an ISO 9001:2008 Registered Company CORVETTE without FACTORY AIR PCZ PCZ REV H 7/30/14, INST CORVETTE wo A/C 1 OF 29

Transcription

1 an ISO 9001:2008 Registered Company CORVETTE without FACTORY AIR PCZ PCZ REV H 7/30/14, INST CORVETTE wo A/C 1 OF 29

2 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. PASSENGER COMPARTMENT FIGURES 2 & 3 8. ASTRO AIR VENTILATION REMOVAL & FRESH AIR COVER FIGURES 4, 4a & 4b 9. CONDENSER, COMPRESSOR BRACKET & PULLEYS FIGURES 5 & OEM DEFROST DUCT MODIFICATION FIGURES 7, 7a & DEFROST DUCT INSTALLATION, PASSENGER & DRIVER SIDE A/C DUCT HOSE ADAPTER INSTALLATION FIGURES 9 & CENTER LOUVER DUCT HOSE ADAPTER INSTALLATION FIGURES 11, 11a & 11b 13. FIREWALL MODIFICATION & EVAPORATOR INSTALLATION FIGURES 11C & 11d 14. EVAPORATOR INSTALLATION CONT. FIGURES 12 & DRAIN HOSE INSTALLATION FIGURE FIREWALL COVER INSTALLATION FIGURE A/C HOSE KIT, MODIFIED A/C HOSE KIT, HEATER HOSE & HEATER CONTROL VALVE INSTALLATION 18. SMALL BLOCK A/C HOSE ROUTING FIGURES 16, 17 & HEATER CONTROL VALVE INSTALLATION & FINAL STEPS FIGURES 19 & CONTROL PANEL WIRING & DUCT HOSE ROUTING FIGURES 21 & 21a 21. EVAPORATOR HARDLINE & BRACKET INSTALLATION FIGURE WIRING DIAGRAM 23. GEN IV WIRING CONNECTION INSTRUCTIONS 24. OPERATION OF CONTROLS 25. TROUBLESHOOTING 26. TROUBLESHOOTING CONT. 27. DEFROST DUCT TEMPLATE 28. FIREWALL MODIFICATION 29. EVAPORATOR KIT PACKING LIST PCZ REV H 7/30/14, INST CORVETTE wo A/C 2 OF 29 2

3 OFF A C E C O N O DEF FLR PNL PNL FLR C H HI EVAPORATOR KIT PACKING LIST No. QTY. PART No. DESCRIPTION VCE PCN CORVETTE without A/C EVAP. SUB CASE CORVETTE without A/C ACCESSORY KIT EVAPORATOR KIT PCZ ** 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 CORVETTE without A/C EVAP. SUB CASE VCE 2 3 ACCESSORY KIT PCN NOTE: IMAGES MAY NOT DEPICT ACTUAL PARTS AND QUANTITIES. REFER TO PACKING LIST FOR ACTUAL PARTS AND QUANTITIES PCZ REV H 7/30/14, INST CORVETTE wo A/C 3 OF 29

4 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# 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 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) PCZ REV H 7/30/14, INST CORVETTE wo A/C 4 OF 29 4

5 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. 5 For proper system operation, the heater control valve must be connected to the ECU PCZ REV H 7/30/14, INST CORVETTE wo A/C 5 OF 29

6 INSTALLATION INSTRUCTIONS FOR CORVETTE 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. ENGINE COMPARTMENT DISCONNECT BATTERY. REMOVE HOOD TO EASE INSTALLATION. DRAIN RADIATOR. REMOVE OEM BLOWER ASSEMBLY AND COVER. REMOVE OEM HEATER CORE AND COVER. HEATER HOSES FIGURE PCZ REV H 7/30/14, INST CORVETTE wo A/C 6 OF 29 6

7 PASSENGER COMPARTMENT REMOVE PASSENGER SIDE DASH. DISCONNECT CENTER DASH AND PULL FORWARD TO REMOVE OEM CENTER DASH BEZEL. REMOVE OEM RADIO. REMOVE CONTROL PANEL (RETAIN). REFER TO CONTROL PANEL CONVERSION KIT TO ASSEMBLE CONTROL PANEL. DROP STEERING COLUMN. DISCONNECT DRIVER SIDE DASH AND PULL FORWARD. CENTER DASH BEZEL CORVETTE DRIVER SIDE DASH STEERING COLUMN CENTER DASH CONTROL PANEL FIGURE 2 RADIO PASSENGER SIDE DASH REMOVE THE DEFROST DUCT (RETAIN), FLOOR HEATER DUCT AS SHOWN IN FIGURE 3, BELOW. REMOVE THE HEATER AS SHOWN. DEFROST DUCT 7 FIGURE 3 FLOOR HEATER DUCT PCZ REV H 7/30/14, INST CORVETTE wo A/C 7 OF 29 HEATER

