1967-68 ford mustang mercury cougar - vintage air
TRANSCRIPT
an ISO 9001:2008 Registered Company
1967-68 Ford MustangMercury Cougar
without Factory AirEvaporator Kit
(551168)
18865 Goll St. San Antonio, TX 78266 Phone: 210-654-7171
Fax: 210-654-3113www.vintageair.com
901277 REV G 02/02/21, PG 1 OF 24
FO
RD
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901277 REV G 02/02/21, PG 2 OF 24
Thank you for purchasing this evaporator kit from Vintage Air. When installing these components as part of a complete SureFit™ system, Vintage Air recommends working from front to back on the vehicle, installing the condenser kit, hose kit, and compressor first, followed by the wiring, evaporator, and finally the control panel.
Cover..................................................................................................................................Table of Contents.................................................................................................................Packing List/Parts Disclaimer..................................................................................................Information Page..................................................................................................................Wiring Notice.......................................................................................................................Engine Compartment Disassembly, Condenser Assembly and Installation, Compressor and Brackets, Passenger Compartment Disassembly........................................................................Defrost Duct and Fresh Air Cap Installation..............................................................................Firewall Cover Installation.....................................................................................................Evaporator Installation.......................................................................................................... Vintage Air Center Louver Installation, (Optional) Center Louver Installation Using OEM Center Vent Trim................................................................................................Drain Hose Installation, Lubricating O-rings, A/C Hose Installation............................................ Heater Hose & Heater Control Valve Installation.....................................................................A/C and Heater Hose Routing............................................................................................... Under Dash Louver Installation............................................................................................ Final Steps........................................................................................................................ Control Panel & Duct Hose Routing....................................................................................... Evaporator Hardline Installation...........................................................................................Wiring Diagram..................................................................................................................Gen IV Wiring Connection Instruction....................................................................................Operation of Controls..........................................................................................................Troubleshooting Guide.........................................................................................................Troubleshooting Guide (Cont.).............................................................................................OEM Center Vent Trim Louver Template.................................................................................Packing List.......................................................................................................................
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Table of Contents
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901277 REV G 02/02/21, PG 3 OF 24
Packing List: Evaporator Kit (551168)
No. 1.2.
Qty.11
Part No.744004-VUE781067
DescriptionGen IV 4-Vent Evaporator Sub CaseAccessory Kit
** Before beginning installation, open all packages and check contents of shipment. Please report any shortages directly to Vintage Air within 15 days. After 15 days, Vintage Air will not be responsible for missing or damaged items.
NOTE: Images may not depict actual parts and quantities. Refer to packing list for actual parts and quantities.
1
2
Gen IV 4-VentEvaporator Sub Case
744004-VUE
Accessory Kit781067
4
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901277 REV G 02/02/21, PG 4 OF 24
Important Notice—Please ReadFor Maximum System Performance, Vintage Air Recommends the Following:
New Vintage Air-Supplied Sanden Compressor: No additional oil needed (Compressor is shipped with proper oil charge).All Other Compressors: Consult manufacturer (Some compressors are shipped dry and will need oil added).
NOTE: Vintage Air systems are designed to operate with R134a refrigerant only. Use of any other refrigerant could damage your A/C system and/or vehicle, and possibly cause a fire, in addition to potentially voiding the warranties of the A/C system and its components.
Refrigerant Capacities:Vintage Air System: 1.8 lbs. (28.8 oz.) or 816 grams of R134a, charged by weight with a quality charging station or scale. NOTE: Use of the proper type and amount of refrigerant is critical to system operation and performance.Other Systems: Consult manufacturer’s guidelines.
Lubricant Capacities:
Safety Switches
Service Info:Protect Your Investment: Prior to assembly, it is critical that the compressor, evaporator, A/C hoses and fittings, hardlines, condenser and receiver/drier remain 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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901277 REV G 02/02/21, PG 5 OF 24
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 and 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 and 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 or 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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901277 REV G 02/02/21, PG 6 OF 24
Engine Compartment Disassembly
1.2.3.4.5.
