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901155 REV E 02/15/17, INST 1962-65 NOVA EVAP PG 1 OF 23
an ISO 9001: 2008 Registered Company
1962-65 NOVAWITH & WITHOUT A/C
561164
2901155 REV E 02/15/17, INST 1962-65 NOVA EVAP PG 2 OF 23
PAGES
Table of Contents
1. COVER 2. TABLE OF CONTENTS 3. PACKING LIST/PARTS DISCLAIMER 4. INFORMATION PAGE 5. WIRING NOTICE 6. ENGINE COMPARTMENT, CONDENSER ASSEMBLY, COMPRESSOR & BRACKETS FIGURES 1 & 1a 7. PASSENGER COMPARTMENT FIGURE 2 8. DEFROST DUCT HOSE ADAPTER/FRESH AIR CAP INSTALLATION FIGURE 3 9. FIREWALL COVER INSTALLATION FIGURES 4 & 4a 10. EVAPORATOR INSTALLATION FIGURES 5, 6 & 6a11. DRAIN HOSE INSTALLATION, LUBRICATING O-RINGS, A/C HOSE INSTALLATION, & MODIFIED A/C HOSE KIT FIGURES 7 & 812. HEATER HOSE & HEATER CONTROL VALVE INSTALLATION FIGURE 913. A/C & HEATER HOSE ROUTING FIGURE 1014. UNDER DASH LOUVER INSTALLATION FIGURES 11 & 11a15. FINAL STEPS FIGURE 1216. CONTROL PANEL & DUCT HOSE ROUTING FIGURE 1317. EVAPORATOR HARDLINE INSTALLATION FIGURE 1418. WIRING DIAGRAM19. GEN IV WIRING CONNECTION INSTRUCTIONS20. OPERATION OF CONTROLS21. TROUBLESHOOTING INFORMATION22. TROUBLESHOOTING INFORMATION CONT.23. EVAPORATOR KIT PACKING LIST
3901155 REV E 02/15/17, INST 1962-65 NOVA EVAP PG 3 OF 23
** 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.
EVAPORATOR KIT 561164
EVAPORATOR KIT PACKING LIST
No. QTY. PART No. DESCRIPTION
1.2.
11
744004-VUE784065
GEN IV 4-VENT EVAP. SUB CASE 1962-65 NOVA ACCESSORY KIT
GEN IV 4-VENT EVAP. SUB CASE
744004-VUE
1
ACCESSORY KIT784065 NOTE: IMAGES MAY NOT DEPICT ACTUAL PARTS AND QUANTITIES.
REFER TO PACKING LIST FOR ACTUAL PARTS AND QUANTITIES.
2
4901155 REV E 02/15/17, INST 1962-65 NOVA EVAP PG 4 OF 23
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.
5901155 REV E 02/15/17, INST 1962-65 NOVA EVAP PG 5 OF 23
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.
•
•
•
6901155 REV E 02/15/17, INST 1962-65 NOVA EVAP PG 6 OF 23
ENGINE COMPARTMENT
CONDENSER ASSEMBLY & INSTALLATION
COMPRESSOR & BRACKETS
REMOVE THE FOLLOWING:
DRIER
A/C HOSES
COMPRESSOR&
BRACKET
HEATERHOSES
2 ⅝” PLASTIC PLUG
331731
GROMMET
FIGURE 1
FIGURE 1a
BEFORE STARTING THE INSTALLATION, CHECK THE FUNCTIONOF THE VEHICLE (HORN, LIGHTS, ETC.) FOR PROPER OPERATION.
STUDY THE INSTRUCTIONS, ILLUSTRATIONS, & DIAGRAMS.
BATTERY, BATTER TRAY (RETAIN).DRAIN RADIATOR, REMOVE RADIATOR (RETAIN).EVACUATE THE A/C SYSTEM IF NECESSARY.OEM CONDENSER AND DRIER (DISCARD). SEE FIGURE 1, BELOW.OEM COMPRESSOR AND BRACKET (DISCARD). SEE FIGURE 1.OEM HEATER HOSES (DISCARD). SEE FIGURE 1.OEM A/C HOSES AND FIREWALL GROMMET (DISCARD). SEE FIGURE 1.INSTALL 2 ⅝” PLASTIC PLUG IN FIREWALL (A/C CARS ONLY). SEE FIGURE 1a, BELOW.
REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH THE CONDENSER KIT TO INSTALL THECONDENSER.
BINARY SWITCH INSTALLATION (REFER TO CONDENSER INSTRUCTIONS).
REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH THE BRACKET KIT TO INSTALL THECOMPRESSOR BRACKET.
7901155 REV E 02/15/17, INST 1962-65 NOVA EVAP PG 7 OF 23
GLOVE BOX DOOR (RETAIN). SEE FIGURE 2. GLOVE BOX (DISCARD).FRESH AIR ASSEMBLY.UNDER DASH A/C EVAPORATOR (IF EQUIPPED).HEATER ASSEMBLY (DISCARD), RETAIN SCREWS.(3) CONTROL KNOBS (DISCARD), BEZELS (RETAIN).REFER TO CONTROL PANEL CONVERSION KIT INSTRUCTIONS FOR INSTALLATION OF CONTROLS.OEM DEFROST DUCT HOSES (DISCARD).
GLOVE BOXDOOR
OEMDEF DUCT
HOSES
UNDER DASH A/C EVAPORATOR
PASSENGER COMPARTMENTREMOVE THE FOLLOWING:
GLOVE BOX
OEM HEATERASSEMBLY
FRESH AIR ASSEMBLY
(3) CONTROLKNOBS
FIGURE 2
8901155 REV E 02/15/17, INST 1962-65 NOVA EVAP PG 8 OF 23
INSTALL (4) S-CLIPS ON DEFROST DUCT HOSE ADAPTERS AS SHOWN BELOW IN FIGURE 3. INSTALL HOSE ADAPTERS ON DEFROST DUCTS AS SHOWN BELOW. HOLD FRESH AIR CAP UNDER COWL AND MARK THE (3) MOUNTING HOLES.DRILL (3) 1/8” MOUNTING HOLES UNDER COWL.APPLY A 1/4” BEAD OF SILICONE AROUND THE BACK SIDE OF THE FRESH AIR CAP AS SHOWN.SECURE FRESH AIR CAP TO FRESH AIR HOLE USING (3) #10 x 1/2” SHEET METAL SCREWS AS SHOWN.
DRILL HOLES
SILICONE
FRESH AIRCAP
62354-VFE(3) #10 x 1/2”SHEET METAL
SCREWS18247-VUB
(2) DEFROST DUCTHOSE ADAPTERS
629961
DEFROST DUCT HOSE ADAPTER/FRESH AIR CAP INSTALLATION
FIGURE 3
(4) S-CLIPS65980-VUE
9901155 REV E 02/15/17, INST 1962-65 NOVA EVAP PG 9 OF 23
ENLARGE OEM HEATER HOLES TO 1 ¼” AS SHOWN IN FIGURE 4 & 4a, BELOW.INSTALL (2) GROMMETS IN FIREWALL AS SHOWN BELOW.APPLY A 1/4“ BEAD OF SILICONE AROUND THE BACK SIDE OF THE FIREWALL COVER AS SHOWN INFIGURE 4b.SECURE FIREWALL COVER TO FIREWALL USING (2) 1/4-20 x 1” HEX BOLTS w/ FLAT WASHERS AND NUTS. NOTE: FIREWALL COVER INSTALLS ON INSIDE PASSENGER SIDE COMPARTMENT.
