an ISO 9001:2015 Registered Company
18865 Goll St. San Antonio, TX 78266 Phone: 800-862-6658
Sales: [email protected] Support: [email protected]
www.vintageair.com
908174 REV G 11/19/19, PG 1 OF 22
1966-77 Ford BroncoEvaporator Kit
751150
2
www.vintageair.com
908174 REV G 11/19/19, PG 2 OF 22
Cover..................................................................................................................................Table of Contents.................................................................................................................Packing List/Parts Disclaimer..................................................................................................Information Page..................................................................................................................Wiring Notice.......................................................................................................................Engine Compartment Disassembly, Condenser Assembly and Installation, Compressor and Brackets.............................................................................................................................Passenger Compartment Disassembly..................................................................................... 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......................................................................Louver Assembly 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.......................................................................................................................
1 2 3 4 5
6 7 8 910111213141516171819202122
Table of Contents
Additional Info: Please Read Before BeginningThe 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
NOTE: Many customers are replacing the OEM panels with new aftermarket parts such as dash, firewall, transmission tunnel and floor pans. Proper mounting and leveling of the evaporator unit onto these aftermarket parts is the customer’s responsibility. OEM transmission tunnels have a shelf built into them at the firewall, the evaporator’s driver side floor vents sits just above this OEM transmission tunnel shelf. Aftermarket transmission tunnel panels do not have this shelf and can interfere with the proper installation and leveling of the evaporator unit. Modifying the aftermarket transmission tunnel to fit the driver side floor vent is the customer’s responsibility. Also, with aftermarket panels, customers may have to modify the evaporator’s front mounting bracket (648161) for proper installation and leveling of the evaporator unit.
3
www.vintageair.com
908174 REV G 11/19/19, PG 3 OF 22
Packing List: Evaporator Kit (751150)
No. 1.2.
Qty.11
Part No.744004-VUE791176
DescriptionGen IV 4-Vent Evaporator Sub Case with 204 ECUAccessory Kit
** Before beginning installation, open all packages and check contents of shipment. Please report any shortages directly to Vintage Air within 15 days. After 15 days, Vintage Air will not be responsible for missing or damaged items.
NOTE: Images may not depict actual parts and quantities. Refer to packing list for actual parts and quantities.
1
2
Gen IV 4-Vent Evaporator Sub Case with 204 ECU
744004-VUE
Accessory Kit791176
4
www.vintageair.com
908174 REV G 11/19/19, PG 4 OF 22
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. (28.8 oz.) or 816 grams 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.
5
www.vintageair.com
908174 REV G 11/19/19, PG 5 OF 22
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.
•
•
•
6
www.vintageair.com
908174 REV G 11/19/19, PG 6 OF 22
Engine Compartment Disassembly
1.2.3.4.5.
Disconnect the battery.Remove the battery and battery tray (retain).Remove the OEM fan and fan shroud (retain).Drain and remove the radiator (retain).Remove all OEM heater hoses (discard).
NOTE: Before starting the installation, check the function of the vehicle (horn, lights, etc.) for proper operation, and study the instructions, illustrations, & diagrams.Perform the Following:
Figure 1
Condenser Assembly and Installation1.2.
Refer to separate instructions included with the condenser kit to install the condenser.Binary switch installation (Refer to condenser instructions).
Compressor and Brackets1. Refer to separate instructions included with the bracket kit to install the compressor bracket.
Fan and Fan Shroud
Battery
Radiator
7
www.vintageair.com
908174 REV G 11/19/19, PG 7 OF 22
Passenger Compartment Disassembly
1.2.3.4.5.6.
Remove the glove box door (retain) and the glove box (discard) (See Figure 1, below).Disconnect all wires and cables from the OEM heater control knobs.Remove the OEM heater control knobs (See Figure 1, below).Remove the OEM heater assembly (discard) (See Figure 2, below).Remove the OEM duct hoses from the defrost ducts (discard) (See Figure 2, below).Remove the passenger side OEM kick panel fresh air cap (discard) (See Figure 3, below).
