Chevrolet - Nova - Wiring Diagram - 1969 - 1974

an ISO 9001:2015 Registered Company 1969-74 Chevrolet Nova with Factory Air Evaporator Kit (565072) 18865 Goll St. San Antonio, TX 78266 Phone: 800-862-6658 Sales: [email protected] Tech Support: [email protected] www.vintageair.com 905073 REV E 04/09/19, PG 1 OF 31 www.vintageair.com Table of Contents Cover.................................................................................................................................. 1 Table of Contents................................................................................................................. 2 Packing List/Parts Disclaimer.................................................................................................. 3 Information Page.................................................................................................................. 4 Wiring Notice....................................................................................................................... 5 Engine Compartment Disassembly, Condenser Assembly and Installation, Compressor and Brackets............................................................................................................................. 6 Passenger Compartment Disassembly......................................................................................7 Kick Panel Modification......................................................................................................... 8 Defrost Duct Installation, Hose Adapter Installation.................................................................. 9 Fresh Air & Kick Panel Cover Preparation................................................................................10 Fresh Air & Kick Panel Cover Preparation (Cont.), Wiring Installation..........................................11 Wiring Installation (Cont.)....................................................................................................12 Kick Panel Cover Installation, Fresh Air Cap Installation........................................................... 13 Firewall Modification, Firewall Cover Insulation....................................................................... 14 Firewall Cover Installation, Evaporator Bracket Installation....................................................... 15 Evaporator Bracket Installation (Cont.).................................................................................. 16 Evaporator Installation........................................................................................................ 17 Center Louver Installation....................................................................................................18 Drain Hose Installation, Lubricating O-rings, Modified A/C Hose Installation................................ 19 A/C and Heater Hose Installation (1969-72 Vehicles Only), A/C and Heater Hose Installation (1973-74 Vehicles Only)..................................................................................... 20 A/C and Heater Hose Routing (1969-72 Vehicles Only)............................................................ 21 A/C and Heater Hose Routing (1973-74 Vehicles Only)............................................................ 22 Heater Control Valve Installation...........................................................................................23 Control Panel & Duct Hose Routing....................................................................................... 24 Final Steps........................................................................................................................ 25 Wiring Diagram.................................................................................................................. 26 Gen IV Wiring Connection Instruction................................................................................... 27 Operation of Controls.......................................................................................................... 28 Troubleshooting Guide......................................................................................................... 29 Troubleshooting Guide (Cont.).............................................................................................. 30 Packing List....................................................................................................................... 31 2 905073 REV E 04/09/19, PG 2 OF 31 Packing List: Evaporator Kit (565072) www.vintageair.com No. 1. 2. Qty. 1 1 Part No. 744004-VUE 784177 Description Gen IV 4-Vent Evaporator Accessory 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. 1 Gen IV 4-Vent Evaporator Sub Case 744004-VUE 2 Accessory Kit 784177 NOTE: Images may not depict actual parts and quantities. Refer to packing list for actual parts and quantities. 