an ISO 9001:2008 Registered Company

1955-56 Chevrolet Full-Size with 4-Vent Plenum

Evaporator Kit(56156-PCZ)

18865 Goll St. San Antonio, TX 78266 Phone: 210-654-7171

Fax: 210-654-3113www.vintageair.com

906156 REV G 12/07/15, PG 1 OF 25

2

www.vintageair.com

906156 REV G 12/07/15, PG 2 OF 25

Thank you for purchasing this evaporator kit from Vintage Air. When installing these components as part of a complete SureFit™ system, Vintage Air recommends working from front to back on the vehicle, installing the condenser kit, hose kit, and compressor first, followed by the wiring, evaporator, and finally the control panel.

Cover..................................................................................................................................Table of Contents.................................................................................................................Packing List/Parts Disclaimer..................................................................................................Information Page.................................................................................................................Wiring Notice.......................................................................................................................Engine Compartment Disassembly, Passenger Compartment Disassembly....................................Condenser Assembly Installation, Core Support Modification......................................................Compressor and Brackets, Pulleys, Defrost Duct Installation, Control Panel Conversion..................Evaporator Installation.......................................................................................................... Evaporator Installation (Cont.)............................................................................................. Center Vent Installation, Under Dash Louver Installation, Drain Hose Installation........................Lubricating O-rings, Heater Control Valve Installation.............................................................. A/C Hardline and Hose Installation, Liquid Line Installation...................................................... A/C and Heater Hose Routing............................................................................................... Firewall Cover Installation................................................................................................... Control Panel & Duct Hose Routing....................................................................................... Glove Box Installation, Final Steps........................................................................................ Evaporator Hardline Installation........................................................................................... Wiring Diagram..................................................................................................................Gen IV Wiring Connection Instruction...................................................................................Operation of Controls.........................................................................................................Troubleshooting Guide........................................................................................................Troubleshooting Guide (Cont.).............................................................................................Core Support Modification Template......................................................................................Packing List.......................................................................................................................

1 2 3 4 5 6 7 8 91011121314 1516171819202122232425

Table of Contents

3

www.vintageair.com

906156 REV G 12/07/15, PG 3 OF 25

Packing List: Evaporator Kit (56156-PCZ)

No. 1.2.

Qty.11

Part No.744004-VUE78256-PCN

DescriptionGen IV Evaporator Sub Case 4-Vent Plenum with 204 ECUAccessory 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.

NOTE: Images may not depict actual parts and quantities. Refer to packing list for actual parts and quantities.

1

2

Gen IV Evaporator Sub Case 4-Vent Plenum

with 204 ECU744004-VUE

Accessory Kit78256-PCN

Passenger SideDriver Side

4

www.vintageair.com

906156 REV G 12/07/15, PG 4 OF 25

Important Notice—Please ReadFor Maximum System Performance, Vintage Air Recommends the Following:

New Vintage Air-supplied Sanden Compressor: No additional oil needed (Compressor is shipped with proper oil charge).All Other Compressors: Consult manufacturer (Some compressors are shipped dry and will need oil added).

NOTE: Vintage Air systems are designed to operate with R134a refrigerant only. Use of any other refrigerant could damage your A/C system and/or vehicle, and possibly cause a fire, in addition to potentially voiding the warranties of the A/C system and its components.

Refrigerant Capacities:Vintage Air System: 1.8 lbs. (1 lb., 12 oz.) of R134a, charged by weight with a quality charging station or scale. NOTE: Use of the proper type and amount of refrigerant is critical to system operation and performance.Other Systems: Consult manufacturer’s guidelines.

Lubricant Capacities:

Safety Switches

Service Info:Protect Your Investment: Prior to assembly, it is critical that the compressor, evaporator, A/C hoses and fittings, hardlines, condenser and receiver/drier remained capped. Removing caps prior to assembly will allow moisture, insects and debris into the components, possibly leading to reduced performance and/or premature failure of your A/C system. This is especially important with the receiver/drier. Additionally, when caps are removed for assembly, BE CAREFUL! Some components are shipped under pressure with dry nitrogen.Evacuate the System for 35-45 Minutes: Ensure that system components (Drier, compressor, evaporator and condenser) are at a temperature of at least 85° F. On a cool day, the components can be heated with a heat gun or by running the engine with the heater on before evacuating. Leak check and charge to specifications.