Perform the Following:
Figure 2
Figure 1
Figure 3
OEM Heater Control Knobs
Glove Box & Glove Box Door
AshtrayRadio
Defrost Duct Hoses
OEM Heater Assembly
Passenger Side OEM Kick Panel Fresh Air Cap
8
www.vintageair.com
908174 REV G 11/19/19, PG 8 OF 22
Defrost Duct Hose Adapter Installation
1.2.
Install (2) S-clips onto the driver and passenger side hose adapters (See Figure 1a, below).Install the driver and passenger side hose adapters onto the OEM defrost ducts as shown in Figure 1, below.
Figure 1
Figure 1a
Figure 1
Evaporator Bracket and Heater Hose Fitting Installation
1.
2.
On a workbench, install the evaporator rear bracket and heater hose fittings with properly lubricated O-rings (See Figure 2, Page 9, and Lubricating O-rings, Page 12).Install the front mounting bracket onto the evaporator using (2) 1/4-20 x 1/2” hex bolts (supplied on sub case), and tighten as shown in Figure 1, below.
(2) S-Clips
Hose Adapter
49168-VCI
Evaporator Front Bracket 648161
(2) 1/4-20 x 1/2” Hex Bolts
(Supplied on Sub Case)
9
www.vintageair.com
908174 REV G 11/19/19, PG 9 OF 22
Evaporator Bracket and Heater Hose Fitting Installation (Cont.)
Figure 2
ECU Module
Rear Evaporator
Bracket 648162
Twist With This
Wrench
(2) Heater Fittings 121004
Lubricate O-ring (See Lubricating O-ring, Page 12)
Hold With This Wrench
(2) #10 O-rings
(2) 1/4-20 x 1/2” Hex Bolts
(Supplied on Sub Case)
(2) 1/4-20 x 1/2” Hex Bolts
(Supplied on Sub Case)
10
www.vintageair.com
908174 REV G 11/19/19, PG 10 OF 22
Figure 1
Figure 2
Figure 1
Figure 1a
Figure 1b
Airbox Modification1.2.
Drill (4) 1 ¼” holes into the airbox (See Figure 1, below).Install (4) 1 ¼” grommets into the airbox (See Figure 2, below).
Kick Panel Fresh Air Cap Installation1.2.
3.
4.
Install (4) grommets into the kick panel fresh air cap (See Figure 1b, below).Route the A/C and heater hoses through the fresh air box and kick panel fresh air cap as shown in Figure 1 and 1a, below.Apply a 1/4” bead of silicone around the mating surface of the kick panel fresh air cap as shown in Figure 1b, below.Secure the kick panel fresh air cap using (3) OEM screws as shown in Figure 1a, below.
2”2”
2”2”
2”
2”2”
2”
Figure 7a
Drill (4) 1 ¼” Holes
Kick Panel Fresh Air Cap
648166(2) Heater Hoses
(3) OEM Screws#10 A/C
Hose
Heater Hoses
#6 A/C Hose
#6 A/C Hose#10 A/C
Hose
(4) 1 ¼” Grommets
(4) Grommets 33137-VUI
Mating Surface of Kick Panel Fresh Air Cap
Silicone
11
www.vintageair.com
908174 REV G 11/19/19, PG 11 OF 22
Figure 1a
Photo 1
Figure 1
Evaporator Installation1.2.
3.4.
5.
6.
7.
