1969 pontiac firebird - vintage air · 3 901124 rev c 8/01/18, inst 69 firebird w/ a/c evap kit pg...

1969 Pontiac Firebird with Factory AirEvaporator Kit

564468

901124 REV C 8/01/18, INST 69 FIREBIRD w/ A/C EVAP KIT PG 1 OF 25

an ISO 9001:2015 Registered Company

18865 Goll St. San Antonio, TX 78266 Phone: 800-862-6658

Sales: [email protected] Support: [email protected]

www.vintageair.com


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 & 3 8. Passenger Compartment (Cont.), Fresh Air Door and Kick Panel Removal Figures 3a, 3b, 4 & 4a 9. Defrost Duct & Fresh Air Cap Installation, Driver and Passenger Side Hose Adapter Installation Figures 5 & 610. Center Louver Installation Figure 711. Fresh Air Cover Installation, Kick Panel Fresh Air Cap Installation Figures 8, 9, 9a & 9b12. Firewall Cover, Evaporator Bracket and Heater Hose Fitting Installation Figures 10 & 1113. Evaporator Bracket and Heater Hose Fitting Installation (Cont.) Figure 1214. Kick Panel Installation Figures 13 & 13a15. Evaporator Installation Figures 14 & 14a16. Drain Hose Installation, Lubricating O-rings, A/C Hose Installation Figures 15 & 1617. Heater Hose & Heater Control Valve Installation Figure 1718. Final Steps, Glove Box Installation Figures 18, 19 & 2019. Control Panel & Duct Hose Routing Figure 2120. Wiring Diagram21. Gen IV Wiring Connection Instruction22. Operation of Controls23. Troubleshooting Information24. Troubleshooting Information (Cont.)25. Evaporator Kit Packing List


1

2

Accessory Kit781180

Gen IV Evaporator Sub Case with 90 Defrost with 204 ECU

744013

** Before beginning installation, open all packages and check contents of shipment. Please report any shortages directly to Vintage Air within 15 days. After 15 days, Vintage Air will not be responsible for missing or damaged items.

1.2.

11

744013781180

Gen IV Evap Sub Case with 90 Defrost with 204 ECUAccessory Kit 1969 Firebird with A/C

No. Qty. Part No. Description

Packing List:Evaporator Kit (564468)

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.

•

•

•


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. Evacuate the A/C system if necessary.4. Remove condenser and lines (discard) (See Figure 1, below).5. Remove OEM compressor and bracket (discard) (See Figure 1, below).6. Remove hood latch assembly (retain) including hood latch support.7. Remove evaporator and blower assembly (discard). NOTE: To remove the evaporator and blower assembly (under hood) and the air distribution system (under dash), the factory manual indicates doing the following: Remove right lower rocker molding. Remove lower fender attaching bolts. Remove skirt to fender and skirt to reinforcement screws. Pull out on lower portion of fender, moving the skirt away from the fender flange and firewall. Block the skirt with a 2 x 4 block of wood. To avoid damage to paint and sheet metal, and for ease of removal and replacement of components, Vintage Air suggests that the right fender be removed and the inner panel be lowered (See Figure 1, below).8. Remove OEM heater hoses, A/C hoses, hardlines and drier (discard) (See Figure 1, below).9. Remove OEM heater wiring/vacuum harness molded grommet (See Figure 1, below).

