Classic AutoAir Mustang 1969 Installation Manual Download | Manualshive

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Installation Manual

1969-1970 Mustang

DOCUMENT #1-2027

©2012 ClassicAutoAir / 2.12vs3

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Summary of Contents for Mustang 1969

Page 1: ...Installation Manual 1969 1970 Mustang DOCUMENT 1 2027 2012 ClassicAutoAir 2 12vs3 ...

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Page 3: ...mbined experience achieved thru thousands of successful installations and feedback from customers like you Please remember that our 1 goal is that you ll have a successful installation and a system that performs at a very high level for many years to come Before starting read the instructions carefully from beginning to end and follow the proper sequence On the next page you ll find a safety and g...

Page 4: ...g over it The blower fan moves cool air out into the car interior Compressor The compressor pumps and circulates the refrigerant through the system Condenser The condenser is a heat exchanger mounted at the front of the vehicle Heat drawn out of the interior of the car is expelled here Receiver Drier The drier not only dries refrigerant it also filters the refrigerant and stores it under certain o...

Page 5: ...lation you might find the opportunity to repair or upgrade non working or out of date components When you re ready to start the installation DISCONNECT THE BATTERY FIRST Drain the radiator Retain the coolant and reuse or dispose of properly SAFETY FIRST Wear eye protection while drilling cutting deburr sharp edges and never get in a hurry or force a part Tools Your installation only requires the b...

Page 6: ...1 2 3 4 5 6 7 8 9 10 11 Face A C 100 Defrost 100 Floor 20 Defrost 80 Floor 40 Defrost 60 Floor 60 Defrost 40 Floor 80 Defrost 20 Face 80 Defrost 20 Face 60 Defrost 40 Face 40 Defrost 60 Face 20 Defrost 80 Floor 100 FLOOR DASH DEF www classicautoair com 866 435 7801 PAGE 1 TEMP LEVER FAN SWITCH MODE LEVER The FAN switch works like the OEM switch the DOWN position is OFF all power to the system is O...

Page 7: ...attached to the Vent Heat door see figure 3 Disconnect the electrical harness from the assembly Also remove attachment screw located in front of the air inlet see figure 4 FIGURE 4 FIGURE 3 FIGURE 2 FIGURE 1 INTERIOR COMPARTMENT When retaining parts it s a good idea to store parts in a zip lock bag labeled with info where the parts came from and what size type of tool is needed to reinstall Cleani...

Page 8: ...res at grommet in firewall DRAIN COOLANT FROM RADIATOR and store safely to reuse or recycle accordingly Cut heater hose approximately 1 from firewall see figure 5B Also to prevent forgetting to refill the coolant when the installation is completed do not put the cap back into place instead put the cap to the side and cover radiator hole with a clean rag or something similar this will help remind y...

Page 9: ...ply Cable Integrators Ground Ground Ground OEM Power Supply ECU Pressure Switch engine compartment Thermostat Relay Blower Switch Connection Fan Plug Blower Switch Bracket THESE ARE THE PARTS YOU WILL FIND IN BAG KIT A You will use all of these parts and hardware during the next series of installation steps www classicautoair com 866 435 7801 PAGE 4 ...

Page 10: ...original blower switch and set aside these will not be reused see figure 8 3 Attach the new blower switch bracket to the top part of the back of the face plate see figure 9 10 utilizing the OEM screw and then attach the blower switch to the bracket with the two supplied 6 20x3 8 screws Reinstall the switch knob Retain all the OEM parts that you remove at least until the installation is completed G...

Page 11: ...3 Once you have completed these steps you have just a few quick tasks before you can reinstall the control head back into the dash We ve included a new face sticker that corresponds to the actions of your controls Make sure the surface is clean and oil free peel off backing and stick the sticker to the control head face this is optional of course but will be helpful see figure 14 Plug in the blowe...

Page 12: ...ews Evaporator Support Bracket One Fresh Air Inlet Block Off Defrost Heat Duct Assembly One 1 2 Washer One J Clip One Male Spade Connector THESE ARE THE PARTS YOU WILL FIND IN BAG KIT B You will use all of these parts and hardware during the next series of installation steps www classicautoair com 866 435 7801 PAGE 7 ...

Page 13: ...t both wires see figure 15 On the OEM power supply wire attach a 1 4 insulated male spade connector Within the OEM fuse box upgrade the factory HEATER fuse with a 20 amp fuse VERY IMPORTANT Locate the bottom left mounting hole in the firewall that attached the original heater motor From inside of the vehicle drill a 5 8 dia hole for the drain tube TEMPLATE NOTIFICATION A handy drilling template is...

Page 14: ...ing tab location as shown and attach the 1 4 20 J clip supplied see figure 18B Install a Fresh Air inlet block off over the vent opening at the drivers side in the same way using the four OEM nuts Remove evaporator unit from box and place on a flat work surface Locate defrost heat duct assembly and attach to the evaporator using two 10 10 x 5 8 Phillips screws see figure 19 NOTE Be sure that the s...

