1957 CHEVY WITHOUT FACTORY AIR WITH 4-VENT PLENUM 561058 an ISO 9001:2008 Registered Company 901258 REV D 6/30/16 1957 CHEVY w/o AC w/4 VENT PLENUM GEN IV INST PG 1 OF 25
1957 CHEVYWITHOUT FACTORY AIRWITH 4-VENT PLENUM
561058
an ISO 9001:2008 Registered Company
901258 REV D 6/30/16 1957 CHEVY w/o AC w/4 VENT PLENUM GEN IV INST PG 1 OF 25
2901258 REV D 6/30/16 1957 CHEVY w/o AC w/4 VENT PLENUM GEN IV INST PG 2 OF 25
PAGES
1. 2. 3. 4. 5. 6. 7. 8. 9.
10.
11.
12.
13. 14.
15.
16.
17.
18.
19. 20. 21.22.23.24.25.
COVERTABLE OF CONTENTSPACKING LIST/PARTS DISCLAIMERINFORMATION PAGEWIRING NOTICEENGINE COMPARTMENT FIGURE 1PASSENGER COMPARTMENT FIGURE 2ENGINE COMPARTMENT & DEFROST DUCT INSTALLATION FIGURE 3EVAPORATOR INSTALLATION FIGURES 4 & 5EVAPORATOR INSTALLATION CONT. FIGURES 6 & 7DUCT HOSE ROUTING - CONTROL WIRING FIGURE 8CENTER VENT INSTALLATION & PASSENGER & DRIVER SIDE UNDER DASH LOUVER INSTALLATION FIGURES 9 & 10HARDLINE INSTALLATIONO-RING LUBRICATING/FITTING TIGHTENING, FIGURES 11 & 12HEATER CONTROL VALVE INSTALLATION, FIGURE 13A/C HOSE AND HARDLINE ROUTING FIGURES 14-14bFIREWALL COVER INSTALLATION/FRESH AIR CAP FIGURE 15FINAL STEPS/GLOVE BOX INSTALLATION PHOTO 1 AND FIGURE 16EVAPORATOR HARDLINE INSTALLATION FIGURE 17WIRING DIAGRAMGEN IV WIRING CONNECTION INSTRUCTIONSOPERATION OF CONTROLSTROUBLESHOOTINGTROUBLESHOOTING CONT.CORE SUPPORT TEMPLATEEVAPORATOR KIT PACKING LIST
Table of Contents
3901258 REV D 6/30/16 1957 CHEVY w/o AC w/4 VENT PLENUM GEN IV INST PG 3 OF 25
EVAPORATOR KIT561058
No.
1.2.
QTY.
11
PART No.
761158781158
DESCRIPTION
57 CHEVY w/o AC w/ 4 VENT PLENUM GEN IV EVAP SUB CASE1957 CHEVY w/o AC 4 VENT ACC KIT
57 CHEVY w/o AC4 VENT PLENUM GEN IVEVAP SUB CASE 761158
ACCESSORY KIT781158
1
2DASH
FLOORDEF
INSIDE
OUTSIDE
OFFHEAT
COLDOFF AIR
**BEFORE BEGINNING INSTALLATION OPEN ALL PACKAGES AND CHECK CONTENTS OF SHIPMENTPLEASE REPORT ANY SHORTAGES DIRECTLY TO VINTAGE AIR WITHIN 15 DAYS. AFTER 15 DAYS,VINTAGE AIR WILL NOT BE RESPONSIBLE FOR MISSING OR DAMAGED ITEMS.
4901258 REV D 6/30/16 1957 CHEVY w/o AC w/4 VENT PLENUM GEN IV INST PG 4 OF 25
Important Notice—Please ReadFor Maximum System Performance, Vintage Air Recommends the Following:
New Vintage Air-supplied Sanden Compressor: No additional oil needed (Compressor is shipped with proper oil charge).All Other Compressors: Consult manufacturer (Some compressors are shipped dry and will need oil added).
NOTE: Vintage Air systems are designed to operate with R134a refrigerant only. Use of any other refrigerant could damage your A/C system and/or vehicle, and possibly cause a fire, in addition to potentially voiding the warranties of the A/C system and its components.
Refrigerant Capacities:Vintage Air System: 1.8 lbs. (1 lb., 12 oz.) of R134a, charged by weight with a quality charging station or scale. NOTE: Use of the proper type and amount of refrigerant is critical to system operation and performance.Other Systems: Consult manufacturer’s guidelines.