Your Vintage Air system is equipped with a binary pressure safety switch. A binary switch disengages the compressor clutch in cases of extreme low pressure conditions (Refrigerant Loss) or excessively high head pressure (406 PSI) to prevent compressor damage or hose rupture. A trinary switch combines Hi/Lo pressure protection with an electric fan operation signal at 254 PSI, and should be substituted for use with electric fans. Compressor safety switches are extremely important since an A/C system relies on refrigerant to circulate lubricant.

Bolts Passing Through Cowl and/or Firewall:To ensure a watertight seal between the passenger compartment and the vehicle exterior, for all bolts passing through the cowl and/or firewall, Vintage Air recommends coating the threads with silicone prior to installation.

Heater Hose (Not Included With This Kit):Heater hose may be purchased from Vintage Air (Part# 31800-VUD) or your local parts retailer. Routing and required length will vary based on installer preference.

5

www.vintageair.com

906156 REV G 12/07/15, PG 5 OF 25

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.

•

•

•

6

www.vintageair.com

906156 REV G 12/07/15, PG 6 OF 25

Engine Compartment Disassembly

1.2.3.4.5.

Disconnect battery.Remove battery and battery tray.Remove air cleaner.Drain radiator.Disconnect heater hoses.

NOTE: Before starting the installation, check the function of the vehicle (horn, lights, etc.) for proper operation, and study the instructions, illustrations, & diagrams.Perform the Following:

Figure 1

Passenger Compartment Disassembly

1.

2.3.

4.5.6.7.8.9.

10.11.

Remove the OEM heater assembly by removing the control cables, along with (2) 7/16” nuts on the firewall and (1) under the dash (discard).Remove the heater blower (discard) (See Figure 1, below).Remove the butterfly duct above the kick panel vent, as well as the panel flange (discard). Install the new vent cover as shown in Figure 2, below.Remove the glove box door (retain).Remove the glove box (discard).Remove the original defrost duct from the heater to the windshield (discard).Remove the ash tray (retain).Remove the ash tray slider assembly (retain).Remove the vent and cables from the dash (retain) (See Figure 1, below).Remove the control panel (retain).Remove the passenger side speaker grille (retain) (See Figure 1, below).

Perform the Following:

Figure 2

10

11

14

7

8

5

6

29

3

OEMScrews

7

www.vintageair.com

906156 REV G 12/07/15, PG 7 OF 25

Core Support Modification

Condenser Assembly Installation

1.

2.

3.4.

1.2.

Locate the core support modification template on Page 24, and align the template on the passenger side of the core support panel. Using the template, mark holes and cut a 1 ¼” hole using a hole saw. Drill a 5/16” hole in the noted location (See Figure 3a, below).Install the #6 and #8 condenser hardlines through the 1 ¼” hole. Lubricate a #6 and #8 O-ring as shown in Figure 11, Page 12, and connect the #6 and #8 condenser hardlines to the condenser.Locate the split grommet and install as shown in Figure 3b, below.Install the drier loosely as shown in Figure 3b, below. NOTE: Refrigerant flow follows the arrow on the drier.

Loosen the (6) bolts that secure the radiator to the core support.Slide the condenser assembly into position. The condenser brackets will be held between the radiator and the core support. Secure with the (6) radiator bolts (See Figures 3 and 3b, below). Holding the condenser in position, tighten the (6) radiator bolts.

CORE SUPPORTTEMPLATE

1 ¼”

5/16”

Figure 3

Figure 3a

Figure 3b

OEM Radiator

Vintage AirCondenser

NOTE: #8 (Larger)Fitting is at Top of Radiator.

#8 Condenser Hardline

35018-VCG

#6 Condenser Hardline

35017-VCG

Install (8) #6 x 3/8”Pan Head Screws

Side of CoreSupport

Hole inCore Support

1/4” Nut with Flat Washer

Drier

5/16” Bolts

1/4” x 1” Bolt

Split Grommet

Mount Drier to Inside of Core Support

Through 5/16” Hole

8

www.vintageair.com

906156 REV G 12/07/15, PG 8 OF 25

Defrost Duct Installation1.

2.

