an ISO 9001:2008 Registered Company 1955-56 Chevrolet Full-Size Evaporator Kit (56155-PCZ) 18865 Goll St. San Antonio, TX 78266 Phone: 210-654-7171 Fax: 210-654-3113 www.vintageair.com 906155-PCZ REV F 12/07/15, PG 1 OF 25 PROTOTYPE NOT FOR PRODUCTION
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Transcript
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906155-PCZ REV F 12/07/15, 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.
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906155-PCZ REV F 12/07/15, 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.
•
•
•
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906155-PCZ REV F 12/07/15, PG 6 OF 25
Engine Compartment Disassembly
1.2.3.4.5.
Disconnect battery.Remove battery and battery tray.Remove air cleaner.Drain radiator.Disconnect heater hoses.
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
Passenger Compartment Disassembly
1.
2.3.
4.5.6.7.8.9.
10.11.
Remove the OEM heater assembly by removing the control cables, along with (2) 7/16” nuts on the firewall and (1) under the dash (discard).Remove the heater blower (discard) (See Figure 1, below).Remove the butterfly duct above the kick panel vent, as well as the panel flange (discard). Install the new vent cover as shown in Figure 2, below.Remove the glove box door (retain).Remove the glove box (discard).Remove the original defrost duct from the heater to the windshield (discard).Remove the ash tray (retain).Remove the ash tray slider assembly (retain).Remove the vent and cables from the dash (retain) (See Figure 1, below).Remove the control panel (retain).Remove the passenger side speaker grille (retain) (See Figure 1, below).
Perform the Following:
Figure 2
6
52
3
11
4
1
7
8
OEM Screws
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906155-PCZ REV F 12/07/15, PG 7 OF 25
Core Support Modification
Condenser Assembly Installation
1.
2.
3.4.
1.2.
Locate the core support modification template on Page 24, and align the template on the passenger side of the core support panel. Using the template, mark holes and cut a 1 ¼” hole using a hole saw. Drill a 5/16” hole in the noted location (See Figure 3a, below).Install the #6 and #8 condenser hardlines through the 1 ¼” hole. Lubricate a #6 and #8 O-ring as shown in Figure 10, Page 12, and connect the #6 and #8 condenser hardlines to the condenser.Locate the split grommet and install as shown in Figure 3b, below.Install the drier loosely as shown in Figure 3b, below. NOTE: Refrigerant flow follows the arrow on the drier.
Loosen the (6) bolts that secure the radiator to the core support.Slide the condenser assembly into position. The condenser brackets will be held between the radiator and the core support. Secure with the (6) radiator bolts (See Figures 3 and 3b, below). Holding the condenser in position, tighten the (6) radiator bolts.
Figure 3
Figure 3a
Figure 3b
CORE SUPPORTTEMPLATE
1 ¼”
5/16”
OEM Radiator
Vintage AirCondenser
NOTE: #8 (Larger)Fitting is at Top of Radiator.
#8 Condenser Hardline
35018-VCG
#6 Condenser Hardline
35017-VCG
Install (8) #6 x 3/8”Pan Head Screws
Side of CoreSupport
Hole inCore Support
1/4” Nut with Flat Washer
Drier
5/16” Bolts
1/4” x 1” Bolt
Split Grommet
Mount Drier to Inside of Core Support
Through 5/16” Hole
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906155-PCZ REV F 12/07/15, PG 8 OF 25
Defrost Duct Installation1.
2.
Install the defrost ducts with 2” duct hose: 10” (passenger side) and 24” (driver side) (See Figure 5, below, and Figure 14, Page 16).Install the defrost ducts (See Figures 5 and 5a, below). NOTE: The rounded side of the defrost ducts face the passenger compartment.
Figure 5
Figure 5a
Compressor and Brackets
Control Panel Conversion
1.
1.
Refer to separate instructions included with the bracket kit to install the compressor bracket. Refer to Figure 4, below, for compressor mounting position.
Locate the control panel conversion kit. Refer to the instructions supplied with the conversion kit to assemble the control panel.
Pulleys1. In most instances, the belt lengths will remain the same (See Figure 4, below).
