1961-62 corvette - vintage air · 2017-10-16 · 1961-62 corvette 561060 901047 rev b 7/3/14, 61-62...

1961-62 CORVETTE 561060

901047 REV B 7/3/14, 61-62 COVETTE EVAP INST PG 1 OF 24

an ISO 9001:2008 Registered Company

2901047 REV B 7/3/14, 61-62 CORVETTE EVAP INST PG 2 OF 24

PAGES

Table of Contents

1. COVER 2. TABLE OF CONTENTS 3. PACKING LIST / PARTS DISCLAIMER 4. INFORMATION PAGE 5. WIRING NOTICE 6. ENGINE COMPARTMENT FIGURE 1 7. CONDENSER ASSEMBLY, COMPRESSOR & BRACKET, PASSENGER COMPARTMENT FIGURES 2 & 2a 8. KICK PANEL MODIFICATION FIGURE 3 9. FIREWALL COVER INSTALLATION & EVAPORATOR INSTALLATION FIGURES 4 & 510. BRACKET INSTALLATION FIGURE 611. EVAPORATOR INSTALLTION CONT. FIGURES 7, 8 & 8a12. DRAIN HOSE INSTALLATION, LUBRICATING O-RINGS, A/C HOSE INSTALLATION, & MODIFIED A/C HOSE KIT FIGURES 9 & 1013. DRIVER SIDE COMPRESSOR MOUNT AC & HEATER HOSE ROUTING FIGURE 1114. PASSENGER SIDE COMPRESSOR MOUNT AC & HEATER HOSE ROUTING FIGURE 1215. FINAL STEPS FIGURE 1316. CONTROL PANEL & DUCT HOSE ROUTING FIGURE 1417. DRIVER SIDE UNDER DASH LOUVER & PASSENGER SIDE UNDER DASH LOUVER INSTALLATION FIGURES 15, 15a & 1618. WIRING DIAGRAM19. GEN IV WIRING CONNECTION INSTRUCTIONS20. OPERATION OF CONTROLS21. TROUBLE SHOOTING INFORMATION22. TROUBLE SHOOTING INFORMATION CONT.23. UNDER DASH FRONT EVAP BRKT TEMPLATE24. EVAPORATOR KIT PACKING LIST


** 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.

EVAPORATOR KIT561060

EVAPORATOR KIT PACKING LIST

1.

No. QTY. PART No. DESCRIPTION

2.11

744008781062

1

ACCESSORY KIT781062

2

GEN IV 4 VENTEVAP SUB CASE

w/ 204 ECU744008

GEN IV 4 VENT EVAP SUB CASE w/ 204 ECUACC KIT 61-62 CORVETTE

NOTE: IMAGES MAY NOT DEPICT ACTUAL PARTS AND QUANTITIES.REFER TO PACKING LIST FOR ACTUAL PARTS AND QUANTITIES.


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.

•

•

•


ENGINE COMPARTMENTREMOVE THE FOLLOWING

FIGURE 1

DRAIN RADIATOR.

DISCONNECT BATTERY.

OEM BLOWER MOTOR ASSEMBLY (UNDER HOOD)

OEM HEATER HOSES (DISCARD). SEE FIGURE 1.

OEM HEATERHOSES OEM HEATER

& DUCTING

BEFORE STARTING THE INSTALLATION, CHECK THE FUNCTION OF THE VEHICLE (HORN, LIGHTS,ETC.) FOR PROPER OPERATIONS.

STUDY THE INSTRUCTIONS, ILLUSTRATIONS, & DIAGRAMS.


PACKAGE TRAY. IF EQUIPPED (RETAIN). SEE FIGURE 2PASSENGER SIDE UNDER DASH COVER (RETAIN). DOOR STEP. (RETAIN).KICK PANEL (RETAIN).KICK PANEL BRACE (DISCARD).RE-SECURE TOP KICK PANEL BRACE USING 1/4-20 x 3/4HEX BOLT, (2) 1/4 x 3/4 FLAT WASHERS AND 1/4-20NUT w/ STAR WASHER AS SHOWN IN FIGURE 2a. DISCONNECT ALL WIRES AND CABLE FROM CONTROL PANEL.

