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Vintage Air 565701, Manual

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an ISO 9001:2015 Registered Company

1957 Chevrolet Full-Size

Evaporator Kit

(565701)

18865 Goll St.  San Antonio, TX 78266  

Phone: 800-862-6658  

Sales: [email protected]

Tech Support: [email protected]

www.vintageair.com

905701 REV B 09/18/18, PG 1 OF 34

Summary of Contents for 565701

Page 1: ...ered Company 1957 Chevrolet Full Size Evaporator Kit 565701 18865 Goll St San Antonio TX 78266 Phone 800 862 6658 Sales sales vintageair com Tech Support tech vintageair com www vintageair com 905701 REV B 09 18 18 PG 1 OF 34 ...

Page 2: ... Installation Cont Evaporator Dash and Center Louver Bracket Installation Fresh Air Cover Plate Rubber Boot Installation Evaporator Leveling Fresh Air Vent Duct Cap Installation Wiring Installation Cont Wiring Installation Cont Drain Hose Installation Lubricating O rings A C Hose Installation Heater Hose Heater Control Valve Installation A C and Heater Hose Routing Wiring Installation Cont Wiring ...

Page 3: ...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 Evaporator Sub Case 761159 Accessory...

Page 4: ... 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 runnin...

Page 5: ... 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 Th...

Page 6: ...the instructions illustrations diagrams Retain OEM bolts washers and nuts unless otherwise indicated as some hardware will be reused When the installation is complete make sure all holes through the firewall are sealed to prevent water intrusion and be sure the windshield wiper escutcheon is sealed Any water damage to the evaporator system may void the warranty Perform the Following NOTE Vintage A...

Page 7: ...y pulling up the retaining brackets See Photo 14 below NOTE Save the retaining brackets Remove the OEM heater core See Photo 15 below Remove the heater control water valve and cable by removing the screw discard See Photo 16 below Locate the supplied OEM heater control water valve cover and apply seam sealer or silicone to the mating surface Install the cover and secure it using 4 8 x 1 2 screws S...

Page 8: ... conversion kit instructions for installation of controls Remove the glove box door by removing 3 screws as shown in Photo 3 below Remove the glove box by removing 5 screws as shown in Photo 4 below Remove the clock from the dash by detaching the light sockets and hardware from behind the dash See Photo 5 below Perform the Following Photo 1 Photo 2 Photo 5 Photo 4 Photo 3 Remove 4 Screws Remove Gl...

Page 9: ...sh remove the 4 screws on the heater assembly cover See Photo 8 below D Remove the 2 screws securing the OEM defrost duct to the dash See Photo 9 below Disconnect the wiring and remove the screw securing the cable to the defrost duct See Photo 10 below E Remove the 3 screws securing the fresh air vent cover to the firewall See Photo 11 below Photo 6 Photo 7 Photo 8 Photo 9 Photo 10 Photo 11 Remove...

Page 10: ...ssenger side fender directly above the wheel and the cable grommet from the firewall See Photos 12 13 below B Remove the fresh air vent tube from the passenger side fender and remove the cable by removing the screw and clamp See Photos 14 15 below Reinstall the passenger side hood hinge using the 4 OEM bolts Photo 12 Photo 13 Photo 14 Photo 15 Remove 3 Bolts Remove Bolt Fresh Air Vent Tube Fresh A...

Page 11: ...vaporator unit as shown in Photo 1 below Install a 1 4 20 x 1 stud into the previously installed U nut on the evaporator firewall bracket and thread it until approximately 1 4 of the stud is showing See Photo 2 below NOTE The 1 4 20 x 1 studs are provided for easier installation of the evaporator unit All studs will be replaced with bolts at the end of the installation Photo 1 Photo 1 Photo 2 Phot...

Page 12: ...rst bend Temporarily install the fresh air plate onto the evaporator firewall bracket using 3 1 4 20 x 1 studs See Photo 5 below Center the hardlines into the holes on the fresh air plate and tighten the fittings See Photo 5 below Remove the fresh air plate and keep the studs on the evaporator firewall bracket with approximately 1 4 of the studs showing Apply press tape to the 10 evaporator compre...

