1955-59 chevrolet pickup - vintage air · sub case wo a/c plenum w/ 204 ecu 744012 gen iv...

1955-59 Chevrolet Pickup with Deluxe Controls

751156

901193 REV D 07/21/14, INST 55-59 CHEV P-UP w/ DELUXE CONTROLS EVAP KIT PG 1 OF 24

an ISO 9001:2008 Registered Company

18865 Goll St. San Antonio, TX 78266 ph: 210-654-7171 fax: 210-654-3113


Table of Contents 1. Cover 2. Table of Contents 3. Packing List/Parts Disclaimer 4. Information Page 5. Wiring Notice 6. Engine Compartment, Condenser Assembly, Compressor & Bracket Figure 1 7. Passenger Compartment Figures 2, 2a & 2b 8. Defrost Duct Installation, Bracket & Evaporator Hardline Installation Figures 3 & 4 9. Bracket & Evaporator Hardline Installation (Cont.) & Evaporator Plenum Installation Figures 5 & 610. Firewall Modification & Firewall Modification (Cont.) Figures 7 & 811. Evaporator Installation Figures 9, 9a & 9b12. Drain Hose Installation, Lubricating O-rings, A/C Hose Installation & Modified A/C Hose Kit Figures 10 & 1113. Heater Hose & Heater Control Valve Installation Figure 1214. 1955-57 Chevy Pickup A/C & Heater Hose Routing Figure 1315. 1958-59 Chevy Pickup A/C & Heater Hose Routing Figure 1416. Driver Side Under Dash Louver & Passenger Side Under Dash Louver Installation Figures 15 & 1617. Final Steps Figures 17 & 1818. Control Panel & Duct Hose Routing Figure 1919. Wiring Diagram20. Gen IV Wiring Connection Instructions21. Operation of Controls22. Troubleshooting Information23. Troubleshooting Information (Cont.)24. Evaporator Kit Packing List


Evaporator Kit (751156)

1

Accessory Kit791156

2

No. Qty. Part No. Description

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

Gen IV Evaporator Sub Case wo A/C Plenum

w/ 204 ECU744012

Gen IV Evaporator Sub Case wo A/C Plenum w/ 204 ECUAccessory Kit 55-59 Chevy Pickup wo A/C w/ DELX

1.2.

11

744012791156

** 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

MODEFAN

C

H


Use of Any Other Refrigerants Will Void All Warranties of the Air Conditioning System and Components. Use of the Proper Type and

Amount of Refrigerant Is Critical to Proper System Operation. VintageAir Recommends Our Systems Be Charged By Weight With a Quality

Charging Station or Scale.

Service Info:

Safety Switches:

Important Notice—Please Read

Attention: The following system components are capped: Compressor, evaporator, condenser & drier. Caps may be under pressure with dry nitrogen. Be careful removing caps. Do not remove caps prior to installation. Removing caps prior to installation will cause components to collect moisture and lead to premature failure and reduced performance.

Evacuate the system for 35-45 minutes with system components (Drier, compressor, evaporator and condenser) 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.

For Maximum System Performance, Vintage Air Recommends the Following:

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.

Vintage Air Systems Are Designed to Operate With R134a Refrigerant Only! Use of Any Other Refrigerants Is a Fire Hazard and Could Damage Either Your Air Conditioning System or Your Vehicle.

Refrigerant Capacity for Vintage Air Systems:(For other systems, consult manufacturer’s guidelines)

R134a SystemCharge with 1.8 lbs. (1 lb., 12 oz.) of refrigerant.

Lubricant Capacities:New Vintage Air-supplied Sanden Compressor: No additional oil needed (Compressor is shipped with proper oil charge).All Other Compressors: Consult manufacturer (Some compressors are shipped dry and will need oil added).

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.

Heater Hose (Not Included With This Kit):

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.

Bolts Passing Through Cowl and/or Firewall:


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.

•

•

•


Figure 1

Core SupportCover

Horns

Battery

BatteryTray

Engine Compartment

1.

2.

3.

4.

5.

6.

7.

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

Remove the Following:

Disconnect battery.

Remove battery and battery tray (retain).

Remove top cover on radiator core support (retain).

Remove OEM fan & fan shroud (retain).

Drain and remove radiator (retain).

Remove passenger side horn (retain).

Remove all OEM heater hoses (discard).

Condenser Assembly and Installation Refer to separate instructions included with the condenser kit to install the condenser.

Binary switch installation (Refer to condenser instructions).

1.

2.

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


Figure 2

OEM DefrostDucts

OEM HeaterAssembly

Glove BoxOEM

ControlPanel

(Remove)Passenger Side

OEM Vent Control

(Relocate)Driver Side

OEM Vent Control

Glove BoxDoor

Figure 2b

Figure 2a

Approx.3”

Cut & Remove

AfterBend

Bend

½”

Passenger Side Fresh Air

Door

Silicone

Passenger Compartment

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

Remove the Following:

Remove glove box door (retain) and glove box (discard).