Install the defrost ducts with 2” duct hose: 10” (passenger side) and 24” (driver side) (See Figure 5, below, and Figure 15, Page 16).Install the defrost ducts (See Figures 5 and 5a, below). NOTE: The rounded side of the defrost ducts face the passenger compartment.

Figure 4

Compressor and Brackets

Control Panel Conversion

1.

1.

Refer to separate instructions included with the bracket kit to install the compressor bracket. Refer to Figure 4, below, for compressor mounting position.

Locate the control panel conversion kit. Refer to the instructions supplied with the conversion kit to assemble the control panel.

Pulleys1. In most instances, the belt lengths will remain the same (See Figure 4, below).

Pulleys (Vintage Air) Short Pump Small Block Chevrolet (Steel Pulley)22503-VCA

22506- VCA

22507-VCA

NOTE: Belt routing may vary with different bracket sets. Always refer to instructions included with brackets.

Water Pump Pulley(2-Groove)Crankshaft Pulley(2-Groove)(With Power Steering, a 3-Groove Crank Pulleyis Required)Crankshaft Pulley(3-Groove)

Tab“E” Tab

“A”

Tab“G”

Tab“C”Mount the

CompressorUsing Tabs “G” & “C”

Generatoror Alternator

Compressor

Water PumpPulley

Crankshaft Pulley

Figure 5

Figure 5a

#8 x 1/2” Pan Head Screw(For 1955 Models

using Existing Holes)

#8 x 1/2” Pan Head Screw(For 1956 Models

using Existing Holes) Seat Bracketin Defrost Hole

Defrost Duct(Rounded Side Out)

Defrost Hole

9

www.vintageair.com

906156 REV G 12/07/15, PG 9 OF 25

Evaporator Installation

1.

2.

3.

4.5.

On a workbench, install the evaporator rear brackets and the evaporator hardlines with properly lubricated O-rings (See Figure 17, Page 18, and Figure 11, Page 12).Lift the evaporator unit up and under the dashboard (See Figures 6 and 6a, below, and Figure 6b, Page 10). Secure loosely to the firewall from the engine compartment side with (2) 1/4-20 x 1” bolts and washers (See Figure 7, Page 10, and Figure 17, Page 18). 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.Install the front mounting bracket to the evaporator unit using a 1/4-20 button head bolt, and tighten as shown in Figure 7, Page 10. Loosely attach the front mounting bracket to the dash with a 1/4-20 x 1” bolt, washer and nut (See Figure 7, Page 10).Install the 4-vent A/C plenum to the evaporator with (2) 10-32 x 1/2” screws (See Figure 7, Page 10).Verify that the evaporator unit is level and square to the dash, then tighten all mounting bolts. NOTE: Tighten the (2) bolts on the firewall first. Then tighten the front mounting bracket bolt and nut. Tighten the center plenum mounting bolt last.

NOTE: To ensure a watertight seal between the passenger compartment and the vehicle exterior, for all bolts passing through the firewall, Vintage Air recommends coating the threads with silicone prior to installation.

Figure 6

Figure 6a

NOTE: Install the evaporator unit from the passenger side floorboard.

NOTE: Rotate the evaporator unit so the lines pass through the opening in the firewall. Lift into place.

10

www.vintageair.com

906156 REV G 12/07/15, PG 10 OF 25

Evaporator Installation (Cont.)

Figure 6b

Figure 7

1/4-20 x 1” Bolt & Washer

1/4-20 x 1” Bolt & Washer

1/4-20 x 1/2” Button Head

Screw

Firewall

DefrostDoor

Dash/FloorDoor

10-32 x 1/2”Screw

Bottom Lip of Dash

To Evaporator

To Dash

Front MountingBracket1/4-20

Nut

ECU Module

A/C & HeatBlend Door

4-VentA/C Plenum

NOTE: Once in place, secure the evaporator unit to the firewall.

11

www.vintageair.com

906156 REV G 12/07/15, PG 11 OF 25

Figure 8

Figure 9

Figure 10

Center Vent Installation

Under Dash Louver Installation

1.

1.

Place the center vent under the dash in the desired position (See Figure 8, below). Drill (2) 1/8” mounting holes into the bottom lip of the dash, and secure the center vent to the dash using (2) #8 x 1/2” pan head screws (See Figure 8, below).

