an ISO 9001: 2008 Registered Company NOVA WITHOUT AC CONTROL PANEL CONVERSION KIT OFF COLD DASH F L R DEF HOT

Transcription

1 an ISO 9001: 2008 egistered Company NOVA WITHOUT AC CONTO PANE CONVESION KIT COD EV D 4/14/15, NOVA w/o AC CONTO PANE KIT PG 1 O 16

2 Table of Contents PAGES COVE TABE O CONTENTS PACKING IST/ PATS DISCAIME EMOVING OEM CONTO PANE ASSEMBY MODIICATION IGUES 1 & 2 ASM MOUNTING CAMP INSTAATION PACAD INSTAATION IGUES & 4 ASM INSTAATION (// ASM) IGUE 5 CONTO HANESS IGUES 5a & 5b ASSEMBY INSTAATION (/ ASM) & CONTO HANESS IGUES 6 & 6a CONTO HANESS CONT. & COD/ ASM INSTAATION IGUES 6b & 7 CONTO HANESS IGUES 7a & 7b CONTO HANESS CONT. INA STEPS IGUES 8 & 9 CONTO PANE CAIBATION POCEDUE CONTO PANE CAIBATION POCEDUE CONT. WIING DIAGAM OPEATION O CONTOS CONTO PANE KIT PACKING IST EV D 4/14/15, NOVA w/o AC CONTO PANE KIT PG 2 O 16 2

3 CONTO KIT PACKING IST No QTY PAT No. DESCIPTION CONTO KIT PC SUA VUA VUE VU 2101-VUP CAMAO w/o AC PACAD w/ BACK BACKING SHEET ASM GEN IV UNIVESA CONTO HANESS /16 PUSH-ON ING CAMP 4 TIE WAP GOUND WIE COD EV D 4/14/15, NOVA w/o AC CONTO PANE KIT PG O 16

4 EMOVING OEM CONTO PANE EMOVE THE () OEM MOUNTING SCEWS OM INSTUMENT PANE O SEE IGUE 1 BEOW CONTO PANE CONVESION INSTUCTIONS O NOVA w/o AC DISCONNECT CABES AND WIES OM BACK O CONTO PANE. NOTE: MAKE SUE THE GOVE BOX AND GOVE BOX DOO HAVE BEEN EMOVED. COD EMOVE THE CONTO PANE OM BEND THE THOUGH THE GOVE BOX OPENING IN. EMOVE () OEM SCEWS EMOVE OEM BOWE SWITCH AND SCEWS (DISCAD) IGUE 1 ASSEMBY MODIICATION OCATE THE THEE ASSEMBIES, AND USING A PAI O WIE CUTTES, CUT SIDE POT ACTUATO ODS AS SHOWN BEOW IN IGUE 2. CUT AT EACH SIDE O HOE AS SHOWN / EVE CUT AT 5TH HOE (EMOVE SHADED POTION) ACTUATO OD COD/ EVE CUT AT 4TH HOE (EMOVE SHADED POTION) IGUE 2 /OO/ EVE CUT AT D HOE (EMOVE SHADED POTION) EV D 4/14/15, NOVA w/o AC CONTO PANE KIT PG 4 O 16 4

5 ASSEMBY MOUNTING CAMP INSTAATION INSTA ASM MOUNTING CAMPS, SEE IGUE. BEOW ASM MOUNTING CAMP ASM IGUE / ASSEMBY COD/ ASSEMBY // ASSEMBY OIENT ASSEMBIES AS SHOWN AND INSTA MOUNTING CAMPS AS SHOWN. (NOTE: OIENT CAMPS IN EATION TO THE () HOUSING SNAPS ON ASSEMBY) PACAD INSTAATION EMOVE EVE KNOBS EMOVE PACAD ETAINING CIPS SEE IGUE 4 BEOW. EMOVE BACKING SHEET OM CONTO PANE. INSTA NEW BACK BACKING SHEET ON CONTO PANE. SEE IGUE 4 BEOW. INSTA NEW PACAD AND SECUE USING OEM ETAINING CIPS. SEE IGUE 4 BEOW. E-INSTA KNOBS. KNOB PACAD 5 PACAD ETAINING CIPS PACAD IGUE EV D 4/14/15, NOVA w/o AC CONTO PANE KIT PG 5 O 16 BACK BACKING SHEET