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

Passenger Side Core Support to

Fender Brace

InnerFender Panel

PassengerFender Drier

Heater HoseClamp

Condenser

OEMCompressor

OEMEvaporatorAssembly

OEMBlower Motor

OEM A/C& Heater

Wiring/VacuumHarness

Molded Grommet

Hood Latchand Support

Assembly

Figure 1


Astro Vent Door Assembly(Passenger & Driver Side)

OEM Glove Box Door

Radio

Ashtray

AshtraySlider Assembly

View From Inside Vehicle

OEM ControlPanel

Instrument PanelAssembly

SteeringColumn

Passenger CompartmentPerform the Following: 1. Remove the ashtray (retain) (See Figure 2, below). 2. Remove ashtray slider assembly (retain) (See Figure 2, below). 3. Remove glove box door (retain) (See Figure 2, below). 4. Remove and discard OEM glove box. 5. Remove astro ventilation ducts (See Figure 2, below). 6. Remove the radio (retain) (See Figure 2, below). 7. Remove OEM control panel (See Figure 2, below). 8. Loosen and lower steering column (See Figure 2, below). 9. Remove the instrument panel assembly (retain) (See Figure 2, below).10. Remove the OEM defrost duct (discard) (See Figure 3, below).11. Remove the center louver, driver side and passenger side louver OEM ducts (discard) (See Figure 3a, Page 8).12. Remove the evaporator (discard) (See Figure 3b, Page 8).NOTE: Remove the front seats (Optional, for ease of A/C installation only).

OEM Glove Box

Figure 2

DefrostDuct

Figure 3


Passenger Compartment (Cont.)

Fresh Air Door and Kick Panel Removal

Evaporator

Fresh AirDoor Assembly

Fresh AirDoor Assembly

OEMScrews

OEMScrewsOEM

Screws

Center Louver,Driver and

Passenger SideLouver OEM Ducts

Figure 3a

Figure 4 Figure 4a

Figure 3b

Remove (2) OEM screws from the fresh air door assembly. Disconnect and discard pull cable assemblies from thekick panel as shown in Figure 4, below.Remove kick panel by removing the (4) OEM screws as shown in Figure 4a, below.

1.

2.


Figure 6

Figure 5

Passenger SideFresh Air Cover

640712

Passenger SideDefrost Duct626676-VCA

(2) #10 X 1/2” Hex Sheet Metal Screws

18247-VUB

OEMLouver

Passenger Side

HoseAdapter

49870-VCI

Driver SideDefrost Duct626676-VCA

Driver SideFresh Air Cover

640711

1. Install defrost ducts under dash as shown in Figure 5, below. Align defrost duct with defrost opening in dash, and hold in place. Use bracket as a template and drill a 7/64” hole. Secure using a #10 X 1/2” hex sheet metal screw.2. Install driver and passenger side fresh air covers, and secure using OEM hardware (See Figure 5, below).

Defrost Duct& Fresh Air Cap Installation

1. Install driver and passenger side hose adapters on OEM louvers, and secure using (3) #8 x 1/2” PH pan head screws (See Figure 6, below).

Driver and Passenger SideHose Adapter Installation

OEMLouver

Driver Side

(3) #8 x 1/2” PHPan Head Screws

(3) #8 x 1/2” PHPan Head Screws

HoseAdapter

49870-VCI


Center Louver Installation1. Install (2) #8 U-nuts on center louver hose adapter (See Figure 7, below). 2. Install center louver hose adapter and OEM center louver in dash using (2) #8 x 1/2” PH pan head screws (See Figure 7, below).

Figure 7

Center LouverHose Adpater

626681

(2) #8 U-Nuts

(2) #8 x 1/2”PH Pan Head

Screws


1/4-20 X 1 ½”Bolt w/ Washer

Fresh Air Cover Installation

Silicone

Fresh AirCap(4) Grommets

33137-VUI

Back Sideof Fresh Air

Cap

EngineCompartment

Firewall

Silicone

Back Side of Kick Panel

Fresh Air Cap

#10 A/C Hose

#6 A/C Hose(2) Heater

Hose

(4)Grommets33137-VUI

Figure 8

Figure 9b

Figure 9

Figure 9a

1 ½” Plug33173-VUI

7/8” Plug317100

1 ¼” Grommet33139-VUI

1. Install (4) grommets in fresh air cap (See Figure 8, below).2. Apply a 1/4” bead of silicone around the back side of the fresh air cap as shown in Figure 8, below.3. Attach fresh air cap to firewall using a 1/4-20 X 1 ½” bolt and washer (See Figure 8, below). NOTE: Fresh air cap installs on engine side of firewall.4. Install 1 ¼”, 7/8” and 1 ½” plugs in firewall (See Figure 8, below).