Install (2) 1 ¼” grommets into the firewall (See Figure 1, below).Enlarge the 1/2” hole on the firewall to 5/8” and install the 3/8” grommet as shown in Figure 1 and Photo 1, below.Install the A/C & heater hoses as shown in Figure 1a, below.Lift the evaporator unit up under the dashboard. Secure it 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 the level on the flat portions of the case around the drain.Using the front evaporator bracket as a guide, mark and drill (2) 3/16” holes in the cowl (See Figure 1, below).Using (2) #14 x 3/4” sheet metal screws, secure the front evaporator mounting bracket to the inner cowl (See Figure 1, below).Verify that the 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
Hose Clamps
1/4” Flat Washer
Press Tape
#10 A/C Hose
Heater Hose (To Water Pump)
3/8” Grommet 33144-VUI
Heater Hose (To Heater Control Valve,
Then to Manifold)
Engine Compartment View
NOTE: After installing #10 suction line, wrap all exposed metal (fittings & tube) with supplied press tape.
Enlarge 1/2” Hole to 5/8”
Drill (2) 3/16” Holes
(2) #14 x 3/4” Sheet Metal
Screws
1/4-20 x 1” Hex Bolt
1/4” Nut with Star Washer
(2) 1 ¼” Grommets 33132-VUI
12
www.vintageair.com
908174 REV G 11/19/19, PG 12 OF 22
A/C Hose Installation
1.
2.
3.
Locate the #8 compressor A/C hose. Lubricate (2) #8 O-rings (See Lubricating O-rings, above) and connect the 135° female fitting with service port to the #8 discharge port on the compressor. Route the 90° female fitting to the #8 condenser hardline (See Figure 1, Page 13). Tighten each fitting connection as shown in Lubricating O-rings, above.Locate the #10 compressor A/C hose. Lubricate (2) #10 O-rings (See Lubricating O-rings, above) and connect the #10 135° female fitting with service port to the #10 suction port on the compressor. Route the 90° female fitting to the #10 fitting on the evaporator (See Figure 1a, Page 11, and Figure 1, Page 13). Tighten each fit-ting connection as shown in Lubricating O-rings, above.Locate the #6 evaporator A/C hose. Lubricate (2) #6 O-rings (See Lubricating O-rings, above) and connect the 90° female fitting to the drier. Route the 90° female fitting to the #6 fitting on the evaporator (See Figure 1a, Page 11, and Figure 1, Page 13). Tighten each fitting connection as shown in Lubricating O-rings, above.
Standard Hose Kit:
1. Refer to separate instructions included with modified hose kit.Modified Hose Kit:
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.
Drain Hose Installation1.
2.
3.
Locate the evaporator drain on the bottom of the evaporator case.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 1, below). Install the drain hose to the bottom of the evaporator unit and route it through the firewall (See Figure 1, below).
Figure 1
1”Drain Hose
Drain
13
www.vintageair.com
908174 REV G 11/19/19, PG 13 OF 22
Heater Hose & Heater Control Valve Installation
1.
2.
Route a piece of heater hose (not supplied) from the water pump to the top heater fitting of the heater core as shown in Figure 1a, Page 11, and Figure 1, below. Secure using hose clamps.Route a piece of heater hose (not supplied) from the intake to the bottom heater fitting of the heater core as shown in Figure 1a, Page 11, and Figure 1, below. NOTE: Install the heater control valve in line with the intake manifold (pressure side) heater hose, and secure using hose clamps as shown in Figure 1, below. Also note proper flow direction.
Fig
ure
1
NO
TE:
Vin
tag
e A
ir S
yste
ms
use
5/
8”
hea
ter
con
nec
tion
s. O
n e
ng
ines
eq
uip
ped
wit
h 3
/4
” h
ose
nip
ple
s, t
hes
e w
ill n
eed
to
be
rem
oved
an
d r
epla
ced
wit
h 5
/8
” n
ipp
les
(not
su
pp
lied
). F
or w
ater
p
um
ps
wit
h a
cas
t-in
3/
4”
hea
ter
outl
et,
a 3
/4
” x
5/
8”
red
uce
r fi
ttin
g in
th
e h
eate
r h
ose
(not
su
pp
lied
) or
mol
ded
hos
e (V
inta
ge
Air
Par
t #
09
90
10
) w
ill n
eed
to
be
inst
alle
d.