3 905073 REV E 04/09/19, PG 3 OF 31 www.vintageair.com Important Notice—Please Read For Maximum System Performance, Vintage Air Recommends the Following: 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: 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). Safety Switches 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. 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. 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. 4 905073 REV E 04/09/19, PG 4 OF 31 www.vintageair.com 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. 5 905073 REV E 04/09/19, PG 5 OF 31 www.vintageair.com Engine Compartment Disassembly 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: 1. Disconnect battery. 2. Remove battery and battery tray (retain). 3. Drain and remove the radiator (retain). 4. Evacuate the A/C system if necessary. 5. Remove OEM condenser and drier (discard). 6. Remove OEM compressor and bracket (discard). 7. Remove OEM evaporator/blower motor assembly (discard) (See Figure 1, below). NOTE: To remove the evaporator and blower assembly (under hood) and the air distribution system (under dash), the factory manual recommends doing the following: Remove right lower rocker molding. Remove fender attaching bolts. Remove skirt to fender and skirt to reinforcement screws. Pull out on lower portion of fender, moving the skirt away from the fender flange and firewall. Block the skirt with a 2” x 4” block of wood. To avoid damage to paint and sheet metal, and for ease of removal and replacement of components, Vintage Air recommends that the right fender be removed, and the inner panel lowered (See Figure 1, below). 8. Remove OEM heater hoses, A/C hoses and hardlines (discard). 9. Remove OEM A/C & firewall grommet (discard). 10. Install a 1 ¾” plastic plug into the firewall (A/C cars only) (See Figure 1a, below). Heater Hoses Inner Fender Panel Drier A/C Hoses Grommet Figure 1 Compressor and Bracket 1 ¾” Plastic Plug 317102 Condenser Assembly and Installation 1. Refer to separate instructions included with the condenser kit to install the condenser. 2. Binary switch installation (Refer to condenser instructions). Compressor and Brackets 1. Refer to separate instructions included with the bracket kit to install the compressor bracket. 6 905073 REV E 04/09/19, PG 6 OF 31 Passenger Compartment Disassembly www.vintageair.com NOTE: Removal of the instrumental panel is required to install the evaporator. Vintage Air recommends that you utilize the factory service manual when you disassemble and reassemble the instrumental panel. Retain all items removed from vehicle, as some parts and hardware will be reused. Perform the Following: 1. Remove glove box door. (See Figure 1, below) 2. Remove glove box. 3. Remove OEM control panel assembly. 4. Remove OEM heater control knobs. 5. Disconnect all wires and cables from OEM control panel. 6. Disconnect all wires and cables from OEM heater control knobs. 7. Remove OEM heater assembly. 8. Remove OEM duct hoses from defrost ducts. 9. Remove OEM defrost ducts. 10. Remove passenger side kick panel fresh air cap. 11. Remove passenger side kick panel fresh air grille. Defrost Duct Assembly Control Panel 1972-74 Nova A/C Heater Assembly & Related Ducting Glove Box Passenger Side Kick Panel Fresh Air Cover Figure 1 Passenger Side Kick Panel Defrost Duct Assembly Control Panel Glove Box 1969-71 Nova A/C Heater Assembly & Related Ducting 7 Passenger Side Kick Panel Fresh Air Cover Passenger Side Kick Panel 905073 REV E 04/09/19, PG 7 OF 31 Kick Panel Modification www.vintageair.com 1. Remove (2) OEM screws from the fresh air door assembly. 2. Disconnect and discard the pull cable assemblies from the kick panel (See Figure 1, below). 3. Remove the kick panel by removing the (2) OEM screws (See Figure 1, below). 4. Remove the fresh air door assembly from the OEM kick panel by lifting up on the door toward the spring and sliding it out of the hinge housing (See Photo 1, below). 5. Trim the fresh air door housing to make it flush with the back of the kick panel (See Photos 2 & 3, below). Fresh Air Door Assembly OEM Screws OEM Screws Fresh Air Door Assembly Figure 1 Lift Door Toward Spring to Remove Photo 1 Fresh Air Door Housing Trim Housing Photo 2 8 Trim Flush with Kick Panel Housing Photo 3 905073 REV E 04/09/19, PG 8 OF 31 Defrost Duct Installation www.vintageair.com 1. Install the defrost ducts under the dash as shown in Figure 1, below. Align the defrost ducts with the defrost opening in the dash, hold in place and use the bracket as a template to drill a 7/64” hole. Secure using a #10 x 1/2” sheet metal screw. Driver Side Defrost Duct Passenger Side Defrost Duct (2) #10 x 1/2” Sheet Metal Screws Figure 1 FIGURE 5 Hose Adapter Installation 1. Install S-clips onto the hose adapters as shown in Figures 1 & 2, below. 