1959-60 Chevrolet Full-Size/El Camino - Vintage Air1959-60 Chevrolet Full-Size/El Camino with...
Transcript of 1959-60 Chevrolet Full-Size/El Camino - Vintage Air1959-60 Chevrolet Full-Size/El Camino with...
1959-60 Chevrolet Full-Size/El Camino
with 4-Lever Controls561056
901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT PG 1 OF 23
an ISO 9001:2008 Registered Company
18865 Goll St. San Antonio, TX 78266 ph: 210-654-7171 fax: 210-654-3113
2901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT PG 2 OF 23
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 & Installation, Compressor & Brackets, Pulleys Figure 1 7. Passenger Compartment Figures 2 & 2a 8. Defrost Duct Installation, Fresh Air Cap Installation Figures 3 & 4 9. Kick Panel Fresh Air Plate Installation Figures 5, 5a, 5b & 5c10. Firewall Cover Installation, Evaporator Bracket and Heater Hose Fitting Installation Figures 6 & 711. Evaporator Bracket and Heater Hose Fitting Installation (Cont.) Figure 812. Evaporator Installation Figures 9 & 9a13. Drain Hose Installation, Lubricating O-rings, A/C Hose Installation Figures 10 & 1114. Heater Hose & Heater Control Valve Installation Figure 1215. Driver Side Under Dash Louver Installation, Center/Passenger Side Under Dash Louver Installation Figures 13, 13a, 14 & 14a16. Final Steps Figures 15 & 1617. Control Panel & Duct Hose Routing Figure 1718. Wiring Diagram19. Gen IV Wiring Connection Instruction20. Operation of Controls21. Troubleshooting Information22. Troubleshooting Information (Cont.)23. Evaporator Kit Packing List
3901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT PG 3 OF 23
1
Accessory Kit781160
No. Qty. Part No. Description
NOTE: Images may not depict actual parts and quantities. Refer to packing list for actual parts and quantities.
1.2.
11
** 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.
2
Packing ListEvaporator Kit (561056)
Gen IV 4-Vent Evaporator Sub Case w/ 204 ECUAccessory Kit 59-60 Chevrolet Full-Size/El Camino w/ 4-Lever Controls
Gen IV 4-Vent Evaporator Sub Case w/ 204 ECU
744004-VUE
744004-VUE781160
4901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT PG 4 OF 23
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:
5901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT 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.
•
•
•
6901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT PG 6 OF 23
Condenser Assembly & Installation
Compressor & Brackets
Pulleys
Engine CompartmentBefore starting the installation, check the function of the vehicle (horn, lights, etc.) for proper operation. Study the instructions, illustrations & diagrams.
Perform the Following:
1. Remove battery and battery tray (retain) (See Figure 1, below).
2. Drain radiator.
3. Remove heater blower motor assembly (discard) (See Figure 1, below).
4. Remove OEM heater hoses (discard) (See Figure 1, below).
5. Remove OEM heater wiring.
1. Refer to separate instructions included with the condenser kit to install the condenser.
2. Binary switch installation (Refer to condenser instructions).
1. Refer to separate instructions included with the bracket kit to install the compressor bracket.
1. In most instances, the belt lengths will remain the same.
Battery &Battery Tray
OEMBlower Motor
Assembly
Radiator
Figure 1
7901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT PG 7 OF 23
Passenger Compartment Perform the Following:
1. Remove glove box door (retain) and glove box (discard) (See Figure 2, below).
2. Disconnect all wires and cables from OEM control panel.
3. Remove OEM control panel (retain) (See Figure 2, below).
4. Remove OEM heater assembly (discard) (See Figure 2a, below).
5. Remove OEM duct hose from defrost ducts (discard) (See Figure 2a, below).
6. Remove passenger side OEM kick panel fresh air grille and door (discard) (See Figure 2a, below).
OEM Control Panel
Glove Box Door & Glove Box
Passenger SideKick PanelFresh Air
Grille & Door
OEM Heater
Defrost Duct Hose
Figure 2
Figure 2a
8901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT PG 8 OF 23
Defrost Duct Installation1. Install (2) S-clips onto driver and passenger side defrost duct hose adapters (See Figure 3, below).2. Attach hose adapters to driver and passenger side OEM defrost ducts as shown in Figure 3, below.