Lubricant Capacities:
Safety Switches
Service Info:Protect Your Investment: Prior to assembly, it is critical that the compressor, evaporator, A/C hoses and fittings, hardlines, condenser and receiver/drier remained capped. Removing caps prior to assembly will allow moisture, insects and debris into the components, possibly leading to reduced performance and/or premature failure of your A/C system. This is especially important with the receiver/drier. Additionally, when caps are removed for assembly, BE CAREFUL! Some components are shipped under pressure with dry nitrogen.Evacuate the System for 35-45 Minutes: Ensure that system components (Drier, compressor, evaporator and condenser) are at a temperature of at least 85° F. On a cool day, the components can be heated with a heat gun or by running the engine with the heater on before evacuating. Leak check and charge to specifications.
Your Vintage Air system is equipped with a binary pressure safety switch. A binary switch disengages the compressor clutch in cases of extreme low pressure conditions (Refrigerant Loss) or excessively high head pressure (406 PSI) to prevent compressor damage or hose rupture. A trinary switch combines Hi/Lo pressure protection with an electric fan operation signal at 254 PSI, and should be substituted for use with electric fans. Compressor safety switches are extremely important since an A/C system relies on refrigerant to circulate lubricant.
Bolts Passing Through Cowl and/or Firewall:To ensure a watertight seal between the passenger compartment and the vehicle exterior, for all bolts passing through the cowl and/or firewall, Vintage Air recommends coating the threads with silicone prior to installation.
Heater Hose (Not Included With This Kit):Heater hose may be purchased from Vintage Air (Part# 31800-VUD) or your local parts retailer. Routing and required length will vary based on installer preference.
5901258 REV D 6/30/16 1957 CHEVY w/o AC w/4 VENT PLENUM GEN IV INST PG 5 OF 25
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.
•
•
•
6901258 REV D 6/30/16 1957 CHEVY w/o AC w/4 VENT PLENUM GEN IV INST PG 6 OF 25
INSTALLATION INSTRUCTIONS FOR 1957-CHEVY
ENGINE COMPARTMENT
DISCONNECT BATTERY AND REMOVE.REMOVE BATTERY TRAY.REMOVE AIR CLEANER.DRAIN RADIATOR.DISCONNECT HEATER HOSES.REMOVE OEM BLOWER ASSEMBLY FROM FIREWALL AND FENDER. KEEP THE TWO OEM FIREWALL COVER RETAINING BRACKETS FOR USE WITH THE NEW FIREWALL COVER.
INSTALL HEATER CONTROL VALVE BLOCK-OFF PLATE AS SHOWN IN FIGURE 1, BELOW. REMOVE OEM HEATER CONTROL VALVE AND DISCARD.
BEFORE STARTING THE AIR CONDITIONER INSTALLATION, CHECK FOR PROPER OPERATION OF ALL COMPONENTS (RADIO,LIGHTS, WIPERS, ETC.). STUDY THE INSTRUCTIONS, ILLUSTRATIONS AND DIAGRAMS. FOR EASE OF INSTALLATION,
CHECK OFF ( ) EACH PROCEDURE PRIOR TO MOVING ON TO THE NEXT STEP.
FIGURE 1
HEATER CONTROLVALVE BLOCK-OFF
PLATE
7901258 REV D 6/30/16 1957 CHEVY w/o AC w/4 VENT PLENUM GEN IV INST PG 7 OF 25
PASSENGER COMPARTMENT
REMOVE CONTROL PANEL BEZEL.
REMOVE GLOVE BOX (DISCARD).REMOVE GLOVE BOX DOOR.REMOVE RADIO (OPTIONAL).REMOVE CLOCK.REMOVE AND DISCARD THE OEM HEATER ASSEMBLY AND HEATER DUCT.REMOVE AND DISCARD DEFROSTER DUCT.
REMOVE THE OEM CONTROL PANEL ASSEMBLY & DISCONNECT CABLES (RETAIN OEM CONTROLPANEL AND DISCARD CABLES) AS SHOWN IN FIGURE 2, BELOW. REFER TO CONTROL PANEL CONVERSION KIT INSTRUCTIONS FOR INSTALLATION OF CONTROLS.
FIGURE 2
DEFROST DUCTS
GLOVE BOX DOOR
GLOVE BOX
CONTROL PANEL BEZEL
OEM HEATER ASSEMBLY
RADIO CLOCK
CONTROL PANEL
8901258 REV D 6/30/16 1957 CHEVY w/o AC w/4 VENT PLENUM GEN IV INST PG 8 OF 25
CONDENSER ASSEMBLY & INSTALLATION
COMPRESSOR & BRACKETS
PULLEYS
DEFROST DUCT INSTALLATION
FIGURE 3
ENGINE COMPARTMENT
REFER TO SEPARATE INSTRUCTIONS INCLUDED WITHTHE CONDENSER KIT TO INSTALL THE CONDENSER.BINARY SWITCH INSTALLATION (REFER TO CONDENSER INSTRUCTIONS).