NO
TE:
Flow
Dir
ecti
on F
ollo
ws
Mol
ded
Arr
ow o
n V
alve
A/
C &
Hea
ter
Hos
e R
outi
ng
Tie
Wra
pH
eate
r H
ose
#6
A/C
Hos
e 08
6075
From
Int
ake
Man
ifold
From
Hea
ter
Con
trol
Val
ve
to H
eate
r Cor
e
#6
Con
dens
er/
Drier
Har
dlin
e 08
6008
#10
Suc
tion
Hos
e 08
6077
#8
Dis
char
ge
Hos
e 08
6076
Com
pres
sor
Saf
ety
Switc
h (B
inar
y Ty
pe)
Scr
ew-o
n D
rier
(R
efer
to
Con
dens
er
Inst
ruct
ions
)
#8
Con
dens
er
Har
dlin
e 08
6009
Hea
ter
Hos
e (H
eate
r Con
trol
Va
lve/
Inta
ke)
14
www.vintageair.com
908174 REV G 11/19/19, PG 14 OF 22
Figure 1
Louver Assembly Installation1.
2.
3.
Temporarily install the center/passenger side louver assembly onto the bottom of the dash using (2) OEM screws. Mark and drill a 1/8” hole as shown in Figure 1, below. Secure the assembly with OEM screws and a #10 x 1/2” sheet metal screw.Install the driver side louver assembly into the center/passenger side louver assembly, and secure it to the bottom of the dash using an OEM screw as shown in Figure 1, below.Insert (4) 1/2” plastic plugs into the louver assemblies as shown in Figure 1, below.
OEM Screw
OEM Screw
Drill 1/8” Hole
OEM Screw
Driver Side Louver Assembly
621023
Center/Passenger Side Louver Assembly
621022
(4) 1/2” Plastic Plugs
31102-GUR
#10 x 1/2” Sheet Metal
Screw
15
www.vintageair.com
908174 REV G 11/19/19, PG 15 OF 22
Figure 1
Figure 2
Wiring Harness (Heater Control Valve)
Wiring Harness (12 Volt/Grounds/Binary Switch)
3/8” Grommet 33144-VUI
Glove Box 49577-LFI
Final Steps1.2.
3.4.
5.
6.7.8.
9.10.11.
12.13.
Install duct hoses as shown in Figure 1, Page 16.Route the A/C wires (12 volt/grounds/binary switch/heater valve) through the 3/8” grommet as shown in Figure 1, below.Install the control panel assembly. Refer to the control panel instructions.Plug the wiring harnesses into the ECU module on the sub case as shown in Figure 1, Page 16 (Wire according the to wiring diagrams on Pages 17 and 18).Trim the driver side of the new glove box insert for the OEM fuse panel (See Figure 2, below). NOTE: Applies to 1972-77 Bronco only.Install the glove box door using OEM screws.Reinstall all previously removed items.Fill radiator with at least a 50/50 mixture of approved antifreeze and distilled water. It is the owner’s responsibility to keep the freeze protection at the proper level for the climate in which the vehicle is operated. Failure to follow antifreeze recommendations will cause heater core to corrode prematurely and possibly burst in A/C mode and/or freezing weather, voiding your warranty.Double check all fittings, brackets and belts for tightness.Vintage Air recommends that all A/C systems be serviced by a licensed automotive A/C technician.Evacuate the system for a minimum of 45 minutes prior to charging, and perform a leak check prior to servicing.Charge the system to the capacities stated on Page 4 of this instruction manual.See Operation of Controls procedures on Page 19.
NOTE: On 1972-77 Bronco Only, Trim Glove Box for OEM Fuse Panel.
