an ISO 9001:2008 Registered Company

901238 REV C 02/28/2017, PG 1 OF 23

1968 Mopar B-Body without Factory Air

Evaporator Kit571062

Fits:Dodge: Coronet, Super Bee, Charger

Plymouth: Satellite, Road Runner, GTX

18865 Goll St. San Antonio, TX 78266 Phone: 800-862-6658

Sales: sales@vintageair.comTech Support: tech@vintageair.com

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901238 REV C 02/28/2017, PG 2 OF 23

Table of ContentsCover................................................................................................................................Table of Contents..............................................................................................................Packing List/Parts Disclaimer.............................................................................................Information Page...............................................................................................................Wiring Notice....................................................................................................................Engine Compartment, Condenser Assembly & Installation, Compressor & Brackets, Pulleys.............................................................................................................................Passenger Compartment Disassembly.............................................................................. Defrost Duct Hose Adapter & Cowl Cover Installation, Evaporator Bracket, Evaporator Hardline & Heater Hose Fitting Installation......................................................................Evaporator Bracket, Evaporator Hardline & Heater Hose Fitting Installation (Cont.)........ Firewall Cover Installation, Firewall Modification...........................................................Evaporator Installation.................................................................................................. Inner Fender Cover & Hardline Installation.................................................................... Drain Hose Installation, Lubricating O-rings, A/C Hose Installation...............................Heater Hose & Heater Control Valve Installation, A/C & Heater Hose Routing................ Driver & Passenger Side Under Dash Louver Installation, Center Louver Installation.....Final Steps..................................................................................................................... Control Panel & Duct Hose Routing................................................................................ Wiring Diagram...............................................................................................................Gen IV Wiring Connection Instructions.............................................................................Operation of Controls.....................................................................................................Troubleshooting Guide....................................................................................................Troubleshooting Guide (Cont.).........................................................................................Packing List...................................................................................................................

1 2 3 4 5

6 7 8 91011121314151617181920212223

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901238 REV C 02/28/2017, PG 3 OF 23

Evaporator Kit (571062)

1

Accessory Kit781072

No. Qty. Part No. Description

Gen IV Evaporator Sub Case w/ 204 ECU

744004-VUE

Gen IV Evaporator Sub Case w/ 204 ECUAccessory Kit, 68 Mopar B-Body without A/C

1.2.

11

744004-VUE781072

** 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.

Packing List

2

NOTE: Images may not depict actual parts and quantities. Refer to packing list for actual parts and quantities.

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901238 REV C 02/28/2017, PG 4 OF 23

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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901238 REV C 02/28/2017, PG 5 OF 23

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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901238 REV C 02/28/2017, PG 6 OF 23

Disconnect battery.Remove battery (retain).Drain radiator.Remove OEM heater hoses (discard).Remove OEM blower assembly (discard).Remove OEM heater wiring (discard).Remove front passenger side wheel.

Engine Compartment Disassembly

1.2.3.4.5.6.7.

Perform the Following:

NOTE: Before starting the installation, check the function of the vehicle (horn, lights, etc.) for properoperation, and study the instructions, illustrations, & diagrams.

Figure 1

Condenser Assembly and Installation

Compressor and Brackets

Pulleys

1. Refer to separate instructions included with the condenser kit to install the condenser.2. Binary switch installation (Refer to condenser instructions).

1. Refer to separate instructions included with the bracket kit to install the compressor bracket.

1. In most instances, the belt lengths will remain the same.

OEM HeaterHoses Heater Hose

Clamp

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901238 REV C 02/28/2017, PG 7 OF 23

Passenger Compartment Disassembly

Perform the Following:

Figure 2

Figure 3

OEM Heater Assembly

Glove Box

Center LouverCover

Remove Driver SideFresh Air Duct Pull

Cable(Discard)

OEM Control Panel

1968 Dodge Coronet Shown

OFF A/CMAX

A/CHEAT DEF

Fresh AirDuct

Remove glove box (discard).Disconnect all wires and cables from OEM control panel (discard).Remove OEM control panel assembly (discard).On all models except 1968 Dodge Chargers, remove center louver cover (discard).Remove OEM duct hoses from defrost ducts (discard).Remove passenger side OEM fresh air duct (discard).Remove OEM heater assembly (discard).Remove driver side fresh air duct pull cable assembly (discard).Relocate passenger side fresh air duct pull cable to driver side fresh air duct.

