1966-77 Ford Bronco - Vintage Air · 2017-10-16 · Sub Case w/ 204 ECU 744004-VUE Gen IV 4-Vent...

1966-77 Ford BroncoEvaporator Kit

with 4-Vent Plenum751151

908179 REV F 5/24/16, INSTRUCTIONS, EVAPORATOR KIT 751151, PG 1 OF 22

an ISO 9001:2008 Registered Company

18865 Goll St. San Antonio, TX 78266 ph: 210-654-7171 fax: 210-654-3113


Cover..................................................................................................................................Table of Contents.................................................................................................................Packing List/Parts Disclaimer..................................................................................................Information Page..................................................................................................................Wiring Notice.......................................................................................................................Engine Compartment Disassembly, Condenser Assembly and Installation, Compressor and Brackets.............................................................................................................................Passenger Compartment....................................................................................................... Defrost Duct Hose Adapter Installation, Evaporator Bracket and Heater Hose Fitting Installation .............................................................................................Evaporator Bracket and Heater Hose Fitting Installation (Cont.).................................................. Airbox Modification............................................................................................................. Evaporator Installation........................................................................................................Drain Hose Installation, Lubricating O-rings, A/C Hose Installation............................................ Heater Hose & Heater Control Valve Installation...................................................................... Under Dash Louver Installation............................................................................................. Final Steps........................................................................................................................ Control Panel & Duct Hose Routing........................................................................................ Wiring Diagram..................................................................................................................Gen IV Wiring Connection Instruction....................................................................................Operation of Controls..........................................................................................................Troubleshooting Guide........................................................................................................Troubleshooting Guide (Cont.)..............................................................................................Packing List.......................................................................................................................

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6 7

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Table of Contents

Additional Info: Please Read Before Beginning

The following parts (not included with this kit) may be required for some installations:

Fan Shroud: Vintage Air Part # 32067-LFFFan Blade: Vintage Air Part # 32917-VUFUpper Radiator Hose: Gates Hose Part # 22628


Evaporator Kit (751151)

1

Accessory Kit791178

2

No. Qty. Part No. Description

NOTE: Images may not depict actual parts and quantities. Refer to packing list for actual parts and quantities.

Gen IV 4-Vent Evaporator Sub Case w/ 204 ECU

744004-VUE

Gen IV 4-Vent Evaporator Sub Case w/ 204 ECUAccessory Kit, 66-77 Ford Bronco with 4-Vent Plenum

1.2.

11

744004-VUE791178

** 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.

Packing List


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.


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.

•

•

•


Engine Compartment

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:

Condenser Assembly and Installation Refer to separate instructions included with the condenser kit to install the condenser.

Binary switch installation (Refer to condenser instructions).

1.

2.

Compressor and Bracket Refer to separate instructions included with the bracket kit to install the compressor and bracket.1.

1. Disconnect battery.

2. Remove battery and battery tray (retain).

3. Remove OEM fan & fan shroud (retain).

4. Drain and remove radiator (retain).

5. Remove all OEM heater hoses (discard).

Radiator

Battery

Fan & Fan Shroud

Figure 1


Figure 2aFigure 2b

OEM HeaterAssembly

OEM Heater Control Knobs

Ashtray

Glove Box & Glove Box

Door

Passenger Compartment Perform the Following:

Radio

1. Remove glove box door (retain) and glove box (discard).2. Disconnect all wires and cables from OEM heater control knobs.3. Remove OEM heater control knobs. 4. Remove OEM heater assembly (discard).5. Remove OEM duct hose from defrost ducts (discard).6. Remove passenger side OEM kick panel fresh air cap (discard).

Figure 2

Defrost Duct Hose

Passenger SideOEM Kick Panel Fresh Air Cap


Figure 3a

Figure 4

Evaporator FrontBracket648161

(2)1/4-20 X ½”Hex Bolts

1. On a workbench, install evaporator rear bracket and heater hose fittings with properly lubricated O-rings (See Figure 5, Page 9, and Figure 10, Page 12).

2. Install front mounting bracket onto evaporator using (2) 1/4-20 x 1/2” hex bolts, and tighten as shown in Figure 4, below.

