Pontiac GTO with Factory Air Control Panel Conversion Kit (473167)

Transcription

1 an ISO 900:008 Registered Company Pontiac GTO with Factory Air Control Panel Conversion Kit (4767) DE-ICE HEAT OFF VENT OUT INSIDE 8865 Goll St. San Antonio, TX 7866 Phone: Fax: REV E 09/0/6, PG OF

2 Table of Contents Thank you for purchasing this control panel kit from Vintage Air. When installing these components as part of a complete SureFit system, Vintage Air recommends working from front to back on the vehicle, installing the condenser kit, hose kit, and compressor first, followed by the wiring, evaporator, and finally the control panel. Cover... Table of Contents... Packing List/Parts Disclaimer... OEM Control Panel Removal... 4 OEM Switch Removal, Mode Bracket Installation ( Models Only)... 5 Modification (964 Models Only), Mounting Clamp Installation... Modification ( Models Only), Mounting Clamp Installation... Mode Installation (964 Models Only)... 8 Temperature Installation (964 Models Only)... 9 Mode Installation ( Models Only)... 0 Temperature Installation ( Models Only)... Mode Control Harness Installation... Temperature Control Harness Installation... Blower Switch Installation... 4 Control Harness Final Step, Final Steps... 5 Control Panel Calibration Procedure... 6 Control Panel Calibration Procedure (964 Models Only)... 7 Control Panel Calibration Procedure ( Models Only)... 8 Wiring Diagram... 9 Operation of Controls (964 Models Only)... 0 Operation of Controls ( Models Only)... Packing List REV E 09/0/6, PG OF

3 No Qty Part No. 00-SUA 00-VUA VUR 0-VUP VUB VUI VUI 8-VUB 84-VUB 8400-VUB 857-VUB Packing List: Control Panel Kit (4767) Description Control Harness, Gen IV Universal Cable, Blower Switch Blower Switch PC Board Clamp Tie Wrap, 4 Ground Wire Bracket, Mode Screw, #0 x /, Sheet Metal Nylon Insert, /8 ID x /64 OD Nylon Spacer, /8 Flat Washer, #6 Locknut, 4-40 Screw, 4-40 x 5/8 Screw, #0 x /4, Sheet Metal ** Before beginning installation, open all packages and check contents of shipment. Please report any shortages directly to Vintage Air within 5 days. After 5 days, Vintage Air will not be responsible for missing or damaged items NOTE: Images may not depict actual parts and quantities. Refer to packing list for actual parts and quantities REV E 09/0/6, PG OF

4 OEM Control Panel Removal Perform the Following:. Remove (4) OEM mounting nuts from the dash instrument panel.. Disconnect all cables and wires from the back side of the OEM controls.. Remove the OEM control panel from the dash (retain) (See Figure, below). DE-ICE HEAT OFF VENT OUT INSIDE 965 Model Shown (Others Similar) Control Panel Figure REV E 09/0/6, PG 4 OF

5 . OEM Switch Removal Remove the OEM A/C vacuum selector switch (if equipped), the clutch switches and the master switch (See Figures &, below). Master Switch Clutch Switch Clutch Switch A/C Vacuum Selector Switch Clutch Switch Master Switch 964 Models Figure Models. Figure Mode Bracket Installation ( Models Only) Install the mode cable converter bracket onto the control panel using () #0 x / sheet metal screws as shown in Figure 4, below. Mode Bracket () #0 x / Sheet Metal Screws 5 Figure REV E 09/0/6, PG 5 OF

6 . Modification (964 Models Only) Locate the () cable converter assemblies. Using wire cutters, cut the cable converter actuator rods as shown in Figure 5, below.. Trim each cable converter rod, rounding off corners as shown in Figure 5a, below. Cut at rd hole (Remove Shaded Portion) Trim Actuator Rods and Round Off Corners Temperature Figure 5a Cut at Each Side Of Hole as Shown Cut at 4th hole (Remove Shaded Portion) Actuator Rod Mode Figure 5 Reference Only Mounting Clamp Installation. Install the cable converter assembly mounting clamps. NOTE: Orient clamps in relation to the () housing snaps on the cable converter assembly as shown in Figure 6, below. Mounting Clamp Figure 6 Temperature 6 Mode REV E 09/0/6, PG 6 OF

7 . Modification ( Models Only) Locate the () cable converter assemblies. Using wire cutters, cut the cable converter actuator rods as shown in Figure 7, below.. Trim each cable converter rod, rounding off corners as shown in Figure 7a, below. Trim Actuator Rods and Round Off Corners Figure 7a Cut at Each Side Of Hole as Shown Cut Both Assemblies at the nd Hole (Remove Shaded Portion) Actuator Rod Figure 7 Mounting Clamp Installation. Install the cable converter assembly mounting clamps. NOTE: Orient clamps in relation to the () housing snaps on the cable converter assembly as shown in Figure 8, below. Reference Only Mounting Clamp Figure 8 Temperature 7 Mode REV E 09/0/6, PG 7 OF