Install the driver and passenger side under dash louvers with the flange facing the dash and kick panel as shown in Figure 9, below. Tuck the kick panel side of the louver flange behind the kick panel windlace retainer, and slide the louver up until the flange is seated against the dash. Secure the louver to the kick panel with (2) #8 x 1/2” pan head screws (See Figure 9, below). NOTE: In most cases, the louvers will fit as described. However, due to dash and kick panel variances, the presence of aftermarket components or modifications, etc., it may be necessary to trim the louver flange and/or slightly move the parking brake lever for proper fit.

Drain Hose Installation1.

2.

In line with the drain, lightly make a mark on the firewall. Measure 1” down and drill a 5/8” hole through the firewall (See Figure 10, below). NOTE: See Figure 14, Page 15, for the rough location of the drain hole.Install the drain hose onto the bottom of the evaporator unit, and route through the firewall (See Figure 10, below, and Figure 14, Page 15).

(2) #8 x 1/2”Pan Head ScrewsCenter

Vent

1” DrainDrain Hose

(2) #8 x 1/2”Pan Head Screws

Flange

NOTE: Install louvers with flange facing the dash and kick panel.

Windlace Retainer

Dash

Windlace Retainer

12

www.vintageair.com

906156 REV G 12/07/15, PG 12 OF 25

Figure 12

Heater Control Valve Installation1. Install the heater control valve in line with the intake manifold (pressure side) heater hose (See Figure 12,

below).

Figure ##

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.

Figure 11

ECU Module

#10 SuctionHose

HeaterHoses

#6 Hardline

NOTE: Flow Direction Follows Molded Arrow on Valve.

HoseClamps

From HeaterControl Valve

to Heater Core

From IntakeManifold to

Heater ControlValve

From Heater Coreto Water Pump

13

www.vintageair.com

906156 REV G 12/07/15, PG 13 OF 25

A/C Hardline and Hose Installation

1.2.

3.

4.5.

6.7.

8.

9.

Locate the (2) compressor hardlines (See Figure 13, Page 14).Locate the #8 compressor hardline. Lubricate (1) #8 O-ring (See Figure 11, Page 12), and connect the #8 compressor hardline to the #8 discharge port on the compressor. Tighten the connection (See Figure 11, Page 12, and Figure 13, Page 14).Locate the #10 compressor hardline. Lubricate (1) #10 O-ring (See Figure 11, Page 12), and connect the #10 compressor hardline to the #10 suction port on the compressor. Tighten the connection (See Figure 11, Page 12, and Figure 13, Page 14).Secure the (2) compressor hardlines to the compressor using the supplied clamp (See Figure 13a, Page 14).Locate the #8 A/C hose. The hose will connect the #8 compressor hardline and the #8 hardline from the condenser. Lubricate (2) #8 O-rings (See Figure 11, Page 12) and install (1) onto each end of the #8 A/C hose. Route the #8 A/C hose as shown in Figure 13, Page 14 and tighten (See Figure 11, Page 12). NOTE: The 90° hose fitting connects to the #8 condenser hardline.Install the firewall cover (See Figure 14, Page 15).Lubricate (1) #6 O-ring (See Figure 11, Page 12). Install the #6 liquid line and tighten (See Figure 11, Page 12, and Figure 13b, Page 14).Locate the #10 A/C hose. The hose will connect the #10 compressor hardline and the #10 hardline from the evaporator. Lubricate (2) #10 O-rings (See Figure 11, Page 12) and install (1) onto each end of the #10 A/C hose. Route the #10 A/C hose as shown in Figure 13, Page 14, and tighten (See Figure 11, Page 12). NOTE: The 90° hose fitting connects to the #10 compressor hardline.Install the heater hoses onto the heater lines, and route as shown in Figures 13 and 13b, Page 14. Secure with hose clamps. NOTE: This kit does not contain heater hose. The 5/8” heater hose may be purchased from Vintage Air or a local parts retailer.

Standard Hose Kit:

1. Refer to separate instructions included with modified hose kit.Modified Hose Kit:

Liquid Line and Binary Switch Installation1.

2.3.