8 ASTRO AIR VENTILATION DUCTS REMOVAL REMOVE DRIVER SIDE & PASSENGER SIDE ASTRO AIR VENTILATION DUCTS AND DISCARD. SEE FIGURE 4, BELOW. REMOVE PASSENGER SIDE DASH SUPPORT BRACE (DISCARD) AND CUT OFF MOUNTING TAB ON THE KICK PANEL AS SHOWN IN FIGURE 4. REMOVE THE DRIVER SIDE & PASSENGER SIDE ASTRO AIR VENTILATION DUCT MOUNTING BRACKETS AS SHOWN IN FIGURE 4. INSTALL (2) S-CLIPS ON INSIDE FRESH AIR CAPS AS SHOWN BELOW IN FIGURE 4a. INSTALL INSIDE FRESH AIR CAPS ON DRIVER & PASSENGER SIDE AS SHOWN IN FIGURE 4a, BELOW. FIGURE 4 ASTRO AIR VENTILATION DUCT CUT REMOVE DASH SUPPORT BRACE CUT CUT ASTRO AIR VENTILATION DUCT DRIVER SIDE KICK PANEL S-CLIP INSIDE FRESH AIR CAP FRESH AIR COVER INSTALLATION APPLY A 1/4 BEAD OF SILICONE AROUND THE BACK SIDE OF THE FRESH AIR CAP AS SHOWN IN FIGURE 4b, BELOW. ATTACH FRESH AIR CAP TO FIREWALL USING A 1/4-20 x 1 BOLT AND WASHER. SEE FIGURE 4b. FIGURE 4a S-CLIP PASSENGER SIDE KICK PANEL SILICONE BACK SIDE OF FRESH AIR CAP FIGURE 4b FRESH AIR CAP PCZ REV H 7/30/14, INST CORVETTE wo A/C 8 OF 29 1/4-20 x 1 BOLT w/ WASHER 8

9 CONDENSER ASSEMBLY & INSTALLATION REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH THE CONDENSER KIT TO INSTALL THE CONDENSER. REFER TO FIGURE 5, BELOW, FOR CONDENSER LOCATION. OEM RADIATOR CORE SUPPORT FIGURE CCL #6 DRIER/CORE SUPPORT HARDLINE OUT IN FLOW CCD #8 COND/CORE SUPPORT HARDLINE BINARY SWITCH DRIER 9 COMPRESSOR & BRACKETS REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH THE BRACKET KIT TO INSTALL THE COMPRESSOR BRACKET. REFER TO FIGURE 6, BELOW, FOR COMPRESSOR MOUNTING LOCATION. PULLEYS IN MOST INSTANCES, EXISTING BELT LENGTHS WILL REMAIN THE SAME. SEE FIGURE 6, BELOW. PULLEYS (VINTAGE AIR) SHORT PUMP SMALL BLOCK CHEVY (STEEL PULLEY) VCA - WATER PUMP PULLEY (DOUBLE GROOVE) VCA - CRANKSHAFT PULLEY (DOUBLE GROOVE) (WITH POWER STEERING, A 3-GROOVE CRANK PULLEY IS REQUIRED) VCA - CRANKSHAFT PULLEY (TRIPLE GROOVE) NOTE: BELT ROUTING MAY VARY WITH DIFFERENT BRACKET SETS. ALWAYS REFER TO INSTRUCTIONS INCLUDED WITH BRACKETS. COMPRESSOR TAB G MOUNT THE COMPRESSOR USING TABS G & C TAB E TAB C TAB A FIGURE PCZ REV H 7/30/14, INST CORVETTE wo A/C 9 OF 29 GENERATOR OR ALTERNATOR WATER PUMP PULLEY CRANKSHAFT PULLEY

10 OEM DEFROST DUCT MODIFICATION MEASURE 6 FROM THE TOP OF THE DEFROST DUCT AND MARK AS SHOWN IN FIGURE 7, BELOW. CUT OFF THE BOTTOM PORTION OF THE DEFROST DUCT AS SHOWN. MARK AND CUT ALONG DOTTED LINE 6 6 REMOVE SHADED PORTION FIGURE 7 LOCATE THE DEFROST DUCT TEMPLATE ON PAGE 28 AND TAPE TOGETHER AS SHOWN BELOW IN FIGURE 7a. PLACE THE TEMPLATE OVER THE OVER THE DEFROST DUCT AS SHOWN IN FIGURE 7a, BELOW. USING A PENCIL OR SCRIBE, MARK ALONG THE EDGE OF THE TEMPLATE AS SHOWN. REMOVE THE TEMPLATE AND CUT ALONG THE DOTTED LINE AND REMOVE THE TOP PORTION OF THE DEFROST DUCT AS SHOWN IN FIGURE 7a. NOTE: DO NOT CUT COMPLETELY THROUGH THE DEFROST DUCT. ONLY REMOVE THE SHADED PORTION AS SHOWN VETTE DEFROST DUCT TEMPLATE MARK AND CUT ALONG DOTTED LINE MARK OR SCRIBE ALONG ALIGN WITH TOP TEMPLATE MARK OR SCRIBE ALONG MARK OR SCRIBE ALONG 3 3/16 MARK OR SCRIBE ALONG MARK OR SCRIBE ALONG ALIGN WITH TOP TEMPLATE MARK OR SCRIBE ALONG FIGURE 7a MARK OR SCRIBE ALONG MARK OR SCRIBE ALONG INSTALL THE DEFROST DUCT ASSEMBLY AS SHOWN IN FIGURE 8, BELOW. INSTALL (3) S-CLIPS ON DEFROST DUCT ASSEMBLY AS SHOWN IN FIGURE 8, BELOW. 3 3/ VETTE DEFROST DUCT TEMPLATE MARK OR SCRIBE ALONG MARK OR SCRIBE ALONG MARK OR SCRIBE ALONG MARK AND CUT ALONG DOTTED LINE REMOVE SHADED PORTION DO NOT CUT OFF BOTTOM PORTION OF THE DEFROST DUCT S-CLIP DEFROST DUCT ASSEMBLY S-CLIP FIGURE PCZ REV H 7/30/14, INST CORVETTE wo A/C 10 OF 29 10