PASSENGER COMPARTMENT

CONDENSER ASSEMBLY & INSTALLATIONREFER TO SEPARATE INSTRUCTIONS INCLUDED WITH THE CONDENSER KIT TO INSTALL THE CONDENSER.BINARY SWITCH INSTALLATION (REFER TO CONDENSER INSTRUCTIONS)

REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH THE BRACKET KIT TO INSTALL THE COMPRESSOR BRACKET.NOTE: RADIATOR EXPANSION TANK MUST BE RELOCATED FOR AC BRKT OR ALT BRKT INSTALLATION. VINTAGE AIR RELOCATION BRACKET KIT #154730. (AVAILABLE SEPARATELY)

COMPRESSOR & BRACKETS

REMOVE THE FOLLOWING:

FIGURE 2

FIGURE 2a

CONTROL PANEL

PACKAGETRAY

KICK PANEL

PASSENGER SIDEUNDER DASH

COVER

DOOR STEP

KICK PANELBRACE

1/4-20 x 3/4HEX BOLT

1/4-20 NUT w/

STAR WASHER

(2)1/4 x 3/4FLAT WASHER

TOP KICK PANEL BRACE


KICK PANEL MODIFICATIONREMOVE KICK PANEL BY REMOVING (6) OEM SCREWS.MODIFY PASSENGER SIDE KICK PANEL AS SHOWN IN FIGURE 3 BELOW.

FIGURE 3

8 ½

6 ⅜

1 ⅜

CUT


(2)1/4-20 x 1/2”HEX BOLT

FRONTEVAPORATOR

BRACKET644052FIGURE 5

FIREWALL COVER INSTALLATIONAPPLY A 1/4” BEAD OF SILICONE AROUND THE BACK SIDE OF THE FIREWALL COVER AS SHOWN INFIGURE 4, BELOW.

FROM INSIDE THE CAR, INSTALL FIREWALL COVER ON FIREWALL USING (3) 1/4-20 x 1 HEX BOLTS, FLAT WASHERS AND 1/4-20 NUT WITH STAR WASHER, SEE FIGURE 4, BELOW. (NOTE: USE SEAM SEALERTO FILL GAP BETWEEN COVER & LIP IN FIREWALL BEFORE PAINTING.)

ENLARGE OEM HEATER HOLE TO 1 1/4 AS SHOWN BELOW.

INSTALL GROMMETS IN FIREWALL AS SHOWN BELOW.

FIGURE 4

(3) 1/4-20 x 1HEX BOLTS

(3) 1/4 x 3/4FLAT WASHER

(3) 1/4-20 NUTS WITH

STAR WASHER

(2) LARGEGROMMETS33137-VUI

BACK SIDEOF FIREWALL

COVERSILICONE

FIREWALLCOVER

EVAPORATOR INSTALLATIONON A WORK BENCH INSTALL (2) HEATER FITTINGS WITH PROPERLY LUBRICATED O-RINGS. (SEE FIGURE 10, PAGE 12, AND FIGURE 6, PAGE 10.)INSTALL (2) 1/4-20 x 1 HEX BOLTS, AND (2) 1/4 PUSH NUT BOLT RETAINERS ON EVAP REAR BRKT AS SHOWN IN FIGURE 6, PAGE 10.INSTALL EVAPORATOR FRONT & REAR MOUNTING BRACKETS ON EVAPORATOR USING (6)1/4-20 x 1/2 HEX BOLTS AND TIGHTEN AS SHOWN IN FIGURE 5 BELOW & FIGURE 6,PAGE 10.LAY EVAPORATOR SUBCASE ON PASSENGER SIDEFLOOR BOARD. INSTALL A/C & HEATER HOSEON EVAPORATOR AS SHOWN IN FIGURE 7, PAGE 11 AND HOSE INSTALLATION ON PAGE 13 AND PAGE 14.(NOTE: WRAP THE #10 FITTING CONNECTIONS WITH PRESS TAPE. SEE FIGURE 7, PAGE 11.)

