Transcript
an ISO 9001:2008 Registered Company
1963-66 CORVETTE
WITH FACTORY AC 564163
904149 REV B 7/16/14, INST 63-66 CORVETTE EVAP w/ AC PG 1 OF 26
Table of Contents
PAGES 1. 2. 3. 4. 5. 6.
COVER TABLE OF CONTENTS PACKING LIST / PARTS DISCLAIMER INFORMATION PAGE WIRING NOTICE ENGINE COMPARTMENT FIGURE 1 7. CONDENSER ASSEMBLY, COMPRESSOR & BRACKET, PASSENGER COMPARTMENT FIGURES 2 & 2a 8. DEFROST DUCT INSTALLATION & FIREWALL MODIFICATION FIGURES 3, 3a & 4 9. FIREWALL MODIFICATION CONT. FIGURES 5 & 5a 10. KICK PANEL COVER INSTALLATION & EVAPORATOR INSTALLATION FIGURES 6, 6a, 6b & 7 11. BRACKET INSTALLATION FIGURE 8 12. EVAPORATOR INSTALLATION CONT. FIGURES 9 & 10 13. FIREWALL BLOWER COVER INSTALLATION & FIREWALL COVER INSTALLATION FIGURES 11, 11a, 12 & 12a 14. DRIVER & PASSENGER SIDE COURTESY LAMP INSTALLATION & LUBRICATING O-RINGS, A/C HOSE INSTALLATION & MODIFIED A/C HOSE KIT FIGURES 13, 13a & 14 15. HEATER HOSE & HEATER CONTROL VALVE INSTALLATION FIGURE 15 16. DRAIN HOSE INSTALLATION CENTER CONSOLE TRIM MODIFICATION FIGURE 16 & 17 17. PASSENGER SIDE UNDER DASH LOUVER INSTALLATION & DRIVER SIDE UNDER DASH LOUVER INSTALLATION FIGURES 18 & 19 18. DRIVER & PASSENGER SIDE CONSOLE PANEL INSTALLATION & FINAL STEPS FIGURES 20, 21, 21a & 21b 19. CONTROL PANEL & DUCT HOSE ROUTING FIGURE 22 20. WIRING DIAGRAM 21. GEN IV WIRING CONNECTION INSTRUCTIONS 22. OPERATION OF CONTROLS 23. TROUBLE SHOOTING INFORMATION 24. TROUBLE SHOOTING INFORMATION CONT. 25.POWER ANTENNA SWITCH INSTALLATION (65-66 VETTE ONLY) 26. EVAPORATOR KIT PACKING LIST
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EVAPORATOR KIT PACKING LIST No.
QTY.
1. 2.
1 1
PART No. 744010 784162
EVAPORATOR KIT 564163
DESCRIPTION 63-67 VETTE w/ AC EVAP SUB CASE ACC KIT 63-66 VETTE w/ AC
** 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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63-67 VETTE w/ AC EVAP SUB CASE 744010
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ACCESSORY KIT 784162
NOTE: IMA GES MA Y NOT DEPICT ACTUAL PARTS AND QUANTITIES. REFER TO PACKING LIST FOR ACTUAL PARTS AND QUANTITIES. 904149 REV B 7/16/14, INST 63-66 CORVETTE EVAP w/ AC PG 3 OF 26
Important Notice—Please Read For Maximum System Performance, Vintage Air Recommends the Following: 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.
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.
Safety Switches: 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.
Service Info:
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.
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.
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. Vintage Air Recommends Our Systems Be Charged By Weight With a Quality Charging Station or Scale. Refrigerant Capacity for Vintage Air Systems: (For other systems, consult manufacturer’s guidelines)
R134a System Charge 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). 904149 REV B 7/16/14, INST 63-66 CORVETTE EVAP w/ AC PG 4 OF 26
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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.
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• For proper system operation, the heater control valve must be connected to the ECU. 904149 REV B 7/16/14, INST 63-66 CORVETTE EVAP w/ AC PG 5 OF 26
ENGINE COMPARTMENT
BEFORE STARTING THE INSTALLATION, CHECK THE FUNCTION OF THE VEHICLE (HORN, LIGHTS,ETC.) FOR PROPER OPERATIONS. STUDY THE INSTRUCTIONS, ILLUSTRATIONS, & DIAGRAMS.
REMOVE THE FOLLOWING HOOD AND HOOD LATCH FOR EASE OF INSTALLATION DISCONNECT BATTERY AND REMOVE, IF MOUNTED ON PASSENGER SIDE. IF MOUNTED ON DRIVER SIDE, DISCONNECT (-) TERMINAL. DRAIN RADIATOR. EVACUATE THE A/C SYSTEM IF NECESSARY OEM A/C BLOWER MOTOR ASSEMBLY (UNDER HOOD) (DISCARD). OEM FRESH AIR ADAPTER ASSEMBLY (DISCARD) OEM CONDENSER AND DRIER (DISCARD) SEE FIGURE 1 OEM A/C LINES FROM COMPRESSOR TO EVAPORATOR (DISCARD). OEM COMPRESSOR AND BRACKET (DISCARD). OEM HEATER HOSES, A/C HOSES, AND HARDLINES (DISCARD). SEE FIGURE 1. REMOVE OEM RADIATOR EXPANSION TANK (RETAIN) (IF EQUIPPED).
