1970-78 Camaro · 1970-78 Camaro without Factory Air 561173 901196 REV C 12/10/15, INST 1970-78...

1970-78 Camarowithout Factory Air

561173

901196 REV C 12/10/15, INST 1970-78 CAMARO wo AC EVAP KIT PG 1 OF 29

an ISO 9001:2008 Registered Company

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


Table of Contents 3. Packing List/Parts Disclaimer 4. Information Page 5. Wiring Notice 6. Engine Compartment, Condenser Assembly & Installation, Compressor & Brackets, Pulleys Figure 1 7. Passenger Compartment Figures 2 & 3 8. Passenger Side Kick Panel Modification Figures 4 & 4a 9. Defrost Duct/Fresh Air Cover Installation & Hose Adapter Installation Figures 5, 5a & 610. Fresh Air Cap Installation & Kick Panel Fresh Air Cap Installation Figures 7, 8, 8a & 8b11. Firewall Cover & Evaporator Bracket and A/C & Heater Hose Installation Figures 9 & 1012. Evaporator Bracket and Heater Fitting Installation (Cont.) Figure 1113. Evaporator Installation Figures 12 & 12a14. Drain Hose Installation & Center Louver Mounting Holes Figures 13, 14 & 14a15. Center Louver Installation Figures 15 & 15a16. Lubricating O-rings, Standard Hose Kit & Modified A/C Hose Kit Figure 16 17. 1970-73 Camaro Heater Hose & Heater Control Valve Installation Figure 1718. 1974-78 Camaro Heater Hose & Heater Control Valve Installation Figure 1819. Final Steps and Glove Box Installation Figures 19, 20 & 20a20. Control Panel & Duct Hose Routing Figures 21 & 2221. Wiring Diagram22. Gen IV Wiring Connection Instruction23. Operation of Controls24. Troubleshooting Information25. Troubleshooting Information (Cont.)26. Kick Panel Modification Template27. Center Louver Template28. Glove Box Light Template29. Evaporator Kit Packing List


1

Accessory Kit781178

2

4-Vent Evaporator Sub Case w/ 204 ECU

744004-VUE

** Before beginning installation, open all packages and check contents of shipment. Please report any shortages directly to Vintage Air within 15 days. After 15 days, Vintage Air will not be responsible for missing or damaged items.

1.2.

11

744004-VUE781178

4-Vent Evap orator Sub Case w/ 204 ECUAccessory Kit 1970-78 Camaro wo A/C

No. Qty. Part No. Description

Packing ListEvaporator Kit (561173)

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


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.

•

•

•


Condenser Assembly & Installation

Compressor & Brackets

Pulleys

OEM HeaterWiring/Vacuum

HarnessMolded Grommet

Hood Latchand Support

Assembly

Battery &Battery Tray

InnerFender Panel

OuterFender Heater Hose

Clamp

OEMBlower Motor

Assembly

Radiator

Engine CompartmentBefore starting the installation, check the function of the vehicle (horn, lights, etc.) for proper operation. Study the instructions, illustrations & diagrams.

Remove the Following:

1. Battery and battery tray (retain) (See Figure 1, below).

2. Drain radiator.

3. Hood latch assembly (retain) including hood latch support.

4. Heater blower motor assembly (discard). To remove the heater blower motor assembly (under hood) and the air distribution system (under dash), remove inner fender (See Figure 3, below).

5. OEM heater hoses (discard) (See Figure 1, below).

6. Remove OEM heater wiring/vacuum harness molded grommet (See Figure 1, below).

1. Refer to separate instructions included with the condenser kit to install the condenser.

2. Binary switch installation (refer to condenser instructions).

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

1. In most instances, the belt lengths will remain the same.

Figure 1


NOTE: Removal of dashboard is not required to install the evaporator. Vintage Air recommends that you utilize the factory service manual when you disassemble and reassemble the dashboard.