11 DEFROST DUCT & PASSENGER AND DRIVER SIDE A/C DUCT HOSE ADAPTER INSTALLATION USING THE OEM DEFROST DUCT MOUNTING SCREWS, INSTALL THE DEFROST DUCT WITH HOSE ADAPTER AS SHOWN IN FIGURE 9, BELOW. REMOVE VENT KNOBS AND RETAIN. REMOVE VENT KNOB OEM DEFROST DUCT MOUNTING SCREWS DEFROST DUCT w/ DEFROST DUCT ASSEMBLY REMOVE VENT KNOB FIGURE 9 REMOVE THE PASSENGER AND DRIVER SIDE VENT ADAPTERS (DISCARD) AS SHOWN IN FIGURE 10, BELOW. NOTE: RETAIN MOUNTING HARDWARE. INSTALL THE INNER AND OUTER A/C DUCT HOSE ADAPTERS AS SHOWN IN FIGURE 10, BELOW. USE OEM SCREWS TO SECURE ADAPTERS TO DASH. INSTALL THE VENT KNOB, AS SHOWN, USING A x 1 ¼ PH PAN HEAD SCREW AND 3/16 FLAT WASHER. NOTE: THE PASSENGER SIDE INSTALLATION IS SHOWN BELOW IN FIGURE 10. REPEAT THE SAME STEPS FOR THE DRIVER SIDE INSTALLATION. VENT ADAPTER OUTER A/C DUCT HOSE ADAPTER INNER A/C DUCT HOSE ADAPTER (3) OEM SCREWS VENT KNOB VUB x 1 ¼ PH PAN HEAD SCREW VUB 3/16 FLAT WASHER FIGURE PCZ REV H 7/30/14, INST CORVETTE wo A/C 11 OF 29

12 CENTER LOUVER ADAPTER INSTALLATION REMOVE THE OEM CENTER DASH BEZEL & OEM WIPER SWITCH AS SHOWN IN FIGURE 11, BELOW. REMOVE OEM WIPER SWITCH CORVETTE FIGURE 11 REMOVE OEM SCREWS & REMOVE BEZEL INSTALL THE WIPER SWITCH BRACKET & GROUND WIRE USING (2) x 1/2 PH PAN HEAD SCREWS & (2) NUTS w/ STAR WASHERS AS SHOWN IN FIGURE 11a, BELOW. INSTALL THE OEM WIPER SWITCH ON THE CENTER LOUVER BEZEL USING (2) 6-32 x 3/8 PH FLAT HEAD SCREWS w/ NYLOC NUTS AS SHOWN IN FIGURE 11a, BELOW VUB (2) x 1/2 PH PAN HEAD SCREWS & NUTS w/ STAR WASHERS WIPER SWITCH BRACKET REMOVE OEM WIPER SWITCH GROUND WIRE FSR (2) 6-32 x 3/8 PH FLAT HEAD FIGURE 11a MACHINE SCREWS w/ NYLOC NUTS OEM WIPER SWITCH CENTER LOUVER BEZEL INSTALL RECTANGLE LOUVER, AS SHOWN IN FIGURE 11b, TO CENTER LOUVER BEZEL. USING (2) 8-15 x 3/4 PH FLAT HEAD TAP SCREWS INSTALL THE CENTER LOUVER BEZEL IN THE CENTER DASH BEZEL AS SHOWN IN FIGURE 11b. NOTE: SECURE THE GROUND WIRE BETWEEN THE CENTER LOUVER BEZEL AND THE DASH FSR 8-15 x 3/4 PH FLAT HEAD TAP SCREW OEM SCREW EDGE OF DASH GROUND WIRE CENTER DASH BEZEL RECTANGLE LOUVER CENTER LOUVER BEZEL FIGURE 11b PCZ REV H 7/30/14, INST CORVETTE wo A/C 12 OF FSR 8-15 x 3/4 PH FLAT HEAD TAP SCREW 12