Disconnect battery.Remove battery (retain).Drain radiator.Remove radiator (retain).Remove the OEM heater hoses (discard).
NOTE: Before starting the installation, check the function of the vehicle (horn, lights, etc.) for proper operation, and study the instructions, illustrations, & diagrams.Perform the Following:
Figure 2
Figure 1
Condenser Assembly and Installation1.2.
Refer to separate instructions included with the condenser kit to install the condenser.Binary switch installation (Refer to condenser instructions).
Compressor and Brackets1. Refer to separate instructions included with the bracket kit to install the compressor bracket.
Passenger Compartment Disassembly
1.2.3.4.
5.6.7.
Remove the glove box (retain) (See Figure 1, below).Remove the center console (if equipped).Remove the heater assembly and all related ducting (discard, but retain screws) (See Figure 2, below).Remove OEM control panel assembly (retain) (See Figure 1, below). NOTE: Refer to control panel conversion kit instructions for installation of controls.Remove the radio (retain) (See Figure 1, below).Remove the OEM defrost ducts (discard) (See Figure 2, below).Remove the dash brace (discard) (See Figure 2, below).
Perform the Following:
MUSTANG
Radio
GloveBox
DashBrace OEM Heater
Assembly
DefrostDucts
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901277 REV G 02/02/21, PG 7 OF 24
Defrost Duct and Fresh Air Cap Installation
1.2.3.4.5.
Install the defrost ducts under the dash, and secure using (4) OEM nuts as shown in Figure 3, below.Hold the fresh air cap under the dash and mark the (3) mounting holes.Drill (3) 1/8” mounting holes under the dash (See Figure 3, below).Apply a 1/4” bead of silicone around the mating surface of the fresh air cap as shown in Figure 3, below.Secure the fresh air cap to the fresh air hole using (3) #10 x 1/2” sheet metal screws as shown in Figure 3, below.
Figure 3
Driver SideDefrost Duct
626676
Passenger SideDefrost Duct
626680
(4) OEMNuts
(3) #10 x 1/2”Sheet Metal
Screws
Fresh AirCap
62354-VFE
Silicone
Drill (3) 1/8” Holes
8
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901277 REV G 02/02/21, PG 8 OF 24
Firewall Cover Installation1.2.3.
Install (3) grommets onto the firewall cover as shown in Figure 4, below.Apply a 1/4” bead of silicone around the mating surface of the firewall cover as shown in Figure 4a, below.Secure the firewall cover to the firewall using (4) 1/4-20 x 1” hex bolts, flat washers and nuts, and (1) #10 x 1/2” sheet metal screw (See Figure 4, below). NOTE: The firewall cover installs on the engine compartment side of the firewall.
Figure 4a
Figure 4#10 x 1/2”Sheet Metal
Screw
Silicone
EngineCompartment
Side of Firewall
FirewallCover
642068
Grommet33137-VUI
Grommet33134-VUI
Grommet33135-VUI
(4) 1/4-20 x 1”Hex Bolts
and Washers
OEM DimpleDrill 1/8” Hole
(4) 1/4” Nutswith Star Washers
(4) 1/4” Flat Washers
OEM HeaterCore Holes
(4) OEMBlower Motor
Mounting Holes
OEM Blower MotorHole in Firewall
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901277 REV G 02/02/21, PG 9 OF 24
Evaporator Installation
1.
2.
3.4.
5.
6.
7.
On a workbench, install the evaporator rear brackets and hardlines with properly lubricated O-rings (See Figure 9, Page 11, and Figure 16, Page 17).Install the front mounting bracket onto the evaporator using (2) 1/4-20 x 1/2” hex bolts, and tighten as shown in Figure 5, below.Drill (2) 9/32” holes in firewall using OEM dimples (See Figure 5a, below).Lift the evaporator unit up under the dashboard. Secure loosely to the firewall from the engine compartment side using (2) 1/4-20 nuts and washers (See Figure 5a, below). 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.Using the front evaporator bracket as a guide, mark and drill (2) 3/16” holes in the cowl (See Figure 5b, below).Using (2) #14 x 3/4” sheet metal screws, secure the front evaporator mounting bracket to the inner cowl (See Figure 5b, below).Verify that the evaporator unit is level and square to the dash; then tighten all mounting bolts. NOTE: Tighten the bolt on the firewall first. Then tighten the front mounting bracket sheet metal screws.
