Transcript
an ISO 9001:2008 Registered Company
1969 Chevrolet Camaro with Factory Air Control Panel Conversion Kit (474269)
18865 Goll St. San Antonio, TX 78266 Phone: 210-654-7171 Fax: 210-654-3113 www.vintageair.com 904269 REV F 05/18/15, PG 1 OF 17
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Table of Contents
Thank you for purchasing this control panel kit from Vintage Air. When installing these components as part of a complete SureFit™ system, Vintage Air recommends working from front to back on the vehicle, installing the condenser kit, hose kit, and compressor first, followed by the wiring, evaporator, and finally the control panel. Cover................................................................................................................................. 1 Table of Contents................................................................................................................. 2 Packing List/Parts Disclaimer.................................................................................................. 3 OEM Control Panel Removal, Placard Installation...................................................................... 4 Cable Converter Assembly Modification, Cable Converter Assembly Mounting Clamp Installation..... 5 Mode Cable Converter Assembly Installation............................................................................ 6 Mode Control Harness........................................................................................................... 7 Hot Cable Converter Assembly Installation, Hot Control Harness................................................. 8 Hot Control Harness (Cont.), Cold Cable Converter Assembly Installation..................................... 9 Cold Control Harness.......................................................................................................... 10 Blower Switch Installation, Control Harness Final Step............................................................. 11 Final Steps........................................................................................................................ 12 Control Panel Calibration Procedure....................................................................................... 13 Control Panel Calibration Procedure (Cont.)............................................................................ 14 Wiring Diagram.................................................................................................................. 15 Operation of Controls.......................................................................................................... 16 Packing List....................................................................................................................... 17
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904269 REV F 05/18/15, PG 2 OF 17
Packing List: Control Panel Kit (474269)
www.vintageair.com No. 1. 2. 3. 4. 5. 6. 7. 8.
Description Placard Cable Converter Assembly Control Harness, Gen IV Universal Push-on Ring, 3/16” Clamp, Cable Converter Tie Wrap, 4” Ground Wire PC Board, Blower Switch
Part No. 484169-PCR 112002-SUA 232002-VUA 65976-VUE 491010-VUR 21301-VUP 231520 246108-PUA
Qty. 1 3 1 3 3 5 1 1
** 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.
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NOTE: Images may not depict actual parts and quantities. Refer to packing list for actual parts and quantities.
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904269 REV F 05/18/15, PG 3 OF 17
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OEM Control Panel Removal
Perform the Following: 1. Remove (3) OEM screws from the instrument panel (See Figure 1, below). 2. Disconnect the cables and wires from the back side of the OEM controls. NOTE: Make sure the glove box and glove box door have been removed. 3. Remove the OEM control panel from behind the dash, and through the glove box opening in the dash (retain).
Remove (3) OEM Screws
Figure 1
Placard Installation 1. Remove control panel lever knobs. 2. Remove placard retaining clips (See Figure 2, below). 3. Remove backing sheet from control panel. 4. Install new black backing sheet on control panel (See Figure 2, below). 5. Install new placard and secure using OEM retaining clips (See Figure 2, below). 6. Reinstall knobs.
Placard Knobs Placard Retaining Clips Placard
Figure 2
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Black Backing Sheet 904269 REV F 05/18/15, PG 4 OF 17
Cable Converter Assembly Modification
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1. Locate the (3) cable converter assemblies. Using a pair of wire cutters, cut the cable converter actuator rods as shown in Figure 3, below.
Cut at Each Side of Hole as Shown
Cable Converter Actuator Rod
Cut All (3) Cable Converter Assemblies at 3rd Hole (Remove Shaded Portion) Reference Only
Figure 3
Cable Converter Assembly Mounting Clamp Installation 1. Install cable converter assembly mounting clamps. NOTE: Orient clamps in relation to the (3) housing snaps on the cable converter assembly as shown in Figure 4, below.
