1957 chevy - vintage air · 1957 chevy without factory air with 4-vent plenum 561058 an iso...

1957 CHEVYWITHOUT FACTORY AIRWITH 4-VENT PLENUM

561058

an ISO 9001:2008 Registered Company

901258 REV D 6/30/16 1957 CHEVY w/o AC w/4 VENT PLENUM GEN IV INST PG 1 OF 25


PAGES

1. 2. 3. 4. 5. 6. 7. 8. 9.

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19. 20. 21.22.23.24.25.

COVERTABLE OF CONTENTSPACKING LIST/PARTS DISCLAIMERINFORMATION PAGEWIRING NOTICEENGINE COMPARTMENT FIGURE 1PASSENGER COMPARTMENT FIGURE 2ENGINE COMPARTMENT & DEFROST DUCT INSTALLATION FIGURE 3EVAPORATOR INSTALLATION FIGURES 4 & 5EVAPORATOR INSTALLATION CONT. FIGURES 6 & 7DUCT HOSE ROUTING - CONTROL WIRING FIGURE 8CENTER VENT INSTALLATION & PASSENGER & DRIVER SIDE UNDER DASH LOUVER INSTALLATION FIGURES 9 & 10HARDLINE INSTALLATIONO-RING LUBRICATING/FITTING TIGHTENING, FIGURES 11 & 12HEATER CONTROL VALVE INSTALLATION, FIGURE 13A/C HOSE AND HARDLINE ROUTING FIGURES 14-14bFIREWALL COVER INSTALLATION/FRESH AIR CAP FIGURE 15FINAL STEPS/GLOVE BOX INSTALLATION PHOTO 1 AND FIGURE 16EVAPORATOR HARDLINE INSTALLATION FIGURE 17WIRING DIAGRAMGEN IV WIRING CONNECTION INSTRUCTIONSOPERATION OF CONTROLSTROUBLESHOOTINGTROUBLESHOOTING CONT.CORE SUPPORT TEMPLATEEVAPORATOR KIT PACKING LIST

Table of Contents


EVAPORATOR KIT561058

No.

1.2.

QTY.

11

PART No.

761158781158

DESCRIPTION

57 CHEVY w/o AC w/ 4 VENT PLENUM GEN IV EVAP SUB CASE1957 CHEVY w/o AC 4 VENT ACC KIT

57 CHEVY w/o AC4 VENT PLENUM GEN IVEVAP SUB CASE 761158

ACCESSORY KIT781158

1

2DASH

FLOORDEF

INSIDE

OUTSIDE

OFFHEAT

COLDOFF AIR

**BEFORE BEGINNING INSTALLATION OPEN ALL PACKAGES AND CHECK CONTENTS OF SHIPMENTPLEASE REPORT ANY SHORTAGES DIRECTLY TO VINTAGE AIR WITHIN 15 DAYS. AFTER 15 DAYS,VINTAGE AIR WILL NOT BE RESPONSIBLE FOR MISSING OR DAMAGED ITEMS.


Important Notice—Please ReadFor Maximum System Performance, Vintage Air Recommends the Following:

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

NOTE: Vintage Air systems are designed to operate with R134a refrigerant only. Use of any other refrigerant could damage your A/C system and/or vehicle, and possibly cause a fire, in addition to potentially voiding the warranties of the A/C system and its components.

Refrigerant Capacities:Vintage Air System: 1.8 lbs. (1 lb., 12 oz.) of R134a, charged by weight with a quality charging station or scale. NOTE: Use of the proper type and amount of refrigerant is critical to system operation and performance.Other Systems: Consult manufacturer’s guidelines.

Lubricant Capacities:

Safety Switches

Service Info:Protect Your Investment: Prior to assembly, it is critical that the compressor, evaporator, A/C hoses and fittings, hardlines, condenser and receiver/drier remained capped. Removing caps prior to assembly will allow moisture, insects and debris into the components, possibly leading to reduced performance and/or premature failure of your A/C system. This is especially important with the receiver/drier. Additionally, when caps are removed for assembly, BE CAREFUL! Some components are shipped under pressure with dry nitrogen.Evacuate the System for 35-45 Minutes: Ensure that system components (Drier, compressor, evaporator and condenser) are at a temperature of at least 85° F. On a cool day, the components can be heated with a heat gun or by running the engine with the heater on before evacuating. Leak check and charge to specifications.