REFER TO SEPARATE INSTRUCTIONS INCLUDED WITHTHE BRACKET KIT TO INSTALL THE COMPRESSOR BRACKET.
IN MOST INSTANCES, THE BELT LENGTHS WILL REMAIN THE SAME.
INSTALL DEFROST DUCTS WITH 2” DUCT HOSE(PASSENGER SIDE: 2” x 10”) (DRIVER SIDE: 2” x 24”).SEE FIGURE 3, BELOW, & FIGURE 8, PAGE 11.
#8 x 1/2”PAN HEAD
SCREW
9901258 REV D 6/30/16 1957 CHEVY w/o AC w/4 VENT PLENUM GEN IV INST PG 9 OF 25
EVAPORATOR INSTALLATION
LIFT EVAPORATOR UNIT UP & UNDER THE DASHBOARD (SEE FIGURES 4 & 5, BELOW, & FIGURE 6, PAGE 10). SECURE LOOSELY TO THE FIREWALL FROM THE ENGINE COMPARTMENT SIDE WITH (2) 1/4-20 x 1” BOLTS AND WASHERS. SEE FIGURE 7, PAGE 10, & FIGURE 15, PAGE 16.
INSTALL FRONT MOUNTING BRACKET TO EVAPORATOR UNIT WITH 1/4-20 x 1/2” BUTTON HEAD SCREW & WASHER. TIGHTEN AS SHOWN IN FIGURE 7, PAGE 10. LOOSELY ATTACH FRONT MOUNTING BRACKET TO DASH WITH 1/4-20 x 1” BOLT, WASHER AND NUT. SEE FIGURE 7, PAGE 10.
INSTALL CENTER A/C PLENUM TO EVAPORATOR WITH (2) 10/32 x 1/2” SCREWS. SEE FIGURE 7, PAGE 10.
LOOSELY SECURE THE CENTER PLENUM TO DASH WITH THE CENTER PLENUM MOUNTING BRACKET, USING A 1/4-20 x 1” BOLT AND WASHER. SEE FIGURE 7, PAGE 10.
VERIFY THAT EVAPORATOR UNIT IS LEVEL AND SQUARE TO THE DASH, THEN TIGHTEN ALL SECURING BOLTS.NOTE: TIGHTEN THE TWO BOLTS ON FIREWALL FIRST. THEN TIGHTEN THE FRONT MOUNTING BRACKET BOLT AND NUT. TIGHTEN THE CENTER PLENUM MOUNTING BOLT LAST.
ON A WORKBENCH, INSTALL EVAPORATOR REAR BRACKETS, AND INSTALL EVAPORATOR HARDLINES WITH PROPERLY LUBRICATED O-RINGS (SEE FIGURE 17, PAGE 18, AND FIGURE 12, PAGE 14).
FIGURE 4
FIGURE 5
INSTALL EVAPORATOR UNIT FROMPASSENGER SIDE FLOORBOARD.
ROTATE EVAPORATOR UNIT SO LINES PASS THROUGH OPENING IN FIREWALL, AND LIFT INTO PLACE.
10901258 REV D 6/30/16 1957 CHEVY w/o AC w/4 VENT PLENUM GEN IV INST PG 10 OF 25
ONCE INTO PLACE, SECURE EVAPORATORUNIT TO FIREWALL.
A/C-HEAT BLEND DOOR
FIREWALL
1/4-20 x 1”BOLT & WASHER
ECUMODULE
DEFROSTDOOR
DASH/FLOORDOOR
4-VENTA/C PLENUM
4-VENTA/C PLENUM
10/32 x 1/2”SCREW
FIGURE 7
FIGURE 6
BOTTOM LIP OF DASH
1/4-20 x 1”BOLT & WASHER
1/4-20 x 1/2”BUTTON HEAD
SCREW
FRONTMOUNTING
BRACKET
1/4-20NUT
11901258 REV D 6/30/16 1957 CHEVY w/o AC w/4 VENT PLENUM GEN IV INST PG 11 OF 25
DRILL 5/8” HOLE IN FIREWALL FOR DRAIN HOSE, USING FIREWALL HOLE TEMPLATE ON PAGE 24. SEE FIGURE 15, PAGE 16.CONNECT DRAIN HOSE TO BOTTOM OF EVAPORATOR UNIT AND ROUTE TO FIREWALL (SEE FIGURE 15, PAGE 16).INSTALL DUCT HOSES AS SHOWN IN FIGURE 8, BELOW.INSTALL DRIVER & PASSENGER UNDER-DASH LOUVERS. SEE FIGURE 10, PAGE 12.