HOOD LATCH OEM A/C BLOWER MOTOR ASSEMBLY
OEM FRESH AIR ADAPTER ASM
OEM HEATER HOSES
OEM RADIATOR EXPANSION TANK FIGURE 1
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CONDENSER ASSEMBLY & INSTALLATION REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH THE CONDENSER KIT TO INSTALL THE CONDENSER. BINARY SWITCH INSTALLATION (REFER TO CONDENSER INSTRUCTIONS)
COMPRESSOR & BRACKETS REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH THE BRACKET KIT TO INSTALL THE COMPRESSOR BRACKET.
PASSENGER COMPARTMENT
REMOVE THE FOLLOWING: GLOVE BOX, DOOR AND MOUNTING PANEL (DISCARD GLOVE BOX) (RETAIN HARDWARE). (SEE FIGURE 2) RIGHT AND LEFT SIDE CONSOLE PANELS. (DISCARD) (RETAIN SCREWS) DRIVER AND PASSENGER SIDE UNDER DASH LOUVER, MOUNTING BRACKETS AND ALL DUCTING (DISCARD) HEAT/ AIR DISTRIBUTION DUCTS.(DISCARD) OEM AC/ HEATER ASSEMBLY. (DISCARD) OEM DEFROST DUCT. (DISCARD) (RETAIN NUTS) REMOVE OEM CENTER LOUVER ASSEMBLY WITH CONTROL, BEZEL (RETAIN) SEE FIGURE 2a. (REFER TO CONTROL PANEL INSTRUCTIONS FOR INSTALLATION) DISCONNECT ALL WIRES AND CABLE FROM CONTROL PANEL (DISCARD). REMOVE RADIO AND CLOCK (RETAIN) PASSENGER SIDE KICK PANEL (RETAIN) REMOVE OEM PASSENGER SIDE FRESH AIR CABLE AND KICK PANEL ASSEMBLY(DISCARD) LOOSEN OEM DRIVER SIDE FRESH AIR CABLE ASSEMBLY FROM DASH, FOR LATER INSTALLATION. REMOVE OEM CENTER CONSOLE FLOOR TRIM (RETAIN) (63 MODELS ONLY) CLOCK REMOVE CENTER FLOOR CONSOLE (RETAIN). CONTROL
PANEL
FIGURE 2a
CENTER CONSOLE FLOOR TRIM
RADIO DRIVER SIDE UNDER DASH LOUVER & BRACKETS OEM DRIVER SIDE FRESH AIR CABLE ASSEMBLY
OEM AC/ HEATER ASSEMBLY
PASSENGER SIDE UNDER DASH LOUVER
LEFT & RIGHT CONSOLE PANELS FIGURE 2
DEFROST DUCT HEAT/ AIR DISTRIBUTION DUCT MOUNTING
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PANEL
GLOVE BOX GLOVE BOX DOOR
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DEFROST DUCT INSTALLATION INSTALL DEFROST DUCT UNDER DASH AS SHOWN IN FIGURE 3 BELOW. SECURE USING OEM NUTS. NOTE: DEFROST DUCT MOUNTING HOLES TOWARDS FIREWALL AS SHOWN BELOW IN FIGURE 3a.
DEFROST DUCT MOUNTING HOLES
TOP VIEW DEFROST DUCT
FIGURE 3a
OEM DEFROST DUCT OPENING
(2) OEM NUTS DEFROST DUCT 491634 FIGURE 3
FIREWALL MODIFICATION REMOVE OEM STUD ON FIREWALL BY DRILLING OUT RIVETS. (SEE FIGURE 4 BELOW) INSTALL U-NUT 1/4-20 x 27/32” ON FIREWALL AS SHOWN BELOW.
U-NUT 1/4-20 x 27/32” 189780 DRILL OUT RIVETS FIGURE 4
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FIREWALL MODIFICATION CONT. PLACE FIREWALL COVER ON FIREWALL AND SECURE USING 1/4-20 x 3/4” BOLT AS SHOWN BELOW. USING FIREWALL COVER AS TEMPLATE, MARK THE HOLE ON FIREWALL AS SHOWN BELOW. REMOVE FIREWALL COVER. PLACE BLOWER COVER ON FIREWALL AND MARK THE HOLE AS SHOWN BELOW. REMOVE BLOWER COVER. DRILL HOLES AS SHOWN BELOW IN FIGURE 5a.