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.
Figure 5
Figure 5a Figure 5b
Evaporator Front Bracket643169-FCB
(2) 1/4-20 x 1/2”Hex Bolts
OEM DimpleDrill 9/32”
Hole
OEM DimpleDrill 9/32”
Hole
Passenger SideEvaporator
Mounting Hole
Driver SideEvaporator
Mounting Hole
Approximately 3”
Approximately 3 ½”
OEM HeaterCore Holes
(2) 1/4-20 Nutsand Flat Washers
Passenger Compartment
Side of Firewall
Drill (2) 3/16”
Holes
(2) #14 x 3/4”Sheet Metal
Screws
InnerCowl
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901277 REV G 02/02/21, PG 10 OF 24
Vintage Air Center Louver Installation
(Optional) Center Louver Installation,
Using OEM Center Vent Trim
1.2.3.
1.
2.3.
Remove the OEM center vent trim from the dash as shown in Figure 6, below.Modify the center louver opening on the dash as shown in Figure 6a, below.Install the center louver assembly into the dash as shown in Figure 6b, below.
Cut the OEM center vent trim using the template provided on Page 23 (See Figure 7, below). NOTE: Remove the louver from the center louver assembly.Install the louvers into the OEM center vent trim as shown in Figure 7, below.Reinstall the OEM center vent trim into the dash as shown in Figure 7, below.
Figure 6
Figure 7
Figure 6a
Figure 6b
CUT OUTCUT OUT
OEM CenterVent Trim
Cut &Remove5/8” 5/8”
Center LouverAssembly590068
Assembled View
OEM Center Vent Trim (If Using Aftermarket
Trim, Center Template)
OEM CenterVent Trim
(2) Louvers
Center LouverBracket642060
(2) #6 x 3/8”Pan Head Screws
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901277 REV G 02/02/21, PG 11 OF 24
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 9
Drain Hose Installation1.2.
3.4.
Locate the evaporator drain on the bottom of the evaporator case.In line with the drain, lightly make a mark on the firewall. Then, measure 1” down and drill a 5/8” hole through the firewall (See Figure 8, below).Install the drain hose onto the evaporator drain on the bottom of the unit, and route it through the firewall.Install a 1/2” 90° drain elbow onto the drain hose (See Figure 8, below).
Figure 81”
1/2” Drain Elbow
DrainHose
Drain
A/C Hose Installation
1.
2.
3.
4.
Locate the #8 compressor A/C hose. Lubricate (2) #8 O-rings (See Figure 9, above) and connect the 45° fitting to the #8 discharge port on the compressor. Then route the straight female fitting with service port to the #8 condenser hardline coming through the radiator core support (See Figure 11, Page 13). Tighten each fitting connection as shown in Figure 9, above.Locate the #10 compressor A/C hose. Lubricate (2) #10 O-rings (See Figure 9, above) and connect the 90° female fitting with service port to the #10 suction port on the compressor. Then route the 90° female fitting to the #10 evaporator hardline coming through the firewall (See Figure 10, Page 12, & Figure 11, Page 13). Tighten each fitting connection as shown in Figure 9, above. Wrap the #10 fitting connections with press tape (See Figure 10, Page 12).Locate the #6 evaporator/drier hose. Lubricate (2) #6 O-rings (See Figure 9, above) and connect the straight female fitting to the #6 drier hardline coming through the radiator core support. Then route the 90° female fitting to the #6 evaporator hardline coming through the firewall (See Figure 10, Page 12 and Figure 11, Page 13). Tighten each fitting connection as shown in Figure 9, above.Use (6) tie wraps to secure the #6 A/C hose to the brace as shown in Figure 11, Page 13.
Standard Hose Kit:
1. Refer to separate instructions included with modified hose kit.Modified Hose Kit:
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901277 REV G 02/02/21, PG 12 OF 24
Heater Hose & Heater Control Valve Installation
1.