Page 15: ...ortant to insure proper drainage of condensation On back side of the evaporator is a mounting bracket with a 1 4 20 J clip This bracket will go flush with the inside firewall and you will secure the evaporator by inserting one 1 4 20 x 5 8 bolt with a 1 4 washer from the engine side using the bottom right hole that originally attached the original heater assembly see figure 21 Be sure to align the...

Page 16: ...ate in the Hardware Sack Kit the UPPER MOUNTING BRACKET and attach to evaporator unit using two 10 10 x 5 8 Phillips screws Attach other end to the cowling with a 10 16 x 3 4 Tek Screw see figure 23 IMPORTANT NOTE On the side of the main unit you will see several holes for mounting holes ONLY USE THE ONES IN THE CENTER FOR THIS BRACKET Do not tap into the other holes for any reason see figure 24 A...

Page 17: ...rdware during the next series of installation steps Illustrations NOT shown actual size Clear Plastic Drain Tube Electronic Water Control Valve Firewall Block Off Two 1 Cap Plugs Six Worm Gear Clamps Refrigerant Tape Two 10 16 x 3 4 Tek Screws www classicautoair com 866 435 7801 PAGE 12 ...

Page 18: ...ection on the tubes coming thru the block off assembly is going to be routed to the water outlet on the intake manifold Attach your hose with cable clamps on both ends and route where it will not intefere with linkage or come in contact with exhaust manifolds or headers The upper port coming thru the firewall will be routed to and thru your new your electronic water valve the water valve is marked...

Page 19: ...dware during the next series of installation steps Illustrations NOT shown actual size Five 10 16 x 3 4 Tek Screws Wire Harness System FACE FLOOR POWER CO NT RO L WA TE R VA LV E DEFROST The ECU will be found in it s own box Yellow Blue Orange www classicautoair com 866 435 7801 PAGE 14 ...

Page 20: ...ections at each end Plug the harness with YELLOW band into the YELLOW ECU port and the other end into the servo motor on the main unit motor is marked with YELLOW INDICATOR Repeat this process for the other two harnesses following the color coding indicated on cables and ports Attach cable in the engine compartment to the electronic water valve see figure 27 Using one of the CAP PLUGS provided slo...

Page 21: ...e R e d W i r e B l u e W ire Wh i t e W i r e ECU Ground Ground Ground Servo for Defrost Ducts Servo for Face Floor Ducts Thermostat Evaporator Pressure Switch Compressor Electronic Water Valve Blower Switch To 12V Power Supply Cable Integrators Relay Y e l l o w H a r n e s s B l u e H a r n e s s R e d White Wire O r a n g e H a r n e ss G r een Harness Blue Wire Blue Wires ...

Page 22: ...ght extreme WARM 3 Power Up Board turn fan control to MEDIUM the LED comes ON 4 After 1 second the LED turns OFF 5 After 1 second the LED turns ON 6 Move MODE control to other extreme FLOOR 7 After 1 second the LED turns OFF 8 After 1 second the LED turns ON 9 Move TEMP control to other extreme COLD 10 After 1 second the LED turns OFF 11 After 1 second the LED turns ON 12 The motor calibration sta...

Page 23: ...n actual size Defrost Adaptor Driver Passenger Side Louver Ball Assemblies Center Dash Vent Two Duct Hoses 2 I D To Passenger Side Louver To Center Vent To Drivers Side Louver Face Floor Assembly One Duct Hose 2 I D Bag F Bag G Four Zip Ties Four 10 10 x 5 8 Screws Four Zip Ties Two Zip Ties Two Duct Hoses 2 I D www classicautoair com 866 435 7801 PAGE 18 Bag E CAPPED ...

Page 24: ...er portion and discard Attach our adapter and secure with the screws we ve included see figure 28 Attach flex hoses to the adapter and route to the assembly on the backside of the evaporator see figure 29 The face floor assembly comes pre installed with s clips which allow you to install it onto the evaporator unit quickly and securely see figure 30 FIGURE 30 FIGURE 28 FIGURE 29 www classicautoair...

Page 25: ...ole firmly place the backing plate into place from the back of the dash and then thread the flex hose adapter onto the main assembly This will securely hold the louver ball assembly in place Once both louvers are in place you can attach flex hoses to both securing with zip ties and route to the face floor assembly and attach as shown During installation of the hoses be aware of the eventual moveme...

Page 26: ...2 The dash is somewhat delicate so use a very sharp instrument and cut carefully and cleanly You will encounter a thin metal strip running thru this area of the dash You do not have to remove this metal strip just cut the left and right sides of it down until you can bend it inward Your new center vent should fit very firmly in the new hole Before you fit the center louver into the hole for the fi...