Pulleys (Vintage Air) Short Pump Small Block Chevrolet (Steel Pulley)22503-VCA
22506- VCA
22507-VCA
NOTE: Belt routing may vary with different bracket sets. Always refer to instructions included with brackets.
Water Pump Pulley(2-Groove)Crankshaft Pulley(2-Groove)(With Power Steering, a 3-Groove Crank Pulleyis Required)Crankshaft Pulley(3-Groove)
Tab“E” Tab
“A”
Tab“G”
Tab“C”Mount the
CompressorUsing Tabs “G” & “C”
Generatoror Alternator
Compressor
Water PumpPulley
Crankshaft Pulley
#8 x 1/2” Pan Head Screw(For 1955 Models
using Existing Holes)
#8 x 1/2” Pan Head Screw(For 1956 Models
using Existing Holes) Seat Bracketin Defrost Hole
Defrost Duct(Rounded Side Out)
Defrost Hole
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906155-PCZ REV F 12/07/15, PG 9 OF 25
Evaporator Installation
1.
2.
3.
4.5.
6.
On a workbench, install the evaporator rear brackets and the evaporator hardlines with properly lubricated O-rings (See Figure 16, Page 18, and Figure 10, Page 12).Lift the evaporator unit up and under the dashboard (See Figures 6 and 6a, below, and Figure 6b, 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, and Figure 16, Page 18). NOTE: To ensure proper drainage, it is very important that the evaporator is level, both left-right and fore-aft. Check for level on the flat portions of the case around the drain.Install the front mounting bracket to the evaporator unit using a 1/4-20 button head bolt, and tighten as shown in Figure 7, Page 10. Loosely attach the front mounting bracket to the dash with a 1/4-20 x 1” bolt, washer and nut (See Figure 7, Page 10).Install the center A/C plenum to the evaporator with (2) 10-32 x 1/2” screws (See Figure 7, Page 10).Loosely secure the center plenum to the dash with the center plenum mounting bracket using a 1/4-20 x 1” bolt and washer (See Figure 7, Page 10).Verify that the evaporator unit is level and square to the dash, then tighten all mounting bolts. NOTE: Tighten the (2) bolts on the firewall first. Then tighten the front mounting bracket bolt and nut. Tighten the center plenum mounting bolt last.
Figure 6
Figure 6a
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.
NOTE: Install the evaporator unit from the passenger side floorboard.
NOTE: Rotate the evaporator unit so the lines pass through the opening in the firewall. Lift into place.
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906155-PCZ REV F 12/07/15, PG 10 OF 25
Evaporator Installation (Cont.)
Figure 6b
Figure 7
NOTE: Once in place, secure the evaporator unit to the firewall.
1/4-20 x 1” Bolt & Washer
1/4-20 x 1” Bolt & Washer
1/4-20 x 1/2” Button Head
Screw
Firewall
DefrostDoor
Dash/FloorDoor
1/4-20 x 1”Bolt
Washer
CenterA/C Plenum
CenterA/C Plenum
10-32 x 1/2”Screw
10-32 x 1/2”Screw
Side View
Dash
Center PlenumMounting Bracket
Bottom Lip of Dash
To Evaporator
To Dash
Front MountingBracket1/4-20
Nut
ECU Module
A/C & HeatBlend Door
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906155-PCZ REV F 12/07/15, PG 11 OF 25
Figure 8
Figure 9
Under Dash Louver Installation1. Install the driver and passenger side under dash louvers with the flange facing the dash and kick panel
as shown in Figure 8, below. Tuck the kick panel side of the louver flange behind the kick panel windlace retainer, and slide the louver up until the flange is seated against the dash. Secure the louver to the kick panel with (2) #8 x 1/2” pan head screws (See Figure 8, below). NOTE: In most cases, the louvers will fit as described. However, due to dash and kick panel variances, the presence of aftermarket components or modifications, etc., it may be necessary to trim the louver flange and/or slightly move the parking brake lever for proper fit.
Drain Hose Installation1.
2.