Remove the Following:

1. Glove box door (See Figure 3, below).

2. Glove box (discard, retain screws) (See Figure 2, below).

3. Heater assembly and all related ducting (discard, retain screws) (See Figure 3, below).

4. Driver/passenger side louver outlets (retain). Instrument panel must be removed to get to left outlet and control panel (See Figure 3, below).

5. Control panel assembly (discard) (See Figure 3, below). Refer to control panel conversion kit instructions for installation of controls.

6. Remove passenger side kick panel (retain). Disconnect passenger side fresh air cable from panel (See Figure 3, below). Disconnect driver/passenger cable astro-ventilation ducting (discard).

7. Remove OEM defrost duct assembly (discard).

Driver SideAstro Ventilation

Duct

Figure 3

Driver SideLouver

Driver SideKick Panel

ControlPanel

InstrumentPanel

Passenger SideLouver

Passenger SideAstro

VentilationDuctAstro

Fresh

Passenger SideKick Panel

Glove BoxDoor

HeaterAssembly

Passenger Compartment

Glove Box

Figure 2


Passenger SideKick Panel Modification

Figure 4a

1. Remove kick panel by removing the (5) OEM screws. Disconnect the fresh air door from the lever housing (See Figure 4, below).

2. Cut kick panel grille using template provided on Page 24 (See Figure 4a, below).

3. Enlarge OEM lever housing holes to 1/2” (See Figure 4a, below).

4. Install (2) 1/2” plastic plugs in OEM lever housing holes (See Figure 4a, below).

Grille

Template

Kick Panel

(5) OEMScrews

OEM Lever Housing Kick

Panel

Enlarge OEMLever Housing Holes To 1/2”

1/2” Plastic Plug31102-GUR

Figure 4


Driver SideDefrostDuct

627171-PCA

10-24 Nutw/ Star Washer

10-24 x 3/8”Pan HeadScrew

OEMDefrost Duct

Mounting Flange

Driver SideFresh Air Cover

644175

Passenger SideDefrostDuct

627171-PCA

Passenger SideFresh Air Cover

644176

Silicone

Mating Surfaceof Fresh Air Cover

OEMScrews

OEMScrews

1. Install the defrost ducts onto the OEM defrost duct mounting flange under the dash as shown in Figure 5, below. Secure using a 10-24 x 3/8” pan head screw and a 10-24 nut with star washer.2. Apply a 1/4” bead of silicone around the mating surface of the driver and passenger side fresh air covers as shown in Figure 5a, below.3. Install the driver and passenger side fresh air covers, and secure using OEM screws (See Figure 5, below).

Defrost Duct/Fresh Air Cover Installation

Figure 5

Figure 6

Figure 5a

HoseAdapter

(2) S-clips

Hose Adapter Installation1. Install (2) S-clips on hose adapter as shown in Figure 6, below.2. Install driver & passenger side hose adapters on OEM louvers (See Figure 6, below).


1/4-20 X 1 ½”Bolt w/ Washer

Fresh Air Cap andHeater Cover Bracket Installation

Silicone

Fresh AirCap(4) Grommets

33137-VUI

Mating Surfaceof Fresh Air Cap

EngineCompartment

Firewall

1. Install (4) grommets in fresh air cap (See Figure 7, below).2. Apply a 1/4” bead of silicone around the mating surface of the fresh air cap as shown in Figure 7, below.3. Attach fresh air cap to firewall using a 1/4-20 x 1 ½" bolt and washer, see Figure 7, below. NOTE: Fresh air cap installs on engine side of firewall.4. Install 1 ¼” plug in firewall (See Figure 7, below).

Kick Panel Fresh Air Cap Installation1. Install (4) grommets in kick panel fresh air cap (See Figure 8a, below).2. Route A/C and heater hose through fresh air cap and kick panel fresh air cap as shown in Figures 8 and 8b, below.3. Apply a 1/4” bead of silicone around the mating surface of kick panel fresh air cap as shown in Figure 8a, below.4. Secure kick panel fresh air cap using OEM screws as shown in Figure 8b, below.