FIREWALL COVER INSTALLATION
64-65 NOVA
62-63 NOVA
(2) 1/4-20 x 1” HEX BOLTS
w/ FLAT WASHERS
SILICONE
GROMMET33135-VUI
GROMMET33137-VUI
FIREWALLCOVER642077
(2) 1/4” FLAT WASHERS
(2) 1/4” NUTSw/ STAR WASHERS
ENLARGE OEM HEATER HOLES TO 1 ¼”
OEM BLOWER MOTORHOLE IN FIREWALL
VIEW FROM PASSENGER SIDEINSIDE OF CAR
(2) 1/4-20 x 1” HEX BOLTS
w/ FLAT WASHERS
GROMMET33135-VUI
GROMMET33137-VUI
FIREWALLCOVER642077
(2) 1/4 FLAT WASHERS
(2) 1/4” NUTS w/ STAR WASHERS
ENLARGE OEM HEATER HOLES TO 1 ¼”
FIGURE 4a
OEM BLOWER MOTORHOLE IN FIREWALL
VIEW FROM PASSENGER SIDEINSIDE OF CAR
FIGURE 4
FIGURE 4b
10901155 REV E 02/15/17, INST 1962-65 NOVA EVAP PG 10 OF 23
ON A WORKBENCH, INSTALL EVAPORATOR REAR BRACKETS AND HARDLINES WITH PROPERLY LUBRICATED O-RINGS (SEE FIGURE 8, PAGE 11, AND FIGURE 14, PAGE 17).INSTALL FRONT MOUNTING BRACKET ON EVAPORATOR USING (2) 1/4-20 x 1/2” HEX BOLTS, AND TIGHTENAS SHOWN IN FIGURE 5, BELOW.REMOVE OEM FIREWALL PAD RETAINER PLUG.LIFT EVAPORATOR UNIT UP UNDER THE DASHBOARD. SECURE LOOSELY TO THE FIREWALL FROM THE ENGINE COMPARTMENT SIDE USING (2) 1/4-20 NUTS w/ STAR WASHERS AND FLAT WASHERS. SEE FIGURE 6, BELOW. NOTE: TO ENSURE PROPER DRAINAGE, IT IS VERY IMPORTANT THAT THE EVAPORATOR IS LEVEL, BOTH LEFT-RIGHT AND FORE-AFT. CHECK FOR LEVEL ON THE FLAT PORTIONS OF THE CASE AROUND THEDRAIN, BLOCK THE UNIT UP, THEN DRILL FOR FRONT BRACKET SCREWS.USING (2) #14 x 3/4” SHEET METAL SCREWS, SECURE THE FRONT EVAPORATOR MOUNTING BRACKET TO THEINNER COWL. SEE FIGURE 6a, BELOW.VERIFY THAT EVAPORATOR UNIT IS LEVEL AND SQUARE TO THE DASH, THEN TIGHTEN ALL MOUNTING BOLTS.NOTE: TIGHTEN THE BOLT ON FIREWALL FIRST, THEN THE FRONT MOUNTING BRACKET SCREWS.
EVAP FRONTBRKT
643076
PASSENGER SIDE EVAPMOUNTING HOLE
REMOVE OEMRETAINER
PLUG
INNERCOWL
DRILL (2)3/16” HOLES
(2) #14 x 3/4”SHEET METAL
SCREWS
VIEW FROMPASSENGER SIDEINSIDE OF CAR
(2) 1/4-20 NUTS w/ STAR WASHERSAND FLAT WASHERS
FIGURE 5
FIGURE 6FIGURE 6a
EVAPORATOR INSTALLATION
(2) 1/4-20 x 1/2”HEX BOLTS
DRIVER SIDE EVAPMOUNTING HOLE
11901155 REV E 02/15/17, INST 1962-65 NOVA EVAP PG 11 OF 23
DRAIN HOSE INSTALLATION
REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH MODIFIED HOSE KIT.
DRAIN
O-RINGMALE INSERT
FEMALE NUT
SUPPLIED OILFOR O-RINGS
O-RINGSLIDE OVER
MALE INSERT TOSWAGED LIP
TWIST WITHTHIS
WRENCH
HOLD WITHTHIS
WRENCH
FOR A PROPER SEAL OF FITTINGS:INSTALL SUPPLIED O-RINGS AS SHOWNAND LUBRICATE WITH SUPPLIED OIL.