CONTROL WIRING
DUCT & DRAIN HOSE ROUTING
ECUMODULE
PASSENGERSIDE LOUVER2 ½” x 42”
DRIVER SIDE LOUVER
2 ½” x 48”
DRIVER SIDE CENTER VENT
2 ½” x 15”
PASSENGER SIDE CENTER VENT
2 ½” x 12”
DRIVER SIDE DEFROST DUCT
2” x 24”
FIGURE 8
PASSENGER SIDE DEFROST DUCT
2” x 10”
12901258 REV D 6/30/16 1957 CHEVY w/o AC w/4 VENT PLENUM GEN IV INST PG 12 OF 25
DASHUNDER DASH
LOUVER(PASSENGER SIDE)
(2) #8 x ½” PH SCREWSCENTER VENT
SIDE FLANGE
BOTTOM EDGEOF DASH
KICK PANELRETAINING
STRIPEND VIEW
DRIVER SIDE
#8 X ½”PAN HEAD
SCREW
INSTALL PASSENGER AND DRIVER SIDE BALL LOUVERS BY SLIDING THE SIDE FLANGE OF BALL LOUVERBETWEEN THE KICK PANEL AND KICK PANEL RETAINING STRIP.SLIDE LOUVER UP TOWARD BOTTOM OF DASH UNTIL THE LOUVER IS SEATED AGAINST DASH, ANDSECURE TO KICK PANEL WITH SUPPLIED #8 x ½” PAN HEAD SCREW. SEE FIGURE 10, ABOVE.
PLACE CENTER VENT UNDER DASH IN DESIRED POSITION. SEE FIGURE 9, BELOW. DRILL (2) 1/8” MOUNTINGHOLES IN BOTTOM LIP OF DASH, AND SECURE CENTER VENT TO DASH USING (2) #8 x ½” PAN-HEAD SCREWS.SEE FIGURE 9, BELOW.
CENTER VENT INSTALLATION
PASSENGER AND DRIVER SIDE UNDER DASH LOUVER INSTALLATION
FIGURE 10
FIGURE 9
13901258 REV D 6/30/16 1957 CHEVY w/o AC w/4 VENT PLENUM GEN IV INST PG 13 OF 25
INSTALL HEATER CPNTROL VALVE IN LINE WITH INTAKE MANIFOLD (PRESSURE SIDE) HEATER HOSE. SEE FIGURE 13, PAGE 14.
INSTALL THE #6 LIQUID LINE TO DRIER WITH LUBRICATED O-RING AND TIGHTEN. SEE FIGURE 14, PAGE 15.
INSTALL BINARY SWITCH ON #6 LIQUID LINE. SEE FIGURE 14, PAGE 15.
SECURE THE #6 LIQUID LINE TO THE FENDER USING THE SUPPLIED ADEL CLAMP. SEE FIGURE 14, PAGE 15.
LOCATE THE TWO COMPRESSOR ALUMINUM HARDLINE EXTENSIONS. SEE FIGURE 14, PAGE 15.
LOCATE THE #8 COMPRESSOR ALUMINUM HARDLINE. LUBRICATE (1) #8 O-RING AND INSTALL ON THE FEMALE O-RING END. CONNECT THIS LINE TO THE #8 DISCHARGE PORT ON THE COMPRESSOR AND TIGHTEN. SEE FIGURE 14, PAGE 15.
LOCATE THE #10 COMPRESSOR ALUMINUM HARDLINE. LUBRICATE (1) #8 O-RING AND INSTALL ON THE FEMALE O-RING END. CONNECT THIS LINE TO THE #10 SUCTION PORT ON THE COMPRESSOR AND TIGHTEN. SEE FIGURE 14, PAGE 15.
SECURE THE TWO COMPRESSOR HARDLINES TO THE COMPRESSOR, USING THE SUPPLIED CLAMP. SEEFIGURE 14a, PAGE 15.
LOCATE THE #8 RUBBER HOSE. THIS HOSE WILL CONNECT TO THE #8 ALUMINUM COMPRESSOR HARDLINE AND #8 ALUMINUM HARDLINE FROM CONDENSER. LUBRICATE (2) #8 O-RINGS, AND INSTALL ONE ON EACH END OF THE #8 RUBBER HOSE. ROUTE HOSE AS SHOWN IN FIGURE 14, PAGE 15, AND TIGHTEN. NOTE: THE 90° HOSE END CONNECTS TO THE CONDENSER HARDLINE.