13 FIREWALL MODIFICATION CUT OUT FIREWALL MODIFICATION TEMPLATE ON PAGE 29. ALIGN AND TAPE INTO PLACE AS SHOWN IN FIGURE 11c, AND MARK AROUND THE DOTTED LINE. REMOVE THE TEMPLATE. CUT ALONG THE DOTTED LINE TO REMOVE THE SHADED PORTION OF THE FIREWALL AS SHOWN IN FIGURE 11d. MARK ALONG DOTTED LINE TEMPLATE FIGURE 11c CUT ALONG DOTTED LINE FIGURE 11d EVAPORATOR INSTALLATION ON A WORKBENCH, INSTALL EVAPORATOR REAR BRACKET, AND INSTALL EVAPORATOR HARDLINES WITH PROPERLY LUBRICATED O-RINGS (SEE FIGURE 16, PAGE 18, AND FIGURE 22, PAGE 21). INSTALL FRONT MOUNTING BRACKET ON EVAPORATOR USING (2) 1/4-20 x 1/2 HEX BOLTS, AND TIGHTEN AS SHOWN IN FIGURE 12, PAGE 14. PLACE POLYETHYLENE SHEET OVER THE STEPPER MOTORS. SEE FIGURE 13, PAGE 14. LIFT EVAPORATOR UNIT UP UNDER THE DASHBOARD. SEE FIGURE 13, PAGE 14. SECURE LOOSELY TO THE FIREWALL FROM THE ENGINE COMPARTMENT SIDE USING A 1/4-20 x 1 BOLT AND WASHER. SEE FIGURE 13, PAGE 14. USING A #14 x 3/4 SHEET METAL SCREW, SECURE THE FRONT EVAPORATOR MOUNTING BRACKET TO THE INNER COWL BY ALIGNING THE RIGHT HOLE IN THE FRONT EVAPORATOR MOUNTING BRACKET WITH THE OEM HOLE IN THE INNER COWL. SEE FIGURE 13, PAGE 14. TO SECURE THE LEFT SIDE OF THE FRONT MOUNTING BRACKET, WITH EVAPORATOR MOUNTING BRACKET IN PLACE, DRILL A 3/16 HOLE IN INNER COWL USING THE LEFT MOUNTING BRACKET HOLE AS A GUIDE. SECURE THE BRACKET TO THE INNER COWL USING A #14 x 3/4 SHEET METAL SCREW. SEE FIGURE 13, PAGE 14. VERIFY THAT EVAPORATOR UNIT IS LEVEL AND SQUARE TO THE DASH. THEN TIGHTEN ALL MOUNTING BOLTS. NOTE: TIGHTEN THE BOLT ON FIREWALL FIRST. THEN TIGHTEN THE FRONT MOUNTING BRACKET SCREWS PCZ REV H 7/30/14, INST CORVETTE wo A/C 13 OF 29

14 FIGURE 12 EVAPORATOR FRONT BRACKET PCA 3-VENT A/C PLENUM x 1/2 SCREW (2) 1/4-20 x 1/2 HEX BOLTS OEM HOLE INNER COWL 1/4-20 x 1 BOLT & WASHER (INSTALL BOLT & WASHER FROM ENGINE COMPARTMENT SIDE) FIGURE 7 LEFT MOUNTING HOLE RIGHT MOUNTING HOLE ONCE BRACKET IS IN PLACE, DRILL 3/16 MOUNTING HOLE PLACE POLYETHYLENE SHEET OVER STEPPER MOTORS (2) #14 x 3/4 SHEET METAL SCREWS FIGURE 13 NOTE: INSTALL THIS BOLT FIRST PCZ REV H 7/30/14, INST CORVETTE wo A/C 14 OF 29 14

15 DRAIN HOSE INSTALLATION IN LINE WITH THE DRAIN, LIGHTLY MAKE A MARK ON THE FIREWALL. MEASURE ONE INCH DOWN AND DRILL A 5/8 HOLE THROUGH THE FIREWALL. SEE FIGURE 14, BELOW. INSTALL DRAIN HOSE TO BOTTOM OF EVAPORATOR UNIT AND ROUTE THROUGH FIREWALL. SEE FIGURE 14, BELOW. 1 DRAIN HOSE DRAIN FIGURE PCZ REV H 7/30/14, INST CORVETTE wo A/C 15 OF 29

16 FIREWALL COVER LOCATE THE DIMPLE IN THE BACK SIDE OF THE FIREWALL COVER. USE A 1/2 DRILL BIT AND DRILL 1/2 HOLE IN FIREWALL COVER AS SHOWN IN FIGURE 15, BELOW. APPLY A 1/4 BEAD OF SILICONE AROUND THE BACK SIDE OF THE FIREWALL COVER AS SHOWN IN FIGURE 15, BELOW. PASS LINES THROUGH FIREWALL COVER, AND SECURE WITH (2) 7/16 PANEL RETAINERS. SEE FIGURE 15, BELOW. ONCE THE FIREWALL COVER IS IN PLACE, LOCATE THE HOLE ON THE LEFT SIDE OF THE FIREWALL COVER AND DRILL A 3/8 HOLE THROUGH THE FIREWALL. INSTALL A 7/16 PANEL RETAINER TO SECURE THE LEFT SIDE OF THE FIREWALL COVER TO FIREWALL. SEE FIGURE 15, BELOW. INSTALL (2) GROMMETS IN FIREWALL COVER CAP AS SHOWN IN FIGURE 15, BELOW. APPLY A 1/4 BEAD OF SILICONE AROUND THE BACK SIDE OF THE FIREWALL COVER CAP AS SHOWN IN FIGURE 15, BELOW. USING (2) #8 x 1/2 PAN HEAD SCREWS, INSTALL FIREWALL COVER CAP AS SHOWN IN FIGURE 15, BELOW. BACK SIDE BACKSIDE OF OF FIREWALL FIREWALL COVER COVER DRILL DIMPLE SILICONE FIGURE 15 DRILL 3/8 HOLE LARGE GROMMET VUI (3) 7/16 PANEL RETAINERS #10 SUCTION LINE SILICONE BACK SIDE OF FIREWALL COVER CAP 1 ¼ x 1 w/ 3/8 HOLE GROMMET VUI PCZ REV H 7/30/14, INST CORVETTE wo A/C 16 OF 29 #6 LIQUID LINE (2) #8 x 1/2 PH PAN HEAD SCREWS 16