2.
Route a piece of heater hose from the water pump to the lower heater line coming through the firewall as shown in Figure 10, below. Secure using hose clamps.Route a piece of heater hose from the intake to the upper heater line coming through the firewall as shown in Figure 10, below. NOTE: Install the heater control valve in line with the intake manifold (pressure side) heater hose, and secure using hose clamps. Also note proper flow direction.
FROM EVAPORATOR
TO WATER PUMP
FROM INTAKEMANIFOLD
FROM HTR CNTRL VLV
TO EVAPORATOR
Figure 10
ECUModule
PressTape
#10 Hardline (Insulated)
ExpansionValve
Firewall
Firewall Cover642068
O-rings
#10 A/C Hose
#6 A/CHose
HeaterHose
NOTE: Flow Direction Follows Molded Arrow on Valve.
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ir.c
om
13 901277 REV G 02/02/21, PG 13 OF 24
A/
C a
nd
Hea
ter
Hos
e R
outi
ng
NO
TE:
Vin
tag
e A
ir S
yste
ms
use
5/
8”
hea
ter
con
nec
tion
s. O
n e
ng
ines
eq
uip
ped
w
ith
3/
4”
hos
e n
ipp
les,
th
ese
will
nee
d t
o b
e re
mov
ed a
nd
rep
lace
d w
ith
5/
8”
nip
ple
s (n
ot s
up
plie
d).
For
wat
er p
um
ps
wit
h a
cas
t-in
3/
4”
hea
ter
outl
et,
a 3
/4
” x
5/
8”
red
uce
r fi
ttin
g (
not
su
pp
lied
) w
ill n
eed
to
be
inst
alle
d in
th
e h
eate
r h
ose.
Fig
ure
11
Hea
ter
Hos
e(H
eate
r Cor
e/W
ater
Pum
p)
Cor
eSup
port
Hea
ter
Hos
e(H
eate
r Con
trol
Valv
e/In
take
)
(6)
Tie
Wra
ps#
10 A
/CH
ose
#8
A/C
Hos
e#
6 A/C
Hos
e
Inne
rFe
nder
wel
l
#8
Con
dens
er t
oCor
e Sup
port
Har
dlin
e08
1068
#6
Drier
to
Cor
e Sup
port
Har
dlin
e08
1095
Com
pres
sor
Saf
ety
Switc
h(B
inar
y Ty
pe)
Scr
ew-o
n D
rier
(Ref
er t
oCon
dens
erIn
stru
ctio
ns)
In
Out
14
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901277 REV G 02/02/21, PG 14 OF 24
Figure 12
Under Dash Louver Installation1.
2.
Install the driver and passenger side louver housings under the dash using OEM screws as shown in Figure 12, below.Install the louvers into the driver and passenger side louver housings as shown in Figure 12, below.
ControlPanel
OEMScrews
LouverHousing
Housing
Louver
Adapter
Housing
Louver
Adapter
Passenger SideVent Trim
Passenger SideVent Trim
OEM Screws
LouverHousing
15
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901277 REV G 02/02/21, PG 15 OF 24
Figure 13
Figure 14a
Figure 14
Final Steps1.2.
3.4.
5.6.7.8.
9.10.11.
12.13.
Install duct hoses as shown in Figure 15, Page 16.Route A/C wires (12 volt/grounds/binary switch/heater valve) through 3/8” grommet as shown in Figure 13, below.Install the control panel assembly. Refer to control panel instructions.Plug the wiring harnesses into the ECU module on the sub case as shown in Figure 15, Page 16. Wire according to the wiring diagrams on Pages 18 and 19.Reinstall the glove box.Reinstall the center console (if equipped). Modify the console as shown in Figures 14 & 14a, 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.See Operation of Controls procedures on Page 20.
