FACTORY AIR CONVERSION HEAT/ COOL/ DEFROST CHEVROLET CHEVELLE

Transcription

1 specializing in AIR CONDITIONING, PARTS AND SYSTEMS for your classic vehicle FACTORY AIR CONVERSION HEAT/ COOL/ DEFROST CHEVROLET CHEVELLE CONTROL & OPERATING INSTRUCTIONS The controls on your new Perfect Fit system offers complete comfort capabilities in virtually every driving condition. This includes Temperature control in all of the modes. This system also provides the ability to blend the air between Face, Heat, and Defrost modes simultaneously. FAN SWITCH MODE DOOR TEMPERATURE THE PICTURE YOU SEE ABOVE SHOWS THE CONTROLS IN THE FACE MODE. THIS MEANS THAT ALL OF THE AIR WILL BE DISTRIBUTED THROUGH THE DASH LOUVERS. THIS ALSO HAS THE TEMPERATURE LEVER IN THE COLD POSITION. WITH THE CONTROLS IN THIS POSITION YOU WILL GET THE AIR THROUGH THE SYSTEM AT ROOM TEMPERATURE. 1

2 CAUTION: ALL OF THE OUTSIDE VENTS MUST BE CLOSED WHEN THE SYSTEM IS IN THE A/C MODE. THIS WILL ALLOW THE A/C SYSTEM TO FUCTION AT ITS MAXIMUM PERFORMANCE LEVEL. THE FOLLOWING SUMMARY WILL DESCRIBE EACH OF THE CONTROL LEVERS FUNCTION. FAN SPEED SWITCH: There are 3 speeds plus Off. When the switch is in the off position it will disconnect the 12V power to the Blower Motor and the A/C Clutch. This will shut down the entire system. When the switch is moved to any of the blower speeds 1,2 or 3 there is 12V supplied to the Micro-Switch which is mounted on the defrost air housing. HEAT/ FACE/ DEFROST MODE: When the MODE lever is moved to the LEFT, the air will go to the DEFROST outlets. In this position the compressor clutch is engaged and the system will provide dehumidified defrost. When the lever is moved to the CENTER position the air will be distributed to the FACE louvers and the compressor clutch is engaged. When the lever moved to the RIGHT position the air will be distributed to the floor outlets. TEMPERATURE CONTROL: The temperature lever as shown is in the COLDEST temperature position. As the lever is pushed to the right the temperature of the discharged air will rise to the HOTTEST point. Note: The temperature lever will function in any of the modes. AIR CONDITIONING MODE: When Air Conditioning is required the compressor clutch must be activated. This is accomplished by pushing the top lever to the CENTER position. The Temperature Lever will control the air from maximum cold through maximum heat. 2

3 specializing in AIR CONDITIONING, PARTS AND SYSTEMS for your classic vehicle INSTALLATION INSTRUCTIONS FACTORY AIR CONVERSION CHEVELLE The following instructions are to be used along with the instructions provided for the Chevelle Perfect Fit System The Air Conditioning unit and all of the distribution ducts must be removed. Retain the center louver assembly. The same basic procedures are used to remove the a/c box on the firewall as the main instructions show for the heater only system. REMOVE DUCT Remove the passenger side flex duct and discard. (1) SCREW BEHIND LOUVER (1) SCREW IN CENTRE Remove the center louver assembly and retain. Retain the (2) screws. 3

4 Locate under the center of the dash the air distribution assembly. Remove the (2) screws and remove the assembly. Discard the assembly and the flex hoses to the floor vents. PAGE 5 MAIN INSTRUCTIONS. Remove control assembly. Retain hardware and set aside for modification. Remove the vacumme harness all the way back to the source on the motor. Plug the source. PAGES 6 THRU TOP OF 8 MAIN INSTRUCTIONS. Remove and discard the distribution duct to the drivers louver. DUCT ASSEMBLY CUT NOTCH Modify the defrost duct as shown in the main instructions. 4

5 There is an additional defrost adaptor supplied in the FA kit. Notch the drivers' side duct and attach per the main instructions. Attach 30 of 2 ½ duct hose to the passenger side louver adapter using (2) #10 x 5/8 php. Press the louver adapter over the back of the original passenger side louver. Make sure that the flange on the dash inserts into the s-clips. The driver s side louver and air inlet block off can be installed the same way. Attach 32 of 2 duct hose to the driver s side louver adapter. The picture below shows the evaporator located in the firewall after modifications were done. Locate in the 0034FA kit the Firewall Block off and (3) ¼ -20 x 5/8 hex head screws and flange nuts. Bend down and flat the top of the flange on the firewall opening. Attach the block off to the firewall using the ¼ hex head screws and flange nuts. 5

6 BEND FLANGE FLAT ACROSS THE TOP EDGE. DRILL 9/32 HOLE ORIGINAL HOLE ORIGINAL HOLE ORIGINAL HOLE Using the block off as a template, drill the 9/32 dia. hole for the upper mounting bracket on the evaporator, drill the drain tube hole ¾ dia. Also locate on the firewall the holes for the suction tube and the liquid tube. The refrigerant tubes need to be installed after the unit is attached to the firewall. Open around the tube locations to gain access to install the tubes. Remove the block off and install the evaporator refer to page 9 on main instructions. PAGE 11 MAIN INSTALLATION INSTRUCTIONS. Attach the 0034FA firewall block off. Using the (3) ¼ -20 x 5/8 hex head screws and flange nuts, and (2) #14 x ¾ tek screws. 6