(5) OEMScrews

Silicone

Mating Surfaceof Kick PanelFresh Air Cap

#10 A/CHose

#6 A/CHose

(2) HeaterHoses

#10 A/C Hose

#6 A/C Hose(2) Heater

Hoses

(4)Grommets33137-VUI

Figure 7

Figure 8b

Figure 8

Figure 8a

1 ¼” Plug33132-VUI


EngineCompartment

Side of Firewall

(4) 1/4-20 X 1”Hex Bolts

w/ Washers

NOTE: Firewall cover mounting holes must be enlarged. Enlarge (5) existing holes in firewall to 5/16”.

View Shown From Inside Car Through Dash

Figure 9

Mating Surfaceof Firewall

Cover

Silicone

1/4” Nutw/ Star Washer

1/4” X 3/4”Flat Washer

Evaporator Bracket andA/C & Heater Hose Installation

1. On a work bench, install evaporator rear bracket and A/C & heater hose with properly lubricated O-rings (See Figure 11, Page 12, and Figures 15, Page 15).2. Install front mounting bracket on evaporator using (2) 1/4-20 x 1/2” hex bolts and tighten as shown in Figure 10, below.

Firewall Cover Installation 1. Enlarge (5) OEM firewall holes to 5/16” (See Figure 9, below).2. Apply a 1/4” bead of silicone around the mating surface of the firewall cover as shown in Figure 9, below.3. From inside the car, install firewall cover on firewall (See Figure 9, below). From the engine compartment, secure firewall cover to firewall using (4) 1/4-20 x 1”, hex bolts, (5) flat washers and 1/4” nuts w/ star washers (See Figure 9, below).

(2) 1/4-20 X 1/2”Hex Bolts

Figure 10

Firewall Cover 648233


Rear EvaporatorBracket ASM

644019

Evaporator Bracket andHeater Fittings Installation (Cont.)

Figure 11

(2) HeaterFittings121004

1/4-20 X 1/2” Bolts(Located on Sub Case)

wo A/C

w/ A/C


Kick PanelFresh Air

Cap

(2) #14 X 3/4”Sheet Metal

Screws

1/4-20 X 1” Bolt w/ Washer

Evaporator Installation

1. Lift evaporator unit up under the dashboard (See Figure 12, below). Secure loosely to the firewall from the engine compartment side using a 1/4-20 x 1” bolt and washer (See Figure 12, below).2. Using (2) #14 x 3/4” sheet metal screws, secure the front evaporator mounting bracket to the inner cowl (See Figure 12, below).3. Verify that evaporator unit is level and square to the dash, and then tighten all mounting bolts. NOTE: Tighten the bolt on firewall first. Then tighten the front mounting bracket screws.

#10 A/C Hose

#6 A/C Hose

PressTape

HeaterHoses

HoseClamps

Figure 12a

Figure 12


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 13, below).

3. Install drain hose to bottom of evaporator unit and route through firewall (See Figure 13, below).

1” DrainDrainHose

Drain Hose Installation

Center Louver Mounting Holes

1970-78 CAMARO w/o ACCENTER LOUVERTEMPLATE

1. Cut out template provided on Page 27. Slide the template under the dash as shown in Figure 14, below. Align the left and right sides of template with the crease in the dash as shown in Figures 14 & 14a, below. Align bottom edge of the template along the bottom edge of dash as shown in Figures 14 & 14a, below.

2. Once template is aligned correctly and taped into place, mark mounting holes on dash. Once holes are marked in the correct location, remove template and drill (2) 3/16” holes in dash for the center louver bezel (See Figure 14a, below).

Figure 14

1970-78 CAMARO w/o ACCENTER LOUVERTEMPLATE

OEMHoleFigure 14a

Figure 13


CenterLouver

CenterLouver Bezel

Washer

1. Install the center louver bezel under the dash and secure using (2) 10-32 x 3/4” pan head screws w/ washers and 10-32 nuts w/star washers as shown in Figure 15, below.