3/4”3 ¾”
MUSTANG
Passenger SideUnder Dash
Console
Cut &Remove
Top Side
3/8” Grommet
FirewallCover
16
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901277 REV G 02/02/21, PG 16 OF 24
Control Panel & Duct Hose Routing
Passenger SideDefrost Duct
2” x 14”
Driver SideDefrost Duct
2” x 26”
Passenger SideLouver
2 ½” x 60”
Driver SideLouver
2 ½” x 36”
Driver Side Center Louver
2 ½” x 20”Passenger Side Center Louver
2 ½” x 20”
Plug FromWiring
Harness232600-VUA
Plug FromControlWiring
Harness232002-VUA
Figure 15
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17 901277 REV G 02/02/21, PG 17 OF 24
Evap
orat
or H
ard
line
Inst
alla
tion
Fig
ure
16
Bra
cket
1/4”
Pus
h N
ut
1/4-
20 x
1”
Hex
Bol
t
Drive
r Sid
e Ev
apor
ator
Rear
Bra
cket
6412
73
Hea
ter
Line
(Eva
pora
tor
to I
ntak
e)08
1066
Hea
ter
Line
(Eva
pora
tor
to
Wat
er P
ump)
0810
67
#6
Har
dlin
e08
1064
(2)
#10
O-r
ings
#10
O-r
ing
(2)
1/4-
20 x
1/2
”H
ex B
olts
(Loc
ated
on
Sub
Cas
e)
#6
O-r
ing
#10
Har
dlin
e08
1065
Pres
s Ta
pe
ECU
Mod
ule Pa
ssen
ger
Sid
e Ev
apor
ator
Rear
Bra
cket
6412
72
NO
TE:
Aft
er in
stal
ling
th
e #
10
har
dlin
e, w
rap
all
exp
osed
m
etal
(fi
ttin
gs
& t
ub
es)
insi
de
the
pas
sen
ger
com
par
tmen
t w
ith
th
e su
pp
lied
pre
ss t
ape.
18
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901277 REV G 02/02/21, PG 18 OF 24
WHT/GRN
WHT/YELWHT/RED
RED
WHTBACKLIGHT NEG
FAN WIPER
MODE WIPER
TEMP WIPER
5V-SW
GND
BACKLIGHT POS
AC ANNUNCIATOR
PRE-WIRED
GEN IV WIRING DIAGRAMREV E, 10/6/2017
GEN IV ECU
PROGRAM
Wiring Diagram
TEMP
MODE
FAN
A/C(IF USED)
232007-VUR
232002-VUA
** CIRCUITBREAKER30 AMP
*** WIDE OPENTHROTTLESWITCH
(OPTIONAL)
* DASH LAMP(IF USED)
Dash lamp is used only with type 232007-VUR harness.Warning: Always mount circuit breaker as close to the battery as possible. (NOTE: Wire betweenbattery and circuit breaker is unprotected and should be carefully routed to avoid a shortcircuit).Wide open throttle switch contacts close only at full throttle, which disables A/C compressor.
JF8
BLK
ORA
TAN
VIEWED FROM WIRE SIDE
* **
***
HEATERCONTROL VALVE
19
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901277 REV G 02/02/21, PG 19 OF 24
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 ignition switch source (key on accessory) position must be switched.
When using a Vintage Air-suppliedcontrol panel, connect the tan wirefrom the Gen IV evaporator wiringharness to the factory dash lights toenable panel backlighting.
Binary: Connect as shown (typical compressor wiring). Be sure compressor body is grounded.
Trinary Switch: Connect according to trinary switch wiring diagram.
Install with servo motor facing down, as shown. Note flow direction arrow molded into valve body and install accordingly.
White must run to (-) battery. Red may run to (+) battery or starter. Mount circuit breaker as close to battery as possible.
Heater Control Valve:
Binary/Trinary & Compressor:
Circuit Breaker/Battery:
CONTROL WIRING HARNESS
NOTE: YELLOW & ORANGE
COMING FROM HARNESS ARE NOT
USED.
WIRING HARNESS
GRAY WIRE IS USED FOR PROGRAMING CONTROLS
IF APPLICABLE
WIRING HARNESS
Gen IV Wiring Connection Instruction
HEATERCONTROL VALVE
WARNING: ALWAYS MOUNT CIRCUIT BREAKER
AS CLOSE TO THE BATTERY AS POSSIBLE. (NOTE: WIRE BETWEEN BATTERY AND CIRCUIT BREAKER IS UNPROTECTED
AND SHOULD BE CAREFULLY ROUTED TO AVOID A SHORT CIRCUIT).