7 Remove the evaporator from the system box. Set on the bench. Locate the crank arm for the face door as shown in the picture. Using screw driver remove the crank arm and discard. Locate in the sack kit of the conversion kit the Electronic Actuator Adaptor and (1) #6 x 1 pan head screw. Attach to the face door shaft. Drill a hole through the door shaft using a drill 5/64 dia. NOTE: FLAT ON ACTUATOR ADAPTOR # 6 X 1 PAN HEAD SCREW Install the #6 screw through the hole that you just drilled. The screw should go all the way through the actuator adaptor. 7

8 Using a 3/16 drill, remove the cable attachment bracket and discard. Locate the actuator attachment bracket and (2) #8 x 3/8 pan head screws. Attach the bracket over the door shaft. Install the (2) screws as shown. NOTE: the screws tap into the plastic next to the original holes that the pop rivets were in. Locate (3) #8 x ½ pan head screws, (2) #10 x 5/8 pan head screws and the Defrost / Heat Duct Assembly. Locate the defrost duct assembly from the main unit box. Locate the micro switch and (2) #4-40 screw and nuts from the sack kit in the F.A. kit. Carefully review the next (3) pictures to understand the correct way to add the micro-switch to the duct. Using a pair of pointed nose pliers hold nut in place and attach the micro-switch to the bracket as shown. 8

9 Using the second #4-40 screw and nut attach through the slot as shown below. With door positioned in the center adjust the micro-switch so that it is engaged. Tighten the #4 screws firmly. DOOR IN CENTER OF DUCT. Locate (3) #8 x ½ pan head screws, (2) #10 x 5/8 pan head screws. ACTUATOR RELAY (3) #8 X ½ PAN HEAD SCREWS DEFROST / HEAT DUCT (3) #10 X 5/8 PAN HEAD SCREWS 9

10 Attach the Defrost / Heat duct to the outlet on the evaporator using (2) #10 x 5/8 pan head screws. NOTE: be sure that the s-clips are attached to the flange on the outlet. Attach the actuator to the bracket using (3) #8 x ½ pan head screws. There is a flat on the inside of the actuator that will slide over the door adaptor. Attach the relay to the evaporator behind the actuator as shown. Use (1) #10 x 5/8 pan head screw. (shown on previous page) Remove the passenger kick panel and retain the hardware. Remove the vacuum motor only from the inlet door assembly. Position door closed so that air will not enter cabin. This is to allow clearance for evaporator to be mounted later. Reinstall passenger kick panel, slight trimming may be necessary. PAGE 12 OF MAIN INSTALLATION INSTRUCTIONS. Place the controls on the bench and remove and discard the Vacuum switch, and (3) electrical switches. Discard switch and retain the original hardware. 1 Locate the longest of the control cables, (1) push nut, and (1) cable clip. Attach cable clip to the cable 1 from the end of the housing. 10

11 Attach to the control head using the original screw and push nut. Locate blower switch assembly from the control sack kit. Also from the FA kit locate the mounting bracket for the blower switch. Attach the mounting bracket using original screws and (2) 3/16 flat washers to the bottom of the control head. Attach the blower switch assembly from the control sack kit to the mounting bracket using the (2) #8 x 3/8 pan head screws. Attach the chrome knob to the switch. Locate the shortest of the cables supplied in the 0044 Unit Box. Cut the end off that has the loop. Cut right behind the loop.. Carefully bend the end of the cable with an offset. Locate the Cable Attachment bracket, cable clip, and (3) #8 x 3/8 pan head screw from bag kit. DRILL 5/64 DIA HOLE Using the template supplied on the last page of the instructions. Locate and drill (2) holes 1/8 dia. Attach the cable bracket to the control head using (2) #8 x 3/8 screw. Drill 5/64 dia hole in the center of the arm and 1/16 from the slot. 11

12 ½ Attach cable clip to the end of the modified cable and attach to the mounting bracket as shown using (1) #8 screw. Attach wire harness to the control switch using the diagram on page 8. Reinstall control head into the dash using the original hardware. Locate the (1) hose adaptor from the FA kit. Attach to the inlet of the original center louver assembly. Reinstall louver assembly using original hardware. 12

13 PAGE 15 THRU 17 MAIN INSTRUCTIONS Follow the instructions and use the Heat / Defrost duct supplied in the FA kit. Insert defrost heat cable into the 3 RD hole from the center of the defrost heat duct crank arm. Attach cable to bracket using (1) #8 x ½ PHP screw. Plug the harness into the top of the door actuator. Locate the black wire with the ring terminal from the relay on the main unit and fasten to the body of the car. On page 17 disregard the hookup of the door cable. PAGE 18 MAIN INSTRUCTIONS Locate the face duct from the main unit box, the 2 1/2" hole plug, and (1) #8 x 3/8 pan head screw from the FA kit. Attach the cap plug over the outlet and fasten using the #8 screws as shown below. CENTER CENTER OUTLET OUTLET PASSENGER OUTLET 2 1/2" CAP PLUG DRIVERS DRIVERS OUTLET OULET 13

14 PAGE 19 MAIN INSTRUCTIONS The supplied center louvers are not used. 14