1967-68 ford mustang, mercury cougarstatic.speedwaymotors.com/pdf/725554168.pdf904178 rev d...

1967-68 FORD MUSTANG,MERCURY COUGAR

WITH FACTORY AIREVAPORATOR KIT

554168

904178 REV D 11/20/14, 1967-68 MUSTANG/COUGAR w/ AC EVAP INSTR PG 1 OF 23

an ISO 9001: 2008 Registered Company

FO

RD


PAGES

Table of Contents

1. COVER 2. TABLE OF CONTENTS 3. PACKING LIST / PARTS DISCLAIMER 4. INFORMATION PAGE 5. WIRING NOTICE 6. ENGINE COMPARTMENT, CONDENSER ASSEMBLY, COMPRESSOR & BRACKETS FIGURE 1 7. PASSENGER COMPARTMENT FIGURES 2 & 2a 8. DEFROST DUCT/ FRESH AIR CAP INSTALLATION FIGURE 3 9. FIREWALL COVER INSTALLATION FIGURES 4 & 4a 10. EVAPORATOR INSTALLATION FIGURES 5, 6 & 6a11. LOUVER INSTALLATION FIGURE 712. DRAIN HOSE INSTALLATION, LUBRICATING O-RINGS, A/C HOSE INSTALLATION, & MODIFIED A/C HOSE KIT FIGURES 8 & 913. HEATER HOSE & HEATER CONTROL VALVE INSTALLATION FIGURE 1014. A/C & HEATER HOSE ROUTING FIGURE 1115. FINAL STEPS FIGURES 12 & 12a16. CONTROL PANEL & DUCT HOSE ROUTING FIGURE 1317. EVAPORATOR HARDLINE INSTALLATION FIGURE 1418. WIRING DIAGRAM19. GEN IV WIRING CONNECTION INSTRUCTIONS20. OPERATION OF CONTROLS21. TROUBLE SHOOTING INFORMATION22. TROUBLE SHOOTING INFORMATION CONT.23. EVAPORATOR KIT PACKING LIST


** BEFORE BEGINNING INSTALLATION, OPEN ALL PACKAGES AND CHECK CONTENTS OF SHIPMENT. PLEASE REPORT ANY SHORTAGES DIRECTLY TO VINTAGE AIR WITHIN 15 DAYS. AFTER 15 DAYS, VINTAGE AIR WILL NOT BE RESPONSIBLE FOR MISSING OR DAMAGED ITEMS.

EVAPORATOR KIT 554168EVAPORATOR KIT PACKING LIST

No. QTY. PART No. DESCRIPTION

1.2.

11

762169785167

GEN IV 4 VENT w/ 2 & 2 ½” EVAP. SUB CASE ACCESSORY KIT

GEN IV 4 VENT w/ 2” & 2 ½”

EVAP. SUB CASE762169

1

2

ACCESSORY KIT785167 NOTE: IMAGES MAY NOT DEPICT ACTUAL PARTS AND QUANTITIES.

REFER TO PACKING LIST FOR ACTUAL PARTS AND QUANTITIES.


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.


Important Wiring Notice—Please Read

Some Vehicles May Have Had Some or All of Their Radio Interference Capacitors Removed. There Should Be a Capacitor Found At Each of the Following Locations:

1. On the positive terminal of the ignition coil.2. If there is a generator, on the armature terminal of the generator.3. If there is a generator, on the battery terminal of the voltage regulator.

Most alternators have a capacitor installed internally to eliminate what is called “whining” as the engine is revved. If whining is heard in the radio, or just to be extra cautious, a radio interference capacitor can be added to the battery terminal of the alternator.

It is also important that the battery lead is in good shape and that the ground leads are not compromised. There should be a heavy ground from the battery to the engine block, and additional grounds to the body and chassis.

If these precautions are not observed, it is possible for voltage spikes to be present on the battery leads. These spikes come from ignition systems, charging systems, and from switching some of the vehicle’s other systems on and off. Modern computer-operated equipment can be sensitive to voltage spikes on the power leads, which can cause unexpected resets, strange behavior, and/or permanent damage.

Vintage Air strives to harden our products against these types of electrical noise, but there is a point where a vehicle’s electrical system can be degraded so much that nothing can help.