8 Mode Installation (964 Models Only). Mark and drill a 5/ hole in the control panel as shown in Figure 9a, below Install the cable converter assembly onto the mode lever using a 4-40 x 5/8 machine screw, a /8 nylon insert, a /8 nylon spacer, a #6 flat washer, and a 4-40 locknut as shown in Figure 9, below. Secure the cable converter assembly to the control panel using a #0 x /4 sheet metal screw and () nylon spacers as shown in Figure 9, below. Since the cable converter assembly can slide back and forth in the clamp before the screw is tightened, position the cable converter assembly such that the flat part of the rod is as close to flush as possible with the end of the housing at the lever s innermost position (See Figure 9b, below). /8 /6 Mark and Drill 5/ Hole Figure 9a 4-40 Locknut #0 x /4 Sheet Metal Screw #6 Flat Washer /8 Nylon Spacer /8 Nylon Insert () /8 Nylon Spacers Figure x 5/8 Machine Screw Flush Rod Shown in Approximately Innermost Position NOTE: Do not allow rod to separate housing when rod is in innermost position. Figure 9b REV E 09/0/6, PG 8 OF

9 ... Temperature Installation (964 Models Only) Install the cable converter assembly onto the temperature lever by attaching the cable converter push rod to the OEM cable mounting stud on the lever (See Figure 0, below). Secure the cable converter assembly to the control panel using a #0 x /4 sheet metal screw and () /8 nylon spacers in the OEM cable mounting location (See Figure 0, below). Since the cable converter assembly can slide back and forth in the clamp before the screw is tightened, position the cable converter assembly such that the flat part of the rod is as close to flush as possible with the end of the housing at the lever s innermost position (See Figure 0a, below). #0 x /4 Sheet Metal Screw () /8 Nylon Spacers Temperature Mode Figure 0 Flush Rod Shown in Approximately Innermost Position NOTE: Do not allow rod to separate housing when rod is in innermost position. Figure 0a REV E 09/0/6, PG 9 OF

10 Mode Installation ( Models Only)... Install the cable converter assembly onto the mode lever by attaching the cable converter push rod to the OEM cable mounting stud on the lever (See Figure, below). Secure the cable converter assembly to the mode cable converter bracket using a #0 x / sheet metal screw as shown in Figure, below. Since the cable converter assembly can slide back and forth in the clamp before the screw is tightened, position the cable converter assembly such that the flat part of the rod is as close to flush as possible with the end of the housing at the lever s innermost position (See Figure a, below). #0 x / Sheet Metal Screw Mode Figure Flush Rod Shown in Approximately Innermost Position NOTE: Do not allow rod to separate housing when rod is in innermost position. Figure a REV E 09/0/6, PG 0 OF

11 ... Temperature Installation ( Models Only) Install the cable converter assembly onto the temperature lever by attaching the cable converter push rod to the OEM cable mounting stud on the lever (See Figure, below). Secure the cable converter assembly to the control panel using a #0 x / sheet metal screw as shown in Figure, below. Since the cable converter assembly can slide back and forth in the clamp before the screw is tightened, position the cable converter assembly such that the flat part of the rod is as close to flush as possible with the end of the housing at the lever s innermost position (See Figure a, below). #0 x / Sheet Metal Screw 965 Model Shown #0 x / Sheet Metal Screw Figure 967 Model Shown Flush Rod Shown in Approximately Innermost Position Figure a NOTE: Do not allow rod to separate housing when rod is in innermost position REV E 09/0/6, PG OF

12 .. Mode Control Harness Installation Locate the control panel wiring harness, and plug the corresponding connector into the correct cable converter assembly as shown in Figure, below. Once the connector is correctly plugged into the cable converter assembly, secure the wires to the cable converter assembly using one of the supplied tie wraps. The tie wrap must be located between the end of the wire jacket and the step in the cable converter housing, forcing a bend in each wire as it passes over the step in the cable converter housing. The head of the tie wrap must fall on the edge of the housing to remain tight. Ensure that the tie wrap is tight enough that the wires cannot move (See Figure 4, below). Red White/Yellow White Mode Figure 965 Model Shown (Others Similar) Wire Jacket Force Bend in Wires Over Step Tie Wrap Step in Housing Tie Wrap Wire Jacket Figure Model Shown (Others Similar) REV E 09/0/6, PG OF