Your Vintage Air system is equipped with a binary pressure safety switch. A binary switch disengages the compressor clutch in cases of extreme low pressure conditions (Refrigerant Loss) or excessively high head pressure (406 PSI) to prevent compressor damage or hose rupture. A trinary switch combines Hi/Lo pressure protection with an electric fan operation signal at 254 PSI, and should be substituted for use with electric fans. Compressor safety switches are extremely important since an A/C system relies on refrigerant to circulate lubricant.

Bolts Passing Through Cowl and/or Firewall:To ensure a watertight seal between the passenger compartment and the vehicle exterior, for all bolts passing through the cowl and/or firewall, Vintage Air recommends coating the threads with silicone prior to installation.

Heater Hose (Not Included With This Kit):Heater hose may be purchased from Vintage Air (Part# 31800-VUD) or your local parts retailer. Routing and required length will vary based on installer preference.


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.

•

•

•


INSTALLATION INSTRUCTIONS FOR 1957-CHEVY

ENGINE COMPARTMENT

DISCONNECT BATTERY AND REMOVE.REMOVE BATTERY TRAY.REMOVE AIR CLEANER.DRAIN RADIATOR.DISCONNECT HEATER HOSES.REMOVE OEM BLOWER ASSEMBLY FROM FIREWALL AND FENDER. KEEP THE TWO OEM FIREWALL COVER RETAINING BRACKETS FOR USE WITH THE NEW FIREWALL COVER.

INSTALL HEATER CONTROL VALVE BLOCK-OFF PLATE AS SHOWN IN FIGURE 1, BELOW. REMOVE OEM HEATER CONTROL VALVE AND DISCARD.

BEFORE STARTING THE AIR CONDITIONER INSTALLATION, CHECK FOR PROPER OPERATION OF ALL COMPONENTS (RADIO,LIGHTS, WIPERS, ETC.). STUDY THE INSTRUCTIONS, ILLUSTRATIONS AND DIAGRAMS. FOR EASE OF INSTALLATION,

CHECK OFF ( ) EACH PROCEDURE PRIOR TO MOVING ON TO THE NEXT STEP.

FIGURE 1

HEATER CONTROLVALVE BLOCK-OFF

PLATE


PASSENGER COMPARTMENT

REMOVE CONTROL PANEL BEZEL.

REMOVE GLOVE BOX (DISCARD).REMOVE GLOVE BOX DOOR.REMOVE RADIO (OPTIONAL).REMOVE CLOCK.REMOVE AND DISCARD THE OEM HEATER ASSEMBLY AND HEATER DUCT.REMOVE AND DISCARD DEFROSTER DUCT.

REMOVE THE OEM CONTROL PANEL ASSEMBLY & DISCONNECT CABLES (RETAIN OEM CONTROLPANEL AND DISCARD CABLES) AS SHOWN IN FIGURE 2, BELOW. REFER TO CONTROL PANEL CONVERSION KIT INSTRUCTIONS FOR INSTALLATION OF CONTROLS.

FIGURE 2

DEFROST DUCTS

GLOVE BOX DOOR

GLOVE BOX

CONTROL PANEL BEZEL

OEM HEATER ASSEMBLY

RADIO CLOCK

CONTROL PANEL


CONDENSER ASSEMBLY & INSTALLATION

COMPRESSOR & BRACKETS

PULLEYS

DEFROST DUCT INSTALLATION

FIGURE 3

ENGINE COMPARTMENT

REFER TO SEPARATE INSTRUCTIONS INCLUDED WITHTHE CONDENSER KIT TO INSTALL THE CONDENSER.BINARY SWITCH INSTALLATION (REFER TO CONDENSER INSTRUCTIONS).

REFER TO SEPARATE INSTRUCTIONS INCLUDED WITHTHE BRACKET KIT TO INSTALL THE COMPRESSOR BRACKET.

IN MOST INSTANCES, THE BELT LENGTHS WILL REMAIN THE SAME.

INSTALL DEFROST DUCTS WITH 2” DUCT HOSE(PASSENGER SIDE: 2” x 10”) (DRIVER SIDE: 2” x 24”).SEE FIGURE 3, BELOW, & FIGURE 8, PAGE 11.

#8 x 1/2”PAN HEAD

SCREW


EVAPORATOR INSTALLATION

LIFT EVAPORATOR UNIT UP & UNDER THE DASHBOARD (SEE FIGURES 4 & 5, BELOW, & FIGURE 6, PAGE 10). SECURE LOOSELY TO THE FIREWALL FROM THE ENGINE COMPARTMENT SIDE WITH (2) 1/4-20 x 1” BOLTS AND WASHERS. SEE FIGURE 7, PAGE 10, & FIGURE 15, PAGE 16.