Radio interference capacitors should be available at most auto and truck parts suppliers. They typically are cylindrical in shape, a little over an inch long, a little over a half inch in diameter, and they have a single lead coming from one end of the cylinder with a terminal on the end of the wire, as well as a mounting clip which is screwed into a good ground on the vehicle. The specific value of the capacitance is not too significant in comparison to ignition capacitors that are matched with the coil to reduce pitting of the points.

Care must be taken, when installing the compressor lead, not to short it to ground. The compressor lead must not be connected to a condenser fan or to any other auxiliary device. Shorting to ground or connecting to a condenser fan or any other auxiliary device may damage wiring, the compressor relay, and/or cause a malfunction.

When installing ground leads on Gen IV systems, the blower control ground and ECU ground must be connected directly to the negative battery post.

For proper system operation, the heater control valve must be connected to the ECU.

•

•

•


BEFORE STARTING THE INSTALLATION, CHECK THE FUNCTION OF THE VEHICLE (HORN, LIGHTS,ETC.) FOR PROPER OPERATIONS.

STUDY THE INSTRUCTIONS, ILLUSTRATIONS & DIAGRAMS.

ENGINE COMPARTMENT

BATTERY (RETAIN). DRAIN RADIATOR, REMOVE RADIATOR (RETAIN).

OEM CONDENSER AND DRIER (DISCARD). SEE FIGURE 1, BELOW.OEM COMPRESSOR AND BRACKET (DISCARD). SEE FIGURE 1.OEM HEATER HOSES, A/C HOSES (DISCARD). SEE FIGURE 1.

EVACUATE THE A/C SYSTEM IF NECESSARY.

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

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

COMPRESSOR & BRACKETS

REMOVE THE FOLLOWING:

DRIER

HOSES

CONDENSER

RADIATOR

FIGURE 1

COMPRESSORAND

BRACKET


GLOVE BOX (RETAIN). SEE FIGURE 2. AC/HEATER EVAPORATOR ASSEMBLY AND ALL RELATED DUCTING (DISCARD), RETAIN SCREWS.SEE FIGURE 2a.DRIVER SIDE LOUVER/CONTROL PANEL, PASSENGER SIDE LOUVER, RADIO (RETAIN). SEE FIGURE 2a.REFER TO CONTROL PANEL CONVERSION KIT INSTRUCTIONS FOR INSTALLATION OF CONTROLS.REMOVE OEM DEFROST DUCT ASSEMBLY. SEE FIGURE 2a.CENTER CONSOLE (IF EQUIPPED).DASH BRACE (DISCARD). SEE FIGURE 2a.

FIGURE 2a

PASSENGER COMPARTMENT

REMOVE THE FOLLOWING:

DEFROSTDUCT ASM

DRIVER SIDELOUVER/

CONTROL PANEL

PASSENGER SIDE LOUVER

AC/HEATER ASSEMBLY& RELATED DUCTING

GLOVE BOX

FIGURE 2

RADIODASHBRACE

MUSTANG


INSTALL DEFROST DUCT UNDER DASH AS SHOWN IN FIGURE 3, BELOW. SECURE USING OEM NUTS.

HOLD FRESH AIR CAP UNDER DASH AND MARK THE (3) MOUNTING HOLES.

DRILL (3) 1/8” MOUNTING HOLES UNDER DASH.

APPLY A 1/4” BEAD OF SILICONE AROUND THE BACK SIDE OF THE FRESH AIR CAP AS SHOWN INFIGURE 3, BELOW.

SECURE FRESH AIR CAP TO FRESH AIR HOLE USING (3) #10 x 1/2” SHEET METAL SCREWS AS SHOWNIN FIGURE 3, BELOW.

DRILL HOLES

SILICONE

FRESH AIRCAP

62354-VFE(3) #10 x 1/2”SHEET METAL

SCREWS

(4) OEMNUTS

DRIVER SIDEDEFROST DUCT

626676

DEFROST DUCT/ FRESH AIR CAP INSTALLATION

PASSENGER SIDEDEFROST DUCT

626680

FIGURE 3


INSTALL (3) GROMMETS ON FIREWALL COVER AS SHOWN IN FIGURE 4, BELOW.

APPLY A 1/4“ BEAD OF SILICONE AROUND THE BACK SIDE OF THE FIREWALL COVER AS SHOWN IN FIGURE 4a, BELOW.