16
www.vintageair.com
908174 REV G 11/19/19, PG 16 OF 22
Control Paneland Duct Hose Routing
Figure 1
Driver Side Louver
2 ½” x 36”
Driver Side Defrost Duct
2 ” x 24”
Driver Side Center Louver
2 ½” x 15”
Passenger Side Defrost Duct
2” x 12”
Passenger Side Center Louver
2 ½” x 18”
From Control Panel
Passenger Side Louver
2 ½” x 46”
Plug From Wiring Harness 232600-VUA
Plug From Control Wiring
Harness 232002-VUA
17
www.vintageair.com
908174 REV G 11/19/19, PG 17 OF 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 E, 10/6/2017
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
18
www.vintageair.com
908174 REV G 11/19/19, PG 18 OF 22
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.
When Using A Vintage Air SuppliedControl Panel, Connect The Tan WireFrom The Gen IV Evaporator WiringHarness To The Factory Dash Lights ToEnable Panel Backlighting.
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.
19
www.vintageair.com
908174 REV G 11/19/19, PG 19 OF 22
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
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).
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
Mode Control
Temperature Control
ww
w.v
inta
gea
ir.c
om
20 908174 REV G 11/19/19, PG 20 OF 22
Sym
pto
m
Con
dit
ion
Ch
ecks
A
ctio
ns
Not
es
Blo
wer
sta
ys o
n hi
gh s
peed
whe
n ig
nitio
n is
on.
1a.
No
othe
r fu
nctio
ns w
ork.
Che
ck f
or d
amag
ed p
ins
or
wires
in c
ontr
ol h
ead
plug
.Ve
rify
tha
t al
l pin
s ar
e in
sert
ed in
to p
lug.
Ens
ure
that
no
pins
are
ben
t or
dam
aged
in E
CU
.Che
ck f
or d
amag
ed g
roun
d w
ire
(whi
te)
in c
ontr
ol h
ead
harn
ess.
Verify
con
tinui
ty t
o ch
assi
s gr
ound
with
whi
te c
ontr
ol
head
wire
at v
ario
us p
oint
s.
Loss
of gr
ound
on
this
wire
rend
ers
cont
rol h
ead
inop
erab
le.
All
othe
r fu
nctio
ns w
ork.
Che
ck f
or d
amag
ed b
low
er
switc
h or
pot
entio
met
er a
nd
asso
ciat
ed w
irin
g.
Blo
wer
sta
ys o
n hi
gh s
peed
whe
n ig
nitio
n is
on
or o
ff.
Unp
lug
3-w
ire
BSC c
ontr
ol
conn
ecto
r fr
om E
CU
. If
blo
wer
sh
uts
off,
ECU
is e
ither
im
prop
erly
wired
or
dam
aged
.
Be
sure
the
sm
all,
20 G
A w
hite
gro
und
wire
is c
onne
cted
to
the
bat
tery
gro
und
post
. If
it is
, re
plac
e th
e EC
U.
Unp
lug
3-w
ire
BSC c
ontr
ol
conn
ecto
r fr
om E
CU
. If
blo
wer
st
ays
runn
ing,
BSC is
eith
er
impr
oper
ly w
ired
or
dam
aged
.
Che
ck t
o en
sure
tha
t no
BSC w
irin
g is
dam
aged
or
shor
ted
to v
ehic
le g
roun
d. T
he B
SC o
pera
tes
the
blow
er
by g
roun
d si
de p
ulse
wid
th m
odul
atio
n sw
itchi
ng.
The
posi
tive
wire
to t
he b
low
er w
ill a
lway
s be
hot
. If
the
“g
roun
d” s
ide
of t
he b
low
er is
sho
rted
to
chas
sis
grou
nd,
the
blow
er w
ill r
un o
n H
I.
Repl
ace
BSC (
This
will
req
uire
rem
oval
of ev
apor
ator
fr
om v
ehic
le).
No
othe
r pa
rt r
epla
cem
ents
sh
ould
be
nece
ssar
y.
Com
pres
sor
will
no
t tu
rn o
n (A
ll ot
her
func
tions
w
ork)
.
2.
Syst
em is
not
cha
rged
.Sy
stem
mus
t be
cha
rged
for
co
mpr
esso
r to
eng
age.
Cha
rge
syst
em o
r by
pass
pre
ssur
e sw
itch.