1. Install (2) S-clips onto driver and passenger side hose adapters (See Figure 3a, below).

2. Install driver and passenger side hose adapters onto OEM defrost ducts as shown in Figure 3, below.

Evaporator Bracket andHeater Hose Fitting Installation

Defrost DuctHose Adapter Installation

(2) S-Clips

HoseAdapter

49168-VCI

Figure 3


Evaporator Bracket andHeater Hose Fitting Installation (Cont.)

Figure 5

Twist WithThis

Wrench

Lubricate O-ring(See Figure 10,

Page 12)

Hold With This Wrench

ECU Module

RearEvaporator

Bracket648162

(2) 1/4-20 X ½”Hex Bolts

(2) 1/4-20 x ½”Hex Bolts

(2) HeaterFittings121004

(2) #10 O-rings


Airbox Modification

2”2”

2”2”

2”

2”2”

2”

1. Drill (4) 1 ¼” holes in airbox (See Figure 6, below).

2. Install (4) 1 ¼” grommets in airbox. (See Figure 6a, below).

Figure 6

Figure 6a

Figure 7

Figure 7a

Figure 7b

Drill (4) 1 ¼” Holes

(4) 1 ¼” Grommets

#10 A/CHose

#10 A/C Hose

#6 A/C Hose

(2) HeaterHose

(3) OEMScrews

Kick Panel Fresh Air Cap Installation1. Install (4) grommets in kick panel fresh air cap (See Figure 7b, below).

2. Route A/C and heater hoses through fresh air box and kick panel fresh air cap as shown in Figures 7 and 7a, below.

3. Apply a 1/4” bead of silicone around the back side of the kick panel fresh air cap as shown in Figure 7b, below.

4. Secure kick panel fresh air cap using (3) OEM screws as shown in Figure 7a, below.

HeaterHoses

#6 A/CHose

Back Side of Kick Panel

Fresh Air Cap

Kick PanelFresh Air Cap

648166

Silicone (4)Grommets33137-VUI


Figure 8a

Photo 1

Figure 8

Evaporator Installation

NOTE: After installing #10 suction line, wrap allexposed metal (fittings & tube) with supplied press tape.

1. Install (2) 1 ¼” grommets in firewall (See Figure 8, below).2. Enlarge 1/2” hole on firewall to 5/8” and install 3/8” grommet as shown in Figure 8 and Photo 1, below.3. Install A/C & heater hoses as shown in Figure 8a, below.4. Lift evaporator unit up under the dashboard. Secure loosely to the firewall using a 1/4-20 x 1” hex bolt, (2) flat washers and a 1/4” nut with star washer (See Figure 9, below). NOTE: To ensure proper drainage, it is very important that the evaporator is level, both left-right and fore-aft. Check for level on the flat portions of the case around the drain.5. Using front evaporator bracket as a guide, mark and drill (2) 3/16” holes in cowl (See Figure 8, below).6. Using (2) #14 x 3/4” sheet metal screws, secure the front evaporator mounting bracket to the inner cowl (See Figure 8, below).7. Verify that evaporator unit is level and square to the dash; then tighten all mounting bolts. NOTE: Tighten the bolt on the firewall first. Then tighten the front mounting bracket.

#6 A/C Hose

#10 A/C Hose

Heater Hose(To Heater Control Valve,

Then to Manifold)

Heater Hose(To Water Pump) Hose

Clamps

PressTape

(2) 1 ¼”Grommets33132-VUI

1/4-20 X 1”Hex Bolt

1/4” Nut w/Star Washer

1/4” Flat Washer

(2) #14 x 3/4”Sheet Metal

Screws

(2) Drill 3/16”Holes

Enlarge 1/2” Hole to 5/8”

3/8” Grommet33144-VUI

Engine Compartment View


1. Locate the #8 compressor A/C hose. Lubricate (2) #8 O-rings (See Figure 10, above) and connect the 135° female fitting with 134a service port to the #8 discharge port on the compressor. Route the 90° female fitting to the #8 condenser hardline (See Figure 11, Page 13). Tighten each fitting connection as shown in Figure 10, above.

2. Locate the #10 compressor A/C hose. Lubricate (2) #10 O-rings (See Figure 10, above) and connect the #10 135° female fitting with 134a service port to the #10 suction port on the compressor. Route the 90° female fitting to the #10 fitting on evaporator (See Figure 8a, Page 11, and Figure 11, Page 13). Tighten each fitting connection as shown in Figure 10, above.