Page 27: ...r hanging down The interior of your car should look pretty much the same as before you started or better Plus you probably got to know the underside of your dash a lot better and might even have repaired or upgraded components that needed attention Good Job Let s move on to the major components within the engine compartment If you have any questions before you move on the final phase of this insta...

Page 28: ...be Two 8 20 x 5 8 Bolts and Lock Nuts Condenser Brackets Condenser Three Refrigerant Hoses Pressure Switch Splice and Bullet Connector Pressure Switch Harness Liquid Tube Drier Drier Bracket Four Zip Ties Eight 10 20x5 8 Screws 8 1 3 3 2 D i s c h a r g e H o s e 10 1 2 S u c t i o n H o s e 6 5 16 Liquid Hose B A www classicautoair com 866 435 7801 PAGE 23 ...

Page 29: ...routing the high low pressure lines and the liquid line Since much of this is installed in the OEM location for the condenser you ll need to remove the center grill section horn s and latch support assembly see figure 33 Be sure to retain all the mounting screws you ll reinstall these pieces in the exact reverse order with the OEM screws www classicautoair com 866 435 7801 PAGE 24 FIGURE 33 ...

Page 30: ...ssure switch into the port at the lower end of the drier liquid tube Go ahead and plug the pressure switch harness into the switch at this time black electrical boot with two long white wires STEP FIVE Install the upper condenser bracket A using four 10 20 x 5 8 screws in the 4th 5th 8th and 9th holes on the condenser from the left be sure the bend on the brackets are facing out towards you top br...

Page 31: ... hole as well as the liquid hose and the wiring harness plug for the high pressure switch STEP SEVEN Place the condenser drier unit into place locating it so that the holes in the condenser brackets align with the holes in the core support used to attach the hood latch it will rest on the lower radiator core brace see figure 36 Drill two 1 3 8 holes FIGURE 35 FIGURE 36 FIGURE 34 If you want to ver...

Page 32: ...neral oil provided 2 Attach the 6 liquid hose 5 16 to the drier and route thru the remaining hole previously drilled into the core support and along the underside of the fender struts around the engine and to the connection at the firewall on the evaporator unit see figure 41 Using supplied zip ties you ll attach this hose the suction hose and the lead from the high pressure switch to the strut br...

Page 33: ...alling the grill horns and latch support in reverse order NOTE The OEM screws for the hood latch support will hold your new condenser in place so be sure to fully tighten these during this step Take a look around at your installation and check all fittings and bolts for tightness check the heater hose clamps for tightness and make sure nothing is routed in a way to obstruct any moving parts You ca...

Page 34: ... tested for basic operation Determine the temperature outside of the car Connect gauges or service equipment to high low charging ports Place blower fan switch on medium Close all doors and windows on vehicle Place shop fan directly in front of condenser Run engine idle up to approx 1500 rpm ACCEPTABLE OPERATING PRESSURE RANGES 1 HIGH SIDE PRESSURES 150 250 PSI 2 LOW SIDE PRESSURES 15 25 PSI in a ...

Page 35: ...de pressures should be between 160 260psi Step 2 IF the low side pressures are normal and the high side pressures are high then there might be an airflow issue continue to next step To test air flow to Condenser do the following three tests 1 Place a piece of paper on the condenser with the car in idle and see if paper is held in place 2 With car in idle attach gages and place a large capacity fan...

Page 36: ... Evaporator freezing Freezing can occur both externally and internally on an evaporator core External freeze up occurs when the coil cannot effectively displace the condensation on the outside fins and the water forms ice the evaporator core resembles a block of solid ice it restricts the flow of air that can pass through it which gives the illusion of the air not functioning The common cause of e...

Page 37: ...Center Louver 1969 70 Mustang BOTTOM EDGE OF PADDED DASH BOTTOM EDGE OF PADDED DASH The gray area is indication of the metal bracing contained within an OEM dash pad just cut a bit on each side and bend the strip inward ...

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Page 39: ...OR HARNESS CAUTION BEFORE YOU USE THIS TEMPLATE READ THIS SMALL NOTE 4 Just as a pre cautionary step make sure this ruler is exactly 4 wide before you use this template especially if you printed this manual from a webpage or a digital copy copier and printers can vary from 100 of actual sizing ...

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Page 41: ... MOTOR HARNESS CAUTION BEFORE YOU USE THIS TEMPLATE READ THIS SMALL NOTE 4 Just as a pre cautionary step make sure this ruler is exactly 4 wide before you use this template especially if you printed this manual from a webpage or a digital copy copier and printers can vary from 100 of actual sizing ...

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Page 43: ...llel with floor pan LEVEL CAUTION BEFORE YOU USE THIS TEMPLATE READ THIS SMALL NOTE 4 Just as a pre cautionary step make sure this ruler is exactly 4 wide before you use this template especially if you printed this manual from a webpage or a digital copy copier and printers can vary from 100 of actual sizing ...

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