2. Install the driver and passenger side hose adapters onto the OEM louvers (See Figures 1 & 2, below). Driver Side Hose Adapter 629967 Passenger Side Hose Adapter 498824 Install (2) S-Clips Install (3) S-Clips Driver Side Passenger Side Figure 2 Figure 1 9 905073 REV E 04/09/19, PG 9 OF 31 Fresh Air Cap & Kick Panel Cover Preparation www.vintageair.com 1. Install (4) large grommets and a 7/8” grommet into the fresh air cap (See Photos 1 & 2, below). 2. On the inside of the fresh air cap, the letter “T” indicates the top mounting hole for the firewall (See Photo 3, below). 3. From the center of the bottom left hole in the kick panel cover, measure 1 ½” down. Mark and drill a 5/8” hole for the 7/8” grommet (See Photos 4 & 5, below). 7/8” Grommet 33144-VUI (4) Large Grommets 33137-VUI Fresh Air Cap 622230 Photo 1 Photo 2 “T” Indicates Top Mounting Hole Photo 3 Kick Panel Cover 626667 1 ½” Drill 5/8” Hole Photo 1 Photo 5 Photo 4 10 905073 REV E 04/09/19, PG 10 OF 31 www.vintageair.com Fresh Air Cap & Kick Panel Cover Preparation (Cont.) 4. Install (4) large grommets and a 7/8” grommet into the kick panel cover (See Photos 6 & 7, below). (4) Large Grommets 33137-VUI 7/8” Grommet 33144-VUI Photo 6 Photo 7 Wiring Installation 1. From the passenger compartment, route the heater control valve connector and wiring (red, white and green) through the 7/8” grommet in the kick panel cover (See Figure 1, below). NOTE: Leave approximately 1” of wiring between the kick panel cover and the harness connector. This allows enough wiring to reach the harness. 2. Disconnect the circuit breaker from the main wiring harness (See Photo 1, below). Circuit Breaker Kick Panel Cover 626667 7/8” Grommet 33144-VUI Approximately 1” Heater Control Valve Connector and Wiring (Red, White and Green) Figure 1 11 Photo 1 905073 REV E 04/09/19, PG 11 OF 31 Wiring Installation (Cont.) www.vintageair.com 3. Route the red, white and blue wires from the main wiring harness through the 7/8” grommet in the kick panel cover (See Photo 2, below). NOTE: Leave approximately 5” of wiring between the relay and the kick panel cover. This allows enough wiring to secure the relay to the mounting position. 4. Route the heater control valve wiring (red, white and green) through the 7/8” grommet in the fresh air cap (See Photo 3, below). 5. Route the main harness wiring (red, white and blue) through the 7/8” grommet in the fresh air cap (See Photo 4, below). Kick Panel Cover 626667 Main Wiring Harness (Red, White and Blue) Photo 2 Approximately 5” Fresh Air Cap 622230 7/8” Grommet 33144-VUI Main Wiring Harness (Red, White and Blue) Heater Control Valve Connector and Wiring (Red, White and Green) Photo 3 Photo 4 12 905073 REV E 04/09/19, PG 12 OF 31 Kick Panel Cover Installation www.vintageair.com 1. Route the A/C and heater hoses through the kick panel cover as shown in Figure 1, below. 2. Apply 1/4” bead of silicone around the back side of the kick panel cover as shown in Figure 1, below. 3. Secure the kick panel cover and kick panel using OEM screws as shown in Figure 1, below. Silicone Kick Panel (5) OEM Screws #6 A/C Hose Figure 1 #10 A/C Hose Kick Panel Cover 626667 (2) Heater Hoses Fresh Air Cap Installation NOTE: The fresh air cap installs on the engine side of the firewall. 1. Route the A/C and heater hoses through the fresh air cap as shown in Figure 1, below. 2. Gently pull the slack from the hoses in the passenger compartment, making sure the hoses are not kinked. 3. Slide the fresh air cap into position, and secure it to the firewall using (2) #14 x 3/4” sheet metal screws (See Photo 1, below). 4. Apply silicone around the outer edge of the fresh air cap (See Photo 1, below). Apply Silicone Around Fresh Air Cap #6 A/C Hose Figure 1 #10 A/C Hose (2) Heater Hose Secure Fresh Air Cap with (2) #14 x 3/4” Sheet Metal Screws Photo 1 13 905073 REV E 04/09/19, PG 13 OF 31 Firewall Modification www.vintageair.com NOTE: Firewall modification is required for firewall cover and drain hose installation. 1. Flatten the edges of the firewall opening (See Photo 1, below). 2. Enlarge (6) holes on the firewall to 19/64” as shown in Photo 2, below. 3. From inside the passenger compartment, directly below the lowest OEM hole under the firewall opening, mark and drill a 5/8” hole for the drain hose (See Photo 3, below). NOTE: To ensure a tight fit, do not enlarge the hole to more than 5/8”. Enlarge (6) Holes to 19/64” Use This Hole for Reference Flatten Firewall Opening Edges Photo 2 Photo 1 Drill 5/8” Hole Photo 3 Firewall Cover Insulation NOTE: For proper system operation, Vintage Air recommends using heat blocking insulation in the area around the evaporator unit (firewall, kick panel, inner cowl, firewall covers). Due to tight clearance for the evaporator unit between the firewall and dash, Vintage Air recommends an insulation thickness of no more than 1/4”. 