17 A/C HOSE INSTALLATION STANDARD HOSE KIT LOCATE THE #8 COMPRESSOR A/C HOSE AND LUBRICATE (2) #8 O-RINGS (SEE FIGURE 16, PAGE 18). CONNECT THE 135 FITTING TO THE #8 DISCHARGE PORT ON THE COMPRESSOR AND ROUTE THE STRAIGHT FEMALE FITTING w/ 134a SERVICE PORT TO THE #8 CONDENSER HARDLINE COMING THROUGH THE CORE SUPPORT. SEE FIGURE 18, PAGE 18. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN FIGURE 17, PAGE 18. LOCATE THE #10 COMPRESSOR A/C HOSE AND LUBRICATE (2) #10 O-RINGS (SEE FIGURE 16, PAGE 18). CONNECT THE 45 FEMALE FITTING w/ 134a SERVICE PORT TO THE #10 SUCTION PORT ON THE COMPRESSOR AND ROUTE THE STRAIGHT FITTING TO THE #10 EVAPORATOR HARDLINE COMING THROUGH THE FIREWALL (SEE FIGURE 18, PAGE 18). TIGHTEN EACH FITTING CONNECTION AS SHOWN IN FIGURE 17, PAGE 18. NOTE: WRAP THE #10 FITTING CONNECTIONS AT THE FIREWALL WITH PRESS TAPE. SEE FIGURE 18, PAGE 18. LOCATE THE #6 EVAP/CORE HARDLINE AND LUBRICATE (2) #6 O-RINGS (SEE FIGURE 16, PAGE 18). CONNECT THE HARDLINE TO THE #6 HARDLINE COMING THROUGH THE CORE SUPPORT FROM DRIER. ATTACH THE OTHER END OF THE HARDLINE WITH LUBRICATED O-RINGS TO THE #6 EVAPORATOR HARDLINE COMING THROUGH THE FIREWALL. SEE FIGURE 18, PAGE 18. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN FIGURE 17, PAGE 18. USE A #2 ADEL CLAMP TO SECURE THE #6 EVAP/CORE HARDLINE TO THE INNER FENDER WELL AS SHOWN IN FIGURE 18, PAGE 18. SECURE THE ADEL CLAMP TO THE INNER FENDER USING A x 1/2 MACHINE SCREW AND NUT. MODIFIED A/C HOSE KIT REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH MODIFIED HOSE KIT. HEATER HOSE & HEATER CONTROL VALVE INSTALLATION ROUTE A PIECE OF HEATER HOSE FROM THE WATER PUMP TO THE HEATER LINE COMING THROUGH THE FIREWALL AS SHOWN IN FIGURE 19, PAGE 19. SECURE USING HOSE CLAMPS. ROUTE A PIECE OF HEATER HOSE FROM THE INTAKE TO THE HEATER LINE COMING THROUGH THE FIREWALL AS SHOWN IN FIGURE 19, PAGE 19. NOTE: INSTALL HEATER CONTROL VALVE IN LINE WITH INTAKE MANIFOLD (PRESSURE SIDE) HEATER HOSE, AND SECURE USING HOSE CLAMPS AS SHOWN IN FIGURE 19, PAGE 19. ALSO NOTE PROPER FLOW DIRECTION PCZ REV H 7/30/14, INST CORVETTE wo A/C 17 OF 29

18 SMALL BLOCK HOSE ROUTING FIGURE 16 EVAPORATOR SUB CASE #6 O-RING O-RING MALE INSERT FEMALE NUT #8 O-RING #10 O-RING SUPPLIED OIL FOR O-RINGS PRESS TAPE #10 A/C SUCTION HOSE (COMP/EVAP) O-RING, INSTALLS OVER MALE INSERT TO SWAGED LIP FOR A PROPER SEAL OF FITTINGS: INSTALL SUPPLIED O-RINGS AS SHOWN AND LUBRICATE WITH SUPPLIED OIL. #2 ADEL CLAMP x 1/2 SCREW w/ NUT #6 LIQUID LINE FROM EXPANSION VALVE TO DRIER ( CFL) #8 A/C DISCHARGE HOSE (COMP/COND HARDLINE) OUT IN BINARY SWITCH FLOW TWIST WITH THIS WRENCH FIGURE 18 FIGURE 17 ECU MODULE PRESS TAPE FIREWALL COVER HEATER CONTROL VALVE PCZ REV H 7/30/14, INST CORVETTE wo A/C 18 OF 29 LUBRICATE O-RING (SEE FIGURE 18) HOLD WITH THIS WRENCH 18