ENLARGE TO 1 1/4 HOLE (2) LARGE

GROMMETS33137-VUI


BRACKET INSTALLATION

FIGURE 6

1/4-20 x 1HEX BOLT

18290-VUB

1/4-20 x 1HEX BOLT

18290-VUB

1/4 PUSH NUTBOLT RETAINER189125-MUR

1/4 PUSH NUTBOLT RETAINER189125-MUR

PS REAREVAPORATOR

BRACKET644054

DS REAREVAPORATOR

BRACKET644053

(2) HEATERFITTINGS

(2) 1/4-20 x 1/2HEX BOLT

(2) 1/4-20 x 1/2HEX BOLT


EVAPORATOR INSTALLATION CONT.

USING TEMPLATE PROVIDED ON PAGE 23, DRILL (2) 3/16 HOLES IN DASH BRACE AS SHOWN BELOW IN FIGURE 8a.

LIFT EVAPORATOR UNIT UP UNDER THE DASHBOARD. SECURE LOOSELY TO THE FIREWALL FROM THE ENGINE COMPARTMENT SIDE USING (2) 1/4-20 NUT WITH STAR WASHER, FLAT WASHERS. SEE FIGURE 8.

SECURE THE FRONT EVAPORATOR MOUNTING BRACKET TO COWL USING (2) #14 x 3/4 HEX SHEET METAL SCREWS SEE FIGURE 8 BELOW.

VERIFY THAT EVAPORATOR UNIT IS LEVEL AND SQUARE TO THE DASH, THEN TIGHTEN ALL MOUNTING BOLTS. (NOTE: TIGHTEN THE BOLT ON FIREWALL FIRST, THEN THE FRONT MOUNTING BRACKET.)

FIGURE 8

FIGURE 7

FIGURE 8a

(2) #14 x 3/4HEX SHEET

METAL SCREW18266-VUB

(2)1/4-20NUT WITH STAR

WASHER

(2)1/4 x 3/4FLAT WASHER

DASH BRACE

BACK SIDE OF DASH

BRACE

UNDERDASH FRONT EVAP. BRKT

TEMPLATE

WIPER TRANS

CUTOUT

THIS SIDE FACES

FIREWALLDRILL 3/16”

HOLE

HEATER HOSE

#6 A/C HOSE

#10 A/C HOSE

PRESSTAPE


LOCATE EVAPORATOR DRAIN ON BOTTOM OF EVAPORATOR CASE.IN-LINE WITH DRAIN, LIGHTLY MAKE A MARKON THE FIREWALL MEASURE 1” DOWN ANDDRILL A 5/8” HOLE THROUGH THE FIREWALL. SEE FIGURE 9 BELOW.INSTALL DRAIN HOSE TO BOTTOM OFEVAPORATOR UNIT AND ROUTE THROUGHFIREWALL. INSTALL 1/2” 90° DRAIN ELBOW ON DRAIN HOSE SEE FIGURE 9.

DRAIN HOSE INSTALLATION

EVAPORATORCASE1”

LOCATE THE #8 COMPRESSOR A/C HOSE. LUBRICATE (2) #8 O-RINGS (SEE FIGURE 10, ABOVE) AND CONNECTTHE 90° FEMALE FITTING TO THE #8 DISCHARGE PORT ON THE COMPRESSOR. ROUTE THE STR FEMALE FITTING w/ 134a SERVICE PORT TO THE #8 CONDENSER HARDLINE COMING THROUGH CORE SUPPORT. SEE FIGURE 11 PAGE 13 AND FIGURE 12 PAGE 14. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN FIGURE 10 ABOVE.LOCATE THE #10 COMPRESSOR A/C HOSE. LUBRICATE (2) #10 O-RINGS (SEE FIGURE 10, ABOVE) AND CONNECT THE #10 135° FEMALE FITTING w/134a SERVICE PORT TO THE #10 SUCTION PORT ON THE COMPRESSOR. ROUTE THE 135° FEMALE FITTING TO THE #10 EVAPORATOR. SEE FIGURE 11, PAGE 13 AND FIGURE 12, PAGE 14. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN 10 ABOVE.LOCATE THE #6 EVAPORATOR A/C HOSE. LUBRICATE (2) #6 O-RINGS (SEE FIGURE 10, ABOVE) AND CONNECT THE STR FEMALE FITTING TO THE DRIER. ROUTE THE 90° FEMALE FITTING TO THE #6 EVAPORATOR. SEE FIGURE 11, PAGE 13 AND FIGURE 12, PAGE 14. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN FIGURE 10, ABOVE.