1. To apply insulation to the firewall cover, temporarily install the firewall cover onto the firewall using (2) 1/4-20 x 3/4” bolts and (2) 1/4-20 nuts with star washers (See Photo 1, below). 2. From the passenger compartment, trace the firewall opening onto the firewall cover (See Photo 2, below). 3. Remove the firewall cover, and apply insulation to the traced area (See Photo 3, below). Temporarily Install Firewall Cover with (2) 1/4-20 x 3/4” Bolts & (2) 1/4-20 Nuts with Star Washers Trace Firewall Opening Firewall Cover 640684 Photo 1 Firewall Cover 640684 Photo 2 14 Apply Insulation to Traced Area Photo 3 905073 REV E 04/09/19, PG 14 OF 31 Firewall Cover Installation www.vintageair.com NOTE: To ensure a watertight seal between the passenger compartment and the exterior, for all bolts passing through the firewall, Vintage Air recommends coating the threads with silicone prior to installation. 1. Install (5) 1/4-20 x 3/4” bolts and (5) 1/4” pushnut retainers onto the firewall cover (See Photos 1 & 2, below). 2. Apply a bead of silicone around the mating surface of the firewall cover as shown in Photo 2, below. 3. From the engine side, install the firewall cover onto the firewall from the passenger compartment, secure the firewall cover using (5) 1/4” flat washers and (5) 1/4-20 nuts with star washers. Firewall Cover 640684 Install (5) 1/4-20 x 3/4” Bolts Silicone Engine Compartment View Install (5) 1/4” Pushnut Bolt Retainers Passenger Compartment View Evaporator Bracket Installation 1. On a work bench, install the evaporator front and rear mounting brackets onto the evaporator using (4) 1/420 x 1/2” hex bolts and tighten as shown in Figure 1, below and Figure 2, Page 16. 2. Install the (2) heater fittings onto the evaporator with properly lubricated O-rings as shown in Lubricating O-rings, Page 19 and Figure 3, Page 16. (2) 1/4-20 x ½” Hex Bolt Figure 1 15 905073 REV E 04/09/19, PG 15 OF 31 www.vintageair.com Evaporator Bracket Installation (Cont.) Rear Evaporator Bracket 1/4-20 x 1 ½” Hex Bolt 5/16” Flat Washer 3/4” Nylon Spacer 1/4” Push Nut Bolt Retainer Figure 2 (2) 1/4-20 x 1/2” Hex Bolts Rear Evaporator Bracket 643170-FCB (2) Heater Fittings Figure 3 16 905073 REV E 04/09/19, PG 16 OF 31 Evaporator Installation www.vintageair.com NOTE: To ensure a watertight seal between the passenger compartment and the vehicle exterior, for all bolts passing through the firewall, Vintage Air recommends coating the threads with silicone prior to installation. 1. Place the evaporator unit under the dash. 2. Install the 90° fitting from the #6 drier/evaporator A/C hose onto the expansion valve on the evaporator unit using a properly lubricated #6 O-ring (See Lubricating O-rings, Page 19 and Figure 1, below). 3. Install the heater hose and a hose clamp onto the upper heater hardline on the evaporator unit (See Figure 1, below). 4. Install the lower heater hose and a hose clamp onto the lower heater hardline on the evaporator unit (See Figure 1, below). 5. Lift the evaporator unit up under the dashboard, and secure it loosely to the firewall from the engine compartment side using a 1/4-20 nut with star washer (See Figure 2, below). NOTE: To ensure proper drainage, it is very important that the evaporator level, both left-right and fore-aft. Check leveling on the flat portions of the sub case around the drain. 6. Using (2) #14 x 3/4 sheet metal screws, secure the front evaporator mounting bracket to the inner cowl (See Figure 2a, below). 7. Verify that the evaporator unit is leveled and square to the dash, then tighten all mounting bolts. NOTE: Tighten the bolt on the firewall first, then the front mounting bracket screws. 8. Install the 90° female fitting from the #10 compressor/evaporator A/C hose onto the evaporator unit using a properly lubricated #10 O-ring (See Lubricating O-rings, Page 19 and Figure 1, below). NOTE: After installing the #10 compressor/evaporator A/C hose, wrap all exposed metal with the supplied press tape. (See Figure 1, below). Drill (2) 3/16” Holes (2) #14 x 3/4” Sheet Metal Screws Press Tape Figure 2a Inner Cowl #6 A/C Hose (2) Hose Clamps (2) Heater Hoses #10 A/C Hose Kick Panel Fresh Air Cap Figure 1 1/4-20 Nut with Star Washer Figure 2 17 905073 REV E 04/09/19, PG 17 OF 31 www.vintageair.com Center Louver Installation 1. Install (4) S-clips onto the center louver hose adapter as shown in Figure 1, below. 2. Install the center louver hose adapter onto the center louver assembly (See Figure 1, below). 