PASS THE #6 LIQUID LINE THROUGH THE BOTTOM HOLE IN THE FIREWALL COVER. SEE FIGURE 14b, PAGE 15.
PULL FIREWALL COVER BACK AND INSTALL THE #6 LIQUID LINE, LUBRICATE (1) #6 O-RING AND TIGHTEN.SEE FIGURE 14b, PAGE 15.
SECURE THE FIREWALL COVER USING TWO OEM RETAINING BRACKETS. SEE FIGURE 15, PAGE 16.
LOCATE THE #10 RUBBER HOSE. THIS HOSE WILL CONNECT TO THE #10 ALUMINUM COMPRESSOR HARDLINE AND #10 ALUMINUM HARDLINE FROM EVAPORATOR. LUBRICATE (2) #10 O-RINGS, AND INSTALL ONE ON EACH END OF THE #10 RUBBER HOSE. ROUTE HOSE AS SHOWN IN FIGURE 14, PAGE 15 AND TIGHTEN. NOTE: THE 90° HOSE END CONNECTS TO THE COMPRESSOR HARDLINE.
INSTALL HEATER HOSES TO HEATER LINES AND ROUTE AS SHOWN IN FIGURES 14-14b, PAGE 15. SECURE WITH HOSE CLAMPS. NOTE: THIS KIT DOES NOT CONTAIN HEATER HOSE. IT WILL BE NECESSARY TO PURCHASE 5/8” DIAMETER HEATER HOSE FROM YOUR LOCAL PARTS RETAILER.
STANDARD HOSE KITHARDLINE & HOSE INSTALLATION
MODIFIED HOSE KIT
HEATER CONTROL VALVE & #6 LIQUID LINE
REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH MODIFIED HOSE KIT.
14901258 REV D 6/30/16 1957 CHEVY w/o AC w/4 VENT PLENUM GEN IV INST PG 14 OF 25
O-RING LUBRICATION
FOR A PROPER SEAL OF FITTINGS:INSTALL SUPPLIED O-RINGS AS SHOWNAND LUBRICATE WITH SUPPLIED OIL.
O-RING
TWIST WITHTHIS WRENCHHOLD WITH
THIS WRENCHFIGURE 11
FIGURE 12
#6 O-RING #8 O-RING
SUPPLIED OILFOR O-RINGS O-RING, INSTALLS
OVER MALE INSERTTO SWAGED LIP
#10 O-RING
O-RING
MALEINSERT FEMALE
NUT
HEATER CONTROL VALVE INSTALLATION
FIGURE 13
ECU MODULEBSC
MODULE
#6 LIQUIDLINE
#10 SUCTIONHOSE
HEATER HOSE
FROM INTAKEMANIFOLD
TO WATER PUMP
NOTE: FLOW DIRECTION FOLLOWSMOLDED ARROW ON VALVE.
15901258 REV D 6/30/16 1957 CHEVY w/o AC w/4 VENT PLENUM GEN IV INST PG 15 OF 25
A/C & HEATER HOSEAND HARDLINE ROUTINGPRESS
TAPE ECUMODULE
FIREWALLCOVER HEATER
CONTROLVALVE
HEATERHOSES
BSCMODULE
ECUMODULE #10 SUCTION
LINE (INSULATED)
ALUMINUMCLAMP
(STANDARDHOSE KIT
ONLY)
FIREWALLCOVER
#6 LIQUID LINE
O-RINGO-RING
#6 LIQUID LINE
HEATERHOSE
BSCMODULE
EVAPORATORSUB CASE
EXPANSIONVALVE
BINARY SWITCHINSTALLATION
#6 LIQUID LINE
NOTE: MODIFIED HOSE KITS INCLUDE(2) 135° COMPRESSOR FITTINGS (REFER TO MODIFIED HOSE KIT INSTRUCTIONSINCLUDED WITH HOSE KIT).
PRESSTAPE
#10 RUBBERSUCTION HOSE
ADELCLAMP
#8 RUBBERHOSE
BINARY SWITCH
#6 LIQUID LINE FROMDRIER TO
EXPANSION VALVE 09157-PFL
NOTE: COMPRESSOR HARDLINESARE INCLUDED WITH STANDARD
HOSE KIT ONLY.
#8 COMPRESSORALUMINUM HARDLINEEXT. (DISCHARGE SIDE)
35038-VUG-A
#10 COMPRESSORALUMINUM
HARDLINE EXT. (SUCTION SIDE)35037-VUG-A
#8 CONDENSER LINE35018-VCG
#6 HARDLINE35017-VCG
SPLIT RUBBERGROMMET IN HOLEIN CORE SUPPORT
FIGURE 14a
FIGURE 14
FIGURE 14b
16901258 REV D 6/30/16 1957 CHEVY w/o AC w/4 VENT PLENUM GEN IV INST PG 16 OF 25
FIREWALL COVER & FRESH AIR CAP
INSTALL FRESH AIR CAP TO FRESH AIR DUCT UNDERPASSENGER SIDE FENDER AS SHOWN IN FIGURE 15, BELOW.