A/C HOSE INSTALLATIONSTANDARD HOSE KIT

LUBRICATING O-RINGS

#6 O-RING

#8 O-RING #10 O-RING

HOLD WITHTHIS W RENCH

FOR A PROPER SEAL OF FITTINGS:INSTALL SUPPLIED O-RINGS AS SHOWNAND LUBRICATE WITH SUPPLIED OIL.

O-RING

SUPPLIED OIL FOR O-RINGS O-RING,INSTALLS

OVER MALE INSERTTO SWAGED LIP

MALEINSERT

FEMALENUT

O-RING

TWIST WITHTHIS WRENCH

FIGURE 10

REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH MODIFIED HOSE KIT.

MODIFIED A/C HOSE KIT

FIGURE 9

DRAINHOSE

13901047 REV B 7/3/14, 61-62 CORVETTE EVAP INSTR PG 13 OF 24

FIG

UR

E 11

HEATER HOSE & HEATER CONTROL VALVE INSTALLATIONROUTE A PIECE OF HEATER HOSE FROM THE WATER PUMP TO THE TOP HEATER FITTING OF HEATER CORE AS SHOWN IN FIGURE 7, PAGE 11 AND FIGURE 11 BELOW. SECURE USING HOSE CLAMPS.NOTE: OEM WATER PUMP OUTLET IS 3/4”. A 3/4 x 5/8 REDUCER FITTING IS REQUIRED(NOT SUPPLIED)

ROUTE A PIECE OF HEATER HOSE FROM THE INTAKE TO THE BOTTOM HEATER FITTING OF HEATER COREAS SHOWN IN FIGURE 7, PAGE 11 AND FIGURE 11, BELOW. INSTALL HEATER CONTROL VALVE IN-LINE WITH INTAKE MANIFOLD (PRESSURE SIDE) HEATER HOSE, SECURE USING HOSE CLAMPS AS SHOWN IN FIGURE 11, BELOW. NOTE PROPER FLOW DIRECTION.

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HEATER HOSE & HEATER CONTROL VALVE INSTALLATIONROUTE A PIECE OF HEATER HOSE FROM THE WATER PUMP TO THE TOP HEATER FITTING OF HEATER CORE AS SHOWN IN FIGURE 7, PAGE 11 AND FIGURE 12 BELOW. SECURE USING HOSE CLAMPS.NOTE: OEM WATER PUMP OUTLET IS 3/4”. A 3/4 x 5/8 REDUCER FITTING IS REQUIRED(NOT SUPPLIED)

ROUTE A PIECE OF HEATER HOSE FROM THE INTAKE TO THE BOTTOM HEATER FITTING OF HEATER COREAS SHOWN IN FIGURE 7, PAGE 11 AND FIGURE 12, BELOW. INSTALL HEATER CONTROL VALVE IN-LINE WITH INTAKE MANIFOLD (PRESSURE SIDE) HEATER HOSE, SECURE USING HOSE CLAMPS AS SHOWN IN FIGURE 12, BELOW. NOTE PROPER FLOW DIRECTION.