Disconnect all wires and cables from control panel.

Remove control panel (discard).

Remove passenger side OEM vent control (discard), and close and seal kick panel vent with silicone (See Figure 2b, below).

Relocate driver side OEM vent control next to steering column using OEM screws.

Remove OEM heater assembly (discard).

Remove OEM duct hose from defrost ducts (discard).

Remove OEM defrost ducts (discard).

Modify passenger side glove box door arm as shown in Figure 2a, below.

NOTE: Glove box door travel will be restricted to prevent interference with evaporator case assembly.

Remove & discard driver side glove box door arm.


Defrost Duct

62144-VCE

#8 X 1/2”PH Pan Head

Screw

Figure 4

Figure 3

Defrost Duct

62144-VCE

Twist WithThis

WrenchLubricate O-ring(See Figure 11,

Page 12)

Hold With This Wrench

RearEvaporator

Bracket ASM643082

(2) 1/4-20 X 1/2”Hex Bolts

ECU Module

#6 O-ring

(2) 1/4-20 X 1/2”Hex Bolts

#6 Liquid Line092160

Bracket & Evaporator Hardline Installation On a workbench, install evaporator rear bracket using (4) 1/4-20 x 1/2” hex bolts.

Install hardlines with properly lubricated O-rings (See Figure 4, below, and Figure 11, Page 12).

1.

2.

Defrost Duct Installation Install driver and passenger side defrost ducts using (2) #8 x 1/2” PH pan head screws as shown in Figure 3, below.

1.


Figure 5

Figure 6

#6 Liquid Line092160

Heater Line(Evap To Water Pump)

092162

#10 O-ring

Heater Line(Evap To Intake)

092163

Center LouverA/C Plenum

496102

(2) 10-32 X 1/2”PH Pan Head

Screws

Bracket & Evaporator Hardline Installation (Cont.)

Center Louver A/C Plenum Installation Install center louver A/C plenum ASM onto evaporator sub case as shown in Figure 6, below.1.


Figure 8

OEM FoamInsulation

OEM FoamInsulation (4) Large

Grommets33137-VUI

Cut and Remove

View FromPassenger SideInside of Cab View From

Passenger SideInside of Cab

13 ½”

8 ½”

Firewall Modification (Cont.)Cut & remove OEM foam insulation as shown in Figure 8, below.

Install (4) large grommets as shown in Figure 8, below.

1.

2.

OEM Holes(Enlarge to 1 ¼”

If Necessary)

Enlargeto 5/8”

Figure 7

Firewall ModificationDrill (2) 1 1/4” holes and (2) 3/8” holes in firewall. (See Figure 7, below).

Enlarge OEM hole in firewall to 5/8” (See Figure 7, below).

1.

2.

Drill 1¼” Hole OEM

Hole

5 5/16”7 1/16”

4 27/32”

4 ⅝”

10”

OEM Hole

Drill3/8” Hole

55-59 Chevy PickupFirewall Indention

(Engine Side)

FactoryStamp

FactoryStamp

FactoryStamp

OEMHole

Drill3/8” Hole

15/16”

2 27/32”


(2) 10-32 x 1”PH Pan Head

Screws18253-VUB

(2) 3/16” SAE

Flat Washers

(2) 10-32 Nuts w/ Star Washers

18251-VUB

(2) 1/4-20 x 1/2”

Hex Bolts

Front EvapBracket643083

OEM Glove Box Mounting

Bracket

Replace These OEMScrews Before Installing Evap

(2) 1/4-20 x 1”Hex Bolts

(2) 1/4” Flat Washers

View FromPassenger SideInside of Cab

Figure 9a

Figure 9b

Evaporator Installation

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

Press Tape

#10 SuctionLine

092161

Figure 9

OEM GloveBox Mounting

Bracket

(2) Louvers

Mark & Drill 5/32” Holes

(2) #8 x 1/2”PH Pan Head Screws

(2) 1/2” Plastic Plugs

Lift evaporator unit up under the dashboard. Secure loosely to the firewall using (2) 1/4-20 x 1” hex bolts and (2) flat washers (See Figure 9, 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.Install evaporator front bracket on evaporator using (2) 1/4-20 x 1/2” hex bolts, and tighten as shown in Figure 9, below.Remove & replace OEM screws in glove box mounting brackets. Replace with (2) 10-32 x 1” PH pan head screws.