6 ASSEMBY INSTAATION // ASSEMBY INSTA ASM ON THE // EVE. SEE IGUE 5 BEOW. INSTA EVE PUSH OD ONTO OEM CABE MOUNTING STUD ON EVE. SEE IGUE 5 BEOW. SECUE THE ASM TO THE CONTO PANE USING THE OEM SCEW IN THE OEM CABE CAMP MOUNTING OCATION. SEE IGUE 5 BEOW. SINCE THE ASSEMBY CAN SIDE BACK AND OTH IN CAMP BEOE SCEW IS TIGHTENED,POSITION ASSEMBY SUCH THAT THE AT PAT O THE OD IS AS COSE TO USH AS POSSIBE WITH THE END O HOUSING AT THE EVE S INNE MOST POSITION. SEE IGUE 5 BEOW. SECUE EVE PUSH OD ONTO OEM CABE MOUNTING STUD USING /16 PUSH-ON ING AS SHOWN IN IGUE 5 BEOW. OEM CABE MOUNTING STUD OEM CABE CAMP MOUNTING OCATION // EVE ASM OEM SCEW /16 PUSH-ON ING END O OD AT SECTION END O HOUSING IGUE 5 OD SHOWN IN APPOX. INNE MOST POSITION USH 1/8 MAX EV D 4/14/15, NOVA w/o AC CONTO PANE KIT PG 6 O 16 NOTE: DO NOT AOW OD TO SEPAATE HOUSING WHEN OD IS IN INNE MOST POSITION. 6

7 CONTO HANESS OCATE THE CONTO PANE WIE HANESS AND PUG THE COESPONDING WIES INTO THE COECT ASSEMBY AS SHOWN IN IGUE 5a BEOW. ED WHT/YE WHT WHT/YE // SIDE POT ASSEMBY IGUE 5a ONCE WIES AE COECTY PUGGED INTO ASSEMBY, SECUE WIES TO THE CABE CONVETE ASSEMBY USING TIE WAPS (SUPPIED). SEE IGUE 5b BEOW. THE TIE WAP MUST BE OCATED BETWEEN THE END O THE WIE JACKET AND THE STEP IN THE HOUSING OCING A BEND IN EACH WIE AS THEY PASS OVE THE STEP IN HOUSING. HEAD O TIE WAP MUST A ON EDGE O HOUSING AS SHOWN TO EMAIN TIGHT. ENSUE THAT THE TIE WAPS AE SNUG ENOUGH THAT THE WIES CANNOT MOVE. SEE IGUE 5b. WIE JACKET OCE BEND IN WIES OVE STEP TIE WAP STEP IN HOUSING WIE JACKET TIE WAP IGUE 5b EV D 4/14/15, NOVA w/o AC CONTO PANE KIT PG 7 O 16

8 ASSEMBY INSTAATION / ASSEMBY INSTA ASM ON THE / EVE. SEE IGUE 6 BEOW. INSTA EVE PUSH OD ONTO OEM CABE MOUNTING STUD ON EVE. SEE IGUE 6 BEOW. SECUE THE ASM TO THE CONTO PANE USING THE OEM SCEW IN THE OEM CABE CAMP MOUNTING OCATION. SEE IGUE 6 BEOW. SINCE THE ASSEMBY CAN SIDE BACK AND OTH IN CAMP BEOE SCEW IS TIGHTENED, POSITION ASSEMBY SUCH THAT THE AT PAT O THE OD IS AS COSE TO USH AS POSSIBE WITH THE END O HOUSING AT THE EVE S INNE MOST POSITION. SEE IGUE 5, PAGE 6. SECUE EVE PUSH OD ONTO OEM CABE MOUNTING STUD USING /16 PUSH-ON ING AS SHOWN IN IGUE 6 BEOW. SIDE POT ASM /16 PUSH-ON ING CONTO HANESS IGUE 6 OEM SCEW OCATE THE CONTO PANE WIE HANESS AND PUG THE COESPONDING WIES INTO THE COECT ASSEMBY AS SHOWN IN IGUE 6a BEOW. WHT/GN ED WHT/GN WHT IGUE 6a EV D 4/14/15, NOVA w/o AC CONTO PANE KIT PG 8 O 16 / ASSEMBY 8

9 CONTO HANESS CONT. ONCE WIES AE COECTY PUGGED INTO ASSEMBY, SECUE WIES TO THE CABE CONVETE ASSEMBY USING TIE WAPS (SUPPIED). SEE IGUE 6b BEOW. THE TIE WAP MUST BE OCATED BETWEEN THE END O THE WIE JACKET AND THE STEP IN THE HOUSING OCING A BEND IN EACH WIE AS THEY PASS OVE THE STEP IN HOUSING. HEAD O TIE WAP MUST A ON EDGE O HOUSING AS SHOWN TO EMAIN TIGHT. ENSUE THAT THE TIE WAPS AE SNUG ENOUGH THAT THE WIES CANNOT MOVE. SEE IGUE 6b. OCE BEND IN WIES OVE STEP TIE WAP WIE JACKET STEP IN HOUSING IGUE 6b TIE WAP WIE JACKET COD/ ASSEMBY INSTA ASM ON THE COD/ EVE. SEE IGUE 7 BEOW. INSTA EVE PUSH OD ONTO OEM CABE MOUNTING STUD ON EVE. SEE IGUE 7 BEOW. SECUE THE ASM TO THE CONTO PANE USING THE OEM SCEW IN THE OEM CABE CAMP MOUNTING OCATION. SEE IGUE 7 BEOW. SINCE THE ASSEMBY CAN SIDE BACK AND OTH IN CAMP BEOE SCEW IS TIGHTENED,POSITION ASSEMBY SUCH THAT THE AT PAT O THE OD IS AS COSE TO USH AS POSSIBE WITH THE END O HOUSING AT THE EVE S INNE MOST POSITION. SEE IGUE 5, PAGE 6. SECUE EVE PUSH OD ONTO OEM CABE MOUNTING STUD USING /16 PUSH-ON ING AS SHOWN IN IGUE 7 BEOW. CABE CONVETE ASM 9 OEM SCEW IGUE 7 / 16 PUSH-ON ING EV D 4/14/15, NOVA w/o AC CONTO PANE KIT PG 9 O 16