19 HEATER CONTROL VALVE INSTALLATION ECU MODULE PRESS TAPE #10 SUCTION LINE (INSULATED) FIREWALL COVER EXPANSION VALVE O-RING #10 SUCTION HOSE TO WATER PUMP FIREWALL COVER CAP FIGURE 19 HEATER HOSE FROM HTR CNTRL VLV #6 LIQUID LINE NOTE: FLOW DIRECTION FOLLOWS MOLDED ARROW ON VALVE. FROM INTAKE 19 FINAL STEPS - DUCT HOSE ROUTING & CONTROL PANEL HARNESS INSTALL DRIVER SIDE LOUVER ADAPTER ASSEMBLY AS SHOWN IN FIGURE 20, BELOW. INSTALL DUCT HOSES AS SHOWN IN FIGURES 21 & 21a, PAGE 20. REINSTALL THE CENTER DASH ASSEMBLY. REINSTALL CONTROL PANEL. PLUG THE CONTROL PANEL HARNESS INTO THE ECU MODULE ON SUB CASE AS SHOWN. SEE FIGURE 21, PAGE 20. PLUG THE WIRING HARNESS INTO THE ECU MODULE ON SUB CASE AS SHOWN (WIRE ACCORDING TO WIRING DIAGRAM ON PAGES 22 & 23). NOTE: CONTROLS MUST BE CALIBRATED FOR PROPER OPERATION. REFER TO CONTROL PANEL INSTRUCTIONS. REINSTALL ALL PREVIOUSLY REMOVED ITEMS (BATTERY BOX & BATTERY). FILL RADIATOR WITH AT LEAST A 50/50 MIXTURE OF APPROVED ANTIFREEZE AND DISTILLED WATER. IT IS THE OWNER S RESPONSIBILITY TO KEEP THE FREEZE PROTECTION AT THE PROPER LEVEL FOR THE CLIMATE IN WHICH THE VEHICLE IS OPERATED. FAILURE TO FOLLOW ANTIFREEZE RECOMMENDATIONS WILL CAUSE HEATER CORE TO CORRODE PREMATURELY AND POSSIBLY BURST IN A/C MODE AND/OR FREEZING WEATHER, VOIDING YOUR WARRANTY. DOUBLE CHECK ALL FITTINGS, BRACKETS AND BELTS FOR TIGHTNESS. VINTAGE AIR RECOMMENDS THAT ALL A/C SYSTEMS BE SERVICED BY A CERTIFIED AUTOMOTIVE AIR CONDITIONING TECHNICIAN. EVACUATE THE SYSTEM FOR A MINIMUM OF 45 MINUTES PRIOR TO CHARGING, AND LEAK CHECK PRIOR TO SERVICING. CHARGE THE SYSTEM TO THE CAPACITIES STATED ON THE INFORMATION PAGE (PAGE 4) OF THIS INSTRUCTION MANUAL. FIGURE 20 #10 x 3/4 SHEET METAL SCREW PCZ REV H 7/30/14, INST CORVETTE wo A/C 19 OF 29 DRIVER SIDE LOUVER ADAPTER ASSEMBLY (496137)

20 CONTROL PANEL & DUCT HOSE ROUTING CONTROL WIRING HARNESS VUA PASSENGER SIDE LOUVER 2 ½ x 30 CENTER LOUVER 2 ½ x 18 PLUG FROM WIRING HARNESS VUR PASSENGER SIDE DEFROST DUCT DRIVER SIDE 2 x 15 DEFROST DUCT DRIVER SIDE 2 x 15 FIGURE 21 LOUVER 2 ½ x 12 FIGURE 21a PCZ REV H 7/30/14, INST CORVETTE wo A/C 20 OF 29 20

21 NOTE: AFTER INSTALLING #10 SUCTION LINE, WRAP ALL EXPOSED METAL (FITTINGS & TUBE) WITH SUPPLIED PRESS TAPE. #10 SUCTION LINE (09151-PCS) PRESS TAPE FIGURE 22 EVAPORATOR HARDLINE INSTALLATION ECU MODULE #10 O-RING (33859-VUF) PASSENGER SIDE (EVAP BRACKET) PCB #6 O-RING (33857-VUF) #10 O-RING (33859-VUF) 1/4-20 x 1/2 BOLT (LOCATED ON SUB CASE) HEATER LINE (EVAP TO WATER PUMP) PCH HEATER LINE (EVAP TO INTAKE) PCH #6 LIQUID LINE (09150-PCL) TWIST WITH THIS WRENCH HOLD WITH THIS WRENCH GURE 8 LUBRICATE O-RING (SEE FIGURES 10 & 11, PAGE 12) PCZ REV H 7/30/14, INST CORVETTE wo A/C 21 OF 29