1.2.3.4.5.6.7.8.9.

Defrost Duct Hose

VENT

VENT

Will Now Be Used to Operate Driver Side

Fresh Air Duct

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901238 REV C 02/28/2017, PG 8 OF 23

On a workbench, install evaporator rear bracket and heater hose fittings with properly lubricated O-rings(See Figure 6, Page 9, and Figure 12, Page 13).Install front mounting bracket onto evaporator using (2) 1/4-20 x 1/2” hex bolts, and tighten (See Figure 5, below).

Evaporator Bracket, Evaporator Hardline

& Heater Hose Fitting Installation1.

2.

Front EvaporatorBracket644117

Figure 5

Figure 4

(2) 1/4-20 X 1/2”Hex Bolts

1. Install (2) S-clips onto defrost duct hose adapters (See Figure 4, below). 2. Install defrost duct hose adapters onto OEM driver and passenger side defrost ducts as shown in Figure 4, below.3. Hold cowl cover under dash and mark the location of the (4) mounting holes.4. Drill (4) 9/64” mounting holes under dash.5. Apply a 1/4” bead of silicone around the back side of the cowl cover as shown in Figure 4, below.6. Secure cowl cover to fresh air hole using (4) #10 x 1/2” sheet metal screws as shown in Figure 4, below.

Defrost Duct Hose Adapter& Cowl Cover Installation

Drill (4) 9/64” Holes

(4) #10 x 1/2”Sheet Metal

Screws

Cowl Cover644111

Silicone

OEM DefrostDuct

Defrost DuctHose Adapter

496116Defrost DuctHose Adapter

496116(2) S-clips

OEM DefrostDuct

(2) S-clips

9

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901238 REV C 02/28/2017, PG 9 OF 23

Figure 6

ECU Module

(2) 1/4-20 X 1/2”Hex Bolts

(2) 1/4-20 x 1/2”Hex Bolts

RearEvaporator

Bracket643099

Twist WithThis

WrenchLubricate O-ring(See Figure 12,

Page 13)

Hold With This Wrench

Evaporator Bracket, Evaporator Hardline

& Heater Hose Fitting Installation (Cont.)

(2) HeaterFittings121004

(2) #10 O-rings

10

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901238 REV C 02/28/2017, PG 10 OF 23

Drill (4) 1 ¼” holes in firewall using measurements in Figure 8, below.Drill 5/8” hole in firewall (See Figure 8, below).Install grommets in firewall (See Figure 8, below).

Firewall Modification1.2.3.

View Shown From Inside Car, Through Dash

2”

1 ½”

1 ¼”

1 ¾”

3 ¾”

Drill (4) 1 ¼”Holes in Firewall

(4) Grommets33137-VUI

Drill 5/8” Hole

6 ⅜”

MetalKick Panel

Cowl

Passenger Side Under Dash

3/8” Grommet33144-VUI

If applicable, remove OEM wire clamp from firewall (See Figure 7, below), and ensure firewall surface is smooth. Using firewall cover as a template, mark and drill (4) 3/8” holes in firewall (See Figure 7, below).Apply a 1/4” bead of silicone around the back side of the firewall cover as shown in Figure 7, below.From the engine compartment, install firewall cover onto firewall, and secure to firewall using (3) 1/4-20 x 3/4” hex bolts, (6) 1/4” flat washers and (3) 1/4” nuts w/ star washers as shown in Figure 7, below.

Firewall Cover Installation1.

2.3.4.