In line with the drain, lightly make a mark on the firewall. Measure 1” down and drill a 5/8” hole through the firewall (See Figure 9, below). NOTE: See Figure 13, Page 15, for the rough location of the drain hole.Install the drain hose onto the bottom of the evaporator unit, and route through the firewall (See Figure 9, below, and Figure 13, Page 15).
DrainHose
Drain1”
(2) #8 x 1/2”Pan Head Screws
NOTE: Install louvers with flange facing the dash and kick panel.
Flange
Dash
Windlace Retainer
Windlace Retainer
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906155-PCZ REV F 12/07/15, PG 12 OF 25
Figure 11
Heater Control Valve Installation1. Install the heater control valve in line with the intake manifold (pressure side) heater hose (See Figure 11,
below).
Figure ##
O-ring Installs Over Male Insert to Swaged Lip
O-ring#6 O-ring
#8 O-ring #10 O-ring
O-ring
Supplied Oil for O-rings
Male Insert
Female Nut
Hold With This Wrench
Twist With This Wrench
Lubricating O-rings For a proper seal of fittings: Install supplied O-rings as shown, and lubricate with supplied oil.
NOTE: Standard torque specifications:#6: 11 to 13 ft-lb.#8: 15 to 20 ft-lb.
#10: 21 to 27 ft-lb.
Figure 10
#10 SuctionHose
HeaterHoses
#6 Hardline
NOTE: Flow Direction Follows Molded Arrow on Valve.
ECU Module
HoseClamps
From HeaterControl Valve
to Heater Core
From IntakeManifold to
Heater ControlValve
From Heater Coreto Water Pump
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906155-PCZ REV F 12/07/15, PG 13 OF 25
A/C Hardline and Hose Installation
1.2.
3.
4.5.
6.7.
8.
9.
Locate the (2) compressor hardlines (See Figure 12, Page 14).Locate the #8 compressor hardline. Lubricate (1) #8 O-ring (See Figure 10, Page 12), and connect the #8 compressor hardline to the #8 discharge port on the compressor. Tighten the connection (See Figure 10, Page 12, and Figure 12, Page 14).Locate the #10 compressor hardline. Lubricate (1) #10 O-ring (See Figure 10, Page 12), and connect the #10 compressor hardline to the #10 suction port on the compressor. Tighten the connection (See Figure 10, Page 12, and Figure 12, Page 14).Secure the (2) compressor hardlines to the compressor using the supplied clamp (See Figure 12a, Page 14).Locate the #8 A/C hose. The hose will connect the #8 compressor hardline and the #8 hardline from the condenser. Lubricate (2) #8 O-rings (See Figure 10, Page 12) and install (1) onto each end of the #8 A/C hose. Route the #8 A/C hose as shown in Figure 12, Page 14, and tighten (See Figure 10, Page 12). NOTE: The 90° hose fitting connects to the #8 condenser hardline.Install the firewall cover (See Figure 13, Page 15).Lubricate (1) #6 O-ring (See Figure 10, Page 12). Install the #6 liquid line and tighten (See Figure 10, Page 12, and Figure 12b, Page 14).Locate the #10 A/C hose. The hose will connect the #10 compressor hardline and the #10 hardline from the evaporator. Lubricate (2) #10 O-rings (See Figure 10, Page 12) and install (1) onto each end of the #10 A/C hose. Route the #10 A/C hose as shown in Figure 12, Page 14 and tighten (See Figure 10, Page 12). NOTE: The 90° hose fitting connects to the #10 compressor hardline.Install the heater hoses onto the heater lines, and route as shown in Figures 12 and 12b, Page 14. Secure with hose clamps. NOTE: This kit does not contain heater hose. The 5/8” heater hose may be purchased from Vintage Air or a local parts retailer.
Standard Hose Kit:
1. Refer to separate instructions included with modified hose kit.Modified Hose Kit:
Liquid Line and Binary Switch Installation1.
2.3.
Install the #6 liquid line onto the drier with a lubricated #6 O-ring (See Figure 10, Page 12) and tighten (See Figure 10, Page 12, and Figure 12, Page 14).Install the binary switch onto the #6 liquid line (See Figure 12, Page 14).Secure the #6 liquid line to the fender using the supplied adel clamp (See Figure 12, Page 14).