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INSTALL DUCT HOSES AS SHOWN IN FIGURE 14, PAGE 16.DRILL 5/8 HOLE FOR GROMMET AS SHOWN BELOW.ROUTE A/C WIRES THROUGH 3/8 GROMMENT AS SHOWN ON FIGURE 13(12 VOLT/ GROUND/ BINARY SWITCH/ HEATER VALVE).INSTALL CONTROL PANEL ASM.PLUG THE WIRING HARNESS IN THE ECU MODULE ON SUB CASE AS SHOWN IN FIGURE 14, PAGE 16(WIRE ACCORDING TO WIRING DIAGRAM ON PAGE 18 AND 19.)REINSTALL PASSENGER SIDE UNDER DASH COVER, PACKAGE TRAY. IF EQUIPPED.REINSTALL KICK PANEL.REINSTALL ALL PREVIOUSLY REMOVED ITEMS.FILL RADIATOR WITH AT LEAST A 50/50 MIXTURE OF APPROVED ANTIFREEZE AND DISTILLED WATER. IT IS THEOWNER'S RESPONSIBILITY TO KEEP THE FREEZE PROTECTION AT THE PROPER LEVEL FOR THE CLIMATE INWHICH THE VEHICLE IS OPERATED. FAILURE TO FOLLOW ANTIFREEZE RECOMMENDATIONS WILL CAUSEHEATER CORE TO CORRODE PREMATURELY AND POSSIBLY BURST IN AC MODE AND/OR FREEZING WEATHER,VOIDING YOUR WARRANTY.DOUBLE CHECK ALL FITTINGS, BRACKETS AND BELTS FOR TIGHTNESS.VINTAGE AIR RECOMMENDS THAT ALL AC SYSTEMS BE SERVICED BY A CERTIFIED AUTOMOTIVE AIRCONDITIONING TECHNICIAN. EVACUATE THE SYSTEM FOR A MINIMUM OF 45 MINUTES PRIOR TO CHARGING AND LEAK CHECK PRIORTO SERVICING. CHARGE THE SYSTEM TO THE CAPACITIES STATED ON THE INFORMATION PAGE (PAGE 4) OF THISINSTRUCTION MANUAL. SEE OPERATION OF CONTROLS PROCEDURES ON PAGE 20.

FINAL STEPS

FIGURE 13

2”

OEM HEATERHOLES

GROMMET33144-VUI

DRILL 5/8HOLE


PASS. SIDEUNDER DASH

LOUVER2 ½” x 38”

DRIVER SIDEUNDER DASH




PASS. SIDEUNDER DASH


CONTROL PANEL & DUCT HOSE ROUTING

CONTROL PANELHARNESS

FROM ECU232002-VUA

PLUGFROM

WIRINGHARNESS

232001-VUR

DEFROST DUCTDR. SIDE2” x 32”

DEFROST DUCTPASS. SIDE2” x 32”

FIGURE 14

AIR

12 1

23

4

57

8

910

11

LO HI

TEMP.

DEFROSTER PULLFAN


INSTALL LOUVERS IN DRIVER SIDE UNDER DASH LOUVER HOUSING AS SHOWN IN FIGURE 15.SECURE LOUVER HOUSING TO UNDER DASH STEERING COLUMN USING S-CLIP AND CLAMP AS SHOWN IN FIGURE 15a BELOW.

DRIVER SIDE UNDER DASH LOUVER INSTALLATION

FIGURE 15

FIGURE 15a

S-CLIP

CLAMP

LOCATE PASSENGER SIDE UNDER DASH LOUVER HOUSING AND DRILL (3) 3/16 HOLES. SECURE LOUVER HOUSING TO DASH USING (3) 10-32 x 1/2 PH HEAD SCREWS, (6) 3/16 FLAT WASHERSAND (3) 10-32 NUTS w/ STAR WASHERS AS SHOWN IN FIGURE 16 BELOW.INSTALL LOUVERS IN UNDER DASH HOUSING AS SHOWN IN FIGURE 16.

PASSENGER SIDE UNDER DASH LOUVER INSTALLATION

FIGURE 16

(2)CHROME BALLLOUVER

49053-VUL

(2)CHROME BALLLOUVER

49053-VUL


LOUVER HOUSING

(3)10-32 x ½PH HEAD

SCREW

(6)3/16FLAT WASHER

(3)10-32NUT w/

STAR WASHER

(3)DRILL 3/16 HOLES


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

THIS KNOB CONTROLSTHE BLOWER SPEED,

FROM OFF TO HI

BLOWER SPEED

ROTATE THE KNOB TOTHE LEFT TO DIRECT AIR

FLOW TO THE DASH VENTS

MODE KNOB

TEMPERATURE KNOB IN A/C MODE ROTATE

THE TEMPERATURE KNOBALL THE WAY LEFT TO

THE COLD POSITION TOENGAGE COMPRESSOR.(ROTATE KNOB LEFT OR

RIGHT TO ADJUST DESIRED TEMPERATURE)

ROTATE KNOB RIGHTTO DESIRED BLOWER

SPEED FROM OFF TO HI

BLOWER SPEED

ROTATE THE KNOB TOTHE RIGHT TO DIRECT

AIR FLOW TO THE DEFROST VENTS

MODE KNOB

TEMPERATURE KNOBROTATE KNOB RIGHTTO DESIRED BLOWER

SPEED FROM OFF TO HI

BLOWER SPEED

ROTATE THE KNOB TO THE CENTER TO

DIRECT AIR FLOW TO THE FLOOR.