INSTALL FRONT MOUNTING BRACKET TO EVAPORATOR UNIT WITH 1/4-20 x 1/2” BUTTON HEAD SCREW & WASHER. TIGHTEN AS SHOWN IN FIGURE 7, PAGE 10. LOOSELY ATTACH FRONT MOUNTING BRACKET TO DASH WITH 1/4-20 x 1” BOLT, WASHER AND NUT. SEE FIGURE 7, PAGE 10.

INSTALL CENTER A/C PLENUM TO EVAPORATOR WITH (2) 10/32 x 1/2” SCREWS. SEE FIGURE 7, PAGE 10.

LOOSELY SECURE THE CENTER PLENUM TO DASH WITH THE CENTER PLENUM MOUNTING BRACKET, USING A 1/4-20 x 1” BOLT AND WASHER. SEE FIGURE 7, PAGE 10.

VERIFY THAT EVAPORATOR UNIT IS LEVEL AND SQUARE TO THE DASH, THEN TIGHTEN ALL SECURING BOLTS.NOTE: TIGHTEN THE TWO BOLTS ON FIREWALL FIRST. THEN TIGHTEN THE FRONT MOUNTING BRACKET BOLT AND NUT. TIGHTEN THE CENTER PLENUM MOUNTING BOLT LAST.

ON A WORKBENCH, INSTALL EVAPORATOR REAR BRACKETS, AND INSTALL EVAPORATOR HARDLINES WITH PROPERLY LUBRICATED O-RINGS (SEE FIGURE 17, PAGE 18, AND FIGURE 12, PAGE 14).

FIGURE 4

FIGURE 5

INSTALL EVAPORATOR UNIT FROMPASSENGER SIDE FLOORBOARD.

ROTATE EVAPORATOR UNIT SO LINES PASS THROUGH OPENING IN FIREWALL, AND LIFT INTO PLACE.


ONCE INTO PLACE, SECURE EVAPORATORUNIT TO FIREWALL.

A/C-HEAT BLEND DOOR

FIREWALL

1/4-20 x 1”BOLT & WASHER

ECUMODULE

DEFROSTDOOR

DASH/FLOORDOOR

4-VENTA/C PLENUM

4-VENTA/C PLENUM

10/32 x 1/2”SCREW

FIGURE 7

FIGURE 6

BOTTOM LIP OF DASH

1/4-20 x 1”BOLT & WASHER

1/4-20 x 1/2”BUTTON HEAD

SCREW

FRONTMOUNTING

BRACKET

1/4-20NUT


DRILL 5/8” HOLE IN FIREWALL FOR DRAIN HOSE, USING FIREWALL HOLE TEMPLATE ON PAGE 24. SEE FIGURE 15, PAGE 16.CONNECT DRAIN HOSE TO BOTTOM OF EVAPORATOR UNIT AND ROUTE TO FIREWALL (SEE FIGURE 15, PAGE 16).INSTALL DUCT HOSES AS SHOWN IN FIGURE 8, BELOW.INSTALL DRIVER & PASSENGER UNDER-DASH LOUVERS. SEE FIGURE 10, PAGE 12.

CONTROL WIRING

DUCT & DRAIN HOSE ROUTING

ECUMODULE

PASSENGERSIDE LOUVER2 ½” x 42”

DRIVER SIDE LOUVER

2 ½” x 48”

DRIVER SIDE CENTER VENT

2 ½” x 15”

PASSENGER SIDE CENTER VENT

2 ½” x 12”

DRIVER SIDE DEFROST DUCT

2” x 24”

FIGURE 8

PASSENGER SIDE DEFROST DUCT

2” x 10”


DASHUNDER DASH

LOUVER(PASSENGER SIDE)

(2) #8 x ½” PH SCREWSCENTER VENT

SIDE FLANGE

BOTTOM EDGEOF DASH

KICK PANELRETAINING

STRIPEND VIEW

DRIVER SIDE

#8 X ½”PAN HEAD

SCREW

INSTALL PASSENGER AND DRIVER SIDE BALL LOUVERS BY SLIDING THE SIDE FLANGE OF BALL LOUVERBETWEEN THE KICK PANEL AND KICK PANEL RETAINING STRIP.SLIDE LOUVER UP TOWARD BOTTOM OF DASH UNTIL THE LOUVER IS SEATED AGAINST DASH, ANDSECURE TO KICK PANEL WITH SUPPLIED #8 x ½” PAN HEAD SCREW. SEE FIGURE 10, ABOVE.