GROMMETS:
33137-VUI(2) HEATER
HOSE GROMMETS
33137-VUI#10 SUCTION
LINE GROMMET
33135-VUI#6 LIQUID
LINE GROMMET
62757-PCRFIREWALL COVER
FIREWALL COVER
HEATER LINE FROM INTAKE TO HEATER CORE
HEATER LINE (SUCTION TOWATER PUMP)
#10 SUCTION LINE
FIREWALL
1/4-20 x 1”BOLT
w/ FLAT WASHER
TINNERMANNUT
FIREWALL
REAREVAPORATOR
BRACKET
(4) OEMPINS
DRILLEDDRAINHOLE
90°DRAINELBOW
#6 LIQUIDLINE
OEM SLIDERETAINING BRACKETS
FIGURE 15
FENDERWELL
FRESH AIR CAP
FRESH AIR DUCT
FENDER
17901258 REV D 6/30/16 1957 CHEVY w/o AC w/4 VENT PLENUM GEN IV INST PG 17 OF 25
FINAL STEPSINSTALL CONTROL PANEL AND WIRE ACCORDING TO WIRING DIAGRAM ON PAGE 19.
PLUG CONTROL WIRING HARNESS INTO ECU MODULE. SEE WIRING DIAGRAMS ON PAGES 19 & 20.
REMOVE THE BACKING FROM THE VELCRO STRIP ON THE INSIDE OF THE ECU COVER, AND INSTALLTHE ECU COVER ONTO THE ECU AS SHOWN IN PHOTO 1, BELOW. NOTE: ENSURE MATING SURFACES ARE CLEAN AND FREE OF GREASE.INSTALL GLOVE BOX BOTTOM AND GLOVE BOX DOOR, AND SECURE TO DASH WITH (3) OEM SCREWS.SEE FIGURE 16, BELOW.
WITH GLOVE BOX BOTTOM AND DOOR IN PLACE, INSTALL GLOVE BOX TOP TO THE S-CLIPS ON THEGLOVE BOX BOTTOM, AND SECURE TOP TO DASH WITH (5) OEM SCREWS. SEE FIGURE 16, BELOW.
(4) S-CLIPS(5) OEM SCREWSGLOVE
BOX DOOR GLOVEBOX TOPDASH
PLASTIC GLOVEBOX BOTTOM
GLOVEBOX HINGE
FIGURE 16
PHOTO 1
REINSTALL ALL PREVIOUSLY REMOVED ITEMS (BATTERY BOX & BATTERY).
FILL RADIATOR WITH AT LEAST A 50/50 MIXTURE OF APPROVED ANTIFREEZE AND 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 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.
(3) OEM SCREWS
ECU COVER620901
18901258 REV D 6/30/16, 1957 CHEVY w/o AC w/ 4 VENT PLENUM GEN IV INST PG 18 OF 25
NO
TE:
AFT
ER I
NST
ALL
ING
#10 S
UC
TIO
N L
INE,
WR
AP
A
LL E
XP
OSE
D M
ETA
L(F
ITTI
NG
S &
TU
BE)
WIT
H
SUP
PLI
ED P
RES
S TA
PE.
#10 O
-RIN
G(3
3859
-VU
F)
#10 S
UC
TIO
NLI
NE
(09159-P
CS) H
EATE
R LI
NE
(EVA
PORA
TOR
TO
WA
TER
PUM
P)09161-P
CH
#6
LIQ
UID
LIN
E(0
91
58
-PC
L)
#1
0 O
-RIN
G(3
38
59
-VU
F)TW
IST
WIT
HTH
IS W
REN
CH
FIG
UR
E 17
ECU
MO
DU
LED
RIV
ER S
IDE
(EVA
PORA
TOR
BRA
CK
ET)
64353-P
CB
1/4
-20 x
1/2
”BO
LT
(LO
CA
TED
ON
SU
B C
ASE
)
1/4
-20 x
1/2
”BO
LT
(LO
CA
TED
ON
SU
B C
ASE
)
HO
LD W
ITH
THIS
WRE
NC
H
LUBR
ICA
TEO
-RIN
G(S
EE F
IGU
RE 1
1,
PAG
E 14)
HEA
TER
LIN
E(E
VA
PORA
TOR
TO IN
TAK
E)0
91
60
-PC
H
PASS
ENG
ER S
IDE
(EVA
PORA
TOR
BRA
CK
ET)
64
35
7-P
CB
#6
O-R
ING
(33
85
7-V
UF)
PRES
S TA
PE
EVA
PO
RA
TOR
HA
RD
LIN
E IN
STA
LLA
TIO
N
19901258 REV D 6/30/16 1957 CHEVY w/o AC w/4 VENT PLENUM GEN IV INST PG 19 OF 25
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
20901258 REV D 6/30/16 1957 CHEVY w/o AC w/4 VENT PLENUM GEN IV INST PG 20 OF 25
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.
