GEN IV MAGNUM HEAT/COOL/DEFROST EVAPORATOR KIT
671400-VUZ
901400-VUZ REV F 6/25/14, INST GEN IV MAGNUM PG 1 OF 18
an ISO 9001:2008 Registered Company
2901400-VUZ REV F 6/25/14, INST GEN IV MAGNUM PG 2 OF 18
TABLE OF CONTENTS
PAGES
1. 2. 3. 4. 5. 6. 7.
8. 9. 10.
11.
12. 13.14.15.16.17.
COVERTABLE OF CONTENTSPACKING LIST/PARTS DISCLAIMERINFORMATION PAGE
PLANNING OVERVIEW AND DEFROST DUCT INSTALLATIONCONSENSER ASSEMBLY & INSTALLATION, COMPRESSOR & BRACKETS, HEATER FITTING INSTALLATIONBRACKET INSTALLATIONEVAPORATOR INSTALLATIONEVAPORATOR INSTALLATION CONT., DRAIN HOSE
HEATER HOSE & HEATER CONTROL VALVE INSTALLATION,
CONTROL PANEL/DUCT HOSE ROUTINGWIRING DIAGRAMGEN IV WIRING CONNECTION DIAGRAMOPERATION OF CONTROLSTROUBLESHOOTING INFORMATIONTROUBLESHOOTING INFORMATION CONT.EVAPORATOR KIT PACKING LIST
18.
WIRING NOTICE
INSTALLATION, A/C HOSE INSTALLATION
FINAL STEPS
3901400-VUZ REV E 6/25/14, INST GEN IV MAGNUM PG 3 OF 18
** 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-VUE784004-VUA
1
2
GEN IV MAGNUM EVAP. SUB CASE GEN IV MAGNUM ACC. KIT
GEN IV MAGNUMEVAP. SUB CASE
744004-VUE
ACCESSORY KIT784004-VUA
NOTE: IMAGES MAY NOT DEPICT ACTUAL PARTS AND QUANTITIES.REFER TO PACKING LIST FOR ACTUAL PARTS AND QUANTITIES.
EVAPORATOR KIT PACKING LISTEVAPORATOR KIT
671400-VUZ
No. QTY. PART No. DESCRIPTION
4901400-VUZ REV F 6/25/14, INST GEN IV MAGNUM PG 4 OF 18
Use of Any Other Refrigerants Will Void All Warranties of the Air Conditioning System and Components. Use of the Proper Type and
Amount of Refrigerant Is Critical to Proper System Operation. VintageAir Recommends Our Systems Be Charged By Weight With a Quality
Charging Station or Scale.
Service Info:
Safety Switches:
Important Notice—Please Read
Attention: The following system components are capped: Compressor, evaporator, condenser & drier. Caps may be under pressure with dry nitrogen. Be careful removing caps. Do not remove caps prior to installation. Removing caps prior to installation will cause components to collect moisture and lead to premature failure and reduced performance.
Evacuate the system for 35-45 minutes with system components (Drier, compressor, evaporator and condenser) 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.
For Maximum System Performance, Vintage Air Recommends the Following:
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.
Vintage Air Systems Are Designed to Operate With R134a Refrigerant Only! Use of Any Other Refrigerants Is a Fire Hazard and Could Damage Either Your Air Conditioning System or Your Vehicle.
Refrigerant Capacity for Vintage Air Systems:(For other systems, consult manufacturer’s guidelines)
R134a SystemCharge with 1.8 lbs. (1 lb., 12 oz.) of refrigerant.
Lubricant Capacities:New Vintage Air-supplied Sanden Compressor: No additional oil needed (Compressor is shipped with proper oil charge).All Other Compressors: Consult manufacturer (Some compressors are shipped dry and will need oil added).
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.
Heater Hose (Not Included With This Kit):
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.
Bolts Passing Through Cowl and/or Firewall:
5901400-VUZ REV E 6/25/14, INST GEN IV MAGNUM PG 5 OF 18
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.