LOCATE EVAPORATOR DRAIN ON BOTTOM OF EVAPORATOR CASE.IN LINE WITH THE DRAIN, LIGHTLY MAKE A MARK ONTHE FIREWALL. MEASURE ONE INCH DOWN AND DRILLA 5/8” HOLE THROUGH THE FIREWALL. SEE FIGURE 7.INSTALL DRAIN HOSE TO BOTTOM OF EVAPORATORUNIT AND ROUTE THROUGH FIREWALL. INSTALL1/2” 90° DRAIN ELBOW ON DRAIN HOSE AS SHOWN.
LOCATE THE #8 COMPRESSOR A/C HOSE. LUBRICATE (2) #8 O-RINGS (SEE FIGURE 8, ABOVE) AND CONNECTTHE 45° FEMALE w/ 134a SERVICE PORT FITTING TO THE #8 DISCHARGE PORT ON THE COMPRESSOR. ROUTE THE STRAIGHT FEMALE FITTING TO THE #8 CONDENSER HARDLINE COMING THROUGH THE RADIATOR CORE SUPPORT. SEE FIGURE 10, PAGE 13. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN FIGURE 8, ABOVE.
LOCATE THE #10 COMPRESSOR A/C HOSE. LUBRICATE (2) #10 O-RINGS AND CONNECT THE 90° FEMALE FITTING TO THE #10 SUCTION PORT ON THE COMPRESSOR, ROUTE THE STRAIGHT FEMALE w/ 134a SERVICE PORT FITTING TO THE #10 EVAPORATOR HARDLINE COMING THROUGH THE FIREWALL. SEE FIGURE 9, PAGE 12, & FIGURE 10, PAGE 13. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN FIGURE 8, ABOVE. WRAP THE #10 FITTING CONNECTION WITH PRESS TAPE. SEE FIGURE 14, PAGE 17.
LOCATE THE #6 EVAP/DRIER HARDLINE. LUBRICATE (2) #6 O-RINGS AND CONNECT THE HARDLINE TO THE DRIER AND THE #6 EVAPORATOR HARDLINE COMING THROUGH THE FIREWALL. SEE FIGURE 9, PAGE 12, &FIGURE 10, PAGE 13. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN FIGURE 8, ABOVE.
O-RING
#6 O-RING
#8 O-RING #10 O-RING
FIGURE 8
DRAINHOSE
LUBRICATING O-RINGS
STANDARD HOSE KIT
MODIFIED A/C HOSE KIT
1”FIGURE 7
12901155 REV E 02/15/17, INST 1962-65 NOVA EVAP PG 12 OF 23
ROUTE HEATER HOSE FROM THE WATER PUMP TO THE HEATER LINE COMING THROUGH THE FIREWALL AS SHOWN IN FIGURE 9, BELOW. SECURE USING HOSE CLAMPS.
ROUTE HEATER HOSE FROM THE INTAKE TO THE HEATER LINE COMING THROUGH THE FIREWALL AS SHOWN BELOW. NOTE: INSTALL HEATER CONTROL VALVE IN LINE WITH INTAKE MANIFOLD (PRESSURE SIDE) HEATER HOSE, AND SECURE USING HOSE CLAMPS AS SHOWN. ALSO NOTE PROPER FLOW DIRECTION.
HOSE SHOULD PROTRUDE THROUGH THE FIREWALL COVER SLIGHTLY TO CLOSE THE GAP BETWEEN THE ALUMINUM LINE AND THE FIREWALL COVER. SEAL ANY REMAINING GAP WITH RTV SILICONE.
#10 SUCTIONLINE
FIGURE 9
O-RINGS
#6 A/CHARDLINE
HEATERHOSE
NOTE: FLOW DIRECTION FOLLOWSMOLDED ARROW ON VALVE.
HEATER HOSE & HEATER CONTROL VALVE INSTALLATION
FROM HTR CNTRL VLV
TO EVAPORATOR
FROM INTAKEMANIFOLD
FROM EVAPORATOR
TO WATER PUMP
13901155 REV E 02/15/17, INST 1962-65 NOVA EVAP PG 13 OF 23
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14901155 REV E 02/15/17, INST 1962-65 NOVA EVAP PG 14 OF 23
PLACE THE DRIVER SIDE LOUVER HOUSING UNDER THE DASH. ALIGN 1” FROM THE FRONT EDGE OF THEDASH AND MARK MOUNTING HOLES. DRILL 7/64“ MOUNTING HOLES IN BOTTOM OF DASH. SEE FIGURE11, BELOW.PLACE THE CENTER/PASSENGER SIDE LOUVER BEZEL UNDER THE DASH AND ALIGN 1” FROM THE FRONT EDGE OF THE DASH. MARK MOUNTING HOLES. DRILL 7/64“ MOUNTING HOLES IN BOTTOM OF THE DASHAS SHOWN BELOW.USING (2) #8 x 1/2” PH PAN HEAD SCREWS, INSTALL THE DRIVER SIDE LOUVER HOUSING UNDER DASH ASSHOWN BELOW.USING (2) #8 x 1/2” PH PAN HEAD SCREWS, INSTALL THE CENTER/PASSENGER SIDE LOUVER BEZEL UNDERDASH AS SHOWN BELOW.INSTALL LOUVERS IN DRIVER SIDE HOUSING AND CENTER/PASSENGER SIDE LOUVER BEZEL AS SHOWN IN FIGURE 11a, BELOW.ONCE THE LOUVER ASSEMBLY IS IN PLACE, ROUTE THE DUCT HOSES AND ATTACH THEM TO THE CORRECT LOCATION ON EVAPORATOR AS SHOWN IN FIGURE 13, PAGE 16.
UNDER DASH LOUVER INSTALLATION
PASSENGERSIDE
1” 1”
DRIVERSIDE
(2) #8 x 1/2” PH PAN HEAD
SCREWS
(2) #8 x 1/2” PH PAN HEAD
SCREWS
DRIVER SIDEHOUSING
FIGURE 11
FIGURE 11a
(2) BALL LOUVERS
(2) LOUVERS
15901155 REV E 02/15/17, INST 1962-65 NOVA EVAP PG 15 OF 23
INSTALL DUCT HOSES AS SHOWN IN FIGURE 13, PAGE 16. EXTEND DUCT HOSE TO A TAUT CONDITION,THEN CUT TO LENGTH AS NOTED. THERE SHOULD BE LITTLE OR NO SLACK IN HOSE ONCE INSTALLED.
ROUTE A/C WIRES THROUGH 3/8” GROMMET AS SHOWN IN FIGURE 12.(12 VOLT/GROUND/BINARY SWITCH/HEATER VALVE).
REINSTALL CONTROL PANEL ASSEMBLY.
PLUG THE WIRING HARNESS INTO THE ECU MODULE ON THE SUB CASE AS SHOWN IN FIGURE 13, PAGE 16(WIRE ACCORDING TO WIRING DIAGRAM ON PAGE 18 AND 19).
INSTALL NEW GLOVE BOX AND GLOVE BOX DOOR USING OEM SCREWS.
REINSTALL ALL PREVIOUSLY REMOVED ITEMS (BATTERY, RADIATOR, RADIO).
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 INWHICH THE VEHICLE IS OPERATED. FAILURE TO FOLLOW ANTIFREEZE RECOMMENDATIONS WILL CAUSEHEATER 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. REFER TO CHARGE/SERVICE INFORMATION ON PAGE 4.
CHARGE THE SYSTEM TO THE CAPACITY STATED ON THE INFORMATION PAGE (PAGE 4) OF THIS INSTRUCTION MANUAL.
SEE OPERATION OF CONTROLS PROCEDURES, PAGE 20.
FINAL STEPS
FIGURE 12
GROMMET33144-VUI
WIRING HARNESS(12 VOLT/GROUNDS/BINARY SWITCH)
WIRING HARNESS(HEATER CONTROL VALVE)
16901155 REV E 02/15/17, INST 1962-65 NOVA EVAP PG 16 OF 23
FIGURE 13
NOTE: WHILE LOOKING THROUGH THE GLOVE BOX AND SPEAKER HOLES, TURN ON THE WIPERS AND CHECK FORCLEARANCE THROUGH THE FULL RANGE OF MOTION.
CONTROL PANEL CABLE & DUCT HOSE ROUTING
PLUGFROM
CONTROLWIRING
HARNESS232002-VUA
PLUGFROM
WIRINGHARNESS
232001-VUR
PASS. SIDELOUVER
2 ½” x 40”
DRIVER SIDELOUVER
2 ½” x 36”
CENTER LOUVERDRIVER SIDE2 ½” x 18”
CENTER LOUVERPASS SIDE2 ½” x 15”
PASS. SIDEDEF. DUCT2” x 12”
FROMCONTROLS
DRIVER SIDEDEF DUCT2” x 20”
17901155 REV E 02/15/17, INST 1962-65 NOVA EVAP PG 17 OF 23
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E 14
#1
0 O
-RIN
G(3
38
59
-VU
F)#
10
SU
CTI
ON
LIN
E0
91
97
2
3/4
” N
YLO
NSP
AC
ER18040-V
UB
1/4
-20 x
1 ½
”BO
LT
#6
O-R
ING
(33857-V
UF)
FLA
T W
ASH
ER
1/4
” PU
SH-N
UT
BOLT
RET
AIN
ER1
89
12
5-M
UR
18901155 REV E 02/15/17, INST 1962-65 NOVA EVAP PG 18 OF 23
WHT/GRN
WHT/YELWHT/RED
RED
WHTBACKLIGHT NEG
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
19901155 REV E 02/15/17, INST 1962-65 NOVA EVAP PG 19 OF 23
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.
20901155 REV E 02/15/17, INST 1962-65 NOVA EVAP PG 20 OF 23
Operation of Controls
Adjust to desiredspeed.
Blower SpeedAdjust to desired
speed.
Adjust to desiredmode position (DASH position recommended).
Adjust to desiredspeed.
Adjust to DEFROST position for maximum defrost, or between FLOOR and DEFROST positions for a bi-level
blend (Compressor is automatically engaged).
Adjust to desired temperature.
For A/C operation, adjust tocoldest position to engage
compressor (Adjust between HOT and COLD to reachdesired temperature).
A/C Operation
Heat Operation
Defrost/De-fog Operation
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 control panel instructions for calibration procedure.
Blower Speed
Blower Speed
This lever/knob controlsblower speed, from
OFF to HI.
This lever/knob controls the mode positions,from DASH to FLOORto DEFROST, with a blend in between.
This lever/knob controlsthe temperature,
from HOT to COLD.
Blower Speed
Mode Control
Temperature Control
Blower Speed
TemperatureControl
ModeControl
Temperature Control
Temperature Control
Temperature Control
Mode Control
Mode Control
Mode Control
For maximum heating, adjust to hottest position (Adjust between HOT and COLD to reach desired temperature).Adjust to desired
mode position(FLOOR position recommended).
OFF HI DASH
FLOOR
DEF COLDHOT
TEMPMODEFAN
TEMP
MODEFAN TEMP
MODEFAN
TEMPMODEFAN
21901155 REV E 02/15/17, INST 1962-65 NOVA EVAP PG 21 OF 23
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
evap
ora
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
.
22901155 REV E 02/15/17, INST 1962-65 NOVA EVAP PG 22 OF 23
Sym
pto
m
C
on
dit
ion
Ch
eck
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.
901155 REV E 02/15/17, INST 1962-65 NOVA EVAP PG 23 OF 23
EVAPORATOR KIT 561164
CHECKED BY:PACKED BY:
DATE:
EVAPORATOR KIT PACKING LIST
No. QTY. PART No. DESCRIPTION
1.2.
11
744004-VUE784065
GEN IV 4-VENT EVAP. SUB CASE 1962-65 NOVA ACCESSORY KIT
GEN IV 4-VENT EVAP. SUB CASE
744004-VUE
1
ACCESSORY KIT784065
NOTE: IMAGES MAY NOT DEPICT ACTUAL PARTS AND QUANTITIES.REFER TO PACKING LIST FOR ACTUAL PARTS AND QUANTITIES
2
.
Recommended