3. Locate the #6 evaporator A/C hose. Lubricate (2) #6 O-rings (See Figure 10, above) and connect the 90° female fitting to the drier. Route the 90° female fitting to the #6 fitting on evaporator (See Figure 8a, Page 11, and Figure 11, Page 13). Tighten each fitting connection as shown in Figure 10, above.

A/C Hose InstallationStandard Hose Kit:

Modified A/C Hose Kit:1. Refer to separate instructions included with modified hose kit.

1. Locate evaporator drain on bottom of evaporator case.

2. In line with the drain, lightly make a mark on the firewall. Measure one inch down and drill a 5/8” hole through the firewall (See Figure 9, below).

3. Install drain hose to bottom of evaporator unit and route through firewall (See Figure 9, below).

Drain Hose Installation

1” DrainDrainHose

Figure 10

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 9


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Heater Hose & Heater Control Valve Installation1. Route a piece of heater hose from the water pump to the top heater fitting of the heater core as shown in Figure 8a, Page 11, and Figure 11, below. Secure using hose clamps.2. Route a piece of heater hose from the intake to the bottom heater fitting of the heater core as shown in Figure 8a, Page 11, and Figure 11, below. NOTE: Install heater control valve in line with intake manifold (pressure side) heater hose, and secure using hose clamps as shown in Figure 11, below. Also note proper flow direction.


Under Dash Louver Installation

Figure 12

1. Install louvers under dash using (8) #8 x 1/2” Phillips pan head screws (See Figure 12, below).

Under DashRectangle Louver

49059-VUL

Under DashRectangle Louver

49059-VUL

Under DashBall Louver49054-VUL

Under DashBall Louver49054-VUL


Figure 13

Figure 14

Final Steps 1. Install duct hoses as shown in Figure 15, Page 16. 2. Route A/C wires (12 volt/grounds/binary switch/heater valve) through 3/8” grommet as shown in Figure 13, 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 15, Page 16 (Wire according to wiring diagrams on Pages 17 and 18). 5. Trim the driver side of the new glove box insert for the OEM fuse panel (See Figure 14, below). NOTE: Applies to 1972-77 Bronco only. 6. Install glove box into opening. NOTE: Carefully squeeze glove box to fit into opening in dash. Then insert glove box and allow it to spring back into shape. Install fuse panel using OEM screws. Secure glove box with OEM screws. 7. Install glove box door using OEM screws. 8. Reinstall all previously removed items. 9. 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.10. Double check all fittings, brackets and belts for tightness.11. Vintage Air recommends that all A/C systems be serviced by a certified automotive air conditioning technician. 12. Evacuate the system for a minimum of 45 minutes prior to charging, and perform a leak check prior to servicing. 13. Charge the system to the capacities stated on Page 4 of this instruction manual. 14. See Operation of Controls procedures on Page 19.

GloveBox

49577-LFI

NOTE: On 1972-77 Bronco Only, Trim Glove Box for OEM Fuse Panel.

Grommet33144-VUI

Wiring Harness(12 Volt/Grounds/Binary Switch)

Wiring Harness(Heater Control Valve)


Figure 15

Passenger SideDefrost Duct

2” X 12”

Driver SideDefrost Duct

2” X 24”

Driver SideLouver

2 ½” X 36”

Passenger SideLouver

2 ½” X 46”

Control Paneland Duct Hose Routing

Plug FromControl Wiring

Harness232002-VUA

FromControl Panel

Driver SideCenter Louver

2 ½” X 15”

Passenger SideCenter Louver

2 ½” X 18”

Plug FromWiring Harness232001-VUR


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


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.


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

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).

Blower Speed

ModeControl

TemperatureControl


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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

.


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.


Gen IV 4-Vent Evaporator Sub Case w/ 204 ECU

744004-VUE

Checked By:Packed By:

Date:

Evaporator Kit (751151)

Accessory Kit791178

No. Qty. Part No. Description

NOTE: Images may not depict actual parts and quantities. Refer to packing list for actual parts and quantities.

Gen IV 4-Vent Evaporator Sub Case w/ 204 ECUAccessory Kit, 66-77 Ford Bronco with 4-Vent Plenum

1.2.

11

744004-VUE791178

Packing List

1

2

Date post:	15-Apr-2020
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1966-77 Ford Bronco - Vintage Air · 2017-10-16 · Sub Case w/ 204 ECU 744004-VUE Gen IV 4-Vent...

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