NOTE: HEATER CONTROL VALVE CONNECTION AND CHASSIS GROUND MAY BE LOCATED ON EITHER SIDE OF THE FIREWALL. ENSURECONNECTOR IS LATCHED
FIRMLY.
20
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901277 REV G 02/02/21, PG 20 OF 24
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).
OEM BlowerSwitch Not Used
TEMP DEFHEAT
TEMP DEF
HEAT
TEMP
DEFHEAT
TEMP
DEF
HEAT
TemperatureControl
ww
w.v
inta
gea
ir.c
om
21 901277 REV G 02/02/21, PG 21 OF 24
Sym
pto
m
Con
dit
ion
Ch
ecks
A
ctio
ns
Not
es
Blo
wer
sta
ys o
n hi
gh s
peed
whe
n ig
nitio
n is
on.
1a.
No
othe
r fu
nctio
ns w
ork.
Che
ck for
dam
aged
pin
s or
w
ires
in c
ontr
ol h
ead
plug
.Ve
rify
tha
t al
l pin
s ar
e in
sert
ed in
to p
lug.
Ens
ure
that
no
pins
are
ben
t or
dam
aged
in E
CU
.Che
ck for
dam
aged
gro
und
wire
(whi
te)
in c
ontr
ol h
ead
harn
ess.
Verify
con
tinui
ty t
o ch
assi
s gr
ound
with
whi
te c
ontr
ol
head
wire
at v
ario
us p
oint
s.
Loss
of gr
ound
on
this
wire
rend
ers
cont
rol h
ead
inop
erab
le.
All
othe
r fu
nctio
ns w
ork.
Che
ck for
dam
aged
blo
wer
sw
itch
or p
oten
tiom
eter
and
as
soci
ated
wirin
g.
Blo
wer
sta
ys o
n hi
gh s
peed
whe
n ig
nitio
n is
on
or o
ff.
Unp
lug
3-w
ire
BSC c
ontr
ol
conn
ecto
r fr
om E
CU
. If
blo
wer
sh
uts
off,
ECU
is e
ither
im
prop
erly
wired
or
dam
aged
.
Be
sure
the
sm
all,
20 G
A w
hite
gro
und
wire
is c
onne
cted
to
the
bat
tery
gro
und
post
. If
it is
, re
plac
e th
e EC
U.
Unp
lug
3-w
ire
BSC c
ontr
ol
conn
ecto
r fr
om E
CU
. If
blo
wer
st
ays
runn
ing,
BSC is
eith
er
impr
oper
ly w
ired
or
dam
aged
.
Che
ck t
o en
sure
tha
t no
BSC w
irin
g is
dam
aged
or
shor
ted
to v
ehic
le g
roun
d. T
he B
SC o
pera
tes
the
blow
er
by g
roun
d si
de p
ulse
wid
th m
odul
atio
n sw
itchi
ng.
The
posi
tive
wire
to t
he b
low
er w
ill a
lway
s be
hot
. If
the
“g
roun
d” s
ide
of t
he b
low
er is
sho
rted
to
chas
sis
grou
nd,
the
blow
er w
ill r
un o
n H
I.
Repl
ace
BSC (
This
will
req
uire
rem
oval
of ev
apor
ator
fr
om v
ehic
le).
No
othe
r pa
rt r
epla
cem
ents
sh
ould
be
nece
ssar
y.
Com
pres
sor
will
no
t tu
rn o
n (A
ll ot
her
func
tions
w
ork)
.
2.
Syst
em is
not
cha
rged
.Sy
stem
mus
t be
cha
rged
for
co
mpr
esso
r to
eng
age.
Cha
rge
syst
em o
r by
pass
pre
ssur
e sw
itch.
Dan
ger
: N
ever
byp
ass
safe
ty s
wit
ch w
ith
en
gin
e ru
nn
ing
. S
erio
us
inju
ry c
an r
esu
lt.