Install the #6 liquid line onto the drier with a lubricated #6 O-ring (See Figure 11, Page 12) and tighten (See Figure 11, Page 12, and Figure 13, Page 14).Install the binary switch onto the #6 liquid line (See Figure 13, Page 14).Secure the #6 liquid line to the fender using the supplied Adel clamp (See Figure 13, Page 14).

14

www.vintageair.com

906156 REV G 12/07/15, PG 14 OF 25

Figure 13

Figure 13a

Figure 13b

A/C and Heater Hose Routing

NOTE: Compressor hardlinesare included with standardhose kit only.

#8 CompressorHardline

35038-VUG-A

#10 CompressorHardline

35037-VUG-A

#8 Condenser Hardline

35018-VCG

#6 Hardline35017-VCGSplit Rubber

Grommet in Core Support Hole

#6 Hardline

#10 Suction Hose

HeaterHoses

O-rings

Firewall Cover

#10 Suction Line (Insulated)

Hardline Clamp(Standard Hose Kit Only)

ECU Module

ECU Module

NOTE: Modified hose kits include (2) 135° compressor fittings (Refer to instructions included with modified hose kit).

#6 Hardline

Binary Switch Installation

Binary Switch

#8 Discharge Hose

#6 Hardline FromDrier to Expansion

Valve09154-PFL

AdelClamp

FirewallCover

ExpansionValve

Press Tape

EvaporatorSub Case

#10 SuctionHose

Heater ControlValve

HeaterHoses

15

www.vintageair.com

906156 REV G 12/07/15, PG 15 OF 25

Figure 14

Firewall Cover Installation1. Pass lines through the firewall cover and secure with (2) 7/16” panel retainers (See Figure 14, below).

Passenger SideEvaporator Mounting

Hole1/4-20 x 1”

Bolt & Washer

1/4-20 x 1”Bolt & Washer

(2) 7/16” Panel Retainers

DrainHole

Driver SideEvaporator Bracket

Mounting Hole

16

www.vintageair.com

906156 REV G 12/07/15, PG 16 OF 25

1.2.

3.

Install the duct hoses as shown in Figure 15, below.Plug the control panel wiring harness (232002-VUA) into the ECU module on the sub case as shown in Figure 15, below.Plug the wiring harness (232001-VUR) into the ECU module on the sub case as shown in Figure 15, below. Wire according to the wiring diagrams on Page 19 and 20.

Control Panel & Duct Hose Routing

Figure 15

Passenger SideLouver

2 ½” x 42”

Driver SideLouver

2 ½” x 48”

ECU Module

Driver SideDefrost Duct

2” x 24”

Passenger SideDefrost Duct

2” x 10”

Plug FromWiring Harness232001-VUR

Plug FromControl Panel

Wiring Harness

232002-VUA

Driver SideCenter Vent2 ½” x 15”

Passenger SideCenter Vent2 ½” x 12”

17

www.vintageair.com

906156 REV G 12/07/15, PG 17 OF 25

Glove Box Installation

Final Steps

1.

2.

3.

1.2.

3.4.5.

6.

Install the glove box bottom and glove box door. Secure to the dash with (3) OEM screws (See Figure 16, below).With the glove box bottom and door in place, install the glove box top as shown in Figure 16, below. Using (3) #6 x 3/8” pan head screws, attach the glove box top to the glove box bottom as shown in Figure 16, below.Secure the glove box top to the dash using (2) OEM screws (See Figure 16, below).

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 A/C mode and/or freezing weather, voiding your warranty.Double check all fittings, brackets and belts for tightness.Vintage Air recommends that all A/C systems be serviced by a licensed automotive A/C technician.Evacuate the system for a minimum of 45 minutes prior to charging, and perform a leak check prior to servicing.Charge the system to the capacities stated on Page 4 of this instruction manual.

Figure 16

Glove BoxDoor

(3) OEMScrews

(2) OEMScrews

PlasticGlove BoxBottom

Glove BoxHinge

Glove BoxTop

(3) #6 x 3/8”Pan HeadScrews

ww

w.v

inta

gea

ir.c

om

18 906156 REV G 12/07/15, PG 18 OF 25

Evap

orat

or H

ard

line

Inst

alla

tion

Fig

ure

17

NO

TE:

Wra

p t

he

#1

0 fi

ttin

g

con

nec

tion

s w

ith

pre

ss t

ape.