2. Install the center louver into the bezel as shown in Figure 15, below.

3. Reinstall center console (if equipped) (See Figure 15a, below).

CenterLouver Bezel

Center Louver Installation

(2)10-32 X 3/4”Pan Head Screws

w/ 10-32 Nuts w/ Star Washers

FinalInstallation Final

Installationw/ Center Console

(If Equipped)

Figure 15a

Figure 15


1. Refer to separate instructions included with modified hose kit.

1974-78 Camaro Standard Hose Kit

Modified A/C Hose Kit

1. Locate the #8 compressor A/C hose. Lubricate (2) #8 O-rings (See Figure 16, above) and connect the 90° female fitting w/ R134a service port to the #8 discharge port on the compressor. Route the 45° female fitting to the #8 condenser hardline coming through the core support (See Figure 18, Page 18). Tighten each fitting connection as shown in Figure 16, above.2. Locate the #10 compressor A/C hose. Lubricate (2) #10 O-rings (See Figure 16, above) and connect the #10 135° female fitting w/ R134a service port to the #10 suction port on the compressor. Route the 90° female fitting to the #10 evaporator (See Figure 12a, Page 13, and Figure 18, Page 18). Tighten each fitting connection as shown in Figure 16, above.3. Locate the #6 evaporator A/C hose. Lubricate (2) #6 O-rings (See Figure 16, above) and connect the 90° female fitting to the #6 hardline coming through the core support from the drier. Route the 90° female fitting to the #6 evaporator (See Figure 12a, Page 13, and Figure 18, Page 18). Tighten each fitting connection as shown in Figure 16, above.

1970-73 Camaro Standard Hose Kit1. Locate the #8 compressor A/C hose. Lubricate (2) #8 O-rings (See Figure 16, above) and connect the 90° female fitting w/ R134a service port to the #8 discharge port on the compressor. Route the 45° female fitting to the #8 condenser hardline coming through the core support (See Figure 17, Page 17). Tighten each fitting connection as shown in Figure 16, above.2. Locate the #10 compressor A/C hose. Lubricate (2) #10 O-rings (See Figure 16, above) and connect the #10 135° female fitting w/ R134a service port to the #10 suction port on the compressor. Route the 90° female fitting to the #10 evaporator (See Figure 12a, Page 13, and Figure 17, Page 17). Tighten each fitting connection as shown in Figure 16, above.3. Locate the #6 evaporator A/C hose. Lubricate (2) #6 O-rings (See Figure 16, above) and connect the 45° female fitting to the #6 hardline coming through the core support from the drier. Route the 90° female fitting to the #6 evaporator (See Figure 12a, Page 13, and Figure 17, Page 17). Tighten each fitting connection as shown in Figure 16, above.

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 16


A/C

& H

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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 12a, Page 13, and Figure 17, 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 12a, Page 13, and Figure 17, below. NOTE: Install heater control valve in line with intake manifold (pressure side) heater hose, and secure using hose clamps as shown in Figure 17, below. Also note proper flow direction.

#10

Ade

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w/

10-3

2 x

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0916

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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 12a, Page 13, and Figure 18, 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 12a, Page 13, and Figure 18, below. NOTE: Install heater control valve in line with intake manifold (pressure side) heater hose, and secure using hose clamps as shown in Figure 18, below. Also note proper flow direction.

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.


1. Install duct hoses as shown in Figure 21, Page 18.

2. Install 3/8” ID grommet (See Figure 19, below).

3. Route A/C wires through 3/8 ID grommet as shown on Figure 19, below (12 volt/ground/binary switch/ heater valve).

4. Install control panel assembly.

5. Plug the wiring harness into the ECU module on the sub case as shown in Figure 21, Page 20 (Wire according to wiring diagram on Pages 21 & 22).

6. Install glove box (See Figure 20, below).

7. Reinstall all previously removed items (battery tray & battery).

8. Fill radiator with at least a 50/50 mixture of approved antifreeze and distilled water. It is the owner’s responsibility to keep the freeze protection at the proper level for the climate in which the vehicle is operated. Failure to follow antifreeze recommendations will cause heater core to corrode prematurely and possibly burst in A/C mode and/or freezing weather, voiding your warranty.