•
•
•
6901400-VUZ REV F 6/25/14, INST GEN IV MAGNUM PG 6 OF 18
DEFROST DUCT
ALIGN DEFROST DUCT WITH OPENING IN DASH, IF APPLICABLE. USE OEM MOUNTING HOLE LOCATIONS OR MARK AND DRILL 1/8” MOUNTING HOLES. USE (4) #8 x ½” SCREWS TO SECURE THE NEW DEFROST DUCTS AS SHOWN IN FIGURE 1, BELOW.
NOTE: FOR AN ALTERNATE INSTALLATION METHOD, APPLY SILICONE, EPOXY, ETC., TO DEFROST DUCTS AND ALIGN WITH OPENINGS IN DASH.
PLANNING OVERVIEWEVERY VEHICLE IS A LITTLE DIFFERENT, DEPENDING ON THE: 1. TYPE OF VEHICLE/ENGINE AND LOCATION OF ENGINE. 2. TYPE OF AIR CONDITIONING EQUIPMENT USED. 3. OWNER’S PREFERENCES.
THERE ARE MANY FACTORS THAT GO INTO MAKING EACH AIR CONDITIONING INSTALLATIONDIFFERENT. USUALLY, ALL OF THE ABOVE DECISIONS ARE MADE BEFORE ANY CONSIDERATIONIS GIVEN TO THE AIR CONDITIONING INSTALLATION. THE A/C SYSTEM IS THEN TAILORED TO FITYOUR PARTICULAR APPLICATION.
THE MOUNTING LOCATION OF THE EVAPORATOR UNIT IS DETERMINED IN PART BY THE SPACEAVAILABLE FOR THE HOSE ROUTING. THE COMPONENTS USED IN THE HOSE ROUTING PROCESS (I.E.BULKHEAD PLATES, FITTINGS, AND GROMMETS, ETC.) WILL ALSO INFLUENCE THE LOCATION OFTHE EVAPORATOR UNIT. WHEN PLANNING YOUR HOSE ROUTING, YOU MUST INSTALL THE MAJORCOMPONENT PARTS. MOUNT THE COMPRESSOR, CONDENSER AND DRIER. THE EVAPORATORMUST BE TEMPORARILY HELD IN POSITION UNDER THE DASH. FINAL MOUNTING OF THE EVAPORATOR TO THE FIREWALL SHOULD NOT BE DONE UNTIL YOU HAVE VERIFIED THAT ALL HOSESATTACHING TO THE EVAPORATOR WILL EXIT THE FIREWALL AND/OR KICK PANEL AS PLANNED. THE HOSES MUST BE RUN EXACTLY THE WAY THEY WILL BE WHEN FINISHED, BEFORE CUTTING THEM TOLENGTH.
DUCT HOSE ROUTING AND A/C VENT LOCATIONS SHOULD ALSO BE GIVEN CAREFUL CONSIDERATIONBEFORE FINAL MOUNTING POSITION OF THE EVAPORATOR IS SELECTED.
THE VINTAGE AIR GEN IV MAGNUM UNIT WAS DESIGNED FOR CLASSIC CARS, CUSTOM CARS, ANDTRUCKS. THE EVAPORATOR UNIT IS DESIGNED TO MOUNT BEHIND THE DASH.
READ THE INSTALLATION INSTRUCTIONS COMPLETELY, AND FAMILIARIZE YOURSELF WITH ALL THE PARTS AND ILLUSTRATIONS.
THE INSTALLATION OF THIS UNIT VARIES ACCORDING TO THE BODY MANUFACTURER OR MODIFICATIONS TO THE ORIGINAL BODY. TAKE YOUR TIME, AND DOUBLE CHECK BEFORE DRILLING OR CUTTING.
REMOVE OEM HEATER, DEFROST DUCTS, CONTROLS, BLOWER ASSEMBLY, A/C EVAPORATOR & CONDENSERIF EQUIPPED.
BEFORE BEGINNING, REMOVE GLOVE BOX TO EASE INSTALLATION. IF THE DASH IS EASILY REMOVABLE, REMOVE IT NOW. CHECK FOR, AND FILL IN ANY HOLES IN THE FIREWALL AND FLOOR. INSULATE AND SEAL FIREWALL, FLOOR, DOOR PANELS, AND HEADLINER TO REDUCE THE AMOUNT OF HEAT ENTERING THE CAR.