EngineCompartment

Side of Firewall

Figure 7

Figure 8

Back Side of Firewall Cover

Silicone

(3) 1/4-20 X 3/4”Hex Bolts

Firewall Cover644116

(6) 1/4” Flat Washers(3) 1/4”

Nuts w/ Star Washers

Drill 3/8”Holes

OEM Hole

Drill 3/8”Holes

Remove OEMClamp

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901238 REV C 02/28/2017, PG 11 OF 23

#6 A/C Hose

HoseClamps

PressTape

#10 A/C Hose

Heater Hose(To Water Pump)

Heater Hose(To Heater Control

Valve, Then to Manifold)

Drill 3/16” Holes in Cowl After Leveling

To Water Pump

To Manifold#10

#6

(2) 1/4-20 x 1”Hex Bolts (2) 1/4”Flat Washers

(2)#14 x 3/4”Hex Sheet Metal

Screws

NOTE: After installing #10 suction line, wrap all exposed metal (fittings & tube) with supplied press tape.

Figure 9

Install A/C and heater hoses (See Figure 9a, below).Lift evaporator unit up under the dashboard. Secure loosely to firewall using (2) 1/4-20 x 1” hex bolts and flatwashers (See Figure 9, below). NOTE: To ensure proper drainage, it is very important that the evaporatoris level, both left-right and fore-aft. Check for level on the flat portions of the case around the drain.Using front evaporator bracket as a guide, mark and drill (2) 3/16” holes in cowl (See Figure 9, below).Using (2) #14 x 3/4” hex sheet metal screws, secure the front evaporator mounting bracket to the cowl (See Figure 9, below).Verify that 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.

Evaporator Installation

1.2.

3.4.

5.

Figure 9a

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: Coat bolt threads with silicone prior to installation.

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901238 REV C 02/28/2017, PG 12 OF 23

(2) #2 Adel Clamps

(Included in Hose Kit)

(5) 10-32 x 3/4”Pan Head Screws

& 10-32 Nuts w/ Star Washers

(Included in Hose Kit)

#6 Inner Fender Hardline 101003

(Included in Hose Kit)

Inner Fender Heater Hardline(Heater Control Valve/Intake)

101012(Included in Hose Kit)

Inner Fender Heater Hardline(Evaporator/Water Pump)

101005(Included in Hose Kit) #10 Inner Fender Hardline

101004(Included in Hose Kit)Drill (5)

3/16” Holes

(4) #4 Adel Clamps

(Included in Hose Kit)

Remove OEM caster/camber access panel from passenger side wheel well (discard) (See Figure 10, below).Install (4) grommets in inner fender cap (See Figure 10a, below).Install inner fender cap in wheel well side using (2) #10 x 1/2” sheet metal screws as shown in Figure 10a, below.Install hardlines in inner fender cap as shown in Figure 10b, below.Install Adel clamps onto hardlines as shown in Figure 10b, below.Using Adel clamps as a guide, drill (5) 3/16” holes in inner fender. Secure Adel clamps and hardlines to inner fender using (5) 10-32 x 3/4” pan head screws and (5) 10-32 nuts with star washers as shown in Figure 10b, below.

Inner Fender Cover & Hardline Installation

1.2.3.

4.5.6.

OEM Caster/CamberAccess Panel

(2) #10 x 1/2” Sheet Metal Screws

(Included in Hose Kit)

Inner Fender Cap496118

(Included in Hose Kit)

Grommet331460

(Included in Hose Kit)

Grommet33135-VUI

(Included in Hose Kit)

(2) Grommets33136-VUI

(Included in Hose Kit)

Figure 10b

Figure 10aFigure 10

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901238 REV C 02/28/2017, PG 13 OF 23

Locate evaporator drain on bottom of evaporator case. In line with drain, measure 1” down and 2” to the left, and drill a 5/8” hole through the firewall (See Figure 11, below).Install drain hose to outlet on bottom of evaporatorunit, and route through the firewall.Install 1/2” drain elbow onto drain hose.

Drain Hose Installation1.

2.

3.

Figure 12

Figure 11

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-ringsFor 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.