Page 13: ...l Insulation 1 2 3 Pull back the carpet and padding as shown in Photo 1 below Remove the OEM insulation See Photo 1 below and clean the surface where the new insulation will be installed See Photo 2 below Install the insulation pieces using spray adhesive and cover the seams using duct tape See Photo 3 below Apply insulation to the firewall cover See Photo 4 below Photo 1 Photo 2 Photo 4 Photo 3 P...

Page 14: ...hed 12V power source on the fuse panel See Photo 2 below Plug the white connector on the heater control valve adapter into the white connector on the main wiring harness See Photo 3 below NOTE The passenger side defrost duct has a notch for the OEM wire clip See Photo 1 below Photo 1 Photo 1 Photo 2 Photo 2 Photo 5 Photo 4 Photo 3 Photo 3 Passenger Compartment Under Dash View Passenger Side Defros...

Page 15: ...ert the 3 1 4 20 x 1 studs through the fresh air vent opening mounting holes See Photo 4 below Once the unit is in place from the passenger compartment turn the studs approximately 1 4 From the engine compartment temporarily secure the unit using 3 1 4 20 nuts with star washers NOTE To ensure a watertight seal between the passenger compartment and the vehicle exterior for all bolts passing through...

Page 16: ...or dash bracket to the under dash lip using a 1 4 20 x 1 2 hex bolt and a 1 4 20 nut with star washer See Photos 1 2 below NOTE Do not fully tighten the bolts at this time Some adjustment may be needed when leveling the evaporator unit Loosely install the center louver dash bracket onto the under dash lip using a 1 4 20 x 1 2 bolt and washer supplied on the center louver plenum assembly See Photo ...

Page 17: ...amination Verify that the evaporator unit is level and then tighten all of the mounting bolts Replace the upper 1 4 20 x 1 stud on the firewall with a 1 4 20 x 3 4 hex bolt and a 1 4 sleeve washer See Photo 1 below Install 3 S clips onto the fresh air vent duct cap See Photo 2 below Install the fresh air vent duct cap over the fresh air opening on the passenger side inner fender See Photo 3 below ...

Page 18: ...trol panel connector into the ECU module See Photo 8 below Apply 2 strips of Velcro and mount the ECU to the right of the radio on the inner dash NOTE Make sure the area is clean and free of debris before applying the Velcro See Photo 9 below Photo 4 Photo 5 Photo 6 Photo 7 Photo 8 Photo 9 ECU Module Plug Main Wiring Harness Connector into ECU Module Main Wiring Harness Control Panel Reinstall Con...

Page 19: ...resh air cover See Photo 10 below Attach the white ground wire from the heater control valve wiring harness to a suitable ground Route the remaining main wiring harness wires white ground red power and blue safety switch wires through the same hole as the heater control valve wiring See Photo 11 below NOTE Disconnect the red wire from the circuit breaker in order to route the wire through the rubb...

Page 20: ...compressor hardline See Photo 4 below Route and connect the 45 fitting with service port to the compressor See Photo 1 below Tighten each fitting connection as shown in Figure 1 above Standard Hose Kit 1 Refer to separate instructions included with modified hose kit Modified Hose Kit 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 ...

Page 21: ...ater hose to the intake coolant port See Figure 2 below Secure it with a hose clamp Route a length of heater hose to the lower heater hardline on the evaporator unit Route the other end to the water pump coolant port See Figure 2 below Secure both ends with hose clamps not supplied NOTE When installing the heater control valve make sure the flow arrow is facing toward the evaporator unit Photo 1 P...

Page 22: ...take Heater Control Valve Upper Heater Hose Heater Core Heater Control Valve Lower Heater Hose Heater Core Water Pump NOTE Vintage Air Systems use 5 8 heater connections On engines equipped with 3 4 hose nipples these will need to be removed and replaced with 5 8 nipples not supplied For water pumps with a cast in 3 4 heater outlet a 3 4 x 5 8 reducer fitting not supplied or molded hose Vintage Ai...