13 .. Temperature Control Harness Installation Locate the control panel wiring harness, and plug the corresponding connector into the correct cable converter assembly as shown in Figure 5, below. Once the connector is correctly plugged into the cable converter assembly, secure the wires to the cable converter assembly using one of the supplied tie wraps. The tie wrap must be located between the end of the wire jacket and the step in the cable converter housing, forcing a bend in each wire as it passes over the step in the cable converter housing. The head of the tie wrap must fall on the edge of the housing to remain tight. Ensure that the tie wrap is tight enough that the wires cannot move (See Figure 6, below). Red White/Red White Temperature 965 Model Shown (Others Similar) Figure 5 Force Bend in Wires Over Step Tie Wrap Wire Jacket Step in Housing 965 Model Shown (Others Similar) Figure 6 Wire Jacket Tie Wrap REV E 09/0/6, PG OF

14 Blower Switch Installation (964 Models Only). Install the blower switch PC board and cable assembly as shown in Figure 7, below.. Using a heat gun, install the heat shrink tubing over the connector as shown in Figure 7, below. Red, White/Green, White From Harness 00-VUA Heat Shrink Tubing Not Used Red White Orange Black (Not Used) Figure 7 Yellow Blower Switch Installation ( Models Only). Install the blower switch PC board and cable assembly as shown in Figure 8, below.. Using a heat gun, install the heat shrink tubing over the connector as shown in Figure 8, below. Red, White/Green, White Heat Shrink Tubing From Harness 00-VUA Type Red White Orange Black (Not Used) Figure 8 Yellow Type Yellow Red Orange White REV E 09/0/6, PG 4 OF

15 Control Harness Final Step. Using the supplied tie wraps, tie the wires to the control panel as shown in Figure 9, below. Confirm the wires are secured and do not interfere with lever operation or cable converter assemblies. Mode Temperature 965 Model Shown (Others Similar) NOTE: Tie the unused wire to the control panel approximately as shown. Ensure that the wire does not interfere with levers or cable converter assemblies. Figure 9. Plug the wiring harnesses into the ECU module on the sub case (See Figure 0, below).. Wire according to the wiring diagram on Page 9.. Calibration procedure and operation instructions: Unused Red, White/Blue, White Wire Tie Wrap Final Steps A. Calibrating the control panel will set the range of travel for the cable converters connected to the OEM control panel levers. Performing this procedure will set the limits of the cable converters at their highest and lowest points. B. Locate the gray wire with an unused connector in the wiring harness near the cable harness relay. This wire is labeled PROGRAM on the wiring diagram. C. It will be necessary to ground the gray wire for approximately five seconds while moving the controls, so it is sometimes helpful to attach one end of the white jumper to the vehicle s ground (for example, the chassis) and have the other end ready to connect to the gray PROGRAM wire when the procedure requires it. D. To calibrate the control panel, follow the calibration procedures on Pages 6, 7 & 8. Plug From Wiring Harness 600-VUA Plug From Control Wiring Harness 00-VUA 5 Figure REV E 09/0/6, PG 5 OF

16 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 compressor relay. 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 REV E 09/0/6, PG 6 OF

17 ON START Control Panel Calibration Procedure (964 Models Only) OFF. Turn on the ignition switch (Do not start the engine).. Move the control levers/knobs to the position shown. AIR SELECT TEMP OFF INSIDE OUTSIDE AIR COND HEAT DE-ICE. Connect the white jumper wire to the gray program wire. Wait for the blower speed to change (Approximately 5 seconds). 4. Move the control levers/knobs to the positions shown. AIR SELECT TEMP OFF INSIDE OUTSIDE AIR COND HEAT DE-ICE 5. Disconnect the white jumper wire from the gray program wire. The blower speed will change, indicating completion of the calibration procedure. 6. Confirm proper operation of controls. Repeat procedure if necessary. When finished, tape over program wire connector with electrical tape to prevent accidental contact with chassis ground REV E 09/0/6, PG 7 OF

18 ON START Control Panel Calibration Procedure ( Models Only) OFF. Turn on the ignition switch (Do not start the engine).. Move the control levers/knobs to the position shown. DE-ICE HEAT OFF VENT OUT INSIDE. Connect the white jumper wire to the gray program wire. Wait for the blower speed to change (Approximately 5 seconds). 4. Move the control levers/knobs to the positions shown. DE-ICE HEAT OFF VENT OUT INSIDE 5. Disconnect the white jumper wire from the gray program wire. The blower speed will change, indicating completion of the calibration procedure. 6. Confirm proper operation of controls. Repeat procedure if necessary. When finished, tape over program wire connector with electrical tape to prevent accidental contact with chassis ground REV E 09/0/6, PG 8 OF