Dan
ger
: N
ever
byp
ass
safe
ty s
wit
ch w
ith
en
gin
e ru
nn
ing
. S
erio
us
inju
ry c
an r
esu
lt.
Syst
em is
cha
rged
.
1b
.
Trou
ble
shoo
tin
g G
uid
e
Che
ck f
or f
aulty
A/C
po
tent
iom
eter
or
asso
ciat
ed
wirin
g (N
ot a
pplic
able
to
3-po
t co
ntro
ls).
Che
ck f
or d
isco
nnec
ted
or
faul
ty t
herm
isto
r.
Che
ck c
ontin
uity
to
grou
nd o
n w
hite
con
trol
hea
d w
ire.
Che
ck f
or 5
V o
n re
d co
ntro
l hea
d w
ire.
Che
ck 2
-pin
con
nect
or a
t EC
U h
ousi
ng.
To c
heck
for
pro
per
pot
func
tion,
che
ck v
olta
ge a
t w
hite
/blu
e w
ire.
Vol
tage
sh
ould
be
betw
een
0V a
nd
5V,
and
will
var
y w
ith p
ot
leve
r po
sitio
n.
Dis
conn
ecte
d or
fau
lty
ther
mis
tor
will
cau
se
com
pres
sor
to b
e di
sabl
ed.
Red
wire
at A
/C p
ot s
houl
d ha
ve a
ppro
xim
atel
y 5V
w
ith ig
nitio
n on
. W
hite
w
ire
will
hav
e co
ntin
uity
to
chas
sis
grou
nd.
Whi
te/
Blu
e w
ire
shou
ld v
ary
betw
een
0V a
nd 5
V w
hen
leve
r is
mov
ed u
p or
dow
n.
3. Com
pres
sor
will
no
t tu
rn o
ff
(All
othe
r fu
nctio
ns
wor
k).
Che
ck f
or f
aulty
A/C
po
tent
iom
eter
or
asso
ciat
ed
wirin
g.
Che
ck f
or f
aulty
A/C
rel
ay.
Repa
ir o
r re
plac
e po
t/co
ntro
l wirin
g.
Repl
ace
rela
y.
See
blo
wer
sw
itch
chec
k pr
oced
ure.
ww
w.v
inta
gea
ir.c
om
21 908174 REV G 11/19/19, PG 21 OF 22
Sym
pto
m
Con
dit
ion
Ch
ecks
A
ctio
ns
Not
es
Syst
em w
ill n
ot
turn
on,
or
runs
in
term
itten
tly.
4.
Wor
ks w
hen
engi
ne is
not
runn
ing;
shu
ts o
ff w
hen
engi
ne is
sta
rted
(T
ypic
ally
ear
ly G
en I
V,
but
poss
ible
on
all
vers
ions
).
Noi
se in
terf
eren
ce f
rom
eith
er
igni
tion
or a
ltern
ator
.
Inst
all c
apac
itors
on
igni
tion
coil
and
alte
rnat
or.
Ensu
re
good
gro
und
at a
ll po
ints
. Re
loca
te c
oil a
nd a
ssoc
iate
d w
irin
g aw
ay f
rom
ECU
and
ECU
wirin
g. C
heck
for
bur
ned
or lo
ose
plug
wires
.
Verify
con
nect
ions
on
pow
er
lead
, ig
nitio
n le
ad,
and
both
whi
te g
roun
d w
ires
.
Verify
pro
per
met
er f
unct
ion
by c
heck
ing
the
cond
ition
of
a kn
own
good
bat
tery
.
Igni
tion
nois
e (r
adia
ted
orco
nduc
ted)
will
cau
se t
he
syst
em t
o sh
ut d
own
due
tohi
gh v
olta
ge s
pike
s. I
f th
isis
sus
pect
ed,
chec
k w
ith a
qu
ality
osc
illos
cope
. Spi
kes
grea
ter
than
16V
will
shu
t do
wn
the
ECU
. In
stal
l a
radi
o ca
paci
tor
at t
he
posi
tive
post
of th
e ig
nitio
nco
il (S
ee r
adio
cap
acito
r in
stal
latio
n bu
lletin
). A
fa
ulty
alte
rnat
or o
r w
orn
out
batt
ery
can
also
res
ult
in t
his
cond
ition
.