MODE KNOB

TEMPERATURE KNOBIN HEAT MODE ROTATE

THE TEMPERATURE KNOB ALL THE WAY RIGHT TO

THE HOT POSTION. (ROTATE KNOB LEFT

OR RIGHT TO ADJUST DESIRED TEMPERATURE)

ROTATE KNOB LEFT OR RIGHT TO ADJUST

DESIRED TEMPERATURE(COMPRESSOR IS AUTOMATICALLY

ENGAGED)

THE TEMPERATURE KNOB TOGGLES BETWEEN A/C AND HEAT MODES. FOR A/C MODE ROTATE THE TEMPERATURE KNOB ALL THE WAY LEFT. FOR HEAT MODE ROTATE THE KNOB ALL THE WAY TO THE RIGHT TO DISENGAGE THE COMPRESSOR, THEN MOVE THE KNOB TO SELECT DESIRED TEMPRERATURE.

NOTE: EACH TIME THE SYSTEM TOGGLES BETWEEN MODES, THE BLOWER WILL MOMENTARILY CHANGE SPEEDS.

ALL SWITCHES ARE VARIABLE BETWEEN POSITIONS, SYSTEM WILL PERFORM A BLEND BETWEEN THE FUNCTIONS.

BLOWER SPEED

MODEKNOB

A/C MODE

TEMPERATUREKNOB

AIR

12 1

23

4

57

8

910

11

LO

OFF

DASH

FLOOR

DEF COLD HOT

HI

HI

TEMP.DEFROSTER PULL

FAN

AIR

12 1

23

4

57

8

910

11

LO HI

TEMP.

DEFROSTER PULLFAN

AIR

12 1

23

4

57

8

910

11

LO HI

TEMP.

DEFROSTER PULLFAN

HEAT MODEDEFROST/ DE-FOG

MODE


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

.


Sym

pto

m

C

on

dit

ion

Ch

eck

s

Act

ion

s

N

ote

s

Sys

tem

will

not

turn

on,

or

runs

inte

rmitte

ntly.

4.

Work

s w

hen

engin

e is

not

runnin

g;

shuts

off w

hen

en

gin

e is

sta

rted

(T

ypic

ally

ear

ly G

en I

V,

but

poss

ible

on a

ll ve

rsio

ns)

.

Nois

e in

terf

eren

ce f

rom

either

ig

nitio

n o

r al

tern

ator.

Inst

all ca

pac

itors

on ignitio

n c

oil

and a

lter

nat

or. E

nsu

re

good g

round a

t al

l poin

ts.

Rel

oca

te c

oil

and a

ssoci

ated

w

irin

g a

way

fro

m E

CU

and E

CU

wirin

g.

Chec

k fo

r burn

edor

loose

plu

g w

ires

.

Ver

ify

connec

tions

on p

ow

er

lead

, ig

nitio

n lea

d,

and b

oth

white

gro

und w

ires

.

Ver

ify

pro

per

met

er f

unct

ion b

y ch

ecki

ng t

he

conditio

n o

f a

know

n g

ood b

atte

ry.

Ignitio

n n

ois

e (r

adia

ted o

rco

nduct

ed)

will

cau

se t

he

syst

em t

o s

hut

dow

n d

ue

tohig

h v

oltag

e sp

ikes

. If

this

is s

usp

ecte

d,

chec

k w

ith a

qual

ity

osc

illosc

ope.

Spik

esgre

ater

than

16V w

ill s

hut

dow

n t

he

ECU

. In

stal

l a

radio

cap

acitor

at t

he

posi

tive

post

of th

e ig

nitio

nco

il (S

ee r

adio

cap

acitor

inst

alla

tion b

ulle

tin).