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906155-PCZ REV F 12/07/15, PG 14 OF 25
Figure 12
Figure 12a
Figure 12b
A/C and Heater Hose Routing
NOTE: Compressor hardlinesare included with standardhose kit only.
#8 CompressorHardline
35038-VUG-A
#10 CompressorHardline
35037-VUG-A
#8 Condenser Hardline
35018-VCG
#6 Hardline35017-VCGSplit Rubber
Grommet in Core Support hole
#6 Hardline
#10 Suction Hose
HeaterHoses
O-rings
Firewall Cover
#10 Suction Line (Insulated)
Hardline Clamp(Standard Hose Kit Only)
ECU Module
ECU Module
NOTE: Modified hose kits include (2) 135° compressor fittings (Refer to instructions included with modified hose kit).
#6 Hardline
Binary Switch Installation
Binary Switch
#8 Discharge Hose
#6 Hardline FromDrier to Expansion
Valve09154-PFL
AdelClamp
FirewallCover
ExpansionValve
Press Tape
EvaporatorSub Case
#10 SuctionHose
Heater ControlValve
HeaterHoses
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906155-PCZ REV F 12/07/15, PG 15 OF 25
Figure 13
Firewall Cover Installation1. Pass lines through the firewall cover and secure with (2) 7/16” panel retainers (See Figure 13, below).
Passenger SideEvaporator Mounting
Hole1/4-20 x 1”
Bolt & Washer
1/4-20 x 1”Bolt & Washer
(2) 7/16” Panel Retainers
DrainHole
Driver SideEvaporator Bracket
Mounting Hole
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906155-PCZ REV F 12/07/15, PG 16 OF 25
Figure 14
1.2.
3.
Install the duct hoses as shown in Figure 14, below.Plug the control panel wiring harness (232002-VUA) into the ECU module on the sub case as shown in Figure 14, below.Plug the wiring harness (232001-VUR) into the ECU module on the sub case as shown in Figure 14, below. Wire according to the wiring diagrams on Pages 19 and 20.
Control Panel & Duct Hose Routing
Passenger SideLouver
2 ½” x 42”
Driver SideLouver
2 ½” x 48”
ECU Module
Driver SideDefrost Duct
2” x 24”
Passenger SideDefrost Duct
2” x 10”
Plug FromWiring Harness232001-VUR
Plug FromControl Panel
Wiring Harness
232002-VUA
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906155-PCZ REV F 12/07/15, PG 17 OF 25
Figure 15
Glove Box Installation
Final Steps
1.
2.
3.
1.2.
3.4.5.
6.
Install the glove box bottom and glove box door. Secure to the dash with (3) OEM screws (See Figure 15, below).With the glove box bottom and door in place, install the glove box top as shown in Figure 15, below. Using (3) #6 x 3/8” pan head screws, attach the glove box top to the glove box bottom as shown in Figure 15, below.Secure the glove box top to the dash using (2) OEM screws (See Figure 15, below).
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.
Glove BoxDoor
(3) OEMScrews
(2) OEMScrews
PlasticGlove BoxBottom
Glove BoxHinge
Glove BoxTop
(3) #6 x 3/8”Pan HeadScrews
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18 906155-PCZ REV F 12/07/15, PG 18 OF 25
Fig
ure
16
Evap
orat
or H
ard
line
Inst
alla
tion
NO
TE:
Wra
p t
he
#1
0 fi
ttin
g
con
nec
tion
s w
ith
pre
ss t
ape.
#10
O-r
ing
3385
9-VU
F
Pres
s Ta
pe
#10
Suc
tion
Line
0915
1-PC
S
#6
O-r
ing
3385
7-VU
F
Hea
ter
Line
(Eva
pora
tor
to I
ntak
e)09
152-
PCH
Hea
ter
Line
(Eva
pora
tor
to
Wat
er P
ump)
0915
3-PC
H
#6
Har
dlin
e09
150-
PCL
#10
O-r
ing
3385
9-VU
F
1/4-
20 x
1/2
” Bol
t (L
ocat
ed o
n Sub
Cas
e)
Drive
r Sid
eEv
apor
ator
Bra
cket
6435
4-PC
B
Pass
enge
r Sid
eEv
apor
ator
Bra
cket
6435
5-PC
B
ECU
Mod
ule
1/4-
20 x
1/2
” Bol
t (L
ocat
ed o
n Sub
Cas
e)
19
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906155-PCZ REV F 12/07/15, 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
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906155-PCZ REV F 12/07/15, 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.