Secure the front evaporator mounting bracket to the OEM glove box mounting bracket using (2) 3/16” SAE flat washers and (2) 10-32 nuts with star washers. (See Figure 9a, below).Using center louver A/C plenum assembly as a guide, mark and drill (2) 5/32” holes in dash bottom (See Figure 9, below). Secure evaporator plenum ASM to dash using (2) #8 x 1/2” PH pan head screws, and install (2) 1/2” plastic plugs in holes as shown in Figure 9, below.Install louvers in evaporator plenum ASM as shown in 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.Install #10 suction line as shown in Figure 9b, below. NOTE: Wrap the #10 fitting connections.

1.

2.

3.

4.5.

6.

7.

8.9.

10.

#10 O-ring


Figure 10Evaporator Case1”

Figure 11

Drain Hose

O-ring Installs Over Male Insert to Swaged Lip

O-ring

Drain Hose Installation Locate evaporator drain on bottom of evaporator case.

In line with drain, lightly make a mark on the firewall. Measure 1” down and drill a 5/8” hole through the firewall.

Install drain hose to bottom of evaporator unit and route through firewall. Install 1/2” 90° drain elbow on drain hose.

1.

2.

3.

#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.

1”


FROM HTR CNTRL VLVTO EVAPORATOR

FROM INTAKEMANIFOLD

#10 SuctionLine

#6 LiquidLine

HoseClamps

HeaterHose

Figure 12

FROM EVAPORATOR TO WATER PUMP

HeaterHose

Heater Hose and Heater Control Valve Installation

Route 90° heater hose through the firewall and connect to heater line on evaporator as shown in Figure 12, below. Route the other end of the hose to the water pump, and secure using hose clamps. Note: A small amount of silicone spray will ease heater hose installation.Route 90° heater hose through the firewall and connect to heater line on evaporator, and then route the other end of the hose to the intake. Note: Install heater control valve in line with intake manifold (pressure side) heater hose, and secure using hose clamps as shown. Also note proper flow direction.

1.

2.


Figure 13

Heater Hose

NOTE: Flow direction followsmolded arrow on valve.

FROM INTAKE MANIFOLD

#8 Cond/CompHardline095020

#6 Cond/DrierHardline095019

From Evaporatorto Water Pump

From Htr Cntrl Vlv to

Evaporator

#6 Adel Clamp

31602-VUD

#8 Discharge Hose

096015

Tie Wrap

#10 SuctionHose

096010

Heater Hose(Heater Cntrl Vlv/Intake)

#6 Hose096014

Safety Switch

(Binary Type)

NOTE: Vintage Air Systems Require (2) 5/8” Hose Nipples (Not Supplied)

1955-57 Chevy Pickup A/C & Heater Hose Routing Standard Hose Kit:

Modified A/C Hose Kit:

1. Locate the #8 compressor A/C hose. Lubricate (2) #8 O-rings (See Figure 11, Page 12) and connect the 135° female fitting with R134a service port to the #8 discharge port on the compressor. Route the 90° female fitting to the #8 condenser hardline coming through the core support (See Figure 13, below). Tighten each fitting connection as shown in Figure 11, Page 12.2. Locate the #10 compressor A/C hose. Lubricate (2) #10 O-rings (See Figure 11, Page 12) and connect the 135° female fitting with R134a service port to the #10 suction port on the compressor. Route the 90° female fitting to the #10 evaporator (See Figure 12, Page 13, and Figure 13, below). Tighten each fitting connection as shown in Figure 11, Page 12.3. Locate the #6 evaporator/drier hose. Lubricate (2) #6 O-rings (See Figure 11, Page 12) and connect the 90° female fitting to the drier. Route the 90° female fitting to the #6 evaporator hardline (See Figure 12, Page 13, and Figure 13, below). Tighten each fitting connection as shown in Figure 11, Page 12.

1. Refer to separate instructions included with modified hose kit.


Figure 14

Heater Hose

#6 Drier/Core Hardline095018

NOTE: Flow direction followsmolded arrow on valve.

Safety Switch

(Binary Type)

#8 Cond/CompHardline095017

#6 Cond/DrierHardline095016

From Evaporatorto Water Pump

From Htr Cntrl Vlv to

Evaporator

#6 Adel Clamp31602-VUD

#8 Discharge Hose

096009#6 Hose096008

Tie Wrap

#10 SuctionHose

096010

Heater Hose(Heater Cntrl Vlv/Intake)

NOTE: Vintage Air Systems Require (2) 5/8” Hose Nipples (Not Supplied)

1958-59 Chevy Pickup A/C & Heater Hose Routing Standard Hose Kit:

Modified A/C Hose Kit:

1. Locate the #8 compressor A/C hose. Lubricate (2) #8 O-rings (See Figure 11, Page 12) and connect the 135° female fitting to the #8 discharge port on the compressor. Route the straight female fitting with R134a service port to the #8 condenser hardline coming through the core support (See Figure 14, below). Tighten each fitting connection as shown in Figure 11, Page 12.2. Locate the #10 compressor A/C hose. Lubricate (2) #10 O-rings (See Figure 11, Page 12) and connect the 135° female fitting with R134a service port to the #10 suction port on the compressor. Route the 90° female fitting to the #10 evaporator (See Figure 12, Page 13, and Figure 14, below). Tighten each fitting connection as shown in Figure 11, Page 12.3. Locate the #6 evaporator/drier hose. Lubricate (2) #6 O-rings (See Figure 11, Page 12) and connect the straight female fitting with binary switch service port to the #6 drier hardline coming through the core support. Route the 90° female fitting to the #6 evaporator hardline (See Figure 12, Page 13, and Figure 14, below). Tighten each fitting connection as shown in Figure 11, Page 12.

1. Refer to separate instructions included with modified hose kit.

FROM INTAKE MANIFOLD


Figure 15

Figure 16

OEM Screw

OEM Screw

Driver SideLouver ASM

496099

Passenger SideLouver ASM

496100

1/2” Plastic Plug31102-GUR

1/2” Plastic Plug31102-GUR

Driver SideUnder Dash Louver Installation

Install driver side louver assembly under dash and secure using OEM screw as shown in Figure 15, below.

Install 1/2” plastic plug in driver side louver assembly as shown in Figure 15, below.

1.

2.

Passenger SideUnder Dash Louver Installation

Install passenger side louver assembly under dash and secure using OEM screw as shown in Figure 16, below.

Install 1/2” plastic plug in passenger side louver assembly as shown in Figure 16, below.

1.

2.


Figure 17

Glove Box624980

(5) OEMScrews

Figure 18

Final Steps

1.2.

3.4.

5.

6.

7.8.

9.10.11.12.13.

Install duct hoses as shown in Figure 19, Page 18.Route A/C wires (12 volt/grounds/binary switch/heater valve) through 3/8” grommet as shown in Figure 17, below.Install control panel ASM.Plug the wiring harnesses into the ECU module on the sub case as shown in Figure 19, Page 18 (Wire according to wiring diagram on Page 19 and 20).Install new glove box using (5) OEM screws (See Figure 18, below). Install glove box door. NOTE: Glove box door opening and capacity will be very limited with Gen IV system.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 certified automotive air conditioning 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 21.

Grommet33144-VUI

Wiring Harness(12 Volt/Grounds/Binary Switch)

Wiring Harness(Heater Control Valve)


Figure 19

Pass. SideDef Duct2” X 10”

Driver SideDef Duct2” X 24”

Glove Box

Duct Hose Retainer624989

Windshield

Duct Hose

Dash

Passenger SideLouver

2 ½” x 40”

Driver SideLouver

2 ½” x 30”

Plug FromControl

Wiring Harness 232002-VUA

Plug FromWiring

Harness232001-VUR

End View ofGlove Box Area

Control Panel and Duct Hose Routing

MODEFAN

C

H


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


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.


Operation of Controls

Blower SpeedAdjust to desired

speed.

Temperature LeverSlide the temperature lever all the way down to the HOT

position (Slide lever up or down to desired

temperature). Slide the lever to the

middle (Floor position).

Mode Lever

Blower SpeedAdjust to desired

speed.

Slide the lever allthe way down

(Dash position).

Mode Lever

Temperature LeverAdjust to desiredspeed.

Blower Speed

Slide the lever all the way up to the defrost

position.

Mode LeverAdjust lever to desired

temperature (Compressor is automatically engaged).

Temperature LeverFor A/C operation, slide the

temperature lever all the way up to engage

compressor (Slide lever up or down to adjust to desired temperature).

A/C Operation

Blower Speed

TemperatureLever

ModeLever

Heat Operation

Defrost/De-fog Operation

On Gen IV systems with three lever/knob controls, the temperature control toggles between economy and A/C operations. To activate A/C, move the temperature lever all the way to cold and then back it off to the desired vent temperature. For economy/heat operation, move the temperature lever 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.

MODEFAN

C

H

MODEFAN

C

H

MODEFAN

C

H

NOTE: For proper control panel function, refer to control panel instructions for calibration procedure.


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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

.


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.


Packing List Evaporator Kit (751156)

Accessory Kit791156

No. Qty. Part No. Description

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

Gen IV Evaporator Sub Case wo A/C Plenum

w/ 204 ECU744012

Checked By:Packed By:

Date:

Gen IV Evaporator Sub Case wo A/C Plenum w/ 204 ECUAccessory Kit 55-59 Chevy Pickup wo A/C w/ DELX

1.2.

11

744012791156

MODEFAN

C

H

1

2

1955-59 chevrolet pickup - vintage air · sub case wo a/c plenum w/ 204 ecu 744012 gen iv...

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