A

faulty

alte

rnat

or

or

worn

out

bat

tery

can

als

o r

esult

in t

his

conditio

n.

Will

not

turn

on u

nder

an

y co

nditio

ns.

Ver

ify

bat

tery

voltag

e is

gre

ater

than

10 v

olts

and les

sth

an 1

6.

Loss

of m

ode

door

funct

ion.

No m

ode

chan

ge

at a

ll.Chec

k fo

r dam

aged

mode

switch

or

pote

ntiom

eter

and

asso

ciat

ed w

irin

g.

Part

ial fu

nct

ion o

f m

ode

doors

.

Typic

ally

cau

sed b

y ev

apora

tor

housi

ng

inst

alle

d in a

bin

d in t

he

vehic

le.

Be

sure

all

mounting loca

tions

line

up

and d

on’t h

ave

to b

e fo

rced

in

to p

osi

tion.

Blo

wer

turn

s on

and o

ff r

apid

ly.

6.

Bat

tery

voltag

e is

at

leas

t 12V.

Chec

k fo

r at

lea

st 1

2V a

t ci

rcuit b

reak

er.

Ensu

re a

ll sy

stem

gro

unds

and p

ow

er c

onnec

tions

are

clea

n a

nd t

ight.

Bat

tery

voltag

e is

les

s th

an 1

2V.

5.

Tro

ub

lesh

oo

tin

g G

uid

e (

Co

nt.

)

Chec

k fo

r fa

ulty

bat

tery

or

alte

rnat

or.

Char

ge

bat

tery

.

Sys

tem

shuts

off b

low

er a

t 10V.

Poor

connec

tions

or

wea

k bat

tery

can

cau

se

shutd

ow

n a

t up t

o 1

1V.

7. When

ignitio

n is

turn

ed o

n,

blo

wer

m

om

enta

rily

co

mes

on,

then

sh

uts

off.

This

occ

urs

with t

he

blo

wer

sw

itch

in

the

OFF

posi

tion.

This

is

an indic

ator

that

the

syst

em h

as b

een r

eset

. Be

sure

the

red p

ow

er w

ire

is o

nth

e bat

tery

post

, an

d n

ot

on a

sw

itch

ed s

ourc

e. A

lso,

if

the

syst

em is

pulle

d b

elow

7V f

or

even

a s

plit

sec

ond,

the

syst

em w

ill r

eset

.

Run r

ed p

ow

er w

ire

direc

tly

to b

atte

ry.

Chec

k fo

r posi

tive

pow

er a

t hea

ter

valv

e gre

en w

ire

and

blo

wer

red

wire.

Chec

k fo

r gro

und o

n c

ontr

ol hea

d w

hite

wire.

Chec

k fo

r obst

ruct

ed o

r bin

din

g m

ode

doors

.

Chec

k fo

r dam

aged

ste

pper

m

oto

r or

wirin

g.

Err

atic

funct

ions

of

blo

wer

, m

ode,

te

mp,

etc.

Chec

k fo

r dam

aged

sw

itch

or

pot

and a

ssoci

ated

wirin

g.

Rep

air

or

repla

ce.

8.


BOTTO

M LIP

UN

DER

DA

SH FR

ON

T EVA

P. BR

KT

TEMP

LATE

THIS SID

E FAC

ES FIR

EWA

LL

DRILL 3

/16

HO

LE WIPER TRA

NS

CU

TOU

T

CUT ALONGDOTTED LINE


EVAPORATOR KIT561060

EVAPORATOR KIT PACKING LIST

1.2.

11

744008781062

1

ACCESSORY KIT781062

2

GEN IV 4 VENTEVAP SUB CASE

w/ 204 ECU744008

GEN IV 4 VENT EVAP SUB CASE w/ 204 ECUACC. KIT 61-62 CORVETTE

NOTE: IMAGES MAY NOT DEPICT ACTUAL PARTS AND QUANTITIES.REFER TO PACKING LIST FOR ACTUAL PARTS AND QUANTITIES.

CHECK BY:PACKED BY:

DATE:

No. QTY. PART No. DESCRIPTION

1961-62 corvette - vintage air · 2017-10-16 · 1961-62 corvette 561060 901047 rev b 7/3/14, 61-62...

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