#10

O-r

ing

3385

9-VU

F

Pres

s Ta

pe

#10

Suc

tion

Line

0915

1-PC

S

#6

O-r

ing

3385

7-VU

F

Hea

ter

Line

(Eva

pora

tor

to I

ntak

e)09

152-

PCH

Hea

ter

Line

(Eva

pora

tor

to

Wat

er P

ump)

0915

3-PC

H

#6

Har

dlin

e09

150-

PCL

#10

O-r

ing

3385

9-VU

F

1/4-

20 x

1/2

” Bol

t (L

ocat

ed o

n Sub

Cas

e)

Drive

r Sid

eEv

apor

ator

Bra

cket

6435

4-PC

B

Pass

enge

r Sid

eEv

apor

ator

Bra

cket

6435

5-PC

B

ECU

Mod

ule

1/4-

20 x

1/2

” Bol

t (L

ocat

ed o

n Sub

Cas

e)

19

www.vintageair.com

906156 REV G 12/07/15, PG 19 OF 25

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

20

www.vintageair.com

906156 REV G 12/07/15, PG 20 OF 25

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.

21

www.vintageair.com

906156 REV G 12/07/15, PG 21 OF 25

Operation of Controls

Adjust to desiredspeed.

Blower SpeedAdjust to desired

speed.

Adjust to desiredmode position (DASH position recommended).

Adjust to desiredspeed.

Adjust to DEFROST position for maximum defrost, or between FLOOR and DEFROST positions for a bi-level

blend (Compressor is automatically engaged).

Adjust to desired temperature.

For A/C operation, adjust tocoldest position to engage

compressor (Adjust between HOT and COLD to reachdesired temperature).

A/C Operation

Heat Operation

Defrost/De-fog Operation

On Gen IV systems with three lever/knob controls, the temperature control toggles between heat and A/C operations. To activate A/C, move the temperature lever/knob all the way to cold and then back it off to the desired vent temperature. For heat operation, move the temperature lever/knob all the way to hot and then adjust to the desired vent temperature. The blower will momentarily change speed, each time you toggle between operations, to indicate the change. NOTE: For proper control panel function, refer to control panel instructions for calibration procedure.

Blower Speed

Blower Speed

This lever/knob controlsblower speed, from

OFF to HI.

This lever/knob controls the mode positions,from DASH to FLOORto DEFROST, with a blend in between.

This lever/knob controlsthe temperature,

from HOT to COLD.

Blower Speed

Mode Control

Temperature Control

Blower Speed

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).

TemperatureControl

DASH FLOOR DEF

OFF FAN HI

HEAT

COLD

DASH FLOOR DEF

OFF FAN HI

HEAT

COLD

DASH FLOOR DEF

OFF FAN HI

HEAT

COLD

DASH FLOOR DEF

OFF FAN HI

HEAT

COLD

ww

w.v

inta

gea

ir.c

om

22 906156 REV G 12/07/15, PG 22 OF 25

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

.

ww

w.v

inta

gea

ir.c

om

23 906156 REV G 12/07/15, PG 23 OF 25

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.

ww

w.v

inta

gea

ir.c

om

24 906156 REV G 12/07/15, PG 24 OF 25

Cor

e S

up

por

t M

odifi

cati

on T

emp

late

3 9/16”

2 5/16”

1”

5/16”Diameter

3 ¼”

2 ⅜”

2 ⅛”

1/2”

1 ¼”Diameter

Fold

Pag

e at

Thi

s Li

ne a

nd P

ositi

on a

t Ed

ge o

f Cor

e Sup

port

(Re

mov

able

Pan

el)

LocateExisting Holes

25

www.vintageair.com

906156 REV G 12/07/15, PG 25 OF 25

Packing List: Evaporator Kit (56156-PCZ)

No. 1.2.

Qty.11

Part No.744004-VUE78256-PCN

DescriptionGen IV Evaporator Sub Case 4-Vent Plenum with 204 ECUAccessory Kit

NOTE: Images may not depict actual parts and quantities. Refer to packing list for actual parts and quantities.

1

2

Gen IV Evaporator Sub Case 4-Vent Plenum

with 204 ECU744004-VUE

Accessory Kit78256-PCN

Checked By:Packed By:

Date:

Passenger SideDriver Side