Will
not
tur
n on
und
er
any
cond
ition
s.Ve
rify
bat
tery
vol
tage
is
grea
ter
than
10
volts
and
less
than
16.
Loss
of m
ode
door
fu
nctio
n.
No
mod
e ch
ange
at
all.
Che
ck f
or d
amag
ed m
ode
switc
h or
pot
entio
met
er a
nd
asso
ciat
ed w
irin
g.
Part
ial f
unct
ion
of m
ode
door
s.
Typi
cally
cau
sed
by
evap
orat
or h
ousi
ng
inst
alle
d in
a b
ind
in t
he
vehi
cle.
Be
sure
all
mou
ntin
g lo
catio
ns li
ne u
p an
d do
n’t
have
to
be for
ced
into
pos
ition
.
Blo
wer
tur
ns o
n an
d of
f ra
pidl
y.
6.
Bat
tery
vol
tage
is a
t le
ast
12V.
Che
ck f
or a
t le
ast
12V a
t ci
rcui
t br
eake
r.En
sure
all
syst
em g
roun
ds a
nd p
ower
con
nect
ions
are
cl
ean
and
tight
.
Bat
tery
vol
tage
is le
ss
than
12V
.
5.
Trou
ble
shoo
tin
g G
uid
e (C
ont.
)
Che
ck f
or f
aulty
bat
tery
or
alte
rnat
or.
Cha
rge
batt
ery.
Syst
em s
huts
off b
low
er a
t 10
V. P
oor
conn
ectio
ns o
r w
eak
batt
ery
can
caus
e sh
utdo
wn
at u
p to
11V
.
7. Whe
n ig
nitio
n is
tu
rned
on,
blo
wer
m
omen
tarily
co
mes
on,
the
n sh
uts
off.
This
oc
curs
with
the
bl
ower
sw
itch
in
the
OFF
pos
ition
.
This
is a
n in
dica
tor
that
the
sy
stem
has
bee
n re
set.
Be
sure
the
red
pow
er w
ire
is o
nth
e ba
tter
y po
st,
and
not
on a
sw
itche
d so
urce
. Als
o, if
the
sy
stem
is p
ulle
d be
low
7V f
orev
en a
spl
it se
cond
, th
e sy
stem
will
res
et.
Run
red
pow
er w
ire
dire
ctly
to
batt
ery.
Che
ck f
or p
ositi
ve p
ower
at
heat
er v
alve
gre
en w
ire
and
blow
er r
ed w
ire.
Che
ck f
or g
roun
d on
con
trol
hea
d w
hite
w
ire.
Che
ck f
or o
bstr
ucte
d or
bi
ndin
g m
ode
door
s.Che
ck f
or d
amag
ed s
tepp
er
mot
or o
r w
irin
g.
Erra
tic fun
ctio
ns o
fbl
ower
, m
ode,
te
mp,
etc
.
Che
ck f
or d
amag
ed s
witc
h or
po
t an
d as
soci
ated
wirin
g.Re
pair o
r re
plac
e.
8.
22
www.vintageair.com
908174 REV G 11/19/19, PG 22 OF 22
Packing List: Evaporator Kit (751150)
No. 1.2.
Qty.11
Part No.744004-VUE791176
DescriptionGen IV 4-Vent Evaporator Sub Case with 204 ECUAccessory Kit
NOTE: Images may not depict actual parts and quantities. Refer to packing list for actual parts and quantities.
1
2
Checked By:Packed By:
Date:
Accessory Kit791176
Gen IV 4-Vent Evaporator Sub Case with 204 ECU
744004-VUE