Kick Panel Fresh Air Cap Installation1. Install (4) grommets in kick panel fresh air cap (See Figure 9a, below).2. Route A/C and heater hose through fresh air cap and kick panel fresh air cap as shown in Figures 9 and 9b, below.3. Apply a 1/4” bead of silicone around the back side of kick panel fresh air cap as shown in Figure 9, below.4. Secure kick panel fresh air cap using (5) OEM screws as shown in Figure 9b, below.

(5) OEMScrews

#10 A/CHose

#6 A/CHose

HeaterHoses

HeaterHoses


EngineCompartment

Side of Firewall

NOTE: Firewall cover mounting holes must be enlarged. Enlarge (4) existing holes in firewall to 5/16”.

View Shown From Inside Car, Through Dash

Figure 10

Back Side of Firewall Cover

Silicone

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 12, Page 13, and Figure 16, Page 16).2. Install front mounting bracket on evaporator using (2) 1/4-20 x 1/2” hex bolts, and tighten as shown in Figure 11, below.

Firewall Cover Installation 1. Enlarge (4) OEM firewall holes to 5/16” (See Figure 10, below).2. Apply a 1/4” bead of silicone around the back side of the firewall cover as shown in Figure 10, below.3. From inside the car, install firewall cover on firewall as shown in Figure 10, below. From the engine compartment, secure firewall cover to firewall using (3) 1/4-20 x 1” hex bolts and (3) flat washers (See Figure 10, below).

(2) 1/4-20 X 1/2”Hex Bolts

Figure 11

(3) 1/4-20 X 1”Hex Bolt

w/ Washer

FirewallCover 648228


Rear EvaporatorBracket Assembly

644018

Evaporator Bracket andHeater Hose Fitting Installation (Cont.)

Figure 12

1/4-20 X 1/2” Bolt(Located on Sub Case)

(2) HeaterFittings121004

(2) #10 O-ring


Kick Panel Installation1. Remove (5) OEM screws from kick panel fresh air cap as shown in Figure 13, below.2. Reinstall kick panel using (5) #8 x 1” PH pan head screws as shown in Figure 13a, below.

Figure 13a

Figure 13

(5) OEM Screws

Kick PanelFresh Air

Cap

(5) #8 x 1”PH Pan Head

Screws

KickPanel


Kick PanelFresh Air

Cap

(2) #14 X 3/4”Sheet Metal

Screws

1/4-20 X 1” Bolt w/ Washer

Evaporator Installation1. Lift evaporator unit up under the dashboard and attach A/C & heater hoses (See Figure 14 & 14a , below). Secure loosely to the firewall from the engine compartment side using a 1/4-20 x 1” bolt and washer (See Figure 14, below).2. Using (2) #14 x 3/4” sheet metal screws, secure the front evaporator mounting bracket to the inner cowl (See Figure 14, below). Level, front-to-rear and side-to-side, and mark & drill 3/16” holes.3. Verify that the evaporator unit is level and square to the dash. Then tighten all mounting bolts. NOTE: Tighten the bolt on firewall first, and then tighten the front mounting bracket screws.

#10 A/C Hose

#6 A/C Hose

PressTape

Heater Hose(To heater control

valve, then to manifold)

Heater Hose(To Water Pump) Figure 14a

Figure 14

HoseClamps

NOTE: Press tape should coverall metal portions of #10 fitting.