SECURE FIREWALL COVER TO FIREWALL USING (4) 1/4-20 x 1” HEX BOLTS w/ FLAT WASHERS AND NUTS,(1) #10 x 1/2” SHEET METAL SCREW. SEE FIGURE 4, BELOW. NOTE: FIREWALL COVER INSTALLS ONENGINE SIDE OF FIREWALL.

FIREWALL COVER INSTALLATION

#10 x 1/2”SHEET METAL

SCREW

(4) 1/4-20 x 1” HEX BOLTS

w/ FLAT WASHERS

GROMMET33135-VUI

GROMMET33134-VUI

GROMMET33137-VUI

SILICONE

FIREWALLCOVER642068

OEM HOLE

(4) 1/4” FLAT WASHERS

(4) 1/4” NUT w/ STAR WASHERS

OEM HEATERCORE HOLES

OEM BLOWER MOTORHOLE IN FIREWALL

(4) OEMBLOWER MOTOR

MOUNTING HOLES

ENGINECOMPARTMENT

SIDE OF FIREWALL

FIGURE 4a

FIGURE 4


ON A WORKBENCH, INSTALL EVAPORATOR REAR BRACKET AND HARDLINES WITH PROPERLY LUBRICATED O-RINGS (SEE FIGURE 9, PAGE 12, AND FIGURE 14, PAGE 17).INSTALL FRONT MOUNTING BRACKET ON EVAPORATOR USING (2) 1/4-20 x 1/2” HEX BOLTS, ANDTIGHTEN AS SHOWN IN FIGURE 5, BELOW.LIFT EVAPORATOR UNIT UP UNDER THE DASHBOARD. SEE FIGURE 6. SECURE LOOSELY TO THE FIREWALLFROM THE ENGINE COMPARTMENT SIDE USING (2) 1/4-20 NUTS AND WASHERS. SEE FIGURE 6, BELOW.USING (2) #14 x 3/4” SHEET METAL SCREWS, SECURE THE FRONT EVAPORATOR MOUNTING BRACKET TOTHE INNER COWL. SEE FIGURE 6a, BELOW.VERIFY THAT EVAPORATOR UNIT IS LEVEL AND SQUARE TO THE DASH. THEN TIGHTEN ALL MOUNTINGBOLTS. NOTE: TIGHTEN THE BOLT ON FIREWALL FIRST. THEN TIGHTEN THE FRONT MOUNTINGBRACKET SCREWS.

EVAP FRONTBRKT

643169-FCB

PASSENGER SIDE EVAPMOUNTING HOLE

INNER COWL

DRILL (2)3/16” HOLES

(2) #14 x 3/4”SHEET METAL

SCREWS

DRIVER SIDE EVAPMOUNTING HOLE

OEM HEATER CORE HOLES

APPROX 3 ½”

APPROX 3”

VIEW FROMPASSENGER SIDEINSIDE OF CAR

OEM HOLE

(2) 1/4-20 NUTSwith

FLAT WASHERS

OEM HOLE

FIGURE 5

FIGURE 6

FIGURE 6a

EVAPORATOR INSTALLATION

(2) 1/4-20 x 1/2”HEX BOLTS


INSTALL S-CLIPS ON CENTER LOUVER HOSE ADAPTER. SEE FIGURE 7, BELOW.

INSTALL CENTER LOUVER HOSE ADAPTER OUTSIDE OEM CENTER LOUVER ASSEMBLY THROUGH RADIOOPENING AS SHOWN IN FIGURE 7.

REMOVE THE DRIVER/PASSENGER SIDE LOUVER DOOR FLAP. SEE FIGURE 7, BELOW.

REINSTALL LOUVERS IN DASH.

LOUVER INSTALLATION

FIGURE 7

CENTER LOUVERHOSE ADAPTER

626679

(2) S-CLIPS

DRIVER/ PASSENGERSIDE LOUVER

MUSTANG

DOORFLAP


DRAIN HOSE INSTALLATION

REFER TO SEPARATE INSTRUCTIONS INCLUDED WITH MODIFIED HOSE KIT.