Cable Converter Assembly Mounting Clamp
Cable Converter Assembly
Figure 4
Cold Cable Converter Assembly
Hot Cable Converter Assembly
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Mode Cable Converter Assembly
904269 REV F 05/18/15, PG 5 OF 17
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Mode Cable Converter Assembly Installation
1. Install the cable converter push rod onto the OEM cable mounting stud on the mode lever (See Figure 5, below). 2. Secure the cable converter assembly to the control panel using the OEM screw in the OEM cable clamp mounting location (See Figure 5, below). 3. Since the cable converter assembly can slide back and forth in the clamp before the screw is tightened, position the cable converter assembly such that the flat part of the rod is as close to flush as possible with the end of the housing at the lever’s innermost position. 4. Secure the cable converter lever push rod onto the OEM cable mounting stud using a 3/16” push-on ring as shown in Figure 5, below. 5. Remove the vacuum module (discard) (See Figure 5, below). End of Rod Flat Section OEM Cable Mounting Stud
End of Housing
OEM Cable Clamp Mounting Location 1/8” Max
Mode Lever
Flush
Vacuum Module
Cable Converter Assembly
Rod Shown in Approximately Innermost Position.
NOTE: Do not allow rod to separate housing when rod is in innermost position.
Figure 5
OEM Screw
3/16” Push-on Ring
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904269 REV F 05/18/15, PG 6 OF 17
Mode Control Harness
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1. Locate the control panel wiring harness, and plug the corresponding connector into the correct cable converter assembly as shown in Figure 6, below. 2. Once the connector is correctly plugged into the cable converter assembly, secure the wires to the cable converter assembly using the supplied tie wraps. The tie wrap must be located between the end of the wire jacket and the step in the cable converter housing, forcing a bend in each wire as it passes over the step in the cable converter housing. The head of the tie wrap must fall on the edge of the housing to remain tight. Ensure that the tie wraps are tight enough that the wires cannot move (See Figure 6a, below).
Red White/Yellow White Mode Connector and Wires
Figure 6
Wire Jacket
Wire Jacket
Force Bend in Wires Over Step Tie Wrap
Step in Cable Converter Housing Tie Wrap
Figure 6a
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904269 REV F 05/18/15, PG 7 OF 17
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Hot Cable Converter Assembly Installation
1. Install the cable converter push rod onto the OEM cable mounting stud on the hot lever (See Figure 7, below). 2. Secure the cable converter assembly to the control panel using the OEM screw in the OEM cable clamp mounting location (See Figure 7, below). 3. Since the cable converter assembly can slide back and forth in the clamp before the screw is tightened, position the cable converter assembly such that the flat part of the rod is as close to flush as possible with the end of the housing at the lever’s innermost position (See Figure 5, Page 6). 4. Secure the cable converter lever push rod onto the OEM cable mounting stud using a 3/16” push-on ring as shown in Figure 7, below.
3/16” Push-on Ring Cable Converter Assembly
OEM Screw
Figure 7
Hot Control Harness 1. Locate the control panel wiring harness, and plug the corresponding connector into the correct cable converter assembly as shown in Figure 8, below.
Red White/Red White
Hot Connector and Wires
Figure 8
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904269 REV F 05/18/15, PG 8 OF 17
Hot Control Harness (Cont.)