Locate the #8 compressor A/C hose. Lubricate (2) #8 O-rings and connect the 90° female fitting to the #8 discharge port on the compressor. Then route the straight female fitting with R134a service port to the #8 condenser hardline coming over the core support. Tighten each fitting connection as shown in Figure 12, above.Locate the #10 compressor A/C hose. Lubricate (2) #10 O-rings and connect the 45° fitting to the #10 suction port on the compressor. Route the 45° female fitting with R134a service port to the #10 hardline on the inner fender cap. Lubricate (2) #10 O-rings and connect the 90° female fitting in the wheel well to the #10 hardline on the inner fender cap. Then route the straight female fitting from the inner fender cap to the #10 fitting on the evaporator (See Figure 9a, Page 11, and Figure 13, Page 14). Tighten each fitting connection as shown in Figure 12, above.Locate the #6 evaporator A/C hose. Lubricate (2) #6 O-rings and connect the straight female fitting to the #6 hardline coming over the core support from the drier. Route the straight female fitting to the #6 hardline onthe inner fender cap. Lubricate (2) #6 O-rings and connect the 90° female fitting in the wheel well to the #6 hardline on the inner fender cap. Then route the 90° female fitting from the inner fender cap to the #6 fitting on the evaporator (See Figure 9a, Page 11, and Figure 13, Page 14). Tighten each fitting connection as shown in Figure 12, above.

A/C Hose Installation1.

2.

3.

Standard Hose Kit:

Refer to separate instructions included with modified hose kit.1.Modified Hose Kit:

Drain Hose

2”

1”

ww

w.v

inta

gea

ir.c

om

14 901238 REV C 02/28/2017, PG 14 OF 23

#6

Con

dens

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Har

dlin

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1000

Heater Hose & Heater Control Valve Installation1. In engine compartment, route a piece of heater hose from the water pump to the top heater fitting on the inner fender cap (See Figure 13, below). Secure using hose clamps.2. In engine compartment, route a piece of heater hose from the intake to the bottom heater fitting on the inner fender cap (See Figure 13, below). Secure using hose clamps.3. In wheel well, route a piece of heater hose from the top heater fitting on the inner fender cap to the top heater fitting of the heater core as shown in Figure 9a, Page 11, and Figure 13, below. Secure using hose clamps.4. In wheel well, route a piece of heater hose from the bottom heater fitting on the inner fender cap to the bottom heater fitting of the heater core as shown in Figure 9a, Page 11, and Figure 13, below. Secure using hose clamps. NOTE: Install heater control valve in line with intake manifold (pressure side) heater hose, and secure using hose clamps as shown in Figure 13, below. Also note proper flow direction.5. Apply a bead of silicone around each hose where it passes through the grommet on the firewall (See Figure 13, below).

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15

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901238 REV C 02/28/2017, PG 15 OF 23

(2) #10 X 1/2”Hex Sheet

Metal Screws

Drill (2) 9/64”

Holes

1. Place driver and passenger side louver housings under dash. Mark and drill (4) 9/64” holes as shown in Figures 14 & 14a, below.2. Secure louver housings to dash using (4) #10 x 1/2” hex sheet metal screws as shown in Figures 14 & 14a, below.3. Install louvers into housings as shown in Figures 14b & 14c, below.

Driver SideUnder Dash

Louver Housing496121

Figure 14aFigure 14

Figure 14bFigure 14c

Figure 15aFigure 15

Driver & Passenger Side Under Dash Louver Installation

Louver49325-VUL

(2) Louvers49325-VUL

Louver49325-VUL

For 1968 Dodge Charger models:1. Place center louver housing under dash. Mark and drill (2) 9/64” holes as shown in Figure 15, below.2. Secure center louver housing to dash using (2) #10 x 1/2” hex sheet metal screws as shown in Figure 15, below.3. Install louvers into center louver housing as shown in Figure 15, below.For all other models:1. Place center louver assembly into center louver opening in dash. Using housing as a guide, mark and drill a 3/16” hole through the dash as shown in Figure 15a, below.2. Secure center louver housing to dash using OEM screw and a #8 x 1 ¾” pan head screw as shown in Figure 15a, below.3. Install louvers into housing as shown in Figure 15a, below.