MARK HOLE
MARK HOLE
1/4-20 x 3/4” BOLT FIGURE 5
DRILL 3/8” HOLE
DRILL 3/16” HOLE FIGURE 5a
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KICK PANEL COVER INSTALLATION INSTALL (4) GROMMETS IN KICK PANEL COVER, SEE FIGURE 6b BELOW. ROUTE A/C AND HEATER HOSE THROUGH FIREWALL BLOWER COVER AND KICK PANEL COVER AS SHOWN IN FIGURE 6 AND 6b, BELOW. APPLY A 1/4” BEAD OF SILICONE AROUND THE BACK SIDE OF KICK PANEL COVER AS SHOWN IN FIGURE 6a, BELOW. SECURE KICK PANEL COVER USING OEM SCREW, OEM NUT AND (2) #10 x 1” PAN HEAD SCREWS, AS SHOWN IN FIGURE 6c. BACK SIDE OF NOTE: NEED TO MATCH DRILL THE (2) CENTER HOLES 1/8” KICK PANEL DIAMETER. FRESH AIR COVER REINSTALL KICK PANEL. (4) GROMMETS OEM 33137-VUI NUT #6 A/C #6 A/C HOSE HOSE
(4) GROMMETS 33137-VUI
FIGURE 6a
#10 A/C HOSE
UPPER HEATER HOSE
#10 A/C HOSE
SILICONE
UPPER HEATER HOSE LOWER HEATER HOSE
FIREWALL FIGURE 6 BLOWER COVER 644028
(2) #10 x 1” PAN HEAD OEM LOWER SCREWS SCREW HEATER NOTE: NEED TO MATCH 18244-VUB HOSE DRILL THE 2 CENTER FIGURE 6b HOLES 1/8” DIAMETER
EVAPORATOR INSTALLATION
ON A WORK BENCH INSTALL (2) HEATER FITTINGS WITH PROPERLY LUBRICATED O-RINGS. (SEE FIGURE 14, PAGE 14, AND FIGURE 8, PAGE 11.) FOR HEATER HOSE ROUTING SEE PAGE 12, 14 AND PAGE 15. PS FRONT INSTALL EVAPORATOR REAR MOUNTING BRACKET ON EVAPORATOR USING EVAPORATOR (2)1/4-20 x 1/2 HEX BOLTS AS SHOWN IN FIGURE 8, PAGE 11. BRACKET LAY EVAPORATOR SUBCASE ON PASSENGER SIDE FLOOR 644045 BOARD. WHEN INSTALLING EVAPORATOR, IT MAY BE NECESSARY TO PULL BACK CARPET FROM FIREWALL AS SHOWN BELOW. AFTER EVAPORATOR IS INSTALLED PUSH CARPET BACK IN PLACE. THIS WILL BE A VERY CLOSE FIT. TAKE CARE NOT TO DAMAGE STEPPER MOTORS DURING (2)1/4-20 x 1/2” INSTALLATION. HEX BOLT DR FRONT EVAPORATOR BRACKET FIGURE 7 644044
PULL BACK CARPET
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BRACKET INSTALLATION
(2) HEATER FITTINGS
REAR EVAPORATOR BRACKET 644040
FIGURE 8
11
(2) 1/4-20 x 1/2” HEX BOLTS 904149 REV B 7/16/14, INST 63-66 CORVETTE EVAP w/ AC PG 11 OF 26
EVAPORATOR INSTALLATION CONT. LIFT EVAPORATOR UNIT UP UNDER THE DASHBOARD. SECURE TO THE FIREWALL FROM THE ENGINE COMPARTMENT SIDE USING (2) 1/4-20 x 1¼” BOLTS AND (2) 1/4” FLAT WASHERS, SEE FIGURE 10 BELOW. INSTALL EVAPORATOR DRIVER/ PASSENGER FRONT MOUNTING BRACKETS ON EVAPORATOR USING (2) 1/4-20 x 1/2“ HEX BOLTS AS SHOWN IN FIGURE 7, PAGE 10. SECURE PASSENGER SIDE FRONT MOUNTING BRACKET TO PASSENGER SIDE DASH BRACE USING #14 x 3/4” HEX SHEET METAL SCREW IN OEM HOLE. NOTE: ON SOME MODELS IT MAY BE NECESSARY TO DRILL 3/16” HOLE. USE DIMENSION IN FIGURE 10 BELOW. DRILL 3/16“ HOLE IN PASSENGER SIDE DASH BRACE USING DRIVER SIDE FRONT MOUNTING BRACKET AS TEMPLATE. (SEE FIGURE 10 BELOW). SECURE DRIVER SIDE FRONT MOUNTING BRACKET TO PASSENGER SIDE DASH BRACE USING #14 x 3/4” HEX SHEET METAL SCREW. (SEE FIGURE 10 BELOW.) VERIFY THAT EVAPORATOR UNIT IS LEVEL AND SQUARE TO THE DASH, THEN TIGHTEN ALL MOUNTING BOLTS. (NOTE: TIGHTEN THE BOLTS ON FIREWALL FIRST, THEN THE FRONT MOUNTING BRACKETS.) CONNECT #10 AC HOSE TO EVAPORATOR AS SHOWN IN FIGURE 10. (NOTE: WRAP THE #10 FITTING CONNECTION NOTE: HEATER HOSE MODIFICATION WITH PRESS TAPE. SEE FIGURE 10.) REFER TO FIGURE 9 CONNECT #6 AND 2 HEATER HOSES 45” FROM OUTSIDE OF FIREWALL 5/8” 3/4” OPENING. (SEE FIGURE 9.)