22 VUR JF8 TAN ORA BLK WHT RED WHT/RED WHT/YEL WHT/GRN AC ANNUNCIATOR BACKLIGHT POS BACKLIGHT NEG GND 5V-SW TEMP WIPER MODE WIPER FAN WIPER Wiring Diagram VIEWED FROM WIRE SIDE PRE-WIRED VUA A/C (IF USED) GEN IV ECU GEN IV WIRING DIAGRAM REV D, 5/6/2014 TEMP MODE FAN *** WIDE OPEN THROTTLE SWITCH (OPTIONAL) PROGRAM * DASH LAMP (IF USED) ** CIRCUIT BREAKER 30 AMP HEATER CONTROL VALVE Dash Lamp Is Used Only With Type 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 PCZ REV H 7/30/14, INST CORVETTE wo A/C 22 OF 29 22

23 WIRING HARNESS CONTROL WIRING HARNESS RED & WHITE A/C COMPRESSOR RELAY RED BLUE VIOLET WIRING HARNESS YELLOW ORANGE TAN GRAY RED GREEN NOTE: MOUNT RELAY IN DESIRED LOCATION UNDER DASH NOTE: YELLOW & ORANGE COMING FROM HARNESS ARE NOT USED. RED WHITE (IGNITION HOT TERMINAL) + 12V IGNITION SWITCH DASH BACK LIGHT+0-12v GRAY WIRE IS USED FOR PROGRAMING CONTROLS IF APPLICABLE RED GREEN RUN BAT Gen IV Wiring Connection Instruction Ignition Switch: Violet 12V Ign Switch Source (Key On Accessory) Position Must Be Switched. Dash Light: Tan Wire Used Only With Vintage Air Supplied Control Panel With LED Back Light. CIRCUIT BREAKER 30 AMP 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). 23 FIREWALL WIRING HARNESS BINARY SAFETY SWITCH BLUE WHITE WHITE RED RED BLACK HEATER CONTROL VALVE BLUE RED BLACK BLUE RED + COMPRESSOR BATTERY - LATCH 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. NOTE: CONNECT WHITE WIRES DIRECTLY TO (-) BATTERY TERMINAL PCZ REV H 7/30/14, INST CORVETTE wo A/C 23 OF 29 Heater Control Valve: 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. 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.

24 OPERATION OF CONTROLS NOTE: FOR PROPER CONTROL PANEL FUNCTION, REFER TO CONTROL PANEL INSTRUCTIONS FOR CALIBRATION PROCEDURE. BLOWER SPEED THIS LEVER CONTROLS THE BLOWER SPEED, FROM OFF TO HI THERMOSTAT DIAL ROLL THE THERMOSTAT DIAL ALL THE WAY UP FOR MAXIMUM COOLING. ROLL THE DIAL DOWN TO DECREASE THE AMOUNT OF COOLING. MODE DIAL ROLL THE DIAL UP OR DOWN TO THE PNL, FLR OR DEF LEGENDS IN THE AC RANGE OF THE MODE DIAL. HEAT OPERATION MODE DIAL A/C OPERATION OFF A C E C O N O DEF FLR PNL PNL FLR C H HI BLOWER SPEED THERMOSTAT DIAL DEFROST OPERATION OFF A C E C O N O DEF FLR PNL PNL FLR C H HI BLOWER SPEED THIS LEVER CONTROLS THE BLOWER SPEED, FROM OFF TO HI THERMOSTAT DIAL ROLL THE THERMOSTAT DIAL ALL THE WAY DOWN FOR MAXIMUM HEATING. ROLL THE DIAL UP TO DECREASE THE AMOUNT OF HEATING. MODE DIAL ROLL THE DIAL DOWN TO THE PNL OR FLR LEGENDS IN THE ECONO RANGE OF THE MODE DIAL. BLOWER SPEED THIS LEVER CONTROLS THE BLOWER SPEED, FROM OFF TO HI THERMOSTAT DIAL ROLL THE THERMOSTAT DIAL ALL THE WAY DOWN FOR MAXIMUM HEATING. ROLL THE DIAL UP TO DECREASE THE AMOUNT OF HEATING. MODE DIAL ROLL THE DIAL UP TO THE DEF LEGEND IN THE AC RANGE OF THE MODE DIAL. MODE DIAL: AC & ECONO RANGES THE AC AND ECONO RANGES OF THE MODE DIAL OPERATE INDENTICALLY. HOWEVER, WHEN THE MODE DIAL IS IN THE ECONO RANGE, THE A/C COMPRESSOR IS SWITCHED OFF. NOTE: WHEN THE MODE DIAL IS MOVED FROM ONE RANGE TO THE OTHER, THE BLOWER WILL MOMENTARILY CHANGE SPEEDS, BEFORE RETURNING TO NORMAL, TO INDICATE THE CHANGE PCZ REV H 7/30/14, INST CORVETTE wo A/C 24 OF 29 OFF A C E C O N O DEF FLR PNL PNL FLR C H HI 24