10 CONTO HANESS OCATE THE CONTO PANE WIE HANESS AND PUG THE COESPONDING WIES INTO THE COECT ASSEMBY AS SHOWN IN IGUE 7a BEOW. ED WHT/ED WHT WHT/ED COD/ ASSEMBY IGUE 7a ONCE WIES AE COECTY PUGGED INTO ASSEMBY, SECUE WIES TO THE CABE CONVETE ASSEMBY USING TIE WAPS (SUPPIED). SEE IGUE 7b BEOW. THE TIE WAP MUST BE OCATED BETWEEN THE END O THE WIE JACKET AND THE STEP IN THE HOUSING OCING A BEND IN EACH WIE AS THEY PASS OVE THE STEP IN HOUSING. HEAD O TIE WAP MUST A ON EDGE O HOUSING AS SHOWN TO EMAIN TIGHT. ENSUE THAT THE TIE WAPS AE SNUG ENOUGH THAT THE WIES CANNOT MOVE. SEE IGUE 7b. WIE JACKET OCE BEND IN WIES OVE STEP TIE WAP TIE WAP STEP IN HOUSING WIE JACKET IGUE 7b EV D 4/14/15, NOVA w/o AC CONTO PANE KIT PG 10 O 16 10

11 CONTO HANESS CONT. USING THE SUPPIED TIE-WAPS, TIE THE WIES TO THE CONTO PANE AS SHOWN IN IGUE 8 BEOW. CONIM THAT WIES AE SECUED AND DO NOT INTEEE WITH EVE OPEATION O CABE CONVETE ASSEMBIES. UNUSED ED, WHT/BUE, WHT WIE NOTE: TIE THE UNUSED WIE TO THE CONTO PANE APPOXIMATEY AS SHOWN, ENSUE THAT THE WIE DOES NOT INTEEE WITH EVES O ASSEMBIES. IGUE 8 TIE WAP INA STEPS E-INSTA CONTO PANE IN. PUG THE WIING HANESS INTO THE ECU MODUE ON SUB CASE. SEE IGUE 9. PUG OM CONTO WIING HANESS VUA WIE ACCODING TO WIING DIAGAM ON PAGE 14. CONTO PANE CAIBATION POCEDUE AND OPEATION INSTUCTIONS: CAIBATING THE CONTO PANE WI SET THE ANGE O TAVE O THE SIDE POTS CONNECTED TO THE OEM CONTO PANE EVES. PEOMING TS POCEDUE WI SET THE IMITS O THE S AT THEI GHEST AND OWEST POINTS. OCATE THE GAY WIE WITH AN UNUSED CONNECTO IN THE WIING HANESS NEA THE TWO CABE HANESS EAYS. TS WIE IS ABEED PGM ON THE WIING DIAGAM ON PAGE 14. IGUE 9 PUG OM WIING HANESS VU IT WI BE NECESSAY TO GOUND THE GAY WIE O APPOXIMATEY IVE SECONDS WE MOVING THE CONTOS SO IT IS SOMETIMES HEPU TO ATTACH ONE END O THE WTE JUMPE WIE TO THE VECE'S GOUND (O EXAMPE THE CHASSIS) AND HAVE THE OTHE END EADY TO CONNECT TO THE GAY PGM WIE WHEN THE POCEDUE EQUIES IT. 11 TO CAIBATE THE CONTO PANE OOW THE CAIBATION POCEDUES ON PAGES 12 & EV D 4/14/15, NOVA w/o AC CONTO PANE KIT PG 11 O 16