#6 A/C HOSE
NOTE: THIS HEATER HOSE TO RADIATOR EXPANSION TANK (IF EQUIPPED) OR WATER PUMP
FIGURE 9
HEATER HOSE (2) 1/4” FLAT WASHERS
KICK PANEL COVER
THIS END TO THIS END TO EVAPORATOR RADIATOR TOP FITTING EXPANSION TANK (IF EQUIPPED) OR WATER PUMP OPTION 1 GATES 18084 3/4” TO 5/8“ x 60” HEATER HOSE NOTE: CUT TO LENGTH OPTION 2 3/4” x 5/8” REDUCER FITTING REQUIRED (NOT SUPPLIED)
#10 A/C HOSE PRESS TAPE
(2) 1/4-20 x 1¼” BOLT
PASSENGER SIDE DASH BRACE 7 ¾”
OEM HOLE (2) #14 x 3/4” DRILL SHEET METAL SCREWS 3/16” HOLE FIGURE 10 904149 REV B 7/16/14, INST 63-66 CORVETTE EVAP w/ AC PG 12 OF 26
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FIREWALL BLOWER COVER INSTALLATION APPLY A 1/4” BEAD OF SILICONE AROUND THE BACK SIDE OF THE FIREWALL BLOWER COVER AS SHOWN IN FIGURE 11a BELOW. ATTACH FIREWALL BLOWER COVER TO FIREWALL USING (4) 1/4“ NUTS w/ STAR WASHERS, (5) FLAT WASHERS AND #14 x 3/4” SHEET METAL SCREW. SEE FIGURE 11 BELOW. FIREWALL BLOWER (4) 1/4” NUTS w/ STAR WASHERS COVER 644028 SILICONE #6 A/C HOSE
FIGURE 11a
UPPER HEATER HOSE
#10 A/C HOSE
LOWER HEATER HOSE
(5) 1/4” FLAT WASHERS
FIREWALL COVER INSTALLATION
#14 x 3/4” SHEET METAL SCREW
FIGURE 11
SUPPORT BOTTOM OF EVAP, REMOVE (2) 1/4-20 x 1¼” BOLTS THRU FIREWALL/ EVAP BRKT. APPLY A 1/4” BEAD OF SILICONE AROUND THE BACK SIDE OF THE FIREWALL COVER AS SHOWN IN FIGURE 12a BELOW. ATTACH FIREWALL COVER TO FIREWALL USING (2) 1/4-20 x 3/4” BOLTS, (2) 1/4-20 x 1¼” BOLTS (6) 1/4” FLAT WASHERS AND (2) 1/4” NUTS w/ STAR WASHERS. SEE FIGURE 12 BELOW. INSTALL 3/8” GROMMET IN FIREWALL COVER AS SHOWN BELOW. FIREWALL COVER (2) 1/4” NUTS w/ 644029 STAR WASHERS SILICONE
FIGURE 12a
GROMMET 33144-VUI
(2) 1/4-20 x 1¼” BOLTS (2) 1/4-20 x 3/4” BOLTS
13
(6) 1/4” FLAT WASHERS
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FIGURE 12
DRIVER & PASSENGER SIDE COURTESY LAMP INSTALLATION USING OEM HOLE, SECURE DRIVER SIDE COURTESY LAMP BRACKET UNDER DASH USING #10 x 1/2” SHEET METAL SCREW AS SHOWN BELOW IN FIGURE 13. OEM INSTALL OEM COURTESY LAMP IN BRACKET AS SHOWN BELOW. COURTESY USING OEM HOLE, SECURE PASSENGER SIDE COURTESY LAMP BRACKET LAMP UNDER DASH USING #10 x 1/2” SHEET METAL SCREW AS SHOWN BELOW IN FIGURE 13a. INSTALL OEM COURTESY LAMP IN BRACKET AS SHOWN BELOW. OEM #10 x 1/2” OEM HOLE SHEET METAL COURTESY #10 x 1/2” SCREW LAMP SHEET METAL OEM SCREW HOLE COURTESY LAMP BRACKET 644030 COURTESY LAMP BRACKET 644030
FIGURE 13
LUBRICATING O-RINGS O-RING
MALE INSERT
FEMALE NUT
FIGURE 13a FOR A PROPER SEAL OF FITTINGS: INSTALL SUPPLIED O-RINGS AS SHOWN AND LUBRICATE WITH SUPPLIED OIL.
O -RING
#6 O-RING SUPPLIED OIL FOR O -RINGS
# 8 O -RING
#10 O -RING
FIGURE 14
A/C HOSE INSTALLATION
O -RING,I NSTALLS OVER M ALE INSERT TO SWAGED LI P
TWIST WITH THIS WREN CH HOLD WITH THIS W RE NC H
STANDARD HOSE KIT LOCATE THE #8 COMPRESSOR A/C HOSE. LUBRICATE (2) #8 O-RINGS (SEE FIGURE 14, ABOVE) AND CONNECT THE 135° FEMALE FITTING TO THE #8 DISCHARGE PORT ON THE COMPRESSOR. ROUTE THE STRAIGHT FEMALE FITTING w/ 134a SERVICE PORT TO THE #8 CONDENSER HARDLINE COMING OVER CORE SUPPORT. SEE FIGURE 15 PAGE 15. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN FIGURE 14 ABOVE. LOCATE THE #10 COMPRESSOR A/C HOSE. LUBRICATE (2) #10 O-RINGS (SEE FIGURE 14, ABOVE) AND CONNECT THE #10 STRAIGHT FEMALE FITTING w/134a SERVICE PORT TO THE #10 SUCTION PORT ON THE COMPRESSOR. ROUTE THE 90° FEMALE FITTING TO THE #10 EVAPORATOR. SEE FIGURE 10, PAGE 12 AND FIGURE 15, PAGE 15. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN 14 ABOVE. LOCATE THE #6 EVAPORATOR A/C HOSE. LUBRICATE (2) #6 O-RINGS (SEE FIGURE 14, ABOVE) AND CONNECT THE 90° FEMALE FITTING TO THE DRIER HARDLINE. ROUTE THE 90° FEMALE FITTING TO THE #6 EVAPORATOR. SEE FIGURE 9, PAGE 12 AND FIGURE 15, PAGE 15. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN FIGURE 14, ABOVE.