3. Install the center louver assembly into the dash using (2) OEM screws (See Figure 2, below). (4) S-Clips Center Louver Hose Adapter 629968 OEM Center Louver Assembly Figure 1 OEM Screws Figure 2 18 905073 REV E 04/09/19, PG 18 OF 31 Drain Hose Installation www.vintageair.com 1. Install the drain hose through the previously drilled 5/8” hole in the firewall. Attach the drain hose onto the drain outlet on the bottom of the evaporator unit (See Photo 1, below). Evaporator Drain Outlet Attach Drain hose to Drain Outlet Install Drain Hose into 5/8” Hole Photo 1 Photo 1 Lubricating O-rings Male O-ring Insert Female Nut #6 O-ring #8 O-ring #10 O-ring For a proper seal of fittings: Install supplied O-rings as shown, and lubricate with supplied oil. O-ring Supplied Oil for O-rings NOTE: Standard torque specifications: #6: 11 to 13 ft-lb. #8: 15 to 20 ft-lb. #10: 21 to 27 ft-lb. O-ring Installs Over Male Insert to Swaged Lip Figure ## Twist With This Wrench Hold With This Wrench Modified A/C Hose Kit 1. Refer to separate instructions included with modified hose kit. 19 905073 REV E 04/09/19, PG 19 OF 31 A/C and Heater Hose Installation (1969-72 Vehicles Only) www.vintageair.com 1. Locate the #8 condenser/compressor A/C hose and install (2) properly lubricated #8 O-rings (See Lubricating O-rings, Page 19). Connect the 90° fitting with service port to the #8 discharge port on the compressor (See Figure 1, Page 21). Install the 45° fitting onto the #8 condenser hardline coming through the core support (See Photo 1, below). Tighten each fitting connection as shown in Lubricating O-rings, Page 19. 2. Locate the #10 evaporator/compressor A/C hose and install a properly lubricated #10 O-ring (See Lubricating O-rings, Page 19). Connect the #10 135° fitting with service port to the #10 suction port on the compressor (See Figure 1, Page 21). 3. Locate the #6 evaporator/drier A/C hose and install a properly lubricated #6 O-ring (See Lubricating O-rings, Page 19). Connect the 90° fitting to the drier and tighten the fitting (See Figure 1, Page 21 and Lubricating O-rings, Page 19). 4. Install a #10 Adel clamp onto the #10 A/C hose. Secure the Adel clamp to the alternator bracket using a 1032 x 1/2” pan head screw and 10-32 nut with star washer (See Figure 1, Page 21). #8 Condenser Hardline 45° Fitting #8 Condenser/ Compressor A/C Hose Photo 1 A/C and Heater Hose Installation (1973-74 Vehicles Only) 1. Locate the #6 evaporator/drier A/C hose and install a properly lubricated #6 O-ring (See Lubricating O-rings, Page 19). Connect the 90° fitting to the #6 condenser hardline coming through the core support and tighten the fitting (See Photo 1, below and Lubricating O-rings, Page 19). 2. Locate the #8 condenser/compressor A/C hose and install (2) properly lubricated #8 O-rings (See Lubricating O-rings, Page 19). Connect the 90° fitting with service port to the #8 discharge port on the compressor (See Photo 3, below). Install the 45° fitting to the #8 condenser hardline coming through the core support (See Photo 2, below). Tighten fitting connection as shown in Lubricating O-rings, Page 19. 3. Locate the #10 evaporator/compressor A/C hose and install a properly lubricated #10 O-ring (See Lubricating O-rings, Page 19). Connect the #10 135° fitting with service port to the #10 suction port on the compressor (See Photo 3, below). 4. Install a #10 Adel clamp onto the #10 A/C hose. Secure the Adel clamp to the alternator bracket using a 1032 x 1/2” pan head screw and 10-32 nut with star washer (See Figure 1, Page 22). 90° Fitting #6 Evaporator/Drier A/C Hose 90° Fitting #6 Condenser Hardline #8 Condenser/ Compressor A/C Hose Photo 1 #10 Compressor Suction Port #8 Condenser Hardline Photo 2 20 #8 90°Fitting with Service Port #10 135° Fitting with Service Port #8 Compressor Discharge Port Photo 3 Compressor 905073 REV E 04/09/19, PG 20 OF 31 21 905073 REV E 04/09/19, PG 21 OF 31 Hose Clamps m Ma Int nif ake old Fro NOTE: Flow Direction Follows Molded Arrow on Valve. From Heater Control Valve To Evaporator Hose Compressor Safety Switch (Binary Type) Screw on Drier (Refer To Condenser Instructions) HeaterR Hose (Heater Control Valve/Intake) Tie Wrap #10 Adel Clamp with 10-32 x 1/2” Pan Head Screw with and 10-32 Nut With Star Washer #6 Drier/Condenser Hardline 091164 #10 Evaporator/ Compressor A/C Hose 096073 #8 Condenser/Compressor Hardline 091690 #8 Compressor/ Condenser A/C Hose 090166 NOTE: Vintage Air Systems use 5/8” heater connections. On engines equipped with 3/4” hose nipples, these will need to be removed and replaced with 5/8” nipples (not supplied). For water pumps with a cast-in 3/4” heater outlet, a 3/4” x 5/8” reducer fitting in the heater hose (not supplied) or molded hose (Vintage Air Part # 099010) will need to be installed. Fro m