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906155-PCZ REV F 12/07/15, PG 21 OF 25
Operation of Controls
Adjust to desiredspeed.
Blower SpeedAdjust to desired
speed.
Adjust to desiredmode position (DASH position recommended).
Adjust to desiredspeed.
Adjust to DEFROST position for maximum defrost, or between FLOOR and DEFROST positions for a bi-level
blend (Compressor is automatically engaged).
Adjust to desired temperature.
For A/C operation, adjust tocoldest position to engage
compressor (Adjust between HOT and COLD to reachdesired temperature).
A/C Operation
Heat Operation
Defrost/De-fog Operation
On Gen IV systems with three lever/knob controls, the temperature control toggles between heat and A/C operations. To activate A/C, move the temperature lever/knob all the way to cold and then back it off to the desired vent temperature. For heat operation, move the temperature lever/knob all the way to hot and then adjust to the desired vent temperature. The blower will momentarily change speed, each time you toggle between operations, to indicate the change. NOTE: For proper control panel function, refer to control panel instructions for calibration procedure.
Blower Speed
Blower Speed
This lever/knob controlsblower speed, from
OFF to HI.
This lever/knob controls the mode positions,from DASH to FLOORto DEFROST, with a blend in between.
This lever/knob controlsthe temperature,
from HOT to COLD.
Blower Speed
Mode Control
Temperature Control
Blower Speed
ModeControl
Temperature Control
Temperature Control
Temperature Control
Mode Control
Mode Control
Mode Control
For maximum heating, adjust to hottest position (Adjust between HOT and COLD to reach desired temperature).Adjust to desired
mode position(FLOOR position recommended).
TemperatureControl
DASH FLOOR DEF
OFF FAN HI
HEAT
COLD
DASH FLOOR DEF
OFF FAN HI
HEAT
COLD
DASH FLOOR DEF
OFF FAN HI
HEAT
COLD
DASH FLOOR DEF
OFF FAN HI
HEAT
COLD
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om
22 906155-PCZ REV F 12/07/15, 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
.
ww
w.v
inta
gea
ir.c
om
23 906155-PCZ REV F 12/07/15, PG 23 OF 25
Sym
pto
m
C
on
dit
ion
Ch
eck
s
Act
ion
s
N
ote
s
Sys
tem
will
not
turn
on,
or
runs
inte
rmitte
ntly.
4.
Work
s w
hen
engin
e is
not
runnin
g;
shuts
off w
hen
en
gin
e is
sta
rted
(T
ypic
ally
ear
ly G
en I
V,
but
poss
ible
on a
ll ve
rsio
ns)
.
Nois
e in
terf
eren
ce f
rom
either
ig
nitio
n o
r al
tern
ator.
Inst
all ca
pac
itors
on ignitio
n c
oil
and a
lter
nat
or. E
nsu
re
good g
round a
t al
l poin
ts.
Rel
oca
te c
oil
and a
ssoci
ated
w
irin
g a
way
fro
m E
CU
and E
CU
wirin
g.
Chec
k fo
r burn
edor
loose
plu
g w
ires
.
Ver
ify
connec
tions
on p
ow
er
lead
, ig
nitio
n lea
d,
and b
oth
white
gro
und w
ires
.
Ver
ify
pro
per
met
er f
unct
ion b
y ch
ecki
ng t
he
conditio
n o
f a
know
n g
ood b
atte
ry.
Ignitio
n n
ois
e (r
adia
ted o
rco
nduct
ed)
will
cau
se t
he
syst
em t
o s
hut
dow
n d
ue
tohig
h v
oltag
e sp
ikes
. If
this
is s
usp
ecte
d,
chec
k w
ith a
qual
ity
osc
illosc
ope.