Hose Adapters
Driver SideOEM Defrost
Duct
Passenger SideOEM Defrost
Duct
Figure 3
1/4-20 X 1 ½”Bolt w/ Washer
Fresh Air Cap Installation
Silicone
Fresh AirCap(4) Grommets
33137-VUI
Back Sideof Fresh Air
Cap
EngineCompartment
Firewall
Figure 4
1. Install (4) grommets in fresh air cap (See Figure 4, below).2. Apply a 1/4” bead of silicone around the back side of the fresh air cap as shown in Figure 4, below.3. Attach fresh air cap to firewall using a 1/4-20 X 1 ½” bolt and washer (See Figure 4, below). NOTE: Fresh air cap installs on engine side of firewall.
9901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT PG 9 OF 23
Figure 5b
Figure 5c
Figure 5a
Figure 5
Kick PanelFresh Air Plate Installation
1. Install (4) grommets in kick panel plate (See Figure 5a, below).2. Route A/C and heater hoses through fresh air cap and kick panel plate as shown in Figures 5 and 5b, below.3. Apply a 1/4” bead of silicone around the back side of the kick panel plate as shown in Figure 5a, below.4. Secure kick panel plate to kick panel using (6) OEM screws as shown in Figure 5b, below.5. Reinstall kick panel (See Figure 5c, below).6. Secure kick panel fresh air cap to kick panel using (4) #8 x 1 ¼” Phillips pan head screws with washers as shown in Figure 5c, below.
Silicone
Back Side of Kick Panel
Plate
#10 A/C Hose
#6 A/C Hose(2) Heater
Hoses
(4) Grommets33137-VUI
Kick PanelPlate
642050
(6) OEMScrews
(4) #8 x 1 ¼”Phillips Pan
Head Screws w/ Washers
Kick PanelFresh Air
Cap626684
Kick Panel
10901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT PG 10 OF 23
EngineCompartment
Side of Firewall
View Shown From Inside Car, Through Dash
Figure 6
Back Side of Firewall Cover
Evaporator Bracket andHeater Hose Fitting Installation
1. On a workbench, install evaporator rear bracket and heater hose fittings with properly lubricated O-rings (See Figure 8, Page 11, and Figure 11, Page 13).2. Install front mounting bracket onto evaporator using (2) 1/4-20 x 1/2” hex bolts and tighten as shown in Figure 7, below.
Firewall Cover Installation 1. Apply a 1/4” bead of silicone around the back side of the firewall cover as shown in Figure 6, below.2. From inside the car, install firewall cover onto firewall as shown in Figure 6, below. From the engine compartment, secure firewall cover to firewall using (4) 1/4-20 x 1” hex bolts and (4) flat washers (See Figure 6, below).
(2) 1/4-20 X 1/2”Hex Bolts
Front EvaporatorBracket643089
Figure 7
Firewall Cover 648235
(4) 1/4-20 x 1”Hex Bolts
Silicone
(4) FlatWashers
11901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT PG 11 OF 23
Figure 8
ECU Module
(2) 1/4-20 x 1/2”Hex Bolts
(2) 1/4-20 x 1/2”Hex Bolts
RearEvaporator
Bracket643090
Evaporator Bracket andHeater Hose Fitting Installation (Cont.)
Twist WithThis
WrenchLubricate O-ring(See Figure 11,
Page 13)
Hold With This Wrench
(2) HeaterFittings121004
(2) #10 O-rings
12901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT PG 12 OF 23
View Shown From Inside Car, Through Dash
Figure 9
Figure 9aInnerCowl
(2) #14 x 3/4”Sheet Metal
ScrewsDrill (2)
3/16” Holes
Evaporator Installation
NOTE: After installing #10 suction line, wrap allexposed metal (fittings & tube) with supplied press tape.
1. Install A/C & heater hoses as shown in Figure 9a, below.2. Lift evaporator unit up under the dashboard. Secure loosely to the firewall using (2) 1/4-20 x 1” hex bolts and (2) flat washers (See Figure 9, 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 the drain.3. Using front evaporator bracket as a guide, mark and drill (2) 3/16” holes in cowl (See Figure 9, below).4. Using (2) #14 x 3/4” sheet metal screws, secure the front evaporator mounting bracket to the inner cowl (See Figure 9, below).5. Verify that evaporator unit is level and square to the dash; then tighten all mounting bolts. NOTE: Tighten the bolt on the firewall first. Then tighten the front mounting bracket.