To E Wa vapo ter rat Pu or mp Heater #6 Evaporator/ Drier A/C Hose www.vintageair.com Figure 1 A/C and Heater Hose Routing (1969-72 Vehicles Only) 22 905073 REV E 04/09/19, PG 22 OF 31 Hose Clamps m Ma Int nif ake old Fro NOTE: Flow Direction Follows Molded Arrow on Valve. From Heater Control Valve To Evaporator Hose Fro m To E Wa vapo ter rat Pu or mp Heater HeaterR Hose (Heater Control Valve/Intake) Tie Wrap #6 Drier/ Condenser Hardline 35368-VCG #8 Condenser/ Compressor Hardline 091690 #6 Drier/ Evaporator Hardline 091691 #10 Adel Clamp with 10-32 x 1/2” Pan Head Screw with and 10-32 Nut With Star Washer #8 Compressor/ Condenser A/C Hose 090166 #10 Evaporator/ Compressor A/C Hose 096073 Figure 1 NOTE: Vintage Air Systems use 5/8” heater connections. On engines equipped with 3/4” hose nipples, these will need to be removed and replaced with 5/8” nipples (not supplied). For water pumps with a cast-in 3/4” heater outlet, a 3/4” x 5/8” reducer fitting in the heater hose (not supplied) or molded hose (Vintage Air Part # 099010) will need to be installed. #6 Evaporator/ Drier A/C Hose www.vintageair.com A/C and Heater Hose Routing (1973-74 Vehicles Only) www.vintageair.com Heater Control Valve Installation 1. Route a piece of heater hose (not provided) from the lower heater core fitting to the water pump. Secure using hose clamps. (See Figure 1, below). 2. Route a piece of heater hose (not provided) from the intake manifold to the heater control valve. Connect the heater hose from the upper heater core fitting to the heater control valve. Secure using hose clamps (See Figure 1, below). NOTE: Ensure proper flow direction through the heater control valve (the flow direction follows the molded arrow on the valve). 3. Plug the heater control valve connector into the connector on the main wiring harness (See Photo 2, below). Secure the white wire from the heater control valve portion of the main harness to a suitable chassis ground. From Heater Control Valve to Heater Core Heater Hoses From Heater Core to Water Pump Secure White Wire to Chasis Ground Hose Clamps Heater Control Valve Connector From Intake Manifold to Heater Control Valve NOTE: Flow Direction Follows Molded Arrow on Valve. Figure 1 Heater Control Harness Connector 23 Photo 1 905073 REV E 04/09/19, PG 23 OF 31 www.vintageair.com Control Panel & Duct Hose Routing Figure 1 Passenger Side Defrost Duct 2” x 12” Plug From Control Wiring Harness 232002-VUA Driver Side Defrost Duct 2” x 20” Driver Side Louver 2 ½ x 36” Center Louver Driver Side 2 ½” x 18” Plug From Wiring Harness 232600-VUA Center Louver Passenger Side 2 ½” x 20” 24 Passenger Side Louver 2 ½” x 40” 905073 REV E 04/09/19, PG 24 OF 31 Final Steps www.vintageair.com 1. Install duct hoses as shown in Figure 1, Page 24. Extend duct hose to a taut condition, then cut to length as noted. There should be little or no slack in hose once installed. 2. Reinstall control panel assembly. NOTE: Controls must be calibrated for proper operation. Refer to control panel instructions. 3. Plug the wiring harness into the ECU module on sub case as shown in Figure 1, Page 24. Wire according to wiring diagram on Pages 25 and 26. 4. Modify the passenger side kick panel fresh air cover as shown in Figure 1, below. 5. Reinstall the passenger side kick panel fresh air cover. 6. Install the glove box behind the dash. Using the mounting holes of the glove box as a template, mark and drill using a 1/16” drill bit. Secure the glove box to the dash using the OEM screws. 7. Reinstall the glove box door. 8. Reinstall all previously removed items (battery, radiator, radio). 9. Fill radiator with at least a 50/50 mixture of approved antifreeze and distilled water or pre mix antifreeze. It is the owner’s responsibility to keep the freeze protection at the proper level for the climate in which the vehicle is operated. Failure to follow antifreeze recommendations will cause heater core to corrode prematurely and possibly burst in A/C mode and/or freezing weather, voiding your warranty. 10. Double check all fittings, brackets and belts for tightness. 11. Vintage air recommends that all A/C systems be serviced by a certified automotive air conditioning technician. 12. Evacuate the system for a minimum of 45 minutes prior to charging and leak check prior to servicing. 13. Charge the system to the capacity stated on the information Page 4 of this instruction manual. 14. See Operation of Controls procedures Page 28. 