MODIFIED A/C HOSE KIT REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH MODIFIED HOSE KIT. 904149 REV B 7/16/14, INST 63-66 CORVETTE EVAP w/ AC PG 14 OF 26
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HEATER HOSE & HEATER CONTROL VALVE INSTALLATION
FROM HEATER CONTROL VALVE TO EVAPORATOR
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FIGURE 15
#6 DRIER/ CORE SUPPORT HARD LINE 63-65 VETTE 091079 66-67 VETTE 091081
#6 DRIER/ CONDENSER HARD LINE COMPRESSOR SAFETY SWITCH 35130-VCG (BINARY TYPE) SCREW ON DRIER (REFER TO CONDENSER INSTRUCTIONS) HOSE CLAMPS
FRO M MA INT NIF AKE OL D
#2 ADEL CLAMP 31600-VUD
#8 DISCHARGE HOSE #10 ADEL 096049
CLAMP 31601-VUD
OUT
IN
#8 CONDENSER/ COMP HARD LINE 63-65 VETTE 091180 66-67 VETTE 091082 #6 AC HOSE 096048
15
FRO M TO EVAP WA O TER RATO PUM R P HEATER HOSE
HEATER HOSE (HEATER CNTRL VALVE/ INTAKE) #10 SUCTION HOSE 096050
NOTE: VINTAGE AIR SYSTEM REQUIRES 5/8” HOSE NIPPLE (NOT SUPPLIED)
HEATER HOSE (HEATER CORE/ RADIATOR EXPANSION TANK) (IF EQUIPPED) OR WATER PUMP
A/C & HEATER HOSE ROUTING
ROUTE A HEATER HOSE FROM THE RADIATOR EXPANSION TANK (IF EQUIPPED) OR WATER PUMP TO THE TOP HEATER FITTING OF HEATER CORE AS SHOWN IN FIGURE 9, PAGE 12 AND FIGURE 15 BELOW. SECURE USING HOSE CLAMPS. NOTE: OEM RADIATOR EXPANSION TANK OUTLET IS 3/4”. (OPTION 1) USE GATES HEATER HOSE PART # 18084 3/4” x 5/8” x 60” (REFER TO PAGE 12) FOR HEATER HOSE MODIFICATION. (OPTION 2) 3/4” x 5/8” REDUCER FITTING IS REQUIRED (NOT SUPPLIED) ROUTE A HEATER HOSE FROM THE INTAKE TO THE BOTTOM HEATER FITTING OF HEATER CORE AS SHOWN IN FIGURE 9, PAGE 12 AND FIGURE 15, BELOW. INSTALL HEATER CONTROL VALVE IN-LINE WITH INTAKE MANIFOLD (PRESSURE SIDE) HEATER HOSE, SECURE USING HOSE CLAMPS AS SHOWN IN FIGURE 15, BELOW. NOTE PROPER FLOW DIRECTION.
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. SEE FIGURE 16 BELOW. INSTALL DRAIN HOSE TO BOTTOM OF EVAPORATOR UNIT AND ROUTE THROUGH FIREWALL. INSTALL 1/2” 90° DRAIN ELBOW ON DRAIN HOSE SEE FIGURE 16.
1”
DRAIN HOSE
EVAPORATOR CASE
1”
FIGURE 16
CENTER CONSOLE TRIM MODIFICATION REMOVE THE CENTER CONSOLE FLOOR TRIM AND PASSENGER SIDE CENTER CONSOLE FLOOR PLATE. CUT & REMOVE 6” FROM CENTER CONSOLE FLOOR TRIM AS SHOWN BELOW IN FIGURE 17. CUT & REMOVE 2” FROM CENTER CONSOLE FLOOR PLATE AS SHOWN BELOW. REINSTALL CENTER CONSOLE FLOOR PLATE AND FLOOR TRIM. CENTER CONSOLE FLOOR TRIM CUT & REMOVE
6”
FIGURE 17
CENTER PASSENGER SIDE CONSOLE CENTER CONSOLE FLOOR TRIM FLOOR PLATE CUT & REMOVE (63 MODELS ONLY)
PASSENGER SIDE CENTER CONSOLE FLOOR PLATE
2”
INSTALL CONTROL SWITCHES AND WIRING. (SEE CONTROL PANEL INSTRUCTIONS)
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PASSENGER SIDE UNDER DASH LOUVER INSTALLATION ALIGN PASSENGER SIDE UNDER DASH LOUVER TO DASH BRACE USING PASSENGER SIDE FRONT EVAP BRACKET AND #14 x 3/4” SHEET METAL SCREW, DRILL (2) 1/8“ HOLES IN DASH BRACE AND SECURE USING (2) #10 x 1/2” SHEET METAL SCREW AS SHOWN BELOW IN FIGURE 18. INSTALL (2) 1/2” PLASTIC PLUGS IN LOUVER ASM. PASSENGER SIDE #14 x 3/4” FRONT EVAP SHEET METAL BRACKET SCREW DASH BRACE DRILL 1/8” HOLE
DRILL 1/8” HOLE
(2) #10 x 1/2” SHEET METAL SCREW
PASSENGER SIDE LOUVER ASM 491631
(2) 1/2” PLASTIC PLUG
FIGURE 18
DRIVER SIDE UNDER DASH LOUVER INSTALLATION LOOSEN THE (2) OEM NUTS FROM STEERING COLUMN BRACKET. DROP STEERING COLUMN FROM DASH BRACE. SLIDE BRACKET BETWEEN DASH BRACE AND STEERING COLUMN BRACKET. ADJUST AND SECURE LOUVER HOUSING TO UNDER DASH STEERING COLUMN BRACKET USING OEM NUTS AS SHOWN IN FIGURE 19 BELOW. STEERING COLUMN