12 Control Panel Calibration Procedure On Vintage Air Gen IV systems using factory controls, it is necessary to calibrate the system to your specific control panel. This procedure ensures that the stroke of your control panel levers or knobs is translated into precise control of the fan speed, temperature blend and mode door position. Please carefully read and understand these procedures before beginning. The procedure may be repeated as many times as necessary to get it right. In preparation for calibration, you will need to attach the supplied white ground jumper wire to a suitable chassis ground. This jumper wire must be easily connected to the gray programming wire located in the main Gen IV wiring harness next to the relays. During the calibration procedure, you will connect the white jumper to the gray program wire, which will teach the Gen IV ECU the upper limits of the control levers or knobs. The blower will momentarily change speeds, signaling that the upper limits have been learned. You will move the levers or knobs to opposite extreme positions of their travel and then disconnect the white jumper. The blower will again change speeds, signaling that the lower limits have been learned and that the calibration procedure is complete. White Jumper Cable Gray Program Wire EV D 4/14/15, NOVA w/o AC CONTO PANE KIT PG 12 O 16 12

13 STAT Control Panel Calibration Procedure (Cont.) ON 1. Turn on the ignition switch (Do not start the engine). COD 2. Move the control levers/knobs to the position shown.. Connect the white jumper wire to the gray program wire. Wait for the blower speed to change (Approximately 5 seconds). COD 4. Move the control levers/knobs to the positions shown. 5. Disconnect the white jumper wire from the gray program wire. The blower speed will change, indicating completion of the calibration procedure Confirm proper operation of controls. epeat procedure if necessary. When finished, tape over program wire connector with electrical tape to prevent accidental contact with chassis ground EV D 4/14/15, NOVA w/o AC CONTO PANE KIT PG 1 O 16

14 22007-VU J8 TAN OA BK WHT ED WHT/ED WHT/YE WHT/GN AC ANNUNCIATO BACKIGHT POS BACKIGHT NEG GND 5V-SW TEMP WIPE MODE WIPE AN WIPE Wiring Diagram VIEWED OM WIE SIDE PE-WIED VUA A/C (I USED) GEN IV ECU GEN IV WIING DIAGAM EV D, 5/6/2014 TEMP MODE AN *** WIDE OPEN THOTTE SWITCH (OPTIONA) POGAM * AMP (I USED) ** CICUIT BEAKE 0 AMP HEATE CONTO VAVE Dash amp Is Used Only With Type VU 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 outed to Avoid a Short Circuit). Wide Open Throttle Switch Contacts Close Only at ull Throttle, Which Disables A/C Compressor EV D 4/14/15, NOVA w/o AC CONTO PANE KIT PG 14 O 16 14

15 OPEATION O CONTOS NOTE: CONTOS MUST BE CAIBATED O POPE OPEATION-EE TO CONTO PANE INSTUCTIONS. THE TEMPEATUE EVE TOGGES BETWEEN A/C AND HEAT MODES. O A/C MODE SIDE THE TEMPEATUE EVE A THE WAY UP, O HEAT MODE SIDE THE EVE DOWN TO DISENGAGE THE COMPESSO, THEN MOVE THE EVE TO SEECT DESIED TEMPATUE. NOTE: EACH TIME THE SYSTEM TOGGES BETWEEN MODES, THE BOWE WI MOMENTAIY CHANGE SPEEDS. A SWITCHES AE VAIABE BETWEEN POSITIONS, SYSTEM WI PEOM A BEND BETWEEN THE UNCTIONS. TEMPEATUE EVE BOWE SPEED MODE EVE COD BOWE SPEED ADJUST TO DESIED SPEED TEMPEATUE EVE IN A/C MODE SIDE THE TEMPEATUE EVE A THE WAY UP TO ENGAGE COMPESSO. (SIDE EVE UP O DOWN TO ADJUST DESIED TEMPEATUE) MODE EVE SIDE THE EVE TO THE POSITION COD A/C MODE COD BOWE SPEED ADJUST TO DESIED SPEED TEMPEATUE EVE SIDE THE TEMPEATUE EVE A THE WAY DOWN TO THE POSITION. (SIDE EVE UP O DOWN TO DESIED TEMPEATUE) BOWE SPEED ADJUST TO DESIED SPEED TEMPEATUE EVE COMPESSO IS OCED ON IN OST MODE. THEE IS NO NEED TO ADJUST TS EVE. MODE EVE SIDE THE EVE TO THE OO POSITION MODE EVE SIDE THE EVE TO THE POSITION 15 HEAT MODE OST/ DE-OG MODE EV D 4/14/15, NOVA w/o AC CONTO PANE KIT PG 15 O 16

16 CONTO KIT PACKING IST No QTY PAT No. DESCIPTION CONTO KIT PC SUA VUA VUE VU 2101-VUP CAMAO w/o AC PACAD w/ BACK BACKING SHEET ASM GEN IV UNIVESA CONTO HANESS /16 PUSH-ON ING CAMP 4 TIE WAP GOUND WIE CHECKED BY: PACKED BY: DATE: COD EV D 4/14/15, NOVA w/o AC CONTO PANE KIT PG 16 O 16