FIGURE 8DRAIN

O-RINGMALE INSERT

FEMALE NUT

SUPPLIED OILFOR O-RINGS

O-RINGSLIDE OVER

MALE INSERT TOSWAGED LIP

TWIST WITHTHIS

WRENCH

HOLD WITHTHIS

WRENCH

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

LOCATE EVAPORATOR DRAIN ON BOTTOM OF EVAPORATOR CASE.INLINE WITH THE DRAIN, LIGHTLY MAKE A MARK ONTHE FIREWALL. MEASURE ONE INCH DOWN AND DRILLA 5/8” HOLE THROUGH THE FIREWALL. SEE FIGURE 8.INSTALL DRAIN HOSE TO BOTTOM OF EVAPORATORUNIT AND ROUTE THROUGH FIREWALL. INSTALL1/2” 90° DRAIN ELBOW ON DRAIN HOSE. SEE FIGURE 8.

LOCATE THE #8 COMPRESSOR A/C HOSE. LUBRICATE (2) #8 O-RINGS (SEE FIGURE 9 ABOVE) AND CONNECTTHE 45° FITTING TO THE #8 DISCHARGE PORT ON THE COMPRESSOR. ROUTE THE STRAIGHT FEMALE w/ 134aSERVICE PORT FITTING TO THE #8 CONDENSER HARDLINE COMING THROUGH THE RADIATOR CORE SUPPORT.SEE FIGURE 11, PAGE 14. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN FIGURE 9, ABOVE.

LOCATE THE #10 COMPRESSOR A/C HOSE. LUBRICATE (2) #10 O-RINGS AND CONNECT THE 90° FEMALE w/ 134a SERVICE PORT FITTING TO THE #10 SUCTION PORT ON THE COMPRESSOR. ROUTE THE 90° FEMALEFITTING TO THE #10 EVAPORATOR HARDLINE COMING THROUGH THE FIREWALL. SEE FIGURE 10, PAGE 13 &FIGURE 11, PAGE 14. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN FIGURE 9, ABOVE.NOTE: WRAP THE #10 FITTING CONNECTIONS WITH PRESS TAPE. SEE FIGURE 10, PAGE 13, &FIGURE 11, PAGE 14.

LOCATE THE #6 EVAP/DRIER A/C HOSE. LUBRICATE (2) #6 O-RINGS AND CONNECT THE STRAIGHT FEMALEFITTING TO THE #6 DRIER HARDLINE COMING THROUGH THE RADIATOR CORE SUPPORT. ROUTE THE 90°FEMALE FITTING TO THE #6 EVAPORATOR HARDLINE COMING THROUGH THE FIREWALL. SEE FIGURES 10,PAGE 13 & FIGURE 11, PAGE 14. TIGHTEN EACH FITTING CONNECTION AS SHOWN IN FIGURE 9, ABOVE.

USE (6) TIE WRAPS TO SECURE THE #6 A/C HOSE TO THE EXPORT BRACE AS SHOWN IN FIGURE 11, PAGE 14.

O-RING

#6 O-RING

#8 O-RING #10 O-RING

FIGURE 9

DRAINHOSE

LUBRICATING O-RINGS

STANDARD HOSE KIT

MODIFIED A/C HOSE KIT

1”


ROUTE A PIECE OF HEATER HOSE FROM WATER PUMP TO THE HEATER LINE COMING THROUGH THE FIREWALL AS SHOWN IN FIGURE 10, BELOW. SECURE USING HOSE CLAMPS.

ROUTE A PIECE OF HEATER HOSE FROM THE INTAKE TO THE HEATER LINE COMING THROUGH THE FIREWALLAS SHOWN IN FIGURE 10, BELOW. NOTE: INSTALL HEATER CONTROL VALVE IN LINE WITH INTAKEMANIFOLD (PRESSURE SIDE) HEATER HOSE. SECURE USING HOSE CLAMPS AS SHOWN IN FIGURE 10,BELOW. ALSO NOTE PROPER FLOW DIRECTION.

