1961-62 CHEVROLET IMPALA - Speedway Motorsstatic.speedwaymotors.com/pdf/725964062.pdf · 1961-62 CHEVROLET IMPALA with FACTORY AIR 564062 904062 REV D 08/01/14, 1961-62 IMPALA w

1961-62 CHEVROLET IMPALA with FACTORY AIR

564062

904062 REV D 08/01/14, 1961-62 IMPALA w/ AC INST PG 1 OF 26

an ISO 9001:2008 Registered Company


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. CONENDER ASSEMBLY, COMPRESSOR & BRACKET, PULLEYS & PASSENGER COMPARTMENT FIGURES 2 & 3 8. DEFROST DUCT INSTALLATION & SPEAKER MOUNTING FIGURES 4, 4a & 5 9. EVAPORATOR INSTALLATION FIGURES 6 & 6a10. EVAPORATOR INSTALLATION CONT. FIGURES 7 & 7a11. FIREWALL COVERS FIGURE 812. DRAIN HOSE INSTALLATION & DRIVER & PASSENGER SIDE UNDER DASH LOUVER MOUNTING HOLES FIGURES 9, 10 & 1113. DRIVER SIDE UNDER DASH LOUVER INSTALLATION & CENTER/PASSENGER SIDE UNDER DASH LOUVER INSTALLATION FIGURES 12, 12a, 13, 13a & 13b14. LUBRICATING O-RINGS, A/C HOSE INSTALLATION & MODIFIED A/C HOSE KIT FIGURE 1415. HEATER HOSE & HEATER CONTROL VALVE INSTALLATION FIGURE 1516. A/C & HEATER HOSE ROUTING FIGURE 1617. FINAL STEPS & GLOVE BOX INSTALLATION FIGURES 17 & 17a18. CONTROL PANEL & DUCT HOSE ROUTING FIGURE 1819. EVAPORATOR HARDLINE INSTALLATION FIGURE 1920. WIRING DIAGRAM21. GEN IV WIRING CONNECTION INSTRUCTIONS22. OPERATION OF CONTROLS23. TROUBLESHOOTING INFORMATION24. TROUBLESHOOTING INFORMATION CONT.25. DRIVER SIDE DASH LOUVER BEZEL & DEFROST DUCT MOUNTING TEMPLATE26. EVAPORATOR KIT PACKING LIST

PAGES


EVAPORATOR KIT PACKING LISTNo. QTY. PART No. DESCRIPTION

1.2.

11

744004-VUE784062

GEN IV MAGNUM EVAP. SUB CASE1961-62 IMPALA with A/C ACCESSORY KIT

** 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 KIT564062

GEN IV MAGNUMEVAP. SUB CASE

744004-VUE

ACCESSORY KIT784062

NOTE: IMAGES MAY NOT DEPICT ACTUAL PARTS AND QUANTITIES.REFER TO PACKING LIST FOR ACTUAL PARTS AND QUANTITIES.

1

2


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. VintageAir Recommends Our Systems Be Charged By Weight With a Quality

Charging Station or Scale.

Service Info:

Safety Switches:

Important Notice—Please Read

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 35-45 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.

For Maximum System Performance, Vintage Air Recommends the Following:

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.

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.

Refrigerant Capacity for Vintage Air Systems:(For other systems, consult manufacturer’s guidelines)

R134a SystemCharge 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).

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.

Heater Hose (Not Included With This Kit):

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.

Bolts Passing Through Cowl and/or Firewall:


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.

•

•

•


BEFORE STARTING THE AIR CONDITIONER INSTALLATION, CHECK FOR PROPER OPERATION OF ALLCOMPONENTS (RADIO, LIGHTS, WIPERS, ETC.). STUDY THE INSTRUCTIONS, ILLUSTRATIONS AND

DIAGRAMS. FOR EASE OF INSTALLATION CHECK OFF ( ) EACH PROCEDURE PRIOR TO MOVING ONTO THE NEXT STEP.

ENGINE COMPARTMENTDISCONNECT BATTERY AND REMOVE.DRAIN RADIATOR.EVACUATE THE A/C SYSTEM IF NECESSARY.REMOVE OEM CONDENSER AND DRIER (DISCARD). SEE FIGURE 1.REMOVE OEM A/C LINES FROM COMPRESSOR TO EVAPORATOR (DISCARD). SEE FIGURE 1.REMOVE OEM A/C COMPRESSOR AND COMPRESSOR BRACKET (DISCARD). SEE FIGURE 1.REMOVE OEM BLOWER ASSEMBLY (DISCARD). SEE FIGURE 1.TO REMOVE OEM EVAPORATOR ASSEMBLY, THE FACTORY MANUAL INDICATES DOING THEFOLLOWING: REMOVE THE RIGHT FENDER AND SKIRT.

OEMHEATER/BLOWER

ASSEMBLYOEM

EVAPORATORASSEMBLY

OEMA/C LINE

OEMDRIER

FIGURE 1

OEMCOMPRESSOR

FENDER


CONDENSER ASSEMBLY & INSTALLATIONREFER TO SEPARATE INSTRUCTIONS INCLUDED WITH THE CONDENSER KIT TO INSTALL THE CONDENSER.BINARY SWITCH INSTALLATION (REFER TO CONDENSER INSTRUCTIONS).

REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH THE BRACKET KIT TO INSTALL THE COMPRESSORBRACKET.

IN MOST INSTANCES, THE BELT LENGTHS WILL REMAIN THE SAME.

SPEAKER

OEMA/C DUCT

HOSE

OEMDEFROST DUCT

DASHSUPPORT DASH

SUPPORTINNER COWL

DEFORST DUCTUSE A CHISEL ORDIE GRINDER TO

BREAK SPOT WELDSOEM

HEATER PLENUM

GLOVEBOX

FIGURE 2

FIGURE 3

OEMCONTROL PANEL

OEMPASSENGER SIDE

LOUVER ASSEMBLY

OEMCENTER LOUVER

ASSEMBLY

OEMDRIVER SIDE

LOUVER ASSEMBLY

RADIO

REMOVE PASSENGER SIDE OEM A/C DUCT ASSEMBLY. SEE FIGURE 2, BELOW.REMOVE DRIVER SIDE OEM A/C DUCT, LOUVER. SEE FIGURE 2.REMOVE OEM CENTER LOUVER ASSEMBLY. SEE FIGURE 2.REMOVE THE OEM CONTROL PANEL ASSEMBLY. SEE FIGURE 2, BELOW.REMOVE OEM HEATER ASSEMBLY. SEE FIGURE 2, BELOW.REMOVE GLOVE BOX (DISCARD).REMOVE RADIO AND SPEAKER (RETAIN).REMOVE OEM DEFROST DUCT ASSEMBLY. SEE FIGURE 3, BELOW(REMOVE (3) SPOT WELDS ON DEFROST DUCT BY CHISEL OR DIE GRINDER.SEE FIGURE 3, BELOW).

COMPRESSOR & BRACKETS

PULLEYS

PASSENGER COMPARTMENT


DEFROST DUCT INSTALLATION

SPEAKER MOUNTING

CUT OUT DEFROST DUCT MOUNTINGTEMPLATE ON PAGE 25.

PLACE TEMPLATE ON INNERCOWL, ALIGN TEMPLATE ASSHOWN, AND TAPE TEMPLATEIN PLACE. SEE FIGURE 4.

USING A CENTER PUNCH OR SCRIBE,MARK THE TWO MOUNTING HOLESON INNER COWL.

ONCE HOLES ARE MARKED, REMOVETHE TEMPLATE AND DRILL (2) 1/8”HOLES IN INNER COWL.

INSTALL A J-NUT ON THE END OF THESPEAKER BRACKET AS SHOWN IN FIGURE4a.

PLACE DEFROST DUCT UNDER DASH, ANDALIGN WITH OEM DEFROST DUCT OPENINGIN DASH AND MOUNTING HOLES IN INNERCOWL.

ONCE DEFROST DUCT AND SPEAKER BRACKET ARE ALIGNED,SECURE DEFROST DUCT AND SPEAKER BRACKET TO INNER COWLUSING (2) #10 x 1/2” SHEET METAL SCREWS. SEE FIGURE 4a, BELOW.

USING A #10 x 1/2”SHEET METAL SCREW,SECURE THE SPEAKERBRACKET TO THEBRACKET ON THEDEFROST DUCT.SEE FIGURE 5.

DASH SUPPORTBRACE

TAPE

TEMPLATE

FIGURE 4

FIGURE 4a

FIGURE 5

INNER COWL

J-NUT

DEFROSTDUCT

SPEAKERBRACKET

#10 x 1/2”SHEET METAL

SCREW

(2) #10 SHEET METALSCREW

VIEW SHOWN THROUGH GLOVEBOX OPENING IN DASH

MARKMOUNTING

HOLES


EVAPORATOR INSTALLATIONON A WORKBENCH, INSTALL EVAPORATOR FRONT & REAR MOUNTING BRACKETS ON EVAPORATOR USING(6) 1/4-20 x 1/2” HEX BOLTS, AND TIGHTEN AS SHOWN IN FIGURES 6 & 6a, BELOW.

INSTALL HARDLINES WITH PROPERLY LUBRICATED O-RINGS (SEE FIGURE 14, PAGE 14, AND FIGURE 19,PAGE 19).

1/4-20 x 1/2”HEX BOLT

1/4-20 x 1/2”HEX BOLT

1/4-20 x 1/2”HEX BOLT

18289-VUB1/4-20 x 1 ½”COARSE BOLTw/ 18125-VUBFLAT WASHER

1/4-20 x 1/2”HEX BOLT

EVAPORATORPASSENGER REAR

BRACKET643063

18040-VUB3/4” NYLON

SPACER

BRACKET

189125-MUR1/4” PUSH NUTBOLT RETAINER

EVAPORATORDRIVER SIDE

REAR BRACKET643064

FIGURE 6

FIGURE 6a

EVAPORATORFRONT BRACKET

643062


EVAPORATOR INSTALLATION CONT.LIFT EVAPORATOR UNIT UP UNDER THE DASHBOARD. SEE FIGURE 7. SECURE LOOSELY TO THE FIREWALLFROM THE ENGINE COMPARTMENT SIDE USING (2) 1/4-20 NUTS AND WASHERS. SEE FIGURE 7.USING A 1/4-20 x 1 ¼” PH PAN HEAD SCREW WITH A 1/4” x 3/4” FLAT WASHER, SECURE THE FRONTEVAPORATOR MOUNTING BRACKET TO DASH. SEE FIGURES 7 AND 7a.VERIFY THAT EVAPORATOR UNIT IS LEVEL AND SQUARE TO THE DASH, THEN TIGHTEN ALL MOUNTINGBOLTS. NOTE: TIGHTEN THE BOLT ON FIREWALL FIRST, THEN THE FRONT MOUNTING BRACKET SCREWS.

BRACKET ONBACK SIDE OF

UNIT

BRACKET ONBACK SIDE OF

UNIT

1/4-20 NUT w/FLAT WASHER

1/4-20 NUT w/FLAT WASHER

EVAPORATOR

FIGURE 7

FIGURE 7a

BRACKET

DASH

1/4-20WELL NUT

1/4” x 3/4”FLAT WASHER

1/4-20 x 1 ¼”PH PAN HEAD

SCREW


FIREWALL COVERSAPPLY A 1/4” BEAD OF SILICONE AROUND THE BACK SIDE OF THE A/C BLOCK-OFF PLATE AS SHOWN INFIGURE 8, BELOW.INSTALL THE A/C BLOCK-OFF PLATE USING (9) #14 x 3/4” SHEET METAL SCREWS AS SHOWN IN FIGURE 8,BELOW.APPLY A 1/4” BEAD OF SILICONE AROUND THE BACK SIDE OF THE HEATER/BLOWER COVER AS SHOWNIN FIGURE 8, BELOW.INSTALL THE HEATER/BLOWER COVER USING (7) #14 x 3/4” SHEET METAL SCREWS AS SHOWN IN FIGURE8, BELOW.DRILL (2) 1/8” HOLES IN FIREWALL USING THE HEATER/BLOWER COVER AS A TEMPLATE. SEE FIGURE 8, BELOW.APPLY A 1/4” BEAD OF SILICONE AROUND THE BACK SIDE OF THE FIREWALL COVER AS SHOWN INFIGURE 8, BELOW.PASS LINES THROUGH FIREWALL COVER, AND SECURE WITH (5) 7/16” PANEL RETAINERS. SEE FIGURE 8,BELOW.

HEATER/BLOWERCOVER627063

FIREWALLCOVER627062

(5) 7/16”PANEL RETAINERS

189002-MSR

RETAINERS

SILICONE

FIGURE 8BACK SIDE

OF FIREWALLCOVER

(9) #14 x 3/4”SHEET METAL SCREWS

18266-VUB

A/CBLOCK-OFF

PLATE627064

(7) #14 x 3/4”SHEET METAL SCREWS

18266-VUB


DRAIN HOSE INSTALLATION

DRIVER SIDE UNDER DASH LOUVER MOUNTING HOLES

PASSENGER SIDE UNDER DASH LOUVER MOUNTING HOLES

LOCATE EVAPORATOR DRAIN ON BOTTOM OFEVAPORATOR CASE.

IN LINE WITH DRAIN, LIGHTLY MAKE A MARKON THE FIREWALL. MEASURE ONE INCH DOWNAND DRILL A 5/8” HOLE THROUGH THE FIREWALL.SEE FIGURE 9, BELOW.

INSTALL DRAIN HOSE TO BOTTOM OFEVAPORATOR UNIT AND ROUTE THROUGHFIREWALL. SEE FIGURE 9, BELOW.

CUT OUT TEMPLATE PROVIDED ON PAGE 25. PLACE THETEMPLATE UNDER THE DASH ON THE DRIVER SIDE, BYALIGNING THE LEFT SIDE OF THE TEMPLATE AGAINSTTHE EDGE OF TEH DASH AS SHOWN. MAKE SURE THEOEM HOLES LINE UP WITH THE HOLES ON THE TEMPLATEAS SHOWN IN FIGURE 10, BELOW.

ONCE TEMPLATE IS ALIGNED CORRECTLY AND TAPED INTOPLACE, MARK MOUNTING HOLES ON DASH. ONCE HOLESARE MARKED IN THE CORRECT LOCATION, DRILL (2) 3/16”HOLES IN THE DASH FOR THE DRIVER SIDE LOUVER BEZEL.SEE FIGURE 10.

USING THE (2) OEM HOLES UNDER THE DASH ASA TEMPLATE, DRILL (2) 3/16” HOLES IN DASH ASSHOWN IN FIGURE 11.

1” DRAINHOSE

DRILL(2) 3/16”HOLES

DRILL(2) 3/16”HOLES

FIGURE 9

FIGURE 10

FIGURE 11


DRIVER SIDE UNDER DASH LOUVER INSTALLATION

CENTER/PASSENGER SIDE UNDER DASH LOUVER INSTALLATION

PLACE LOUVER BEZEL UNDER DASH AND ALIGN WITH THE 3/16” HOLES IN DASH.SECURE LOUVER BEZEL UNDER DASH USING (2) 10-32 x 1/2” PH PAN HEAD SCREWS w/ 10-32 NUTS w/STAR WASHERS. SEE FIGURE 12, BELOW.INSTALL LOUVER IN UNDER DASH BEZEL AS SHOWN IN FIGURE 12a, BELOW.

PLACE LOUVER BEZEL UNDER DASH AND ALIGN WITH OEM HOLES IN DASH, AND SECURE WITH(2) 10-32 x 1/2” PH PAN HEAD SCREWS w/ 10-32 NUTS w/ STAR WASHERS AS SHOWN IN FIGURE 13,BELOW.INSTALL THE CENTER LOUVER HOSE ADAPTER IN THE OEM CENTER VENT HOUSING USING (2) #8 x 1/2”PH PAN HEAD SCREWS w/ WASHERS, AS SHOWN BELOW IN FIGURE 13a.INSTALL OEM CENTER VENT HOUSING UNDER DASH USING (2) OEM SCREWS AS SHOWN IN FIGURE 13b,BELOW.INSTALL OEM LOUVER IN PASSENGER SIDE UNDER DASH BEZEL AS SHOWN BELOW IN FIGURE 13b.

(2) 10-32 x 1/2”PH PAN

HEAD SCREWSw/ NUTS w/ STAR WASHERS

(2) 10-32 x 1/2”PH PAN

HEAD SCREWSw/ NUTS w/ STAR WASHERS

494164DRIVER SIDE

LOUVER BEZELASSEMBLY OEM

LOUVER

OEMLOUVER

OEMLOUVER

FINAL ASSEMBLY

OEMLOUVER

(2) OEMSCREWS

PASSENGER SIDELOUVER ASSEMBLY

(2) 3/16”FLAT WASHERS

(2) #8 x 1/2”PH PAN HEAD

SCREWS

CENTER LOUVERHOSE ADAPTER

ASSEMBLY

FIGURE 12

FIGURE 13 FIGURE 13a

FIGURE 13b

FIGURE 12a


LUBRICATING O-RINGS

O-RING

LOCATE THE #8 COMPRESSOR A/C HOSE. LUBRICATE (2) #8 O-RINGS (SEE FIGURE 14, ABOVE) AND CONNECTTHE 135° FEMALE FITTING w/ 134a SERVICE PORT TO THE #8 DISCHARGE PORT ON THE COMPRESSOR.ROUTE THE STAIGHT FEMALE FITTING TO THE #8 CONDENSER HARDLINE COMING THROUGH CORE SUPPORT.SEE FIGURE 16, PAGE 16. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN FIGURE 14, ABOVE.

LOCATE THE #10 COMPRESSOR A/C HOSE. LUBRICATE (2) #10 O-RINGS (SEE FIGURE 14, ABOVE) ANDCONNECT THE #10 135° FEMALE FITTING w/ 134a SERVICE PORT TO THE #10 SUCTION PORT ON THECOMPRESSOR. ROUTE THE 45° FEMALE FITTING TO THE #10 EVAPORATOR HARDLINE COMING THROUGHTHE FIREWALL. SEE FIGURE 16, PAGE 16. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN FIGURE 14,ABOVE. NOTE: WRAP THE #10 FITTING CONNECTIONS WITH PRESS TAPE. SEE FIGURE 15, PAGE 15.

LOCATE THE #6 EVAP/CORE HARDLINE AND LUBRICATE (2) #6 O-RINGS (SEE FIGURE 14, ABOVE) ANDCONNECT THE HARDLINE TO THE #6 HARDLINE COMING THROUGH THE CORE SUPPORT FROM DRIER.ATTACH THE OTHER END OF THE HARDLINE WITH LUBRICATED O-RING TO THE #6 EVAPORATOR HARDLINECOMING THROUGH THE FIREWALL. SEE FIGURE 16, PAGE 16. TIGHTEN EACH FITTING CONNECTION ASSHOWN IN FIGURE 14, ABOVE.

USE A #2 & #10 ADEL CLAMP TO SECURE THE #6 EVAP/CORE HARDLINE AND THE 5/8” HEATER HOSE TOTHE INNER FENDER WELL AS SHOWN IN FIGURE 16, PAGE 16. SECURE THE ADEL CLAMP TO THE INNERFENDER USING (2) 10-32 x 1/2” PH PAN HEAD SCREWS w/ NUTS.

REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH MODIFIED HOSE KIT.

FIGURE 14

O-RING

FOR A PROPER SEAL OF FITTINGS:INSTALL SUPPLIED O-RINGS AS SHOWNAND LUBRICATE WITH SUPPLIED OIL.

MALEINSERT

FEMALENUT

TWIST WITHTHIS WRENCH

HOLD WITHTHIS WRENCH

SUPPLIED OILFOR O-RINGS O-RING, INSTALLS

OVER MALE INSERTTO SWAGED LIP

#6 O-RING

#8 O-RING #10 O-RING

A/C HOSE INSTALLATIONSTANDARD HOSE KIT

MODIFIED A/C HOSE KIT


HEATER HOSE & HEATER CONTROL VALVE INSTALLATION

ECUMODULE

HEATERHOSE

FROMINTAKE

HEATER VALVE

FIGURE 15

O-RING

NOTE: FLOW DIRECTION FOLLOWSMOLDED ARROW ON VALVE

PRESS TAPE

#6 LIQUID LINE091067

EXPANSIONVALVE

#10 SUCTIONLINE (INSULATED)

09151-PCS#10 SUCTION

HOSE096063

#6 LIQUIDLINE

091062

TOWATER PUMP

FROM HEATERCONTROL VALVE

5/8” HEATER LINE (INTAKE)091065

5/8” HEATER LINE (WATER PUMP)091066PRESS

TAPE

ROUTE A PIECE OF HEATER HOSE FROM THE WATER PUMP TO THE HEATER LINE COMING THROUGHT THEFIREWALL AS SHOWN IN FIGURE 15, BELOW. SECURE USING HOSE CLAMPS.

ROUTE A PIECE OF HEATER HOSE FROM THE INTAKE TO THE HEATER LINE COMING THROUGH THE FIREWALLAS SHOWN IN FIGURE 15, BELOW. NOTE: INSTALL HEATER CONTROL VALVE IN LINE WITH INTAKEMANIFOLD (PRESSURE SIDE) HEATER HOSE. SECURE USING HOSE CLAMPS AS SHOWN IN FIGURE 15,BELOW. NOTE PROPER FLOW DIRECTION.

NOTE: VINTAGE AIR SYSTEMS REQUIRE (2) 5/8” HOSE NIPPLES (NOT SUPPLIED): ONE FOR THE INTAKE(PRESSURE) AND ONE FOR THE WATER PUMP (SUCTION). IF REQUIRED, REMOVE EXISTING HOSE NIPPLEOR NIPPLES AND INSTALL NEW 5/8” HOSE NIPPLES IN INTAKE AND WATER PUMP.


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FINAL STEPS

GLOVE BOX INSTALLATION

INSTALL DUCT HOSES AS SHOWN IN FIGURE 18, PAGE 18.

ROUTE A/C WIRES THROUGH 3/8” GROMMET AS SHOWN IN FIGURE 17a (12 VOLT/GROUND/BINARYSWITCH/HEATER VALVE).

INSTALL CONTROL PANEL ASSEMBLY.

PLUG THE CONTROL PANEL HARNESS INTO THE ECU MODULE ON SUB CASE AS SHOWN ON PAGE 18.

PLUG THE WIRING HARNESS INTO THE ECU MODULE ON SUB CASE AS SHOWN IN FIGURE 18, PAGE 18(WIRE ACCORDING TO WIRING DIAGRAM ON PAGE 20 & 21).

GLOVE BOX INSTALLATION (SEE FIGURE 17).

REINSTALL ALL PREVIOUSLY REMOVED ITEMS (BATTERY, RADIO, SPEAKER).

FILL RADIATOR WITH AT LEAST A 50/50 MIXTURE OF APPROVED ANTIFREEZE AND DISTILLED WATER. IT ISTHE OWNER’S RESPONSIBILITY TO KEEP THE FREEZE PROTECTION AT THE PROPER LEVEL FOR THE CLIMATEIN WHICH THE VEHICLE IS OPERATED. FAILURE TO FOLLOW ANTIFREEZE RECOMMENDATIONS WILL CAUSEHEATER CORE TO CORRODE PREMATURELY AND POSSIBLY BURST IN A/C MODE AND/OR FREEZINGWEATHER, VOIDING YOUR WARRANTY.

DOUBLE CHECK ALL FITTINGS, BRACKET AND BELT FOR TIGHTNESS.

VINTAGE AIR RECOMMENDS THAT ALL A/C SYSTEMS BE SERVICED BY A CERTIFIED AUTOMOTIVE AIRCONDITIONING TECHNICIAN.

EVACUATE THE SYSTEM FOR A MINIMUM OF 45 MINUTES PRIOR TO CHARGING, AND LEAK CHECK PRIORTO SERVICING.

CHARGE THE SYSTEM TO THE CAPACITIES STATED ON THE INFORMATION PAGE (PAGE 4) OF THISINSTRUCTION MANUAL.

INSTALL GLOVE BOX PROVIDED, AND SECURE WITH (3) OEM SCREWS THROUGH OEM HOLES. SEEFIGURE 17.

INSTALL GLOVE BOX DOOR.

(3) OEMSCREWS

FIGURE 17FIGURE 17a

GROMMET33144-VUI

FIREWALLCOVER627062


CONTROL PANEL & DUCT HOSE ROUTING

DRIVER SIDEDEFROST DUCT

2” x 15”

PASSENGER SIDEDEFROST DUCT

2” x 15”

PLUGFROM

WIRINGHARNESS

232001-VUR

PLUGFROM

CONTROLWIRING

HARNESS232002-VUA

DRIVER SIDELOUVER

2 ½” x 36”

PASSENGERSIDE LOUVER2 ½” x 38”

CENTER LOUVERDRIVER SIDE2 ½” x 12”

CENTER LOUVERPASSENGER SIDE

2 ½” x 12”PASSENGER

SIDELOUVER

CENTERLOUVER

PASSENGERSIDE

CENTER LOUVERDRIVER SIDE

FIGURE 18DRIVER SIDE

LOUVER


EVA

PO

RA

TOR

HA

RD

LIN

E IN

STA

LLA

TIO

N

PRES

S TA

PE#

10

O-R

ING

(33

85

9-V

UF)

#10 O

-RIN

G(3

3859-V

UF)

#1

0 S

UC

TIO

NLI

NE

(09

151-P

CS)

#6

O-R

ING

(33857-V

UF)

#6 L

IQU

ID L

INE

091067

FIG

UR

E 19

HEA

TER

LIN

E(E

VA

P TO

INTA

KE)

091065 H

EATE

R LI

NE

(EVA

P TO

WA

TER

PUM

P)091

06

6

ECU

MO

DU

LE


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


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.


OPERATION OF CONTROLS

NOTE:ORIGINAL BLOWERSWITCH WILL NOTBE USED.

BLOWERSPEED

SYSTEM OFF

HEAT MODE DEFROST/DEFOGMODE

A/C MODE

BLOWER SPEEDTHIS LEVER CONTROLS

THE BLOWER SPEED,FROM OFF TO HI

BLOWER SPEEDSLIDE THE FAN LEVER

UP OR DOWNTO SELECT DESIRE

FAN SPEED(SLIDE LEVER ALL THE WAY

DOWN FOR MAXIMUMFAN SPEED)

MODE LEVERSLIDE THE DEF LEVER ALL THE

WAY UP FOR DASH MODE

THERMOSTAT LEVERIN A/C MODE SLIDE THEAIR LEVER ALL THE WAY

DOWN TO ENGAGECOMPRESSOR FOR

MAXIMUM COOLING.(SLIDE LEVER UP OR DOWN TOADJUST DESIRED TEMPERATURE)





MODE LEVERSLIDE THE DEF LEVERTO THE CENTER FOR

FLOOR MODE(SLIDE LEVER UP OR DOWN

TO BLEND BETWEEN DESIREDMODE POSITIONS)

THERMOSTAT LEVERIN HEAT MODE SLIDE THEAIR LEVER ALL THE WAY

UP FOR MAXIMUM HEATING.(SLIDE LEVER UP OR DOWN TOADJUST DESIRED TEMPERATURE)





MODE LEVERSLIDE THE DEF LEVER

ALL THE WAY DOWN FORDEFROST MODE (SLIDE LEVER UPOR DOWN TO BLEND BETWEEN

DESIRED MODE POSITIONS)

THERMOSTAT LEVERIN DEF/DEFOG MODE SLIDE

THE COMPRESSOR ISAUTOMATICALLY ENGAGEDFOR MAXIMUM COOLING.

(SLIDE LEVER UP OR DOWN TOADJUST DESIRED TEMPERATURE)

THERMOSTAT LEVERTHIS LEVER CONTROLS

THE TEMPERATURE,FROM HOT TO COLD

MODE LEVERTHIS LEVER CONTROLSTHE MODE POSITIONS,FROM DASH TO FLOOR

TO DEFROST

MODELEVER

THERMOSTATLEVER

INSTALL KNOBS AS SHOWN

HEAT FAN AIR DEF

NOTE: WHEN BATTER POWER IS FIRST CONNECTED TO THE ECU,THE COMPUTER GOES THROUGH AN INITIALIZATION SEQUENCE.THIS INITIALIZATION MAY TAKE UP TO 30 SECONDS. DURINGINITIALIZATION THE BLOWER WILL NOT OPERATE, BUT THEDOORS INSIDE THE UNIT WILL BE OPERATING. A LOW BATTERY ORDISCONNECTING THE BATTERY MAY ALSO TRIPPER ARE-INITIALIZATION. DURING START UP, A LOW BATTERY MAY DROPBELOW 7 VOLTS, TRIGGERING RE-INITIALIZATION.


Sym

pto

m

C

on

dit

ion

Ch

eck

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

.


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.


DRIVER SIDE UNDER DASH LOUVER BEZEL TEMPLATE & DEFROSTDUCT MOUNTING TEMPLATE

DRILL 3/16”

ALIGN THIS EDGE AGAINSTDASH BRACE

CU

T A

LON

G D

OTT

ED L

INE

CU

T A

LON

G D

OTT

ED L

INE

CU

T ALO

NG

DO

TTED LIN

E

3.3

75”

DRILL 3/16”

DEFR

OST D

UC

T MO

UN

TING

TEMP

LATE

DR

IVER

SID

E U

ND

ER D

ASH

LOU

VER

TEM

PLA

TE


EVAPORATOR KIT PACKING LISTNo. QTY. PART No. DESCRIPTION

1.2.

11

744004-VUE784062

GEN IV MAGNUM EVAP. SUB CASE1961-62 IMPALA with A/C ACCESSORY KIT

CHECKED BY:PACKED BY:

DATE:

EVAPORATOR KIT564062

GEN IV MAGNUMEVAP. SUB CASE

744004-VUE

ACCESSORY KIT784062

NOTE: IMAGES MAY NOT DEPICT ACTUAL PARTS AND QUANTITIES.REFER TO PACKING LIST FOR ACTUAL PARTS AND QUANTITIES.

1

2

Documents

1961-62 CHEVROLET IMPALA - Speedway Motorsstatic.speedwaymotors.com/pdf/725964062.pdf · 1961-62 CHEVROLET IMPALA with FACTORY AIR 564062 904062 REV D 08/01/14, 1961-62 IMPALA w