Syst
em is
cha
rged
.
1b
.
Trou
ble
shoo
tin
g G
uid
e
Che
ck for
fau
lty A
/C
pote
ntio
met
er o
r as
soci
ated
w
irin
g (n
ot a
pplic
able
to
3-po
t co
ntro
ls).
Che
ck for
dis
conn
ecte
d or
fa
ulty
the
rmis
tor.
Che
ck c
ontin
uity
to
grou
nd o
n w
hite
con
trol
hea
d w
ire.
Che
ck for
5V o
n re
d co
ntro
l hea
d w
ire.
Che
ck 2
-pin
con
nect
or a
t EC
U h
ousi
ng.
To c
heck
for
pro
per
pot
func
tion,
che
ck v
olta
ge a
t w
hite
/blu
e w
ire.
Vol
tage
sh
ould
be
betw
een
0V a
nd
5V,
and
will
var
y w
ith p
ot
leve
r po
sitio
n.
Dis
conn
ecte
d or
fau
lty
ther
mis
tor
will
cau
se
com
pres
sor
to b
e di
sabl
ed.
Red
wire
at A
/C p
ot s
houl
d ha
ve a
ppro
xim
atel
y 5V
w
ith ig
nitio
n on
. W
hite
w
ire
will
hav
e co
ntin
uity
to
chas
sis
grou
nd.
Whi
te/
Blu
e w
ire
shou
ld v
ary
betw
een
0V a
nd 5
V w
hen
leve
r is
mov
ed u
p or
dow
n.
3. Com
pres
sor
will
no
t tu
rn o
ff
(All
othe
r fu
nctio
ns
wor
k).
Che
ck for
fau
lty A
/C
pote
ntio
met
er o
r as
soci
ated
w
irin
g.
Che
ck for
fau
lty A
/C r
elay
.
Repa
ir o
r re
plac
e po
t/co
ntro
l wirin
g.
Repl
ace
rela
y.
See
blo
wer
sw
itch
chec
k pr
oced
ure.
ww
w.v
inta
gea
ir.c
om
22 901277 REV G 02/02/21, PG 22 OF 24
Sym
pto
m
Con
dit
ion
Ch
ecks
A
ctio
ns
Not
es
Syst
em w
ill n
ot
turn
on,
or
runs
in
term
itten
tly.
4.
Wor
ks w
hen
engi
ne is
not
runn
ing;
shu
ts o
ff w
hen
engi
ne is
sta
rted
(t
ypic
ally
ear
ly G
en I
V,
but
poss
ible
on
all
vers
ions
).
Noi
se in
terf
eren
ce fro
m e
ither
ig
nitio
n or
alte
rnat
or.
Inst
all c
apac
itors
on
igni
tion
coil
and
alte
rnat
or.
Ensu
re
good
gro
und
at a
ll po
ints
. Re
loca
te c
oil a
nd a
ssoc
iate
d w
irin
g aw
ay fro
m E
CU
and
ECU
wirin
g. C
heck
for
bur
ned
or lo
ose
plug
wires
.
Verify
con
nect
ions
on
pow
er
lead
, ig
nitio
n le
ad,
and
both
whi
te g
roun
d w
ires
.
Verify
pro
per
met
er fun
ctio
n by
che
ckin
g th
e co
nditi
on o
f a
know
n go
od b
atte
ry.
Igni
tion
nois
e (r
adia
ted
orco
nduc
ted)
will
cau
se t
he
syst
em t
o sh
ut d
own
due
tohi
gh v
olta
ge s
pike
s. I
f th
isis
sus
pect
ed,
chec
k w
ith a
qu
ality
osc
illos
cope
. Spi
kes
grea
ter
than
16V
will
shu
t do
wn
the
ECU
. In
stal
l a
radi
o ca
paci
tor
at t
he
posi
tive
post
of th
e ig
nitio
nco
il (s
ee r
adio
cap
acito
r in
stal
latio
n bu
lletin
). A
fa
ulty
alte
rnat
or o
r w
orn
out
batt
ery
can
also
res
ult
in t
his
cond
ition
.