4 ⅞” 3 ⅛” Glove Box 49069-VCI Figure 1 25 Figure 1a 905073 REV E 04/09/19, PG 25 OF 31 Wiring Diagram www.vintageair.com 232007-VUR TAN ORA BLK WHT JF8 RED WHT/RED WHT/YEL WHT/GRN AC ANNUNCIATOR BACKLIGHT POS BACKLIGHT NEG GND 5V-SW TEMP WIPER MODE WIPER FAN WIPER PRE-WIRED VIEWED FROM WIRE SIDE 232002-VUA A/C (IF USED) GEN IV ECU GEN IV WIRING DIAGRAM REV E, 10/6/2017 TEMP MODE FAN PROGRAM * DASH LAMP (IF USED) *** WIDE OPEN THROTTLE SWITCH (OPTIONAL) ** CIRCUIT BREAKER 30 AMP HEATER CONTROL VALVE * Dash Lamp Is Used Only With Type 232007-VUR Harness. ** 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). *** Wide Open Throttle Switch Contacts Close Only at Full Throttle, Which Disables A/C Compressor. 26 905073 REV E 04/09/19, PG 26 OF 31 Gen IV Wiring Connection Instruction www.vintageair.com WIRING HARNESS CONTROL WIRING HARNESS RED & WHITE A/C COMPRESSOR RELAY RED BLUE NOTE: MOUNT RELAY IN DESIRED LOCATION UNDER DASH RED WH IT E Ignition Switch: VIOLET Violet 12V Ign Switch Source (Key On Accessory) Position Must Be Switched. +12V NOTE: WIRING YELLOW & ORANGE (IGNITION HOT HARNESS COMING FROM TERMINAL) HARNESS ARE NOT USED. YELLOW RUN BAT IGNITION SWITCH ORANGE TAN DASH BACK LIGHT+0-12v GRAY GRAY WIRE IS USED FOR PROGRAMING CONTROLS IF APPLICABLE RED GREEN RED GREEN FIREWALL BLACK BLUE Heater Control Valve: RED LATCH WIRING HARNESS WHITE CHASSIS GROUND NOTE: HEATER CONTROL VALVE CONNECTION AND CHASSIS GROUND MAY BE LOCATED ON EITHER SIDE OF THE FIREWALL. ENSURE CONNECTOR IS LATCHED FIRMLY. HEATER CONTROL VALVE K BLAC BLUE COMPRESSOR WHITE NOTE: CONNECT WHITE WIRES DIRECTLY TO (-) BATTERY TERMINAL WHITE RED RED CIRCUIT BREAKER 30 AMP Install With Servo Motor Facing Down, As Shown. Note Flow Direction Arrow Molded Into Valve Body, And Install Accordingly. Binary/Trinary & Compressor: Binary: Connect As Shown (Typical Compressor Wiring). Be Sure Compressor Body Is Grounded. BINARY SAFETY SWITCH BLUE Dash Light: Tan Wire Used Only With Vintage Air Supplied Control Panel With LED Back Light. Circuit Breaker/Battery: White Must Run To (-) Battery. Red May Run To (+) Battery Or Starter. Mount Circuit Breaker As Close to Battery As Possible. RED 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). + Trinary Switch: Connect According To Trinary Switch Wiring Diagram. - BATTERY 27 905073 REV E 04/09/19, PG 27 OF 31 Operation of Controls www.vintageair.com On Gen IV systems with three lever/knob controls, the temperature control toggles between heat and A/C operations. To activate A/C, move the temperature lever/knob all the way to cold and then back it off to the desired vent temperature. For heat operation, move the temperature lever/knob all the way to hot and then adjust to the desired vent temperature. The blower will momentarily change speed, each time you toggle between operations, to indicate the change. NOTE: For proper control panel function, refer to the control panel instructions. Blower Speed This lever/knob controls blower speed, from OFF to HI. Mode Control This lever/knob controls the mode positions, from DASH to FLOOR to DEFROST, with a blend in between. Temperature Control Temperature Control This lever controls the temperature, from HOT to COLD. Blower Speed HI Mode Control COLD DASH F L R OFF HOT DEF A/C Operation Blower Speed Adjust to desired speed. Mode Control Adjust to desired mode position (DASH position recommended). Temperature Control For A/C operation, adjust to coldest position to engage compressor (Adjust between HOT and COLD to reach desired temperature). Mode Control Adjust to desired mode position (FLOOR position recommended). HI HOT DEF COLD DASH Temperature Control For maximum heating, adjust to hottest position (Adjust between HOT and COLD to reach desired temperature). Defrost/De-fog Operation Blower Speed Adjust to desired speed. COLD DASH F L R OFF Heat Operation Blower Speed Adjust to desired speed. HI F L R OFF HOT DEF HI COLD DASH Temperature Control Adjust to desired temperature. Mode Control Adjust to DEFROST position for maximum defrost, or between FLOOR and DEFROST positions for a bi-level blend (Compressor is automatically engaged). 28 F L R OFF HOT DEF 905073 REV E 04/09/19, PG 28 OF 31 29 905073 REV E 04/09/19, PG 29 OF 31 Symptom Compressor will not turn off (All other functions work). 3. Compressor will not turn on (All other functions work). 