1. Locate the #8 compressor A/C hose. Lubricate (2) #8 O-rings (See Figure 16, above) and connect the 135° female fitting w/ 134a service port to the #8 discharge port on the compressor. Route the straight female fitting to the #8 condenser hardline coming through the core support (See Figure 17, Page 17). Tighten each fitting connection as shown in Figure 16, above.2. Locate the #10 compressor A/C hose. Lubricate (2) #10 O-rings (See Figure 16, above) and connect the #10 135° female fitting w/134a service port to the #10 suction port on the compressor. Route the 90° female fitting to the #10 evaporator (See Figure 14a, Page 15, and Figure 17, Page 17). Tighten each fitting connection as shown in Figure 16, above.3. Locate the #6 evaporator A/C hose. Lubricate (2) #6 O-rings (See Figure 16, above) and connect the 90° female fitting to the #6 hardline coming through the core support from the drier. Route the 90° female fitting to the #6 evaporator (See Figure 14a, Page 15, and Figure 17, Page 17). Tighten each fitting connection as shown in Figure 17, above.

A/C Hose InstallationStandard Hose Kit:

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

1. Locate evaporator drain on bottom of evaporator case.2. In line with the drain, lightly make a mark on the firewall. Measure one inch down and drill a 5/8” hole through the firewall (See Figure 15, below).3. Install drain hose to bottom of evaporator unit and route through firewall (See Figure 15, below).

Drain Hose Installation

1” DrainDrainHose

Figure 15

Figure 16

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.

17901124 REV C 8/01/18, INST 69 FIREBIRD w/ A/C EVAP PG 17 OF 25

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0960

84

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 14a, Page 15, and Figure 17, 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 14a, Page 15, and Figure 17, below. NOTE: Install heater control valve in line with intake manifold (pressure side) heater hose, and secure using hose clamps as shown in Figure 17, below. Also note proper flow direction.

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Saf

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Type

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Glove BoxTop

49068-VCI

Glove BoxBottom

49067-VCI

OEM Screws

OEM Screws

Final Steps 1. Install duct hoses as shown in Figure 21, Page 19. 2. Route A/C wires (12 volt/grounds/binary switch/heater valve) through 1 ¼” grommet as shown in Figure 18, below. 3. Install control panel assembly. 4. Plug the wiring harnesses into the ECU module on the sub case as shown in Figure 21, Page 19 (Wire according to wiring diagrams on Pages 20 and 21). 5. Modify passenger side kick panel fresh air cover as shown in Figure 19, below. 6. Reinstall passenger side kick panel fresh air cover. 7. Install new glove box as shown in Figure 20, below. 8. Reinstall all previously removed items (battery tray & battery). 9. 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.10. Double check all fittings, brackets and belts for tightness.11. Vintage Air recommends that all A/C systems be serviced by a certified automotive air conditioning technician. 12. Evacuate the system for a minimum of 45 minutes prior to charging, and perform a leak check prior to servicing. 13. Charge the system to the capacities stated on Page 4 of this instruction manual. 14. See Operation of Controls procedures on Page 22.

Glove Box Installation1. The new glove box is made in (2) pieces for easy installation. Install (5) #8 U-nuts in glove box bottom.2. Insert bottom half of new glove box, securing with only one OEM screw on each side through dash holes (See Figure 20, below).3. Insert top half of glove box and fasten to bottom half using (4) #6 X 3/8” pan head screws (See Figure 20, below).4. Install glove box door using (3) OEM screws as shown in Figure 20, below.

Figure 18

Figure 20

Figure 19

(5) Tinnerman Nuts

1 ¼” ID Grommet33139-VUI

3 ⅛”

3 ¾

”

Wiring Harness(12 Volt/Grounds/Binary Switch)

Wiring Harness(Heater Control Valve)


FromControl Panel

Control Panel& Duct Hose Routing

Driver SideDefrost Duct

2” x 30”

Passenger SideLouver

2 ½” x 38”

Driver SideLouver

2 ½” x 36”

Driver SideCenter Louver

2 ½” x 24”

Passenger SideCenter Louver

2 ½” x 24”

Figure 21

PlugFromWiring

Harness232001-VUR

PlugFrom

ControlWiring

Harness232002-VUA

Passenger SideDefrost Duct

2” x 14”


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 E, 10/6/2017

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

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).

