DEFROST MODE
(SLIDE LEVER UP OR DOWN TO BLEND BETWEEN DESIRED
MODE POSITIONS)
MODE LEVER
THE MODE POSITIONSFROM DASH TO FLOOR
TO DEFROST
THIS LEVER CONTROLS
FANFAN
MODEMODE
TEMPTEMP
FANFAN MODEMODE TEMPTEMP
FAN MODE TEMP
NOTE: CONTROLS MUST BE CALIBRATED PRIOR TO FIRST OPERATION- REFER TO CONTROL PANEL INSTRUCTIONS
23903063 REV C 7/7/14 1963 IMPALA w/o EVAP INST PG 23 OF 25
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
evap
ora
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
.
24903063 REV C 7/7/14 1963 IMPALA w/o EVAP INST PG 24 OF 25
Sym
pto
m
C
on
dit
ion
C
heck
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.
903063 REV C 7/7/14, 1963 IMPALA w/o EVAP INST PG 25 OF 25
CHECKED BY:PACKED BY:
DATE:
EVAPORATOR KIT PACKING LISTEVAPORATOR KIT
561063No. QTY. PART No. DESCRIPTION
1.2.
11 784063
744004-VUE GEN IV 4 VENT EVAP. SUB CASE 1963 IMPALA w/o AC ACC. KIT
1
ACCESSORY KIT784063
2
GEN IV 4 VENTAP. SUB CASE
EV
744004-VUE
NOTE: IMAGES MAY NOT DEPICT ACTUAL PARTS AND QUANTITIES.REFER TO PACKING LIST FOR ACTUAL PARTS AND QUANTITIES.