2. Blower stays on high speed when ignition is on or off. 1b. Blower stays on high speed when ignition is on. 1a. System is charged. System is not charged. All other functions work. No other functions work. Condition www.vintageair.com Repair or replace pot/control wiring. Replace relay. Check for faulty A/C relay. Check 2-pin connector at ECU housing. Check continuity to ground on white control head wire. Check for 5V on red control head wire. Charge system or bypass pressure switch. Replace BSC (This will require removal of evaporator from vehicle). Check to ensure that no BSC wiring is damaged or shorted to vehicle ground. The BSC operates the blower by ground side pulse width modulation switching. The positive wire to the blower will always be hot. If the “ground” side of the blower is shorted to chassis ground, the blower will run on HI. Be sure the small, 20 GA white ground wire is connected to the battery ground post. If it is, replace the ECU. Verify continuity to chassis ground with white control head wire at various points. Verify that all pins are inserted into plug. Ensure that no pins are bent or damaged in ECU. Actions Check for faulty A/C potentiometer or associated wiring. Check for disconnected or faulty thermistor. Check for faulty A/C potentiometer or associated wiring (Not applicable to 3-pot controls). System must be charged for compressor to engage. Unplug 3-wire BSC control connector from ECU. If blower stays running, BSC is either improperly wired or damaged. Unplug 3-wire BSC control connector from ECU. If blower shuts off, ECU is either improperly wired or damaged. Check for damaged ground wire (white) in control head harness. Check for damaged blower switch or potentiometer and associated wiring. Check for damaged pins or wires in control head plug. Checks Red wire at A/C pot should have approximately 5V with ignition on. White wire will have continuity to chassis ground. White/ Blue wire should vary between 0V and 5V when lever is moved up or down. Disconnected or faulty thermistor will cause compressor to be disabled. To check for proper pot function, check voltage at white/blue wire. Voltage should be between 0V and 5V, and will vary with pot lever position. Danger: Never bypass safety switch with engine running. Serious injury can result. No other part replacements should be necessary. See blower switch check procedure. Loss of ground on this wire renders control head inoperable. Notes Troubleshooting Guide 30 905073 REV E 04/09/19, PG 30 OF 31 Symptom 8. When ignition is turned on, blower momentarily comes on, then shuts off. This occurs with the blower switch in the OFF position. Erratic functions of blower, mode, temp, etc. 7. Blower turns on and off rapidly. 6. Loss of mode door function. 5. System will not turn on, or runs intermittently. 4. This is an indicator that the system has been reset. Be sure the red power wire is on the battery post, and not on a switched source. Also, if the system is pulled below 7V for even a split second, the system will reset. Run red power wire directly to battery. Repair or replace. Charge battery. Check for faulty battery or alternator. Battery voltage is less than 12V. Check for damaged switch or pot and associated wiring. Ensure all system grounds and power connections are clean and tight. Verify proper meter function by checking the condition of a known good battery. Check for positive power at heater valve green wire and blower red wire. Check for ground on control head white wire. Install capacitors on ignition coil and alternator. Ensure good ground at all points. Relocate coil and associated wiring away from ECU and ECU wiring. Check for burned or loose plug wires. Actions Check for at least 12V at circuit breaker. Check for damaged stepper motor or wiring. Check for obstructed or binding mode doors. Check for damaged mode switch or potentiometer and associated wiring. Verify battery voltage is greater than 10 volts and less than 16. Verify connections on power lead, ignition lead, and both white ground wires. Noise interference from either ignition or alternator. Checks Battery voltage is at least 12V. Partial function of mode doors. No mode change at all. Will not turn on under any conditions. Works when engine is not running; shuts off when engine is started (Typically early Gen IV, but possible on all versions). Condition www.vintageair.com System shuts off blower at 10V. Poor connections or weak battery can cause shutdown at up to 11V. Typically caused by evaporator housing installed in a bind in the vehicle. Be sure all mounting locations line up and don’t have to be forced into position. Ignition noise (radiated or conducted) will cause the system to shut down due to high voltage spikes. If this is suspected, check with a quality oscilloscope. Spikes greater than 16V will shut down the ECU. Install a radio capacitor at the positive post of the ignition coil (See radio capacitor installation bulletin). A faulty alternator or worn out battery can also result in this condition. Notes Troubleshooting Guide (Cont.) Packing List: Evaporator Kit (565072) www.vintageair.com No. 1. 2. Qty. 1 1 Part No. 744004-VUE 784177 Description Gen IV 4-Vent Evaporator Accessory Kit Checked By: Packed By: Date: 1 Gen IV 4-Vent Evaporator Sub Case 744004-VUE 2 Accessory Kit 784177 NOTE: Images may not depict actual parts and quantities. Refer to packing list for actual parts and quantities. 31 905073 REV E 04/09/19, PG 31 OF 31