OFF INSIDE A/C HEAT

WARM

LO HI

DE-ICE

COOL

NORM VENT

Not Used

(Defrost)(Floor)(Dash)Mode

Control

Blower Speed

TemperatureControl

OFF INSIDE A/C HEAT

WARM

LO HI

DE-ICE

COOL

NORM VENT

OFF INSIDE A/C HEAT

WARM

LO HI

DE-ICE

COOL

NORM VENT

OFF INSIDE A/C HEAT

WARM

LO HI

DE-ICE

COOL

NORM VENT

23901124 REV C 8/01/18, INST 69 FIREBIRD w/ A/C EVAP PG 23 OF 25

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Ch

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wer

sta

ys o

n hi

gh s

peed

whe

n ig

nitio

n is

on.

1a.

No

othe

r fu

nctio

ns w

ork.

Che

ck f

or d

amag

ed p

ins

or

wires

in c

ontr

ol h

ead

plug

.Ve

rify

tha

t al

l pin

s ar

e in

sert

ed in

to p

lug.

Ens

ure

that

no

pins

are

ben

t or

dam

aged

in E

CU

.Che

ck f

or d

amag

ed g

roun

d w

ire

(whi

te)

in c

ontr

ol h

ead

harn

ess.

Verify

con

tinui

ty t

o ch

assi

s gr

ound

with

whi

te c

ontr

ol

head

wire

at v

ario

us p

oint

s.

Loss

of gr

ound

on

this

wire

rend

ers

cont

rol h

ead

inop

erab

le.

All

othe

r fu

nctio

ns w

ork.

Che

ck f

or d

amag

ed b

low

er

switc

h or

pot

entio

met

er a

nd

asso

ciat

ed w

irin

g.

Blo

wer

sta

ys o

n hi

gh s

peed

whe

n ig

nitio

n is

on

or o

ff.

Unp

lug

3-w

ire

BSC c

ontr

ol

conn

ecto

r fr

om E

CU

. If

blo

wer

sh

uts

off,

ECU

is e

ither

im

prop

erly

wired

or

dam

aged

.

Be

sure

the

sm

all,

20 G

A w

hite

gro

und

wire

is c

onne

cted

to

the

bat

tery

gro

und

post

. If

it is

, re

plac

e th

e EC

U.

Unp

lug

3-w

ire

BSC c

ontr

ol

conn

ecto

r fr

om E

CU

. If

blo

wer

st

ays

runn

ing,

BSC is

eith

er

impr

oper

ly w

ired

or

dam

aged

.

Che

ck t

o en

sure

tha

t no

BSC w

irin

g is

dam

aged

or

shor

ted

to v

ehic

le g

roun

d. T

he B

SC o

pera

tes

the

blow

er

by g

roun

d si

de p

ulse

wid

th m

odul

atio

n sw

itchi

ng.

The

posi

tive

wire

to t

he b

low

er w

ill a

lway

s be

hot

. If

the

“g

roun

d” s

ide

of t

he b

low

er is

sho

rted

to

chas

sis

grou

nd,

the

blow

er w

ill r

un o

n H

I.

Repl

ace

BSC (

This

will

req

uire

rem

oval

of ev

apor

ator

fr

om v

ehic

le).

No

othe

r pa

rt r

epla

cem

ents

sh

ould

be

nece

ssar

y.

Com

pres

sor

will

no

t tu

rn o

n (A

ll ot

her

func

tions

w

ork)

.

2.

Syst

em is

not

cha

rged

.Sy

stem

mus

t be

cha

rged

for

co

mpr

esso

r to

eng

age.

Cha

rge

syst

em o

r by

pass

pre

ssur

e sw

itch.