(2) 1/4-20 X 1”Hex Bolts
(2) 1/4” Flat Washers
#6 A/C Hose
Heater Hose(To Water Pump)
PressTape
#10 A/C Hose
HoseClamps
Heater Hose(To Heater Control
Valve, Then to Manifold)
13901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT PG 13 OF 23
1. Locate the #8 compressor A/C hose. Lubricate (2) #8 O-rings (See Figure 11, above) and connect the 135° female fitting with 134a service port to the #8 discharge port on the compressor. Route the 45° female fitting to the #8 condenser hardline (See Figure 12, Page 14). Tighten each fitting connection as shown in Figure 11, above.
2. Locate the #10 compressor A/C hose. Lubricate (2) #10 O-rings (See Figure 11, above) and connect the #10 135° female fitting with 134a service port to the #10 suction port on the compressor. Route the 90° female fitting to the #10 fitting on evaporator (See Figure 9a, Page 12, and Figure 12, Page 14). Tighten each fitting connection as shown in Figure 11, above. Install #10 adel clamp on #10 A/C hose, and secure to passenger side fender well using a 10/32 x 1/2” Phillips pan head screw and a 10/32 nut with star washer (See Figure 12, Page 14).
3. Locate the #6 evaporator A/C hose. Lubricate (2) #6 O-rings (See Figure 11, above) and connect the straight female fitting to the drier. Route the 90° female fitting to the #6 fitting on evaporator (See Figure 9a, Page 12, and Figure 12, Page 14). Tighten each fitting connection as shown in Figure 11, above. Install #6 adel clamp on #6 A/C hose, and secure to passenger side fender well using a 10/32 x 1/2” Phillips pan head screw and 10/32 nut with star washer (See Figure 12, Page 14).
A/C Hose InstallationStandard Hose Kit:
Modified A/C Hose Kit:1. Refer to separate instructions included with modified hose kit.
1. Drill a 5/8” hole in firewall using the measurements in Figure 10, below.
2. Install drain hose to bottom of evaporator unit and route through firewall (See Figure 10a, below).
Drain Hose Installation
DrainDrainHose
Figure 11
Figure 10Figure 10a
O-ring Installs Over Male Insert to Swaged Lip
O-ring#6 O-ring
#8 O-ring #10 O-ring
O-ring
Supplied Oil for O-rings
Male Insert
Female Nut
Hold With This Wrench
Twist With This Wrench
Lubricating O-rings For a proper seal of fittings: Install supplied O-rings as shown, and lubricate with supplied oil.
NOTE: Standard torque specifications:#6: 11 to 13 ft-lb.#8: 15 to 20 ft-lb.
#10: 21 to 27 ft-lb.
2 ½”
4 ½”Drill 5/8”
Hole
14901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT PG 14 OF 23
Heater Hose & Heater Control Valve Installation1. Route a piece of heater hose from the water pump to the top heater fitting of the heater core as shown in Figure 9a, Page 12, and Figure 12, below. Secure using hose clamps.2. Route a piece of heater hose from the intake to the bottom heater fitting of the heater core as shown in Figure 9a, Page 12, and Figure 12, below. NOTE: Install heater control valve in line with intake manifold (pressure side) heater hose, and secure using hose clamps as shown in Figure 12, below. Also note proper flow direction.
A/
C &
Hea
ter
Ho
se R
ou
tin
g
#6
Drier
/Con
dens
er H
ardl
ine
0911
81
#8
Dis
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geH
ose
0960
86
Fig
ure
12
#6
Hos
e09
6085
#6
Ade
lCla
mp
#10
Ade
lCla
mp
NO
TE:
Vin
tag
e A
ir S
yste
ms
Req
uir
e(2
) 5
/8
” H
ose
Nip
ple
s (N
ot S
up
plie
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Enla
rge
OEM
Hol
eto
5/8
”
From
Eva
pora
tor
to W
ater
Pum
p
From
Hea
ter
Con
trol
Val
veto
Eva
pora
tor
Hea
ter
Hos
e
Hea
ter
Hos
e(H
eate
r Cnt
rlVa
lve/
Inta
ke)
Tie
Wra
p
Com
pres
sor
Saf
ety
Sw
itch
(Bin
ary
Type
)Scr
ew-o
n D
rier
(Ref
er t
oCon
dens
erIn
stru
ctio
ns)
#8
Con
dens
er/
Com
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Har
dlin
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1182
#10
Suc
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Hos
e09
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NO
TE:
Flow
dir
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on f
ollo
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mol
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arr
ow o
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alve
.