PLACE CENTER VENT UNDER DASH IN DESIRED POSITION. SEE FIGURE 9, BELOW. DRILL (2) 1/8” MOUNTINGHOLES IN BOTTOM LIP OF DASH, AND SECURE CENTER VENT TO DASH USING (2) #8 x ½” PAN-HEAD SCREWS.SEE FIGURE 9, BELOW.

CENTER VENT INSTALLATION

PASSENGER AND DRIVER SIDE UNDER DASH LOUVER INSTALLATION

FIGURE 10

FIGURE 9


INSTALL HEATER CPNTROL VALVE IN LINE WITH INTAKE MANIFOLD (PRESSURE SIDE) HEATER HOSE. SEE FIGURE 13, PAGE 14.

INSTALL THE #6 LIQUID LINE TO DRIER WITH LUBRICATED O-RING AND TIGHTEN. SEE FIGURE 14, PAGE 15.

INSTALL BINARY SWITCH ON #6 LIQUID LINE. SEE FIGURE 14, PAGE 15.

SECURE THE #6 LIQUID LINE TO THE FENDER USING THE SUPPLIED ADEL CLAMP. SEE FIGURE 14, PAGE 15.

LOCATE THE TWO COMPRESSOR ALUMINUM HARDLINE EXTENSIONS. SEE FIGURE 14, PAGE 15.

LOCATE THE #8 COMPRESSOR ALUMINUM HARDLINE. LUBRICATE (1) #8 O-RING AND INSTALL ON THE FEMALE O-RING END. CONNECT THIS LINE TO THE #8 DISCHARGE PORT ON THE COMPRESSOR AND TIGHTEN. SEE FIGURE 14, PAGE 15.

LOCATE THE #10 COMPRESSOR ALUMINUM HARDLINE. LUBRICATE (1) #8 O-RING AND INSTALL ON THE FEMALE O-RING END. CONNECT THIS LINE TO THE #10 SUCTION PORT ON THE COMPRESSOR AND TIGHTEN. SEE FIGURE 14, PAGE 15.

SECURE THE TWO COMPRESSOR HARDLINES TO THE COMPRESSOR, USING THE SUPPLIED CLAMP. SEEFIGURE 14a, PAGE 15.

LOCATE THE #8 RUBBER HOSE. THIS HOSE WILL CONNECT TO THE #8 ALUMINUM COMPRESSOR HARDLINE AND #8 ALUMINUM HARDLINE FROM CONDENSER. LUBRICATE (2) #8 O-RINGS, AND INSTALL ONE ON EACH END OF THE #8 RUBBER HOSE. ROUTE HOSE AS SHOWN IN FIGURE 14, PAGE 15, AND TIGHTEN. NOTE: THE 90° HOSE END CONNECTS TO THE CONDENSER HARDLINE.

PASS THE #6 LIQUID LINE THROUGH THE BOTTOM HOLE IN THE FIREWALL COVER. SEE FIGURE 14b, PAGE 15.

PULL FIREWALL COVER BACK AND INSTALL THE #6 LIQUID LINE, LUBRICATE (1) #6 O-RING AND TIGHTEN.SEE FIGURE 14b, PAGE 15.

SECURE THE FIREWALL COVER USING TWO OEM RETAINING BRACKETS. SEE FIGURE 15, PAGE 16.

LOCATE THE #10 RUBBER HOSE. THIS HOSE WILL CONNECT TO THE #10 ALUMINUM COMPRESSOR HARDLINE AND #10 ALUMINUM HARDLINE FROM EVAPORATOR. LUBRICATE (2) #10 O-RINGS, AND INSTALL ONE ON EACH END OF THE #10 RUBBER HOSE. ROUTE HOSE AS SHOWN IN FIGURE 14, PAGE 15 AND TIGHTEN. NOTE: THE 90° HOSE END CONNECTS TO THE COMPRESSOR HARDLINE.

INSTALL HEATER HOSES TO HEATER LINES AND ROUTE AS SHOWN IN FIGURES 14-14b, PAGE 15. SECURE WITH HOSE CLAMPS. NOTE: THIS KIT DOES NOT CONTAIN HEATER HOSE. IT WILL BE NECESSARY TO PURCHASE 5/8” DIAMETER HEATER HOSE FROM YOUR LOCAL PARTS RETAILER.