9. Double check all fittings, brackets and belts for tightness.

10. Vintage Air recommends that all A/C systems be serviced by a certified automotive air conditioning technician.

11. Evacuate the system for a minimum of 45 minutes prior to charging, and leak check prior to servicing.

12. Charge the system to the capacities stated on the information page (Page 4) of this instruction manual.

13. See Operation of Controls procedures on Page 23.

1. Install glove box provided, and secure with OEM screws through OEM holes (See Figure 20, below).

2. Install glove box door.

3/8” ID Grommet33144-VUI

FirewallCover

Final Steps

Glove Box Installation

Glove Box

Figure 20a

NOTE: If equipped with the glove box light as shown below in Figure 20a, modify plastic glove box using template provided on Page 25.

Figure 20

Figure 19


Center LouverPassenger Side

2 ½” X 25”

Passenger SideLouver

2 ½” X 47”

Driver Side Louver

2 ½” X 40”Center Louver

Driver Side2 ½” X 25”

Driver SideDefrost Duct

2” X 22”

Passenger SideDefrost Duct

2” X 12”

Control Panel & Duct Hose Routing

Back Sideof PC Board

Assembly

Control PanelHarness

From ECU232007-VUR

Figure 21

Figure 22


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.


A/C Operation

Heat Operation Defrost Operation

DASH

DASH DASH

HOT

HOT HOT

ModeLever

TemperatureLever

Blower Speed

NOTE:A/C operation toggles

on & off when temperature lever

is moved to the HOT or COLD ends of travel. A/C mode is

indicated by the blue A/C light.

Operation of ControlsOn Gen IV systems with three lever/knob controls, the temperature control toggles between economy/heat andA/C operations. To activate A/C, move the temperature lever all the way to COLD and then back it off to the desired vent temperature. For economy/heat operation, move the temperature lever all the way to HOT and thenadjust to the desired vent temperature. The blower will momentarily change speed each time you toggle between operations to indicate the change.

Blower SpeedAdjust to desired

speed.Slide the lever all

the way leftfor DASH mode.

Mode Lever Temperature Lever

For A/C operation, slide the temperature lever all the

way right to engage compressor (Slide lever left or right to adjust to desired temperature).

Blower SpeedAdjust to desired

speed.

Temperature LeverSlide the temperature lever all the way leftto the HOT position

(Slide lever left or rightto desired temperature).

Slide the lever tothe center position

for FLR mode.

Mode Lever

Temperature Lever

Adjust to desiredspeed.

Blower Speed

Slide the lever allthe way rightfor DEF mode.

Mode Lever

Adjust lever todesired temperature

(Compressor is automatically

engaged).


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

.


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.


CUT ALONGDOTTED LINE

CU

T A

LON

GD

OTT

ED L

INE

Kick Panel Modification Template


4.5

00

0”

DRILL 3

/16

”H

OLES

CU

T ALO

NG

DO

TTED LIN

E

Center Louver Template

19

70

-78

Cam

aro

wo

A/

CC

en

ter L

ou

ver

Tem

pla

te


1 ⅜

”

Tem

pla

te

3/4”

Cu

t A

lon

gD

otte

d L

ine 1”

Glo

ve B

ox L

igh

t Te

mp

late


Accessory Kit781178

4-Vent Evaporator Sub Case w/ 204 ECU

744004-VUE

1.2.

11

744004-VUE781178

4-Vent Evap orator Sub Case w/ 204 ECUAccessory Kit 1970-78 Camaro wo A/C

No. Qty. Part No. Description

Packing ListEvaporator Kit (561173)

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

Checked By:Packed By:

Date:

1

2

Date post:	25-Sep-2020
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1970-78 Camaro · 1970-78 Camaro without Factory Air 561173 901196 REV C 12/10/15, INST 1970-78...

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