25 Troubleshooting Guide 25 Symptom Condition Checks Actions Notes Verify that all pins are inserted into plug. Ensure that no pins are bent or damaged in ECU. Check for damaged pins or wires in control head plug. 1a. Loss of ground on this wire renders control head inoperable. Check for damaged ground wire (white) in control head harness. No other functions work. Verify continuity to chassis ground with white control head wire at various points. Blower stays on high speed when ignition is on. See blower switch check procedure. Check for damaged blower switch or potentiometer and associated wiring. All other functions work. Be sure the small, 20 GA white ground wire is connected to the battery ground post. If it is, replace the ECU. Unplug 3-wire BSC control connector from ECU. If blower shuts off, ECU is either improperly wired or damaged. 1b. 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. Blower stays on high speed when ignition is on or off. No other part replacements should be necessary. Replace BSC (This will require removal of evaporator from vehicle). Unplug 3-wire BSC control connector from ECU. If blower stays running, BSC is either improperly wired or damaged. Danger: Never bypass safety switch with engine running. Serious injury can result. 2. Charge system or bypass pressure switch. System must be charged for compressor to engage. System is not charged. 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. Check continuity to ground on white control head wire. Check for 5V on red control head wire. Check for faulty A/C potentiometer or associated wiring (Not applicable to 3-pot controls). Compressor will not turn on (All other functions work) PCZ REV H 7/30/14, INST CORVETTE wo A/C 25 OF 29 System is charged. Disconnected or faulty thermistor will cause compressor to be disabled. Check 2-pin connector at ECU housing. Check for disconnected or faulty thermistor. 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. Check for faulty A/C potentiometer or associated wiring. 3. Repair or replace pot/control wiring. Compressor will not turn off (All other functions work). Replace relay. Check for faulty A/C relay.

26 Troubleshooting Guide (Cont.) Symptom Condition Checks Actions Notes 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. 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. 4. Noise interference from either ignition or alternator. Works when engine is not running; shuts off when engine is started (Typically early Gen IV, but possible on all versions). Check for positive power at heater valve green wire and blower red wire. Check for ground on control head white wire. Verify connections on power lead, ignition lead, and both white ground wires. System will not turn on, or runs intermittently. Will not turn on under any conditions. Verify proper meter function by checking the condition of a known good battery. Verify battery voltage is greater than 10 volts and less than 16. Check for damaged mode switch or potentiometer and associated wiring. 5. 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. No mode change at all. Loss of mode door function. Check for obstructed or binding mode doors. Partial function of mode doors. Check for damaged stepper motor or wiring. System shuts off blower at 10V. Poor connections or weak battery can cause shutdown at up to 11V. Ensure all system grounds and power connections are clean and tight. Check for at least 12V at circuit breaker. Battery voltage is at least 12V. 6. Charge battery. Check for faulty battery or alternator. Battery voltage is less than 12V. Blower turns on and off rapidly PCZ REV H 7/30/14, INST CORVETTE wo A/C 26 OF 29 Repair or replace. Check for damaged switch or pot and associated wiring. 7. Erratic functions of blower, mode, temp, etc. 8. Run red power wire directly to battery. 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. When ignition is turned on, blower momentarily comes on, then shuts off. This occurs with the blower switch in the OFF position. 26

27 MARK OR SCRIBE ALONG DEFROST DUCT TEMPLATE CUT ALONG DOTTED LINE VETTE DEFROST DUCT TEMPLATE 3 3/16 CUT ALONG DOTTED LINE MARK OR SCRIBE ALONG MARK OR SCRIBE ALONG CUT ALONG DOTTED LINE OVER LAP SHADED PORTIONS AND TAPE TOGETHER CUT ALONG DOTTED LINE MARK OR SCRIBE ALONG ALIGN WITH TOP TEMPLATE ALIGN WITH TOP TEMPLATE MARK OR SCRIBE ALONG MARK OR SCRIBE ALONG CUT ALONG DOTTED LINE PCZ REV H 7/30/14, INST CORVETTE wo A/C 27 OF 29 27

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29 FIREWALL MODIFICATION TEMPLATE DO NOT CUT ALIGN WITH EDGE OF FIREWALL OPENING 1969 CORVETTE wo FACTORY AIR FIREWALL TEMPLATE REMOVE SHADED PORTION CUT ALONG DOTTED LINE PCZ REV H 7/30/14, INST CORVETTE wo A/C 28 OF 29 28

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32 OFF A C E C O N O DEF FLR PNL PNL FLR C H HI EVAPORATOR KIT PACKING LIST No. QTY. PART No. DESCRIPTION VCE PCN CORVETTE without A/C EVAP. SUB CASE CORVETTE without A/C ACCESSORY KIT EVAPORATOR KIT PCZ CHECKED BY: PACKED BY: DATE: CORVETTE without A/C EVAP. SUB CASE VCE 2 ACCESSORY KIT PCN NOTE: IMAGES MAY NOT DEPICT ACTUAL PARTS AND QUANTITIES. REFER TO PACKING LIST FOR ACTUAL PARTS AND QUANTITIES PCZ REV H 7/30/14, INST CORVETTE wo A/C 29 OF 29