DEFROST DUCT
INSTALLATION
FIGURE 1
#8 x ½” SCREWS#8 x ½” SCREWS
7901400-VUZ REV E 6/25/14, INST GEN IV MAGNUM PG 7 OF 18
HEATER FITTING INSTALLATION ON A WORKBENCH, INSTALL HEATER FITTINGS WITH PROPERLY LUBRICATED O-RINGS (SEE FIGURES 2 & 2a, BELOW).
CONDENSER ASSEMBLY & INSTALLATION
REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH CONDENSER KIT.
REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH BRACKET KIT.
COMPRESSOR & BRACKETS
EXPANSIONVALVE
#6 O-RING #8 O-RING #10 O-RING
O-RINGSUPPLIED OIL FOR O-RINGS
O-RING,SLIDE OVERMALE INSERT TOSWAGED LIP
MALEINSERT
FEMALENUT
FIGURE 8
HOLD WITHTHIS WRENCH
LUBRICATEO-RING
TWIST WITHTHIS
WRENCH
FIGURE 2a
FIGURE 2
(2) #10 FITTING (2)#10 O-RING
NOTE: 45° AND 90° FITTINGSARE AVAILABLE SEPARATELY.
FOR A PROPER SEAL OF FITTINGS:INSTALL SUPPLIED O-RINGS AS SHOWN,AND LUBRICATE WITH SUPPLIED OIL.
8901400-VUZ REV F 6/25/14, INST GEN IV MAGNUM PG 8 OF 18
BRACKET INSTALLATION ON A WORKBENCH, INSTALL THE FRONT & REAR EVAPORATOR MOUNTING BRACKETS USING (6) 1/4-20 x ½” HEX BOLTS. SEE FIGURE 3, BELOW. NOTE: PASS HEATER FITTINGS THROUGH THE (2) HOLE OPENINGS IN BRACKET AS SHOWN..
(2) 1/4-20 x ½”HEX BOLTS
(2) 1/4-20 x ½”HEX BOLT
(2) 1/4-20 x ½”HEX BOLT
FRONT EVAPORATOR
BRACKET
REAREVAPORATOR
BRACKET
(2) HEATERFITTINGS
FIGURE 3
9901400-VUZ REV E 6/25/14, INST GEN IV MAGNUM PG 9 OF 18
EVAPORATOR INSTALLATION
NOTE: TYPICAL INSTALLATION SHOWN BELOW. IT MAY BENECESSARY TO MODIFY BRACKETS OR ADD ADDITIONALBRACKETS FOR YOUR SPECIFIC INSTALLATION.
LIFT EVAPORATOR UNIT UP UNDER THE DASHBOARD INTO DESIRED POSITION, AND VERIFY THAT EVAPORATOR UNIT IS LEVEL AND SQUARE TO THE DASH. ONCE IN PLACE, USING THE HOLES IN MOUNTING BRACKETS AS TEMPLATES, MARK MOUNTING HOLE LOCATIONS ON INNER COWL AND FIREWALL.NOTE: DEPENDING ON YOUR INSTALLATION, USE ANY COMBINATION OFHOLES IN THE REAR MOUNTING BRACKET TO SECURE EVAPORATORTO FIREWALL. (THE TOP TWO HOLES ARE USED IN FIGURE 4, BELOW)
INSTALL MOUNTING HARDWARE IN REAR BRACKET AS SHOWNIN FIGURE 4a.
FIGURE 4 a(2) 1/4-20 NUTw/ WASHER
MARK & DRILL(2) 9/32” HOLES
FIREWALL
(2) 18289-VUB1/4-20 x 1/12COARSE BOLTw/ 18125-VUBFLAT WASHER
(2) 18040-VUB3/4” NYLON
SPACER
(2) 189125-MUR1/4” PUSH NUTBOLT RETAINER
(2) #14 x 3/4”SHEET METAL
SCREW
INNER COWL
MARK & DRILL(2) 1/8” HOLES
FIGURE 4
10901400-VUZ REV F 6/25/14, INST GEN IV MAGNUM PG 10 OF 18
EVAPORATOR INSTALLATION
ONCE BRACKETS ARE INSTALLED, LIFT EVAPORATOR UNIT UP UNDER THE DASHBOARD INTO DESIRED POSITION AND LOOSELY SECURE TO FIREWALL FROM THE ENGINE COMPARTMENT SIDE USING (2) 1/4-20 NUTS WITH WASHERS. SEE FIGURE 4, PAGE 8.