STEERING COLUMN BRACKET
DASH BRACE
DASH BRACE
(2) OEM NUTS DRIVER SIDE LOUVER BRACKET
(2) OEM NUTS FIGURE 19 DRIVER SIDE LOUVER ASM 491637
17 904149 REV B 7/16/14, INST 63-66 CORVETTE EVAP w/ AC PG 17 OF 26
DRIVER & PASSENGER SIDE CONSOLE PANEL INSTALLATION INSTALL POWER ANTENNA SWITCH (65 AND 66 VETTE ONLY). REFER TO PAGE 25. INSTALL CONTROL SWITCHES AND WIRING. (SEE CONTROL PANEL INSTRUCTIONS) INSTALL DRIVER AND PASSENGER SIDE CONSOLE PANELS USING OEM SCREWS AS SHOWN BELOW IN FIGURE 20. NOTE: LOWER MOUNTING HOLE MUST BE DRILLED IN OEM CONSOLE TO MOUNT NEW CONSOLE. USE DRIVER/ PASSENGER CONSOLE PANEL AS GUIDE TO DRILL 3/16” HOLE IN CONSOLE. OEM RELOCATE OEM J NUT AND ATTACH AS SHOWN. OEM HOLE OEM SCREWS OEM HOLE SCREWS DRILL OEM DRILL 3/16” CONSOLE 3/16” OEM HOLE
DR SIDE CONSOLE PANEL 623204
OEM HOLE
FIGURE 20
PASS SIDE CONSOLE PANEL 623206
FINAL STEPS INSTALL DUCT HOSES AS SHOWN IN FIGURE 22, PAGE 19. ROUTE A/C WIRES THROUGH 3/8” GROMMET AS SHOWN IN FIGURE 21a BELOW (12 VOLT/ GROUND/ BINARY SWITCH/ HEATER VALVE). PLUG THE WIRING HARNESS IN THE ECU MODULE ON SUB CASE AS SHOWN IN FIGURE 22, PAGE 19 (WIRE ACCORDING TO WIRING DIAGRAM ON PAGE 20 AND 21.) INSTALL (9) U-NUTS #8 IN GLOVE BOX AS SHOWN IN FIGURE 21b. INSTALL NEW GLOVE BOX USING OEM SCREWS. REINSTALL CENTER FLOOR CONSOLE. REINSTALL KICK PANEL REINSTALL OEM DRIVER SIDE FRESH AIR CABLE ASSEMBLY TO DASH. SEE FIGURE 21 BELOW. REINSTALL ALL PREVIOUSLY REMOVED ITEMS. FILL RADIATOR WITH AT LEAST A 50/50 MIXTURE OF APPROVED ANTIFREEZE AND DISTILLED WATER. IT IS THE OWNER'S RESPONSIBILITY TO KEEP THE FREEZE PROTECTION AT THE PROPER LEVEL FOR THE CLIMATE IN WHICH THE VEHICLE IS OPERATED. FAILURE TO FOLLOW ANTIFREEZE RECOMMENDATIONS WILL CAUSE HEATER CORE TO CORRODE PREMATURELY AND POSSIBLY BURST IN 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 AIR CONDITIONING TECHNICIAN. EVACUATE THE SYSTEM FOR A MINIMUM OF 45 MINUTES PRIOR TO CHARGING AND LEAK CHECK PRIOR TO SERVICING. CHARGE THE SYSTEM TO THE CAPACITIES STATED ON THE INFORMATION PAGE (PAGE 4) OF THIS INSTRUCTION MANUAL. SEE OPERATION OF CONTROLS PROCEDURES ON PAGE 22. 3/8” GROMMET 33144-VUI
OEM DRIVER SIDE FRESH AIR CABLE ASSEMBLY FIGURE 21
FIGURE 21b FIGURE 21a
904149 REV B 7/16/14, INST 63-66 CORVETTE EVAP w/ AC PG 18 OF 26
(9) U-NUTS #8 189801
18
CO
ND P
-IN-H OL
T O
CO
UL L
AIR
CONTROL PANEL & DUCT HOSE ROUTING
11
12
1 2
10
3
9 8
4 7
5
6
DEF
AI
NING TU
T NE O
VO
L
N L
STER P RO
UL
ULL-F A RP
108 104 100
PLUG FROM CONTROL WIRING HARNESS 232002-VUA
96 92 88
DEFROST DUCT DR. SIDE 3” x 12”
DRIVER SIDE CENTER LOUVER 2” x 18”
PLUG FROM WIRING HARNESS 232001-VUR
DRIVER SIDE UNDER DASH LOUVER 2 ½” x 13”
FIGURE 22
PASSENGER SIDE UNDER DASH LOUVER 2 ½” x 16”
PASS. SIDE CENTER LOUVER 2” x 24”
19 904149 REV B 7/16/14, INST 63-66 CORVETTE EVAP w/ AC PG 19 OF 26
Wiring Diagram 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. 904149 REV B 7/16/14, INST 63-66 CORVETTE EVAP w/ AC PG 20 OF 26
20
Gen IV Wiring Connection Instruction
WIRING HARNESS CONTROL WIRING HARNESS RED & WHITE A/C COMPRESSOR RELAY
RED BLUE
NOTE: MOUNT RELAY IN DESIRED LOCATION UNDER DASH
RED WH IT
E
Ignition Switch:
VIOLET
Violet 12V Ign Switch Source (Key On Accessory) Position Must Be Switched.