Page 23: ...ray using the OEM bolts See Photo 14 below Install the circuit breaker near the battery See Photo 15 below Reconnect the red wire eyelet from the main wiring harness to the circuit breaker See Photo 16 below Photo 12 Photo 13 Photo 14 Photo 15 Photo 16 Drier Connect Blue Wire from Main Wiring Harness to Safety Switch on Drier Safety Switch Run Compressor Lead to Compressor Then to Safety Switch on...

Page 24: ... driver side fender See Photos 19 20 below Install the 6 Adel clamp onto the 6 drier evaporator A C hose and secure it to the inner fender OEM hole next to the battery using a 10 24 x 1 2 screw and 10 24 nut with star washer Use the supplied tie wraps to secure the hoses See Photo 21 below Driver Side Fender View Connect Battery Terminals Firewall Cover 64112 VCB OEM Retaining Brackets Route Fresh...

Page 25: ...hown in Photo 2 below Install a 10 24 x 1 2 square neck carriage bolt into the slot on each louver bracket and secure using a 1 8 push on ring See Photos 3 4 below Separate the hose adapters from the louvers See Photo 5 below Attach the driver and passenger side duct hoses to the hose adapters See Photo 6 below Photo 1 Photo 2 Photo 3 Photo 4 Photo 6 Photo 5 Driver Side Bottom Left Corner of Dash ...

Page 26: ...reviously drilled hole on the bottom of the dash and secure it using a 10 24 nut with star washer See Photo 11 below NOTE The driver side louver housing has a notch for easy installation next to the parking brake This louver will use the louver mounting bracket with a smaller slot Install the passenger side louver assembly onto the previously drilled hole on the bottom of the dash and secure it us...

Page 27: ...ated location Secure using 5 OEM screws See Photo 1 below Install the glove box door using 3 10 x 3 4 sheet metal screws See Photo 2 below Reinstall the glove box light See Photo 3 below Reinstall the ashtray frame using the OEM screws See Photo 4 below Reinstall the ashtray See Photo 5 below Photo 1 Photo 2 Photo 3 Photo 4 Photo 5 Glove Box Door Ashtray Glove Box Light Glove Box 490655 5 OEM Scre...

Page 28: ...o 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 c...

Page 29: ...07 VUR 232002 VUA CIRCUIT BREAKER 30 AMP WIDE OPEN THROTTLE SWITCH 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 Between Battery and Circuit Breaker Is Unprotected and Should Be Carefully Routed to Avoid a Short Circuit Wide Open Throttle Switch Contacts Close Only at Full Throttle W...

Page 30: ...pressor 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 CONTR...

Page 31: ... 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 to coldest position to engage compressor Adjust between HOT and COLD to reach desired temperature A C Operation Heat Operation Defrost De fog Operation Blower Speed Blower Speed This lever knob controls blower s...

Page 32: ...s be hot If the ground side of the blower is shorted to chassis ground the blower will run on HI Replace BSC This will require removal of evaporator from vehicle No other part replacements should be necessary Compressor will not turn on All other functions work 2 System is not charged System must be charged for compressor to engage Charge system or bypass pressure switch Danger Never bypass safety...

Page 33: ...tion No mode change at all Check for damaged mode switch or potentiometer and associated wiring Partial function of mode doors Typically caused by evaporator housing installed in a bind in the vehicle Be sure all mounting locations line up and don t have to be forced into position Blower turns on and off rapidly 6 Battery voltage is at least 12V Check for at least 12V at circuit breaker Ensure all...

Page 34: ...ng List Evaporator Kit 565701 No 1 2 Qty 1 1 Part No 761159 781161 Description Gen IV Evaporator Sub Case Accessory 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 761159 Accessory Kit 781161 Checked By Packed By Date ...

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