STANDARD HOSE KITHARDLINE & HOSE INSTALLATION

MODIFIED HOSE KIT

HEATER CONTROL VALVE & #6 LIQUID LINE

REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH MODIFIED HOSE KIT.


O-RING LUBRICATION

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

O-RING

TWIST WITHTHIS WRENCHHOLD WITH

THIS WRENCHFIGURE 11

FIGURE 12

#6 O-RING #8 O-RING

SUPPLIED OILFOR O-RINGS O-RING, INSTALLS

OVER MALE INSERTTO SWAGED LIP

#10 O-RING

O-RING

MALEINSERT FEMALE

NUT

HEATER CONTROL VALVE INSTALLATION

FIGURE 13

ECU MODULEBSC

MODULE

#6 LIQUIDLINE

#10 SUCTIONHOSE

HEATER HOSE

FROM INTAKEMANIFOLD

TO WATER PUMP

NOTE: FLOW DIRECTION FOLLOWSMOLDED ARROW ON VALVE.


A/C & HEATER HOSEAND HARDLINE ROUTINGPRESS

TAPE ECUMODULE

FIREWALLCOVER HEATER

CONTROLVALVE

HEATERHOSES

BSCMODULE

ECUMODULE #10 SUCTION

LINE (INSULATED)

ALUMINUMCLAMP

(STANDARDHOSE KIT

ONLY)

FIREWALLCOVER

#6 LIQUID LINE

O-RINGO-RING

#6 LIQUID LINE

HEATERHOSE

BSCMODULE

EVAPORATORSUB CASE

EXPANSIONVALVE

BINARY SWITCHINSTALLATION

#6 LIQUID LINE

NOTE: MODIFIED HOSE KITS INCLUDE(2) 135° COMPRESSOR FITTINGS (REFER TO MODIFIED HOSE KIT INSTRUCTIONSINCLUDED WITH HOSE KIT).

PRESSTAPE

#10 RUBBERSUCTION HOSE

ADELCLAMP

#8 RUBBERHOSE

BINARY SWITCH

#6 LIQUID LINE FROMDRIER TO

EXPANSION VALVE 09157-PFL

NOTE: COMPRESSOR HARDLINESARE INCLUDED WITH STANDARD

HOSE KIT ONLY.

#8 COMPRESSORALUMINUM HARDLINEEXT. (DISCHARGE SIDE)

35038-VUG-A

#10 COMPRESSORALUMINUM

HARDLINE EXT. (SUCTION SIDE)35037-VUG-A

#8 CONDENSER LINE35018-VCG

#6 HARDLINE35017-VCG

SPLIT RUBBERGROMMET IN HOLEIN CORE SUPPORT

FIGURE 14a

FIGURE 14

FIGURE 14b


FIREWALL COVER & FRESH AIR CAP

INSTALL FRESH AIR CAP TO FRESH AIR DUCT UNDERPASSENGER SIDE FENDER AS SHOWN IN FIGURE 15, BELOW.

GROMMETS:

33137-VUI(2) HEATER

HOSE GROMMETS

33137-VUI#10 SUCTION

LINE GROMMET

33135-VUI#6 LIQUID

LINE GROMMET

62757-PCRFIREWALL COVER

FIREWALL COVER

HEATER LINE FROM INTAKE TO HEATER CORE

HEATER LINE (SUCTION TOWATER PUMP)

#10 SUCTION LINE

FIREWALL

1/4-20 x 1”BOLT

w/ FLAT WASHER

TINNERMANNUT

FIREWALL

REAREVAPORATOR

BRACKET

(4) OEMPINS

DRILLEDDRAINHOLE

90°DRAINELBOW

#6 LIQUIDLINE

OEM SLIDERETAINING BRACKETS

FIGURE 15

FENDERWELL

FRESH AIR CAP

FRESH AIR DUCT

FENDER


FINAL STEPSINSTALL CONTROL PANEL AND WIRE ACCORDING TO WIRING DIAGRAM ON PAGE 19.

PLUG CONTROL WIRING HARNESS INTO ECU MODULE. SEE WIRING DIAGRAMS ON PAGES 19 & 20.