FIREWALL

ECU MODULE

PRESSTAPE

#10 SUCTIONLINE (INSULATED)

#10 SUCTIONLINE

FIREWALLCOVER642068

FIGURE 10

EXPANSIONVALVE

O-RINGS

#6 A/CHOSE

HEATERHOSE

HEATER HOSE & HEATER CONTROL VALVE INSTALLATION

FROM EVAPORATOR

TO WATER PUMP

FROM INTAKEMANIFOLD

FROM HTR CNTRL VLV

TO EVAPORATOR


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INSTALL DUCT HOSES AS SHOWN IN FIGURE 13, PAGE 16.ROUTE A/C WIRES THROUGH 3/8” GROMMET AS SHOWN IN FIGURE 12.(12 VOLT/ GROUND/ BINARY SWITCH/ HEATER VALVE).INSTALL CONTROL PANEL ASSSEMBLY.PLUG THE WIRING HARNESS INTO THE ECU MODULE ON SUB CASE AS SHOWN IN FIGURE 13, PAGE 16(WIRE ACCORDING TO WIRING DIAGRAM ON PAGE 18 AND 19).REINSTALL GLOVE BOX.REINSTALL CENTER CONSOLE (IF EQUIPPED). MODIFY CONSOLE AS SHOWN IN FIGURE 12a.REINSTALL ALL PREVIOUSLY REMOVED ITEMS (BATTERY, RADIATOR, RADIO).FILL RADIATOR WITH AT LEAST A 50/50 MIXTURE OF APPROVED ANTIFREEZE AND DISTILLED WATER. IT ISTHE OWNER’S RESPONSIBILITY TO KEEP THE FREEZE PROTECTION AT THE PROPER LEVEL FOR THE CLIMATEIN WHICH THE VEHICLE IS OPERATED. FAILURE TO FOLLOW ANTIFREEZE RECOMMENDATIONS WILL CAUSEHEATER CORE TO CORRODE PREMATURELY AND POSSIBLY BURST IN A/C MODE AND/OR FREEZING WEATHER,VOIDING YOUR WARRANTY.DOUBLE CHECK ALL FITTINGS, BRACKETS AND BELTS FOR TIGHTNESS.VINTAGE AIR RECOMMENDS THAT ALL A/C SYSTEMS BE SERVICED BY A CERTIFIED AUTOMOTIVE AIR CONDITIONING TECHNICIAN.EVACUATE THE SYSTEM FOR MINIMUM OF 45 MINUTES PRIOR TO CHARGING, AND LEAK CHECK PRIOR TO SERVICING.CHARGE THE SYSTEM TO THE CAPACITIES STATED ON PAGE 4 OF THIS INSTRUCTION MANUAL.SEE OPERATION OF CONTROLS PROCEDURES, PAGE 20.

FINAL STEPS

FIREWALLCOVER

TOP SIDE

PASSENGER SIDE UNDER DASH

CONSOLE

CUT &

REMOVE

OEM

GROMMET

FIGURE 12

FIGURE 12a

¾”3 ¾”

MUSTANG


FIGURE 13

PLUGFROM

CONTROLWIRING

HARNESS232002-VUA

PASSENGER SIDELOUVER

2 ½” x 60”

DRIVER SIDELOUVER

2 ½” x 36”CENTER LOUVER

DRIVER SIDE2” x 20”

CENTER LOUVERPASSSENGER SIDE

2” x 20”

PASSENGER SIDEDEFROST DUCT

2” x 14”

CONTROL PANEL & DUCT HOSE ROUTING

PLUGFROM

WIRINGHARNESS

232001-VUR

DRIVER SIDEDEFOST DUCT

2” x 26”


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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. 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).

OEM BlowerSwitch Not Used

TEMP DEFHEAT

TEMP DEF

HEAT

TEMP

DEFHEAT

TEMP

DEF

HEAT

TemperatureControl


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

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.


EVAPORATOR KIT 554168

CHECK BY:PACKED BY:

DATE:

EVAPORATOR KIT PACKING LISTNo. QTY. PART No. DESCRIPTION

1.2.

11

762169785167

GEN IV 4 VENT w/ 2” & 2 ½” EVAP. SUB CASE ACCESSORY KIT

GEN IV 4 VENT w/ 2” & 2 ½”

EVAP. SUB CASE762169

1

2

ACCESSORY KIT785167 NOTE: IMAGES MAY NOT DEPICT ACTUAL PARTS AND QUANTITIES.

REFER TO PACKING LIST FOR ACTUAL PARTS AND QUANTITIES.

1967-68 ford mustang, mercury cougarstatic.speedwaymotors.com/pdf/725554168.pdf904178 rev d...

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