21901258 REV D 6/30/16 1957 CHEVY w/o AC w/4 VENT PLENUM GEN IV INST PG 21 OF 25
OPERATION OF CONTROLSFOR MAXIMUM COOLING AND HEATING, THE AIR LEVER MUST BE IN “INSIDE MODE” POSITION
NOTE: WHEN BATTERY POWER IS FIRST CONNECTED TO THE ECU, THE COMPUTER GOES THROUGH AN INITIALIZATION SEQUENCE. THIS INITIALIZATION MAY TAKE UP TO 30 SECONDS. DURING INITIALIZATION THE BLOWER WILL NOT OPERATE, BUT THE DOORS INSIDE THE UNIT WILL BE OPERATING. A LOW BATTERY OR DISCONNECTING THE BATTERY MAY ALSO TRIGGER A REINITIALIZATION. DURING START UP, A LOW BATTERY MAY DROP BELOW 7 VOLTS, TRIGGERING REINITIALIZATION.
SYSTEM OFF A/C MODEBLOWER SPEEDCONTROL
(LOW/MED/HI)
HEAT MODE DEFOST MODE
BI-LEVEL HEAT MODEBI-LEVEL A/C MODE
NOTE: THERE ARE TWO BI-LEVEL POSITIONS: BETWEEN DASH-FLOORBETWEEN FLOOR-DEF
22901258 REV D 6/30/16, 1957 CHEVY w/o AC w/ 4 VENT PLENUM GEN IV INST PG 22 OF 25
Sym
pto
m
C
on
dit
ion
C
heck
s
Act
ion
s
N
ote
s
Blo
wer
sta
ys o
n
hig
h s
pee
d w
hen
ig
nitio
n is
on.
1a.
No o
ther
funct
ions
work
.
Chec
k fo
r dam
aged
pin
s or
wires
in c
ontr
ol hea
d p
lug.
Ver
ify
that
all
pin
s ar
e in
sert
ed into
plu
g.
Ensu
re t
hat
no
pin
s ar
e ben
t or
dam
aged
in E
CU
.
Chec
k fo
r dam
aged
gro
und
wire
(white)
in c
ontr
ol hea
d
har
nes
s.
Ver
ify
continuity
to c
has
sis
gro
und w
ith w
hite
contr
ol
hea
d w
ire
at v
ario
us
poin
ts.
Loss
of gro
und o
n t
his
wire
render
s co
ntr
ol hea
d
inoper
able
.
All
oth
er f
unct
ions
work
.Chec
k fo
r dam
aged
blo
wer
sw
itch
or
pote
ntiom
eter
and
asso
ciat
ed w
irin
g.
Blo
wer
sta
ys o
n
hig
h s
pee
d w
hen
ig
nitio
n is
on o
r off.
Unplu
g 3
-wire
BSC c
ontr
ol
connec
tor
from
ECU
. If
blo
wer
sh
uts
off,
ECU
is
eith
er
impro
per
ly w
ired
or
dam
aged
.
Be
sure
the
smal
l, 2
0 G
A w
hite
gro
und w
ire
is c
onnec
ted
to t
he
bat
tery
gro
und p
ost
. If
it
is,
repla
ce t
he
ECU
.
Unplu
g 3
-wire
BSC c
ontr
ol
connec
tor
from
ECU
. If
blo
wer
st
ays
runnin
g,
BSC is
eith
er
impro
per
ly w
ired
or
dam
aged
.
Chec
k to
ensu
re t
hat
no B
SC w
irin
g is
dam
aged
or
short
ed t
o v
ehic
le g
round.
The
BSC o
per
ates
the
blo
wer
by
gro
und s
ide
puls
e w
idth
modula
tion s
witch
ing.
The
posi
tive
wire
to t
he
blo
wer
will
alw
ays
be
hot.
If th
e “g
round”
side
of
the
blo
wer
is
short
ed t
o c
has
sis
gro
und,
the
blo
wer
will
run o
n H
I.