REMOVE THE BACKING FROM THE VELCRO STRIP ON THE INSIDE OF THE ECU COVER, AND INSTALLTHE ECU COVER ONTO THE ECU AS SHOWN IN PHOTO 1, BELOW. NOTE: ENSURE MATING SURFACES ARE CLEAN AND FREE OF GREASE.INSTALL GLOVE BOX BOTTOM AND GLOVE BOX DOOR, AND SECURE TO DASH WITH (3) OEM SCREWS.SEE FIGURE 16, BELOW.

WITH GLOVE BOX BOTTOM AND DOOR IN PLACE, INSTALL GLOVE BOX TOP TO THE S-CLIPS ON THEGLOVE BOX BOTTOM, AND SECURE TOP TO DASH WITH (5) OEM SCREWS. SEE FIGURE 16, BELOW.

(4) S-CLIPS(5) OEM SCREWSGLOVE

BOX DOOR GLOVEBOX TOPDASH

PLASTIC GLOVEBOX BOTTOM

GLOVEBOX HINGE

FIGURE 16

PHOTO 1

REINSTALL ALL PREVIOUSLY REMOVED ITEMS (BATTERY BOX & BATTERY).

FILL RADIATOR WITH AT LEAST A 50/50 MIXTURE OF APPROVED ANTIFREEZE AND 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 LEAK CHECK PRIOR TO SERVICING.

CHARGE THE SYSTEM TO THE CAPACITIES STATED ON THE INFORMATION PAGE (PAGE 4) OF THISINSTRUCTION MANUAL.

(3) OEM SCREWS

ECU COVER620901

18901258 REV D 6/30/16, 1957 CHEVY w/o AC w/ 4 VENT PLENUM GEN IV INST PG 18 OF 25

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RED

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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 CONTROLSFOR MAXIMUM COOLING AND HEATING, THE AIR LEVER MUST BE IN “INSIDE MODE” POSITION

NOTE: WHEN BATTERY POWER IS FIRST CONNECTED TO THE ECU, THE COMPUTER GOES THROUGH AN INITIALIZATION SEQUENCE. THIS INITIALIZATION MAY TAKE UP TO 30 SECONDS. DURING INITIALIZATION THE BLOWER WILL NOT OPERATE, BUT THE DOORS INSIDE THE UNIT WILL BE OPERATING. A LOW BATTERY OR DISCONNECTING THE BATTERY MAY ALSO TRIGGER A REINITIALIZATION. DURING START UP, A LOW BATTERY MAY DROP BELOW 7 VOLTS, TRIGGERING REINITIALIZATION.

SYSTEM OFF A/C MODEBLOWER SPEEDCONTROL

(LOW/MED/HI)

HEAT MODE DEFOST MODE

BI-LEVEL HEAT MODEBI-LEVEL A/C MODE

NOTE: THERE ARE TWO BI-LEVEL POSITIONS: BETWEEN DASH-FLOORBETWEEN FLOOR-DEF


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 ev

apora

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.


2 ¾”

1/2”

1¼” DIAMETER

5/16” DIAMETER

EXISTINGHOLES

3 9/16

”2

5/16

”2

¼”

2 ⅜”2 ⅛”(TOP)

CORE SUPPORTTEMPLATE

FIREWALLDRAIN HOLE

TEMPLATE

FOLD

PA

GE

AT

THIS

LIN

E A

ND

PO

SITI

ON

AT

EDG

E O

F C

ORE

SU

PPO

RT (

REM

OVA

BLE

PAN

EL)

PASS

ENG

ER S

IDE

FEN

DER

(FROM INSIDE CAR)

5/8” DIAMETERDRAIN HOLE

CU

T A

LON

G D

OTT

ED L

INE

(LIN

E U

P O

PEN

ING

IN F

IREW

ALL

& P

LAC

E ED

GE

AG

AIN

ST F

IREW

ALL

SU

PPO

RT


CHECKED BY:____________PACKED BY:____________

DATE:____________

EVAPORATOR KIT561058

No.

1.2.

QTY.

11

PART No.

761158781158

DESCRIPTION

57 CHEVY w/o AC w/ 4 VENT PLENUM GEN IV EVAP SUB CASE1957 CHEVY w/o AC 4 VENT ACC KIT

57 CHEVY w/o AC4 VENT PLENUM GEN IVEVAP SUB CASE 761158

ACCESSORY KIT781158

1

2DASH

FLOORDEF

INSIDE

OUTSIDE

OFFHEAT

COLDOFF AIR

1957 chevy - vintage air · 1957 chevy without factory air with 4-vent plenum 561058 an iso...

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