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1. Once the connector is correctly plugged into the cable converter assembly, secure the wires to the cable converter assembly using the supplied tie wraps. The tie wrap must be located between the end of the wire jacket and the step in the cable converter housing, forcing a bend in each wire as it passes over the step in the cable converter housing. The head of the tie wrap must fall on the edge of the housing to remain tight. Ensure that the tie wraps are tight enough that the wires cannot move (See Figure 9, below). Force Bend in Wires Over Step Tie Wrap
Wire Jacket Wire Jacket
Step in Cable Converter Housing
Tie Wrap
Figure 9
Cold Cable Converter Assembly Installation 1. Install the cable converter push rod onto the OEM cable mounting stud on the cold lever (See Figure 10, below). 2. Secure the cable converter assembly to the control panel using the OEM screw in the OEM cable clamp mounting location (See Figure 10, below). 3. Since the cable converter assembly can slide back and forth in the clamp before the screw is tightened, position the cable converter assembly such that the flat part of the rod is as close to flush as possible with the end of the housing at the lever’s innermost position (See Figure 5, Page 6). 4. Secure the cable converter lever push rod onto the OEM cable mounting stud using a 3/16” push-on ring as shown in Figure 10, below. 3/16” Push-on Ring
Cable Converter Assembly
OEM Screw
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Figure 10 904269 REV F 05/18/15, PG 9 OF 17
Cold Control Harness
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1. Locate the control panel wiring harness, and plug the corresponding connector into the correct cable converter assembly as shown in Figure 11, below. 2. Once the connector is correctly plugged into the cable converter assembly, secure the wires to the cable converter assembly using the supplied tie wraps. The tie wrap must be located between the end of the wire jacket and the step in the cable converter housing, forcing a bend in each wire as it passes over the step in the cable converter housing. The head of the tie wrap must fall on the edge of the housing to remain tight. Ensure that the tie wraps are tight enough that the wires cannot move (See Figure 11a, below).
Red White/Blue White
Cold Connector and Wires
Figure 11
Force Bend in Wires Over Step Tie Wrap
Wire Jacket
Step in Cable Converter Housing
Wire Jacket Tie Wrap
Figure 11a
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904269 REV F 05/18/15, PG 10 OF 17
Blower Switch Installation
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1. Install the blower switch PC board onto the OEM blower switch as shown in Figure 12, below. 2. Plug the remaining connector (with red, white, and white/green wires) into the blower switch PC board as shown in Figure 12, below.
OEM Blower Switch
Blower Switch PC Board 246108-PUA
Figure 12
Control Harness Final Step 1. Using the supplied tie wraps, tie the wires to the control panel as shown in Figure 13, below. Confirm that wires are secured and do not interfere with lever operation or cable converter assemblies.
Tie Wraps
Figure 13
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904269 REV F 05/18/15, PG 11 OF 17
Final Steps
www.vintageair.com 1. Reinstall the control panel into the dash. 2. Plug the wiring harnesses into the ECU module on the sub case. 3. Wire according to the wiring diagram on Page 15. 4. Calibration procedure and operation instructions:
A. Calibrating the control panel will set the range of travel for the cable converters connected to the OEM control panel levers. Performing this procedure will set the limits of the cable converters at their highest and lowest points. B. Locate the gray wire with an unused connector in the wiring harness near the cable harness relay. This wire is labeled PROGRAM on the wiring diagram. C. It will be necessary to ground the gray wire for approximately five seconds while moving the controls, so it is sometimes helpful to attach one end of the white jumper to the vehicle’s ground (for example, the chassis) and have the other end ready to connect to the gray PROGRAM wire when the procedure requires it. D. To calibrate the control panel, follow the calibration procedures on Pages 13 & 14.
Plug From Control Wiring Harness 232002-VUA
Plug From Wiring Harness 232001-VUR
Figure 14
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904269 REV F 05/18/15, PG 12 OF 17
Control Panel Calibration Procedure
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On Vintage Air Gen IV systems using factory controls, it is necessary to calibrate the system to your specific control panel. This procedure ensures that the stroke of your control panel levers or knobs is translated into precise control of the fan speed, temperature blend and mode door position. Please carefully read and understand these procedures before beginning. The procedure may be repeated as many times as necessary to get it right. In preparation for calibration, you will need to attach the supplied white ground jumper wire to a suitable chassis ground. This jumper wire must be easily connected to the gray programming wire located in the main Gen IV wiring harness next to the relays. During the calibration procedure, you will connect the white jumper to the gray program wire, which will “teach” the Gen IV ECU the upper limits of the control levers or knobs. The blower will momentarily change speeds, signaling that the upper limits have been “learned”. You will move the levers or knobs to opposite extreme positions of their travel and then disconnect the white jumper. The blower will again change speeds, signaling that the lower limits have been learned and that the calibration procedure is complete.