Spik
esgre
ater
than
16V w
ill s
hut
dow
n t
he
ECU
. In
stal
l a
radio
cap
acitor
at t
he
posi
tive
post
of th
e ig
nitio
nco
il (S
ee r
adio
cap
acitor
inst
alla
tion b
ulle
tin).
A
faulty
alte
rnat
or
or
worn
out
bat
tery
can
als
o r
esult
in t
his
conditio
n.
Will
not
turn
on u
nder
an
y co
nditio
ns.
Ver
ify
bat
tery
voltag
e is
gre
ater
than
10 v
olts
and les
sth
an 1
6.
Loss
of m
ode
door
funct
ion.
No m
ode
chan
ge
at a
ll.Chec
k fo
r dam
aged
mode
switch
or
pote
ntiom
eter
and
asso
ciat
ed w
irin
g.
Part
ial fu
nct
ion o
f m
ode
doors
.
Typic
ally
cau
sed b
y ev
apora
tor
housi
ng
inst
alle
d in a
bin
d in t
he
vehic
le.
Be
sure
all
mounting loca
tions
line
up
and d
on’t h
ave
to b
e fo
rced
in
to p
osi
tion.
Blo
wer
turn
s on
and o
ff r
apid
ly.
6.
Bat
tery
voltag
e is
at
leas
t 12V.
Chec
k fo
r at
lea
st 1
2V a
t ci
rcuit b
reak
er.
Ensu
re a
ll sy
stem
gro
unds
and p
ow
er c
onnec
tions
are
clea
n a
nd t
ight.
Bat
tery
voltag
e is
les
s th
an 1
2V.
5.
Tro
ub
lesh
oo
tin
g G
uid
e (
Co
nt.
)
Chec
k fo
r fa
ulty
bat
tery
or
alte
rnat
or.
Char
ge
bat
tery
.
Sys
tem
shuts
off b
low
er a
t 10V.
Poor
connec
tions
or
wea
k bat
tery
can
cau
se
shutd
ow
n a
t up t
o 1
1V.
7. When
ignitio
n is
turn
ed o
n,
blo
wer
m
om
enta
rily
co
mes
on,
then
sh
uts
off.
This
occ
urs
with t
he
blo
wer
sw
itch
in
the
OFF
posi
tion.
This
is
an indic
ator
that
the
syst
em h
as b
een r
eset
. Be
sure
the
red p
ow
er w
ire
is o
nth
e bat
tery
post
, an
d n
ot
on a
sw
itch
ed s
ourc
e. A
lso,
if
the
syst
em is
pulle
d b
elow
7V f
or
even
a s
plit
sec
ond,
the
syst
em w
ill r
eset
.
Run r
ed p
ow
er w
ire
direc
tly
to b
atte
ry.
Chec
k fo
r posi
tive
pow
er a
t hea
ter
valv
e gre
en w
ire
and
blo
wer
red
wire.
Chec
k fo
r gro
und o
n c
ontr
ol hea
d w
hite
wire.
Chec
k fo
r obst
ruct
ed o
r bin
din
g m
ode
doors
.
Chec
k fo
r dam
aged
ste
pper
m
oto
r or
wirin
g.
Err
atic
funct
ions
of
blo
wer
, m
ode,
te
mp,
etc.
Chec
k fo
r dam
aged
sw
itch
or
pot
and a
ssoci
ated
wirin
g.
Rep
air
or
repla
ce.
8.
ww
w.v
inta
gea
ir.c
om
24 906155-PCZ REV F 12/07/15, PG 24 OF 25
3 9/16”
2 5/16”
1”
5/16”Diameter
3 ¼”
2 ⅜”
2 ⅛”
1/2”
1 ¼”Diameter
Fold
Pag
e at
Thi
s Li
ne a
nd P
ositi
on a
t Ed
ge o
f Cor
e Sup
port
(Re
mov
able
Pan
el)
LocateExisting Holes
Cor
e S
up
por
t M
odifi
cati
on T
emp
late
25
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906155-PCZ REV F 12/07/15, PG 25 OF 25
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