USING (2) #14 x 3/4” SHEET METAL SCREWS, SECURE THE FRONT EVAPORATOR MOUNTING BRACKET TO INNER COWL.SEE FIGURE 4, PAGE 8. NOTE: DO NOT COMPLETELY TIGHTEN SCREWS.
VERIFY THAT THE EVAPORATOR UNIT IS LEVEL AND SQUARE TO THE DASH. THEN TIGHTEN ALL MOUNTING LOCATIONS.NOTE: TIGHTEN THE BOLTS ON THE FIREWALL FIRST. THEN TIGHTEN THE FRONT MOUNTING BRACKET SCREWS .
IN LINE WITH THE DRAIN, LIGHTLY MAKE A MARK ON THE FIREWALL. MEASURE ONE INCH DOWN, AND MARKAND DRILL A 5/8” HOLE THOUGH FIREWALL. SEE FIGURE 5, BELOW.
INSTALL DRAIN HOSE ON DRAIN AND ROUTE THROUGH THE FIREWALL. NOTE: FROM THE ENGINE COMPARTMENT SIDE OF THE FIREWALL, CUT DRAIN HOSE TO DESIRED LENGTH.
DRAIN HOSE INSTALLATION
DRAINDRAINHOSE
1”FIGURE 5
REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH HOSE KIT.
A/C HOSE INSTALLATION
11901400-VUZ REV E 6/25/14, INST GEN IV MAGNUM PG 11 OF 18
ROUTE A PIECE OF HEATER HOSE FROM THE WATER PUMP TO THE HEATER LINE COMING THROUGH THE FIREWALLAS SHOWN IN FIGURE 6, BELOW. SECURE USING HOSE CLAMPS. NOTE: WATER PUMP SIDE OF SYSTEM IS LOW PRESSURE (SUCTION) SIDE.
HEATER HOSE & HEATER CONTROL VALVE INSTALLATION
FIGURE 6
INSTALL DUCT HOSES AS SHOWN IN FIGURE 7, PAGE 11. STRETCH THE DUCT HOSE TIGHTLY TO THE DASH VENTS. TRIM TO ENSURE THAT THE DUCT HOSE IS TIGHT WITH AS FEW KINKS OR SHARP BENDS IN HOSE AS POSSIBLE.THIS WILL ENSURE MAXIMUM AIRFLOW.
INSTALL CONTROL PANEL. REFER TO CONTROL PANEL KIT INSTRUCTIONS.
ROUTE THE CONTROL PANEL HARNESS ASSEMBLY AND CONNECT TO THE PC BOARD ASSEMBLY ON THE BACK SIDE OF THE CONTROL PANEL AS SHOWN IN FIGURE 7, PAGE 11.
PLUG THE WIRING HARNESS INTO THE ECU MODULE ON SUB CASE AS SHOWN. (WIRE ACCORDING TO WIRING DIAGRAM ON PAGE 12.)
REINSTALL ALL PREVIOUSLY REMOVED ITEMS
FILL RADIATOR WITH AT LEAST A 50/50 MIXTURE OF APPROVED ANTIFREEZE AND DISTILLED WATER. IT IS THE OWNER'S RESPONSIBILITY TO KEEP THE FREEZE PROTECTION AT THE PROPER LEVEL FOR THE CLIMATE IN WHICH THE VEHICLE IS OPERATED. FAILURE TO FOLLOW ANTIFREEZE RECOMMENDATIONS WILL CAUSE HEATER CORE TO CORRODE PREMATURELY AND POSSIBLY BURST IN AC MODE AND/OR FREEZING WEATHER, VOIDING YOUR WARRANTY.NOTE: PRIOR TO CHARGING A/C SYSTEM, RUN ENGINE AND CYCLE HEATER CONTROL VALVE TO CIRCULATE ANTIFREEZE THROUGH HEATER CORE.