Center Louver Installation

Drill (2) 9/64”

Holes

Drill (2) 9/64”

Holes

(2) #10 X 1/2Hex Sheet

Metal Screws

(2) #10 X 1/2”Hex Sheet

Metal ScrewsDrill 3/16”

Hole

OEMScrew

Passenger SideUnder Dash

Louver Housing496121

(2) Louvers49325-VUL

#8 x 1 ¾”Pan Head Screw

Center LouverAssembly496131Under Dash

Center LouverHousing496136

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901238 REV C 02/28/2017, PG 16 OF 23

Final Steps 1. Install duct hoses as shown in Figure 18, Page 17. 2. Route A/C wires (12 volt/grounds/binary switch/heater valve) through 3/8” grommet (See Figure 16, below). 3. Install control panel assembly. Refer to control panel instructions. 4. Plug the wiring harnesses into the ECU module on the sub case (See Figure 18, Page 17). Wire according to wiring diagrams on Pages 18 and 19. 5. Install (4) #8 U-nuts on glove box, and install glove box in glove box compartment (See Figure 17, below). 6. Mark and drill (3) 7/64” holes through glove box into top of glove compartment and (1) 7/64” hole through glove box into each side of glove compartment, for a total of (5) holes (See Figure 17a, below). 7. Secure glove box in glove box compartment using OEM screws (See Figure 17a, below). 8. Install fuse box cover in glove box using (2) #8 x 1/2” pan head screws (See Figure 17b, below). 9. Reinstall glove box latch using OEM screws (See Figure 17b, below).10. Reinstall all previously removed items.11. 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. 12. Double check all fittings, brackets and belts for tightness.13. Vintage Air recommends that all A/C systems be serviced by a licensed automotive A/C technician.14. Evacuate the system for a minimum of 45 minutes prior to charging, and perform a leak check prior to servicing.15. Charge the system to the capacities stated on Page 4 of this instruction manual.16. See Operation of Controls procedures on Page 20.

(4) #8 U-nuts189801

Glove Box

OEMScrews

Glove BoxDoor Latch

Fuse BoxCover (2) #8 x 1/2”Pan Head ScrewsFigure 17a Figure 17b

Figure 16 Figure 17

Drill (5)7/64” Holes

3/8” Grommet33144-VUI

Wiring Harness(12 Volt/Grounds/Binary Switch)

Wiring Harness(Heater Control Valve)

17

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901238 REV C 02/28/2017, PG 17 OF 23

FromControl Panel

Driver SideDefrost Duct

2” x 20”

Passenger SideLouver

2 ½” x 48”

Driver SideLouver

2 ½” x 30”

Driver SideCenter Louver

2 ½” x 25”

Passenger SideCenter Louver

2 ½” x 20”

Figure 18

PlugFromWiring

Harness232001-VUR

PlugFrom

ControlWiring

Harness232002-VUA

Passenger SideDefrost Duct

2” x 12”

Control Panel& Duct Hose Routing

18

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901238 REV C 02/28/2017, PG 18 OF 23

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

19

www.vintageair.com

901238 REV C 02/28/2017, PG 19 OF 23

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.

20

www.vintageair.com

901238 REV C 02/28/2017, PG 20 OF 23

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

TemperatureControl

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).

ww

w.v

inta

gea

ir.c

om

21 901238 REV C 02/28/2017, PG 21 OF 23

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

evap

ora

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

22 901238 REV C 02/28/2017, PG 22 OF 23

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.

www.vintageair.com

Accessory Kit781072

2

NOTE: Images may not depict actual parts and quantities. Refer to packing list for actual parts and quantities.

Checked By:Packed By:

Date:

Evaporator Kit (571062)

No. Qty. Part No. Description

Gen IV Evaporator Sub Case w/ 204 ECUAccessory Kit, 68 Mopar B-Body without A/C

1.2.

11

744004-VUE781072

Packing List

1

Gen IV Evaporator Sub Case w/ 204 ECU

744004-VUE

901238 REV C 02/28/2017, PG 23 OF 23

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