Hos
eCla
mps
From
Int
ake
Man
ifold
15901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT PG 15 OF 23
(2) #10 x 1/2”Sheet Metal
Screws
1. Place driver side louver housing under dash. Mark and drill (2) 5/32” holes in dash as shown in Figure 13, below.2. Secure louver housing under dash using (2) #10 x 1/2” sheet metal screws as shown in Figure 13, below.3. Install louver into housing as shown in Figure 13a, below.
Driver SideUnder Dash Louver Installation
Driver SideUnder Dash
Louver Housing626683
Ball Louver49053-VUL
(3) #10 x 1/2”Sheet Metal
Screws
Center/PassengerSide Under DashLouver Housing
626682
1. Place louver housing under dash. Align center louvers with center of radio; then mark and drill (3) 5/32” holes in dash as shown in Figure 14, below.2. Secure louver housing under dash using (3) #10 x 1/2” sheet metal screws as shown in Figure 14, below.3. Install louvers into housing as shown in Figure 14a, below.
Center/Passenger SideUnder Dash Louver Installation
(2) Louvers49057-VUL
Ball Louver49053-VUL
Figure 14
Figure 13a
Figure 14a
Figure 13
16901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT PG 16 OF 23
Final Steps 1. Install duct hoses as shown in Figure 17, Page 17. 2. Route A/C wires (12 volt/grounds/binary switch/heater valve) through 3/8” grommet as shown in Figure 15, below. 3. Reinstall OEM control panel assembly. Refer to control panel instructions. 4. Plug the wiring harnesses into the ECU module on the sub case as shown in Figure 17, Page 17 (Wire according to wiring diagrams on Pages 18 and 19). 5. Install (4) S-clips on glove box bottom (See Figure 16, below). 6. Install (4) #8 U-nuts on glove box bottom (See Figure 16, below). 7. The glove box is a two piece assembly. Install bottom piece first, and then the top. Secure assembly using OEM screws. 8. Install glove box door using OEM screws. 9. Reinstall all previously removed items.10. 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 A/C mode and/or freezing weather, voiding your warranty.11. Double check all fittings, brackets and belts for tightness.12. Vintage Air recommends that all A/C systems be serviced by a certified automotive air conditioning technician. 13. Evacuate the system for a minimum of 45 minutes prior to charging, and perform a leak check prior to servicing. 14. Charge the system to the capacities stated on Page 4 of this instruction manual. 15. See Operation of Controls procedures on Page 20.
Figure 15
(4) S-clips
(4) #8 U-nutsFigure 16
Glove BoxTop
62384-VCI
Glove BoxBottom
62385-VCI
Grommet33144-VUI
Wiring Harness(12 Volt/Grounds/Binary Switch)
Wiring Harness(Heater Control Valve)
17901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT PG 17 OF 23
FromControl Panel
Control Panel& Duct Hose Routing
Driver SideDefrost Duct
2” x 24”
Driver SideCenter Louver
2 ½” x 15”
Driver SideLouver
2 ½” x 38”
Passenger SideLouver
2 ½” x 48”
Passenger SideCenter Louver
2 ½” x 15”
Figure 17
PlugFromWiring
Harness232001-VUR
PlugFrom
ControlWiring
Harness232002-VUA
Passenger SideDefrost Duct
2” x 12”
18901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT 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
19901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT 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.
20901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT 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
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).
AIR HEATDEF
FANBlowerSpeed
ModeControl
TemperatureControl
Not Used
AIR HEATDEFFAN
AIR
HEAT
DEF
FAN
AIR HEAT
DEF
FAN
21901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT PG 21 OF 23
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
.
22901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT 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.
901117 REV B 7/22/14, INST 1959-60 CHEVROLET CAR w/ 4-LEVER CONTROL EVAP KIT PG 23 OF 23
1
Accessory Kit781160
No. Qty. Part No. Description
NOTE: Images may not depict actual parts and quantities. Refer to packing list for actual parts and quantities.
Gen IV 4-Vent Evaporator Sub Case w/ 204 ECU
744004-VUE
1.2.
11
2
Gen IV 4-Vent Evaporator Sub Case w/ 204 ECUAccessory Kit 59-60 Chevrolet Full-Size/El Camino w/ 4-Lever Controls
Packing ListEvaporator Kit (561056)
Checked By:Packed By:
Date:
744004-VUE781160