+12V
NOTE: WIRING YELLOW & ORANGE (IGNITION HOT HARNESS COMING FROM TERMINAL) HARNESS ARE NOT USED. YELLOW
RUN
BAT
IGNITION SWITCH
ORANGE TAN
DASH BACK LIGHT+0-12v
GRAY
GRAY WIRE IS USED FOR PROGRAMING CONTROLS IF APPLICABLE
RED GREEN
RED GREEN
FIREWALL
BLACK BLUE
Heater Control Valve:
RED
LATCH
WIRING HARNESS
WHITE CHASSIS GROUND
NOTE: HEATER CONTROL VALVE CONNECTION AND CHASSIS GROUND MAY BE LOCATED ON EITHER SIDE OF THE FIREWALL. ENSURE CONNECTOR IS LATCHED FIRMLY.
HEATER CONTROL VALVE
K BLAC
BLUE
COMPRESSOR
WHITE NOTE: CONNECT WHITE WIRES DIRECTLY TO (-) BATTERY TERMINAL
WHITE RED RED CIRCUIT BREAKER 30 AMP
RED
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).
21
Install With Servo Motor Facing Down, As Shown. Note Flow Direction Arrow Molded Into Valve Body, And Install Accordingly.
Binary/Trinary & Compressor: Binary: Connect As Shown (Typical Compressor Wiring). Be Sure Compressor Body Is Grounded.
BINARY SAFETY SWITCH
BLUE
Dash Light: Tan Wire Used Only With Vintage Air Supplied Control Panel With LED Back Light.
+
-
Trinary Switch: Connect According To Trinary Switch Wiring Diagram.
Circuit Breaker/Battery: White Must Run To (-) Battery. Red May Run To (+) Battery Or Starter. Mount Circuit Breaker As Close to Battery As Possible.
BATTERY
904149 REV B 7/16/14, INST 63-66 CORVETTE EVAP w/ AC PG 21 OF 26
OPERATION OF CONTROLS
AIR
VO
CO
CO
DEF
AI
3
NE
VO
NING TU
T
BLOWER SPEED ROTATE KNOB RIGHT TO DESIRED BLOWER SPEED FROM OFF TO HI. MODE KNOB ROTATE THE KNOB TO THE RIGHT TO DIRECT AIR FLOW TO THE DEFROST VENTS.
904149 REV B 7/16/14, INST 63-66 CORVETTE EVAP w/ AC PG 22 OF 26
S T ER P RO
O
NE
L
5 L
N
AI
ULL-F A
6
DEF
DEF
RP
7
UL
AI
T O
S T ER P RO
O
VO
NE
AIR
L UL
O
L
2 4
8
5
BLOWER SPEED TEMPERATURE KNOB ROTATE THE TEMPERATURE ROTATE KNOB RIGHT KNOB ALL THE WAY LEFT TO DESIRED BLOWER TO THE HOT POSITION. SPEED FROM OFF TO HI. (ROTATE KNOB LEFT MODE KNOB OR RIGHT TO ADJUST ROTATE THE KNOB DESIRED TEMPERATURE) TO THE CENTER TO DIRECT AIR FLOW TO THE FLOOR.
-IN-H OL
1
9
NING TU
T
12
10
L
N L
MODE KNOB
STER P RO
NING TU
T
L
11
UL
ULL-F A RP
6
5
N
ND P CO
4 7
6
DEFROST/ DE-FOG MODE
3 8
7
ULL-F A RP
2
9
3 4
8
1
10
2
9
UL
L
12
CO
L
T O
UL
11
-IN-H OL
1
10
HEAT MODE ND P CO
12
11
TEMPERATURE KNOB BLOWER SPEED ROTATE THE TEMPERATURE THIS KNOB CONTROLS KNOB ALL THE WAY RIGHT THE BLOWER SPEED, TO THE COLD POSITION BLOWER FROM OFF TO HI TO ENGAGE COMPRESSOR. SPEED MODE KNOB (ROTATE KNOB LEFT OR ROTATE THE KNOB TO RIGHT TO ADJUST THE LEFT TO DIRECT AIR DESIRED TEMPERATURE) FLOW TO THE DASH VENTS TEMPERATURE KNOB -IN-H OL
ND P
T O
CO
UL
AIR
ON GEN 4 SYSTEMS WITH THREE LEVER/KNOB CONTROLS, THE TEMPERATURE CONTROL TOGGLES BETWEEN ECONOMY AND A/C MODES. 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 MODE, 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 MODES TO INDICATE THE CHANGE. NOT A/C MODE NOT ALL SWITCHES ARE VARIABLE BETWEEN POSITIONS, USED USED SYSTEM WILL PERFORM A BLEND BETWEEN THE FUNCTIONS.
TEMPERATURE KNOB ROTATE KNOB LEFT OR RIGHT TO ADJUST DESIRED TEMPERATURE. (COMPRESSOR IS AUTOMATICALLY ENGAGED)
22
Symptom
904149 REV B 7/16/14, INST 63-66 CORVETTE EVAP w/ AC PG 23 OF 26
Compressor will not turn off (All other functions work).
3.
Compressor will not turn on (All other functions work).
2.
Blower stays on high speed when ignition is on or off.
1b.
Blower stays on high speed when ignition is on.
1a.
23
System is charged.
System is not charged.
All other functions work.
No other functions work.
Condition
Repair or replace pot/control wiring.
Replace relay. Check for faulty A/C relay.
Check 2-pin connector at ECU housing.
Check continuity to ground on white control head wire. Check for 5V on red control head wire.