Dan

ger

: N

ever

byp

ass

safe

ty s

wit

ch w

ith

en

gin

e ru

nn

ing

. S

erio

us

inju

ry c

an r

esu

lt.

Syst

em is

cha

rged

.

1b

.

Trou

ble

shoo

tin

g G

uid

e

Che

ck f

or f

aulty

A/C

po

tent

iom

eter

or

asso

ciat

ed

wirin

g (N

ot a

pplic

able

to

3-po

t co

ntro

ls).

Che

ck f

or d

isco

nnec

ted

or

faul

ty t

herm

isto

r.

Che

ck c

ontin

uity

to

grou

nd o

n w

hite

con

trol

hea

d w

ire.

Che

ck f

or 5

V o

n re

d co

ntro

l hea

d w

ire.

Che

ck 2

-pin

con

nect

or a

t EC

U h

ousi

ng.

To c

heck

for

pro

per

pot

func

tion,

che

ck v

olta

ge a

t w

hite

/blu

e w

ire.

Vol

tage

sh

ould

be

betw

een

0V a

nd

5V,

and

will

var

y w

ith p

ot

leve

r po

sitio

n.

Dis

conn

ecte

d or

fau

lty

ther

mis

tor

will

cau

se

com

pres

sor

to b

e di

sabl

ed.

Red

wire

at A

/C p

ot s

houl

d ha

ve a

ppro

xim

atel

y 5V

w

ith ig

nitio

n on

. W

hite

w

ire

will

hav

e co

ntin

uity

to

chas

sis

grou

nd.

Whi

te/

Blu

e w

ire

shou

ld v

ary

betw

een

0V a

nd 5

V w

hen

leve

r is

mov

ed u

p or

dow

n.

3. Com

pres

sor

will

no

t tu

rn o

ff

(All

othe

r fu

nctio

ns

wor

k).

Che

ck f

or f

aulty

A/C

po

tent

iom

eter

or

asso

ciat

ed

wirin

g.

Che

ck f

or f

aulty

A/C

rel

ay.

Repa

ir o

r re

plac

e po

t/co

ntro

l wirin

g.

Repl

ace

rela

y.

See

blo

wer

sw

itch

chec

k pr

oced

ure.


Sym

pto

m

Con

dit

ion

Ch

ecks

A

ctio

ns

Not

es

Syst

em w

ill n

ot

turn

on,

or

runs

in

term

itten

tly.

4.

Wor

ks w

hen

engi

ne is

not

runn

ing;

shu

ts o

ff w

hen

engi

ne is

sta

rted

(T

ypic

ally

ear

ly G

en I

V,

but

poss

ible

on

all

vers

ions

).

Noi

se in

terf

eren

ce f

rom

eith

er

igni

tion

or a

ltern

ator

.

Inst

all c

apac

itors

on

igni

tion

coil

and

alte

rnat

or.

Ensu

re

good

gro

und

at a

ll po

ints

. Re

loca

te c

oil a

nd a

ssoc

iate

d w

irin

g aw

ay f

rom

ECU

and

ECU

wirin

g. C

heck

for

bur

ned

or lo

ose

plug

wires

.

Verify

con

nect

ions

on

pow

er

lead

, ig

nitio

n le

ad,

and

both

whi

te g

roun

d w

ires

.

Verify

pro

per

met

er f

unct

ion

by c

heck

ing

the

cond

ition

of

a kn

own

good

bat

tery

.

Igni

tion

nois

e (r

adia

ted

orco

nduc

ted)

will

cau

se t

he

syst

em t

o sh

ut d

own

due

tohi

gh v

olta

ge s

pike

s. I

f th

isis

sus

pect

ed,

chec

k w

ith a

qu

ality

osc

illos

cope

. Spi

kes

grea

ter

than

16V

will

shu

t do

wn

the

ECU

. In

stal

l a

radi

o ca

paci

tor

at t

he

posi

tive

post

of th

e ig

nitio

nco

il (S

ee r

adio

cap

acito

r in

stal

latio

n bu

lletin

). A

fa

ulty

alte

rnat

or o

r w

orn

out

batt

ery

can

also

res

ult

in t

his

cond

ition

.