Will
not
tur
n on
und
er
any
cond
ition
s.Ve
rify
bat
tery
vol
tage
is
grea
ter
than
10
volts
and
less
than
16.
Loss
of m
ode
door
fu
nctio
n.
No
mod
e ch
ange
at
all.
Che
ck for
dam
aged
mod
e sw
itch
or p
oten
tiom
eter
and
as
soci
ated
wirin
g.
Part
ial f
unct
ion
of m
ode
door
s.
Typi
cally
cau
sed
by
evap
orat
or h
ousi
ng
inst
alle
d in
a b
ind
in t
he
vehi
cle.
Be
sure
all
mou
ntin
g lo
catio
ns li
ne u
p an
d do
n’t
have
to
be for
ced
into
pos
ition
.
Blo
wer
tur
ns o
n an
d of
f ra
pidl
y.
6.
Bat
tery
vol
tage
is a
t le
ast
12V.
Che
ck for
at
leas
t 12
V a
t ci
rcui
t br
eake
r.En
sure
all
syst
em g
roun
ds a
nd p
ower
con
nect
ions
are
cl
ean
and
tight
.
Bat
tery
vol
tage
is le
ss
than
12V
.
5.
Trou
ble
shoo
tin
g G
uid
e (C
ont.
)
Che
ck for
fau
lty b
atte
ry o
r al
tern
ator
.Cha
rge
batt
ery.
Syst
em s
huts
off b
low
er a
t 10
V. P
oor
conn
ectio
ns o
r w
eak
batt
ery
can
caus
e sh
utdo
wn
at u
p to
11V
.
7. Whe
n ig
nitio
n is
tu
rned
on,
blo
wer
m
omen
tarily
co
mes
on,
the
n sh
uts
off.
This
oc
curs
with
the
bl
ower
sw
itch
in
the
OFF
pos
ition
.
This
is a
n in
dica
tor
that
the
sy
stem
has
bee
n re
set.
Be
sure
the
red
pow
er w
ire
is o
nth
e ba
tter
y po
st,
and
not
on a
sw
itche
d so
urce
. Als
o, if
the
sy
stem
is p
ulle
d be
low
7V for
even
a s
plit
seco
nd,
the
syst
em w
ill r
eset
.
Run
red
pow
er w
ire
dire
ctly
to
batt
ery.
Che
ck for
pos
itive
pow
er a
t he
ater
val
ve g
reen
wire
and
blow
er r
ed w
ire.
Che
ck for
gro
und
on c
ontr
ol h
ead
whi
te
wire.
Che
ck for
obs
truc
ted
or
bind
ing
mod
e do
ors.
Che
ck for
dam
aged
ste
pper
m
otor
or
wirin
g.
Erra
tic fun
ctio
ns o
fbl
ower
, m
ode,
te
mp,
etc
.
Che
ck for
dam
aged
sw
itch
or
pot
and
asso
ciat
ed w
irin
g.Re
pair o
r re
plac
e.
8.
23
www.vintageair.com
901277 REV G 02/02/21, PG 23 OF 24
OEM Center Vent Trim Louver Template
Cut Along
Dotted Line
Cut A
long D
otted Line
Cut O
utCut O
ut
Cut Along
Line
1 7/16”1 9/16”
3 9/16”
1 7/16”
3 9/16”
7 ⅞”
NOTE: Tolerances are extremely tight on the OEM center vent trim. Due to printing variances, measure the line below before using this template. If template is scaled properly, the line should measure 6 inches.
24
www.vintageair.com
901277 REV G 02/02/21, PG 24 OF 24
Packing List: Evaporator Kit (551168)
No. 1.2.
Qty.11
Part No.744004-VUE781067
DescriptionGen IV 4-Vent Evaporator Sub CaseAccessory Kit
NOTE: Images may not depict actual parts and quantities. Refer to packing list for actual parts and quantities.
1
2
Gen IV 4-Vent Evaporator Sub Case
744004-VUE
Accessory Kit781067
Checked By:Packed By:
Date: