GEN IV MAGNUM - Vintage AirGEN IV MAGNUM HEAT/COOL/DEFROST EVAPORATOR KIT 671400-VUZ 901400-VUZ REV F 6/25/14, INST GEN IV MAGNUM PG 1 OF 18 an ISO 9001:2008 Registered Company 2 901400-VUZ

GEN IV MAGNUM HEAT/COOL/DEFROST EVAPORATOR KIT

671400-VUZ

901400-VUZ REV F 6/25/14, INST GEN IV MAGNUM PG 1 OF 18

an ISO 9001:2008 Registered Company


TABLE OF CONTENTS

PAGES

1. 2. 3. 4. 5. 6. 7.

8. 9. 10.

11.

12. 13.14.15.16.17.

COVERTABLE OF CONTENTSPACKING LIST/PARTS DISCLAIMERINFORMATION PAGE

PLANNING OVERVIEW AND DEFROST DUCT INSTALLATIONCONSENSER ASSEMBLY & INSTALLATION, COMPRESSOR & BRACKETS, HEATER FITTING INSTALLATIONBRACKET INSTALLATIONEVAPORATOR INSTALLATIONEVAPORATOR INSTALLATION CONT., DRAIN HOSE

HEATER HOSE & HEATER CONTROL VALVE INSTALLATION,

CONTROL PANEL/DUCT HOSE ROUTINGWIRING DIAGRAMGEN IV WIRING CONNECTION DIAGRAMOPERATION OF CONTROLSTROUBLESHOOTING INFORMATIONTROUBLESHOOTING INFORMATION CONT.EVAPORATOR KIT PACKING LIST

18.

WIRING NOTICE

INSTALLATION, A/C HOSE INSTALLATION

FINAL STEPS

3901400-VUZ REV E 6/25/14, INST GEN IV MAGNUM PG 3 OF 18

** 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.

1.2.

11

744004-VUE784004-VUA

1

2

GEN IV MAGNUM EVAP. SUB CASE GEN IV MAGNUM ACC. KIT

GEN IV MAGNUMEVAP. SUB CASE

744004-VUE

ACCESSORY KIT784004-VUA

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

EVAPORATOR KIT PACKING LISTEVAPORATOR KIT

671400-VUZ

No. QTY. PART No. DESCRIPTION


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.

•

•

•


DEFROST DUCT

ALIGN DEFROST DUCT WITH OPENING IN DASH, IF APPLICABLE. USE OEM MOUNTING HOLE LOCATIONS OR MARK AND DRILL 1/8” MOUNTING HOLES. USE (4) #8 x ½” SCREWS TO SECURE THE NEW DEFROST DUCTS AS SHOWN IN FIGURE 1, BELOW.

NOTE: FOR AN ALTERNATE INSTALLATION METHOD, APPLY SILICONE, EPOXY, ETC., TO DEFROST DUCTS AND ALIGN WITH OPENINGS IN DASH.

PLANNING OVERVIEWEVERY VEHICLE IS A LITTLE DIFFERENT, DEPENDING ON THE: 1. TYPE OF VEHICLE/ENGINE AND LOCATION OF ENGINE. 2. TYPE OF AIR CONDITIONING EQUIPMENT USED. 3. OWNER’S PREFERENCES.

THERE ARE MANY FACTORS THAT GO INTO MAKING EACH AIR CONDITIONING INSTALLATIONDIFFERENT. USUALLY, ALL OF THE ABOVE DECISIONS ARE MADE BEFORE ANY CONSIDERATIONIS GIVEN TO THE AIR CONDITIONING INSTALLATION. THE A/C SYSTEM IS THEN TAILORED TO FITYOUR PARTICULAR APPLICATION.

THE MOUNTING LOCATION OF THE EVAPORATOR UNIT IS DETERMINED IN PART BY THE SPACEAVAILABLE FOR THE HOSE ROUTING. THE COMPONENTS USED IN THE HOSE ROUTING PROCESS (I.E.BULKHEAD PLATES, FITTINGS, AND GROMMETS, ETC.) WILL ALSO INFLUENCE THE LOCATION OFTHE EVAPORATOR UNIT. WHEN PLANNING YOUR HOSE ROUTING, YOU MUST INSTALL THE MAJORCOMPONENT PARTS. MOUNT THE COMPRESSOR, CONDENSER AND DRIER. THE EVAPORATORMUST BE TEMPORARILY HELD IN POSITION UNDER THE DASH. FINAL MOUNTING OF THE EVAPORATOR TO THE FIREWALL SHOULD NOT BE DONE UNTIL YOU HAVE VERIFIED THAT ALL HOSESATTACHING TO THE EVAPORATOR WILL EXIT THE FIREWALL AND/OR KICK PANEL AS PLANNED. THE HOSES MUST BE RUN EXACTLY THE WAY THEY WILL BE WHEN FINISHED, BEFORE CUTTING THEM TOLENGTH.

DUCT HOSE ROUTING AND A/C VENT LOCATIONS SHOULD ALSO BE GIVEN CAREFUL CONSIDERATIONBEFORE FINAL MOUNTING POSITION OF THE EVAPORATOR IS SELECTED.

THE VINTAGE AIR GEN IV MAGNUM UNIT WAS DESIGNED FOR CLASSIC CARS, CUSTOM CARS, ANDTRUCKS. THE EVAPORATOR UNIT IS DESIGNED TO MOUNT BEHIND THE DASH.

READ THE INSTALLATION INSTRUCTIONS COMPLETELY, AND FAMILIARIZE YOURSELF WITH ALL THE PARTS AND ILLUSTRATIONS.

THE INSTALLATION OF THIS UNIT VARIES ACCORDING TO THE BODY MANUFACTURER OR MODIFICATIONS TO THE ORIGINAL BODY. TAKE YOUR TIME, AND DOUBLE CHECK BEFORE DRILLING OR CUTTING.

REMOVE OEM HEATER, DEFROST DUCTS, CONTROLS, BLOWER ASSEMBLY, A/C EVAPORATOR & CONDENSERIF EQUIPPED.

BEFORE BEGINNING, REMOVE GLOVE BOX TO EASE INSTALLATION. IF THE DASH IS EASILY REMOVABLE, REMOVE IT NOW. CHECK FOR, AND FILL IN ANY HOLES IN THE FIREWALL AND FLOOR. INSULATE AND SEAL FIREWALL, FLOOR, DOOR PANELS, AND HEADLINER TO REDUCE THE AMOUNT OF HEAT ENTERING THE CAR.

DEFROST DUCT

INSTALLATION

FIGURE 1

#8 x ½” SCREWS#8 x ½” SCREWS


HEATER FITTING INSTALLATION ON A WORKBENCH, INSTALL HEATER FITTINGS WITH PROPERLY LUBRICATED O-RINGS (SEE FIGURES 2 & 2a, BELOW).

CONDENSER ASSEMBLY & INSTALLATION

REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH CONDENSER KIT.

REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH BRACKET KIT.

COMPRESSOR & BRACKETS

EXPANSIONVALVE

#6 O-RING #8 O-RING #10 O-RING

O-RINGSUPPLIED OIL FOR O-RINGS

O-RING,SLIDE OVERMALE INSERT TOSWAGED LIP

MALEINSERT

FEMALENUT

FIGURE 8

HOLD WITHTHIS WRENCH

LUBRICATEO-RING

TWIST WITHTHIS

WRENCH

FIGURE 2a

FIGURE 2

(2) #10 FITTING (2)#10 O-RING

NOTE: 45° AND 90° FITTINGSARE AVAILABLE SEPARATELY.

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


BRACKET INSTALLATION ON A WORKBENCH, INSTALL THE FRONT & REAR EVAPORATOR MOUNTING BRACKETS USING (6) 1/4-20 x ½” HEX BOLTS. SEE FIGURE 3, BELOW. NOTE: PASS HEATER FITTINGS THROUGH THE (2) HOLE OPENINGS IN BRACKET AS SHOWN..

(2) 1/4-20 x ½”HEX BOLTS

(2) 1/4-20 x ½”HEX BOLT

(2) 1/4-20 x ½”HEX BOLT

FRONT EVAPORATOR

BRACKET

REAREVAPORATOR

BRACKET

(2) HEATERFITTINGS

FIGURE 3


EVAPORATOR INSTALLATION

NOTE: TYPICAL INSTALLATION SHOWN BELOW. IT MAY BENECESSARY TO MODIFY BRACKETS OR ADD ADDITIONALBRACKETS FOR YOUR SPECIFIC INSTALLATION.

LIFT EVAPORATOR UNIT UP UNDER THE DASHBOARD INTO DESIRED POSITION, AND VERIFY THAT EVAPORATOR UNIT IS LEVEL AND SQUARE TO THE DASH. ONCE IN PLACE, USING THE HOLES IN MOUNTING BRACKETS AS TEMPLATES, MARK MOUNTING HOLE LOCATIONS ON INNER COWL AND FIREWALL.NOTE: DEPENDING ON YOUR INSTALLATION, USE ANY COMBINATION OFHOLES IN THE REAR MOUNTING BRACKET TO SECURE EVAPORATORTO FIREWALL. (THE TOP TWO HOLES ARE USED IN FIGURE 4, BELOW)

INSTALL MOUNTING HARDWARE IN REAR BRACKET AS SHOWNIN FIGURE 4a.

FIGURE 4 a(2) 1/4-20 NUTw/ WASHER

MARK & DRILL(2) 9/32” HOLES

FIREWALL

(2) 18289-VUB1/4-20 x 1/12COARSE BOLTw/ 18125-VUBFLAT WASHER

(2) 18040-VUB3/4” NYLON

SPACER

(2) 189125-MUR1/4” PUSH NUTBOLT RETAINER

(2) #14 x 3/4”SHEET METAL

SCREW

INNER COWL

MARK & DRILL(2) 1/8” HOLES

FIGURE 4


EVAPORATOR INSTALLATION

ONCE BRACKETS ARE INSTALLED, LIFT EVAPORATOR UNIT UP UNDER THE DASHBOARD INTO DESIRED POSITION AND LOOSELY SECURE TO FIREWALL FROM THE ENGINE COMPARTMENT SIDE USING (2) 1/4-20 NUTS WITH WASHERS. SEE FIGURE 4, PAGE 8.

USING (2) #14 x 3/4” SHEET METAL SCREWS, SECURE THE FRONT EVAPORATOR MOUNTING BRACKET TO INNER COWL.SEE FIGURE 4, PAGE 8. NOTE: DO NOT COMPLETELY TIGHTEN SCREWS.

VERIFY THAT THE EVAPORATOR UNIT IS LEVEL AND SQUARE TO THE DASH. THEN TIGHTEN ALL MOUNTING LOCATIONS.NOTE: TIGHTEN THE BOLTS ON THE FIREWALL FIRST. THEN TIGHTEN THE FRONT MOUNTING BRACKET SCREWS .

IN LINE WITH THE DRAIN, LIGHTLY MAKE A MARK ON THE FIREWALL. MEASURE ONE INCH DOWN, AND MARKAND DRILL A 5/8” HOLE THOUGH FIREWALL. SEE FIGURE 5, BELOW.

INSTALL DRAIN HOSE ON DRAIN AND ROUTE THROUGH THE FIREWALL. NOTE: FROM THE ENGINE COMPARTMENT SIDE OF THE FIREWALL, CUT DRAIN HOSE TO DESIRED LENGTH.

DRAIN HOSE INSTALLATION

DRAINDRAINHOSE

1”FIGURE 5

REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH HOSE KIT.

A/C HOSE INSTALLATION


ROUTE A PIECE OF HEATER HOSE FROM THE WATER PUMP TO THE HEATER LINE COMING THROUGH THE FIREWALLAS SHOWN IN FIGURE 6, BELOW. SECURE USING HOSE CLAMPS. NOTE: WATER PUMP SIDE OF SYSTEM IS LOW PRESSURE (SUCTION) SIDE.

HEATER HOSE & HEATER CONTROL VALVE INSTALLATION

FIGURE 6

INSTALL DUCT HOSES AS SHOWN IN FIGURE 7, PAGE 11. STRETCH THE DUCT HOSE TIGHTLY TO THE DASH VENTS. TRIM TO ENSURE THAT THE DUCT HOSE IS TIGHT WITH AS FEW KINKS OR SHARP BENDS IN HOSE AS POSSIBLE.THIS WILL ENSURE MAXIMUM AIRFLOW.

INSTALL CONTROL PANEL. REFER TO CONTROL PANEL KIT INSTRUCTIONS.

ROUTE THE CONTROL PANEL HARNESS ASSEMBLY AND CONNECT TO THE PC BOARD ASSEMBLY ON THE BACK SIDE OF THE CONTROL PANEL AS SHOWN IN FIGURE 7, PAGE 11.

PLUG THE WIRING HARNESS INTO THE ECU MODULE ON SUB CASE AS SHOWN. (WIRE ACCORDING TO WIRING DIAGRAM ON PAGE 12.)

REINSTALL ALL PREVIOUSLY REMOVED ITEMS

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 IN WHICH THE VEHICLE IS OPERATED. FAILURE TO FOLLOW ANTIFREEZE RECOMMENDATIONS WILL CAUSE HEATER CORE TO CORRODE PREMATURELY AND POSSIBLY BURST IN AC MODE AND/OR FREEZING WEATHER, VOIDING YOUR WARRANTY.NOTE: PRIOR TO CHARGING A/C SYSTEM, RUN ENGINE AND CYCLE HEATER CONTROL VALVE TO CIRCULATE ANTIFREEZE THROUGH HEATER CORE.

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

FINAL STEPS - DUCT HOSE ROUTING & CONTROL PANEL HARNESS

FROM IN

TAKE

MANIF

OLD

FROM H

EATER C

ORE

TO WA

TER PU

MP

FROM HEATER CONTROL VALVETO HEATER CORE

FIREWALL

HEATERHOSE

HOSE CLAMPS

ROUTE A PIECE OF HEATER HOSE FROM THE INTAKE TO THE HEATER LINE COMING THROUGH THE FIREWALL AS SHOWN IN FIGURE 6, BELOW. NOTE: INSTALL HEATERCONTROL VALVE IN LINE WITH INTAKE MANIFOLD (PRESSURE SIDE) HEATER HOSE, AND SECURE USING HOSE CLAMPS AS SHOWN IN FIGURE 6, BELOW. ALSO NOTE PROPER FLOW DIRECTION.


CONTROL PANEL & DUCT HOSE ROUTING

REAR VIEW

NOTE: TYPICAL ROUTING SHOWN. LENGTHSAND ROUTING WILL VARY BY INDIVIDUALAPPLICATION.

CENTER LOUVER

DRIVER SIDE

CENTER LOUVER

PASSENGER SIDE

CONTROL PANEL

HARNESS FROM ECU232007-VUR

FIGURE 7

S B

Y

DRIVER SIDE DEF. DUCT

DRIVER SIDE LOUVER

CENTER LOUVERDRIVER SIDE

CENTER LOUVERPASS. SIDE

PASS. SIDE DEF. DUCT

PASS. SIDE LOUVER

PLUGFROM

CONTROLWIRNG

HARNESS232007-VUR

DRIVER SIDE

LOUVER

PASSENGER

SIDELOUVER


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

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.

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).

FAN

C

A/C

FAN

C

A/C

FAN

C

A/C

FAN

C

A/C


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

.


Sym

pto

m

C

on

dit

ion

C

heck

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.


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DATE:

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