Will

not

tur

n on

und

er

any

cond

ition

s.Ve

rify

bat

tery

vol

tage

is

grea

ter

than

10

volts

and

less

than

16.

Loss

of m

ode

door

fu

nctio

n.

No

mod

e ch

ange

at

all.

Che

ck f

or d

amag

ed m

ode

switc

h or

pot

entio

met

er a

nd

asso

ciat

ed w

irin

g.

Part

ial f

unct

ion

of m

ode

door

s.

Typi

cally

cau

sed

by

evap

orat

or h

ousi

ng

inst

alle

d in

a b

ind

in t

he

vehi

cle.

Be

sure

all

mou

ntin

g lo

catio

ns li

ne u

p an

d do

n’t

have

to

be for

ced

into

pos

ition

.

Blo

wer

tur

ns o

n an

d of

f ra

pidl

y.

6.

Bat

tery

vol

tage

is a

t le

ast

12V.

Che

ck f

or a

t le

ast

12V a

t ci

rcui

t br

eake

r.En

sure

all

syst

em g

roun

ds a

nd p

ower

con

nect

ions

are

cl

ean

and

tight

.

Bat

tery

vol

tage

is le

ss

than

12V

.

5.

Trou

ble

shoo

tin

g G

uid

e (C

ont.

)

Che

ck f

or f

aulty

bat

tery

or

alte

rnat

or.

Cha

rge

batt

ery.

Syst

em s

huts

off b

low

er a

t 10

V. P

oor

conn

ectio

ns o

r w

eak

batt

ery

can

caus

e sh

utdo

wn

at u

p to

11V

.

7. Whe

n ig

nitio

n is

tu

rned

on,

blo

wer

m

omen

tarily

co

mes

on,

the

n sh

uts

off.

This

oc

curs

with

the

bl

ower

sw

itch

in

the

OFF

pos

ition

.

This

is a

n in

dica

tor

that

the

sy

stem

has

bee

n re

set.

Be

sure

the

red

pow

er w

ire

is o

nth

e ba

tter

y po

st,

and

not

on a

sw

itche

d so

urce

. Als

o, if

the

sy

stem

is p

ulle

d be

low

7V f

orev

en a

spl

it se

cond

, th

e sy

stem

will

res

et.

Run

red

pow

er w

ire

dire

ctly

to

batt

ery.

Che

ck f

or p

ositi

ve p

ower

at

heat

er v

alve

gre

en w

ire

and

blow

er r

ed w

ire.

Che

ck f

or g

roun

d on

con

trol

hea

d w

hite

w

ire.

Che

ck f

or o

bstr

ucte

d or

bi

ndin

g m

ode

door

s.Che

ck f

or d

amag

ed s

tepp

er

mot

or o

r w

irin

g.

Erra

tic fun

ctio

ns o

fbl

ower

, m

ode,

te

mp,

etc

.

Che

ck f

or d

amag

ed s

witc

h or

po

t an

d as

soci

ated

wirin

g.Re

pair o

r re

plac

e.

8.


1

1.2.

11

744013781180

Gen IV Evap Sub Case with 90 Defrost with 204 ECUAccessory Kit 1969 Firebird with A/C

No. Qty. Part No. Description

Packing List:Evaporator Kit (564468)

Checked By:Packed By:

Date:

Gen IV Evaporator Sub Case with 90 Defrost with 204 ECU

744013

2

Accessory Kit781180

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

1969 pontiac firebird - vintage air · 3 901124 rev c 8/01/18, inst 69 firebird w/ a/c evap kit pg...

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