Charge system or bypass pressure switch.
Replace BSC (This will require removal of evaporator from vehicle).
Check to ensure that no BSC wiring is damaged or shorted to vehicle ground. The BSC operates the blower by ground side pulse width modulation switching. The positive wire to the blower will always be hot. If the “ground” side of the blower is shorted to chassis ground, the blower will run on HI.
Be sure the small, 20 GA white ground wire is connected to the battery ground post. If it is, replace the ECU.
Verify continuity to chassis ground with white control head wire at various points.
Verify that all pins are inserted into plug. Ensure that no pins are bent or damaged in ECU.
Actions
Check for faulty A/C potentiometer or associated wiring.
Check for disconnected or faulty thermistor.
Check for faulty A/C potentiometer or associated wiring (Not applicable to 3-pot controls).
System must be charged for compressor to engage.
Unplug 3-wire BSC control connector from ECU. If blower stays running, BSC is either improperly wired or damaged.
Unplug 3-wire BSC control connector from ECU. If blower shuts off, ECU is either improperly wired or damaged.
Check for damaged ground wire (white) in control head harness. Check for damaged blower switch or potentiometer and associated wiring.
Check for damaged pins or wires in control head plug.
Checks
Red wire at A/C pot should have approximately 5V with ignition on. White wire will have continuity to chassis ground. White/ Blue wire should vary between 0V and 5V when lever is moved up or down.
Disconnected or faulty thermistor will cause compressor to be disabled.
To check for proper pot function, check voltage at white/blue wire. Voltage should be between 0V and 5V, and will vary with pot lever position.
Danger: Never bypass safety switch with engine running. Serious injury can result.
No other part replacements should be necessary.
See blower switch check procedure.
Loss of ground on this wire renders control head inoperable.
Notes
Troubleshooting Guide
904149 REV B 7/16/14, INST 63-66 CORVETTE EVAP w/ AC PG 24 OF 26
Symptom
8. When ignition is turned on, blower momentarily comes on, then shuts off. This occurs with the blower switch in the OFF position.
Erratic functions of blower, mode, temp, etc.
7.
Blower turns on and off rapidly.
6.
Loss of mode door function.
5.
System will not turn on, or runs intermittently.
4.
24
This is an indicator that the system has been reset. Be sure the red power wire is on the battery post, and not on a switched source. Also, if the system is pulled below 7V for even a split second, the system will reset.
Run red power wire directly to battery.
Repair or replace.
Charge battery.
Check for faulty battery or alternator.
Battery voltage is less than 12V.
Check for damaged switch or pot and associated wiring.
Ensure all system grounds and power connections are clean and tight.
Verify proper meter function by checking the condition of a known good battery.
Check for positive power at heater valve green wire and blower red wire. Check for ground on control head white wire.
Install capacitors on ignition coil and alternator. Ensure good ground at all points. Relocate coil and associated wiring away from ECU and ECU wiring. Check for burned or loose plug wires.
Actions
Check for at least 12V at circuit breaker.
Check for damaged stepper motor or wiring.
Check for obstructed or binding mode doors.
Check for damaged mode switch or potentiometer and associated wiring.
Verify battery voltage is greater than 10 volts and less than 16.
Verify connections on power lead, ignition lead, and both white ground wires.
Noise interference from either ignition or alternator.
Checks
Battery voltage is at least 12V.
Partial function of mode doors.
No mode change at all.
Will not turn on under any conditions.
Works when engine is not running; shuts off when engine is started (Typically early Gen IV, but possible on all versions).
Condition
System shuts off blower at 10V. Poor connections or weak battery can cause shutdown at up to 11V.
Typically caused by evaporator housing installed in a bind in the vehicle. Be sure all mounting locations line up and don’t have to be forced into position.
Ignition noise (radiated or conducted) will cause the system to shut down due to high voltage spikes. If this is suspected, check with a quality oscilloscope. Spikes greater than 16V will shut down the ECU. Install a radio capacitor at the positive post of the ignition coil (See radio capacitor installation bulletin). A faulty alternator or worn out battery can also result in this condition.
Notes
Troubleshooting Guide (Cont.)
POWER ANTENNA SWITCH INSTALLATION (65-66 VETTE ONLY) USING TEMPLATE PROVIDED BELOW MARK, DRILL AND CUT HOLES. INSTALL POWER ANTENNA SWITCH USING (2) OEM SCREWS AND (2) OEM NUTS AS SHOWN BELOW.
MARK & CUT
MARK & DRILL
(2) OEM SCREWS
65-66 VETTE POWER ANTENNA SWITCH TEMPLATE
25 904149 REV B 7/16/14, INST 63-66 CORVETTE EVAP w/ AC PG 25 OF 26
(2) OEM NUTS
EVAPORATOR KIT PACKING LIST No.
QTY.
1. 2.
1 1
PART No. 744010 784162
EVAPORATOR KIT 564163
DESCRIPTION 63-67 VETTE w/ AC EVAP SUB CASE ACC KIT 63-66 VETTE w/ AC CHECK BY: PACKED BY: DATE:
1
63-67 VETTE w/ AC EVAP SUB CASE 744010
2
ACCESSORY KIT 784162
NOTE: IMA GES MA Y NOT DEPICT ACTUAL PARTS AND QUANTITIES. REFER TO PACKING LIST FOR ACTUAL PARTS AND QUANTITIES. 904149 REV B 7/16/14, INST 63-66 CORVETTE EVAP w/ AC PG 26 OF 26