Rep
lace
BSC (
This
will
req
uire
rem
oval
of ev
apora
tor
from
veh
icle
).N
o o
ther
par
t re
pla
cem
ents
sh
ould
be
nec
essa
ry.
Com
pre
ssor
will
not
turn
on
(All
oth
er funct
ions
work
).
2.
Sys
tem
is
not
char
ged
.Sys
tem
must
be
char
ged
for
com
pre
ssor
to e
ngag
e.Char
ge
syst
em o
r byp
ass
pre
ssure
sw
itch
.
Dan
ger:
Never
byp
ass
sa
fety
sw
itch
wit
h
en
gin
e r
un
nin
g.
Seri
ou
s in
jury
can
resu
lt.
Sys
tem
is
char
ged
.
1b
.
Tro
ub
lesh
oo
tin
g G
uid
e
Chec
k fo
r fa
ulty
A/C
pote
ntiom
eter
or
asso
ciat
ed
wirin
g (
Not
applic
able
to 3
-pot
contr
ols
).
Chec
k fo
r dis
connec
ted o
r fa
ulty
ther
mis
tor.
Chec
k co
ntinuity
to g
round o
n w
hite
contr
ol hea
d w
ire.
Chec
k fo
r 5V o
n r
ed c
ontr
ol hea
d w
ire.
Chec
k 2-p
in c
onnec
tor
at E
CU
housi
ng.
To c
hec
k fo
r pro
per
pot
funct
ion,
chec
k vo
ltag
e at
w
hite/
blu
e w
ire.
Voltag
e sh
ould
be
bet
wee
n 0
V a
nd
5V,
and w
ill v
ary
with p
ot
leve
r posi
tion.
Dis
connec
ted o
r fa
ulty
ther
mis
tor
will
cau
se
com
pre
ssor
to b
e dis
able
d.
Red
wire
at A
/C p
ot
should
hav
e ap
pro
xim
atel
y 5V
with ignitio
n o
n.
White
wire
will
hav
e co
ntinuity
to
chas
sis
gro
und.
White/
Blu
e w
ire
should
var
y bet
wee
n 0
V a
nd 5
V w
hen
le
ver
is m
oved
up o
r dow
n.
3. Com
pre
ssor
will
not
turn
off
(A
ll oth
er funct
ions
work
).
Chec
k fo
r fa
ulty
A/C
pote
ntiom
eter
or
asso
ciat
ed
wirin
g.
Chec
k fo
r fa
ulty
A/C
rel
ay.
Rep
air
or
repla
ce p
ot/
contr
ol w
irin
g.
Rep
lace
rel
ay.
See
blo
wer
sw
itch
chec
k pro
cedure
.
23901258 REV D 6/30/16, 1957 CHEVY w/o AC w/ 4 VENT PLENUM GEN IV INST PG 23 OF 25
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.
24901258 REV D 6/30/16 1957 CHEVY w/o AC w/4 VENT PLENUM GEN IV INST PG 24 OF 25
2 ¾”
1/2”
1¼” DIAMETER
5/16” DIAMETER
EXISTINGHOLES
3 9/16
”2
5/16
”2
¼”
2 ⅜”2 ⅛”(TOP)
CORE SUPPORTTEMPLATE
FIREWALLDRAIN HOLE
TEMPLATE
FOLD
PA
GE
AT
THIS
LIN
E A
ND
PO
SITI
ON
AT
EDG
E O
F C
ORE
SU
PPO
RT (
REM
OVA
BLE
PAN
EL)
PASS
ENG
ER S
IDE
FEN
DER
(FROM INSIDE CAR)
5/8” DIAMETERDRAIN HOLE
CU
T A
LON
G D
OTT
ED L
INE
(LIN
E U
P O
PEN
ING
IN F
IREW
ALL
& P
LAC
E ED
GE
AG
AIN
ST F
IREW
ALL
SU
PPO
RT
901258 REV D 6/30/16 1957 CHEVY w/o AC w/4 VENT PLENUM GEN IV INST PG 25 OF 25
CHECKED BY:____________PACKED BY:____________
DATE:____________
EVAPORATOR KIT561058
No.
1.2.
QTY.
11
PART No.
761158781158
DESCRIPTION
57 CHEVY w/o AC w/ 4 VENT PLENUM GEN IV EVAP SUB CASE1957 CHEVY w/o AC 4 VENT ACC KIT
57 CHEVY w/o AC4 VENT PLENUM GEN IVEVAP SUB CASE 761158
ACCESSORY KIT781158
1
2DASH
FLOORDEF
INSIDE
OUTSIDE
OFFHEAT
COLDOFF AIR