White Jumper Cable
Gray Program Wire
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904269 REV F 05/18/15, PG 13 OF 17
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Control Panel Calibration Procedure (Cont.) OFF
N O START
1. Turn on the ignition switch (Do not start the engine).
2. Move the control levers/knobs to the position shown.
3. Connect the white jumper wire to the gray program wire. Wait for the blower speed to change (Approximately 5 seconds).
4. Move the control levers/knobs to the positions shown.
5. Disconnect the white jumper wire from the gray program wire. The blower speed will change, indicating completion of the calibration procedure.
6. Confirm proper operation of controls. Repeat procedure if necessary. When finished, tape over program wire connector with electrical tape to prevent accidental contact with chassis ground.
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904269 REV F 05/18/15, PG 14 OF 17
Wiring Diagram
www.vintageair.com 232007-VUR
TAN ORA BLK WHT RED WHT/RED WHT/YEL
JF8
WHT/GRN
AC ANNUNCIATOR BACKLIGHT POS BACKLIGHT NEG GND 5V-SW TEMP WIPER MODE WIPER FAN WIPER
PRE-WIRED
VIEWED FROM WIRE SIDE
232002-VUA A/C (IF USED)
GEN IV ECU GEN IV WIRING DIAGRAM REV D, 5/6/2014
TEMP
MODE
FAN
PROGRAM * DASH LAMP (IF USED) *** WIDE OPEN THROTTLE SWITCH (OPTIONAL)
** CIRCUIT BREAKER 30 AMP
HEATER CONTROL VALVE
• Dash Lamp Is Used Only With Type 232007-VUR Harness. • 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). • Wide Open Throttle Switch Contacts Close Only at Full Throttle, Which Disables A/C Compressor.
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904269 REV F 05/18/15, PG 15 OF 17
Operation of Controls
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NOTE: For proper control panel function, refer to calibration procedure on Pages 13 and 14. Blower Speed Blower Speed This lever controls blower speed, from OFF to HI. Mode Control This lever controls the mode positions, from DASH to FLOOR to DEFROST, with a blend in between.
Temperature Controls These levers control the temperature, from HOT to COLD.
Mode Control
Temperature Controls
A/C Operation Blower Speed Adjust to desired speed. Mode Control Adjust to desired mode position (DASH position recommended).
Cold Lever Slide lever all the way up to engage compressor. Hot Lever For A/C operation, slide lever all the way up for maximum cooling (Slide lever up or down to reach desired temperature).
Heat Operation Blower Speed Adjust to desired speed.
Cold Lever Slide lever all the way down.
Mode Control Adjust to desired mode position (FLOOR position recommended).
Hot Lever For maximum heating, slide lever all the way down (Slide lever up or down to reach desired temperature).
Defrost/De-fog Operation Blower Speed Adjust to desired speed.
Cold Lever Slide lever all the way up to engage compressor.
Hot Lever Slide lever up or down to reach desired temperature.
Mode Control Adjust to DEFROST position for maximum defrost, or between FLOOR and DEFROST positions for a bi-level blend.
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904269 REV F 05/18/15, PG 16 OF 17
Packing List: Control Panel Kit (474269)
www.vintageair.com No. 1. 2. 3. 4. 5. 6. 7. 8.
Qty. 1 3 1 3 3 5 1 1
Description Placard Cable Converter Assembly Control Harness, Gen IV Universal Push-on Ring, 3/16” Clamp, Cable Converter Tie Wrap, 4” Ground Wire PC Board, Blower Switch
Part No. 484169-PCR 112002-SUA 232002-VUA 65976-VUE 491010-VUR 21301-VUP 231520 246108-PUA
Checked By: Packed By: Date:
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NOTE: Images may not depict actual parts and quantities. Refer to packing list for actual parts and quantities.
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904269 REV F 05/18/15, PG 17 OF 17