DOUBLE CHECK ALL FITTINGS, BRACKETS AND BELTS FOR TIGHTNESS.
VINTAGE AIR RECOMMENDS THAT ALL A/C SYSTEMS BE SERVICED BY A CERTIFIED AUTOMOTIVE AIR CONDITIONING TECHNICIAN.
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 THISINSTRUCTION MANUAL.
FINAL STEPS - DUCT HOSE ROUTING & CONTROL PANEL HARNESS
FROM IN
TAKE
MANIF
OLD
FROM H
EATER C
ORE
TO WA
TER PU
MP
FROM HEATER CONTROL VALVETO HEATER CORE
FIREWALL
HEATERHOSE
HOSE CLAMPS
ROUTE A PIECE OF HEATER HOSE FROM THE INTAKE TO THE HEATER LINE COMING THROUGH THE FIREWALL AS SHOWN IN FIGURE 6, BELOW. NOTE: INSTALL HEATERCONTROL VALVE IN LINE WITH INTAKE MANIFOLD (PRESSURE SIDE) HEATER HOSE, AND SECURE USING HOSE CLAMPS AS SHOWN IN FIGURE 6, BELOW. ALSO NOTE PROPER FLOW DIRECTION.
12901400-VUZ REV F 6/25/14, INST GEN IV MAGNUM PG 12 OF 18
CONTROL PANEL & DUCT HOSE ROUTING
REAR VIEW
NOTE: TYPICAL ROUTING SHOWN. LENGTHSAND ROUTING WILL VARY BY INDIVIDUALAPPLICATION.
CENTER LOUVER
DRIVER SIDE
CENTER LOUVER
PASSENGER SIDE
CONTROL PANEL
HARNESS FROM ECU232007-VUR
FIGURE 7
S B
Y
DRIVER SIDE DEF. DUCT
DRIVER SIDE LOUVER
CENTER LOUVERDRIVER SIDE
CENTER LOUVERPASS. SIDE
PASS. SIDE DEF. DUCT
PASS. SIDE LOUVER
PLUGFROM
CONTROLWIRNG
HARNESS232007-VUR
DRIVER SIDE
LOUVER
PASSENGER
SIDELOUVER
13901400-VUZ REV E 6/25/14, INST GEN IV MAGNUM PG 13 OF 18
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
14901400-VUZ REV F 6/25/14, INST GEN IV MAGNUM PG 14 OF 18
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.
15901400-VUZ REV E 6/25/14, INST GEN IV MAGNUM PG 15 OF 18
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.
Blower Speed
Blower Speed
This lever/knob controlsblower speed, from
OFF to HI.
This lever/knob controls the mode positions,from DASH to FLOORto DEFROST, with a blend in between.
This lever/knob controlsthe temperature,
from HOT to COLD.
Blower Speed
Mode Control
Temperature Control
Blower Speed
TemperatureControl
ModeControl
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).
FAN
C
A/C
FAN
C
A/C
FAN
C
A/C
FAN
C
A/C
16901400-VUZ REV F 6/25/14, INST GEN IV MAGNUM PG 16 OF 18
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
.
17901400-VUZ REV E 6/25/14, INST GEN IV MAGNUM PG 17 OF 18
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.
901400-VUZ REV F 6/25/14, INST GEN IV MAGNUM PG 18 OF 18
CHECKED BY:PACKED BY:
DATE:
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ACCESSORY KIT784004-VUA
2
NOTE: IMAGES MAY NOT DEPICT ACTUAL PARTS AND QUANTITIES.REFER TO PACKING LIST FOR ACTUAL PARTS AND QUANTITIES.
GEN IV MAGNUMEVAP. SUB CASE
744004-VUE
EVAPORATOR KIT PACKING LISTEVAPORATOR KIT
671400-VUZ
No. QTY. PART No. DESCRIPTION
1.2.
11
744004-VUE784004-VUA
GEN IV MAGNUM EVAP. SUB CASE GEN IV MAGNUM ACC. KIT