19 007-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 00-VUA A/C (IF USED) GEN IV ECU GEN IV WIRING DIAGRAM REV D, 5/6/04 TEMP MODE FAN *** WIDE OPEN THROTTLE SWITCH (OPTIONAL) PROGRAM * DASH LAMP (IF USED) ** CIRCUIT BREAKER 0 AMP HEATER CONTROL VALVE Dash Lamp Is Used Only With Type 007-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 REV E 09/0/6, PG 9 OF

20 Operation of Controls (964 Models Only) On Gen IV systems with three lever/knob controls, the temperature control toggles between heat and A/C operations. To activate A/C, move the temperature lever/knob all the way to cold and then back it off to the desired vent temperature. For heat operation, move the temperature lever/knob all the way to hot and then adjust to the desired vent temperature. The blower will momentarily change speed, each time you toggle between operations, to indicate the change. NOTE: For proper control panel function, refer to Pages 6 & 7 for calibration procedure. Blower Speed This lever/knob controls blower speed, from OFF to. Mode Control This lever/knob controls the mode positions, from DASH to FOR to DEFROST, with a blend in between. Temperature Control This lever/knob controls the temperature, from HOT to COLD. Blower Speed Not Used AIR SELECT TEMP Mode Control OFF AIR COND HEAT DE-ICE INSIDE OUTSIDE Temperature Control A/C Operation Blower Speed speed. Mode Control mode position (DASH position recommended). Temperature Control For A/C operation, adjust to coldest position to engage compressor (Adjust between HOT and COLD to reach desired temperature). AIR SELECT TEMP OFF INSIDE OUTSIDE AIR COND HEAT DE-ICE Heat Operation Blower Speed speed. Mode Control mode position (FOR position recommended). Temperature Control For maximum heating, adjust to hottest position (Adjust between HOT and COLD to reach desired temperature). AIR SELECT TEMP OFF INSIDE OUTSIDE AIR COND HEAT DE-ICE Defrost/De-fog Operation Blower Speed speed. Temperature Control temperature. Mode Control Adjust to DEFROST position for maximum defrost, or between FOR and DEFROST positions for a bi-level blend (Compressor is automatically engaged). AIR SELECT TEMP OFF INSIDE OUTSIDE AIR COND HEAT DE-ICE REV E 09/0/6, PG 0 OF

21 Operation of Controls ( Models Only) On Gen IV systems with three lever/knob controls, the temperature control toggles between heat and A/C operations. To activate A/C, move the temperature lever/knob all the way to cold and then back it off to the desired vent temperature. For heat operation, move the temperature lever/knob all the way to hot and then adjust to the desired vent temperature. The blower will momentarily change speed, each time you toggle between operations, to indicate the change. NOTE: For proper control panel function, refer to Pages 6 & 8 for calibration procedure. Blower Speed This lever/knob controls blower speed, from OFF to. Mode Control This lever/knob controls the mode positions, from DASH to FOR to DEFROST, with a blend in between. Temperature Control This lever/knob controls the temperature, from HOT to COLD. Blower Speed DE-ICE HEAT OFF Temperature Control VENT OUT INSIDE Mode Control A/C Operation Blower Speed speed. Mode Control mode position (DASH position recommended). Temperature Control For A/C operation, adjust to coldest position to engage compressor (Adjust between HOT and COLD to reach desired temperature). DE-ICE HEAT OFF VENT OUT INSIDE Heat Operation Blower Speed speed. Mode Control mode position (FOR position recommended). Temperature Control For maximum heating, adjust to hottest position (Adjust between HOT and COLD to reach desired temperature). DE-ICE HEAT OFF VENT OUT INSIDE Defrost/De-fog Operation Blower Speed speed. Temperature Control temperature. Mode Control Adjust to DEFROST position for maximum defrost, or between FOR and DEFROST positions for a bi-level blend (Compressor is automatically engaged). DE-ICE HEAT OFF VENT OUT INSIDE REV E 09/0/6, PG OF

22 No Qty Part No. 00-SUA 00-VUA VUR 0-VUP VUB VUI VUI 8-VUB 84-VUB 8400-VUB 857-VUB Packing List: Control Panel Kit (4767) Description Control Harness, Gen IV Universal Cable, Blower Switch Blower Switch PC Board Clamp Tie Wrap, 4 Ground Wire Bracket, Mode Screw, #0 x /, Sheet Metal Nylon Insert, /8 ID x /64 OD Nylon Spacer, /8 Flat Washer, #6 Locknut, 4-40 Screw, 4-40 x 5/8 Screw, #0 x /4, Sheet Metal Checked By: Packed By: Date: NOTE: Images may not depict actual parts and quantities. Refer to packing list for actual parts and quantities REV E 09/0/6, PG OF