Vintage Air 551168 User manual

an ISO 9001:2008 Registered Company
1967-68 Ford Mustang
Mercury Cougar
without Factory Air
Evaporator Kit
(551168)
18865 Goll St. San Antonio, TX 78266
Phone: [phone]
Fax: [phone]
www.vintageair.com
901277 REV F 11/18/16, PG 1 OF 24
FOR
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www.vintageair.com
901277 REV F 11/18/16, PG 2 OF 24
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
rst, followed by the wiring, evaporator, and nally the control panel.
Cover..................................................................................................................................
Table of Contents.................................................................................................................
Packing List/Parts Disclaimer..................................................................................................
Information Page..................................................................................................................
Wiring Notice.......................................................................................................................
Engine Compartment Disassembly, Condenser Assembly and Installation, Compressor and
Brackets, Passenger Compartment Disassembly........................................................................
Defrost Duct and Fresh Air Cap Installation..............................................................................
Firewall Cover Installation.....................................................................................................
Evaporator Installation..........................................................................................................
Vintage Air Center Louver Installation, (Optional) Center Louver Installation
Using OEM Center Vent Trim................................................................................................
Drain Hose Installation, Lubricating O-rings, A/C Hose Installation............................................
Heater Hose & Heater Control Valve Installation.....................................................................
A/C and Heater Hose Routing...............................................................................................
Under Dash Louver Installation............................................................................................
Final Steps........................................................................................................................
Control Panel & Duct Hose Routing.......................................................................................
Evaporator Hardline Installation...........................................................................................
Wiring Diagram..................................................................................................................
Gen IV Wiring Connection Instruction....................................................................................
Operation of Controls..........................................................................................................
Troubleshooting Guide.........................................................................................................
Troubleshooting Guide (Cont.).............................................................................................
OEM Center Vent Trim Louver Template.................................................................................
Packing List.......................................................................................................................
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Table of Contents

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901277 REV F 11/18/16, PG 3 OF 24
Packing List:
Evaporator Kit (551168)
No.
1.
2.
Qty.
1
1
Part No.
744004-VUE
781067
Description
Gen IV 4-Vent Evaporator Sub Case
Accessory 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 4-Vent
Evaporator
Sub Case
744004-VUE
Accessory Kit
781067

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901277 REV F 11/18/16, PG 4 OF 24
Important Notice—Please Read
For 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.

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901277 REV F 11/18/16, PG 5 OF 24
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.
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