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Classic Auto Air Perfect Fit Elite Series Installation Manual
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Classic Auto Air Perfect Fit Elite Series Installation Manual

For corvette 1968-74
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1968-74 Corvette
©
DOCUMENT #1-2053

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Summary of Contents for Classic Auto Air Perfect Fit Elite Series

  • Page 1 1968-74 Corvette © DOCUMENT #1-2053...
  • Page 3 PAGE You have just purchased the highest quality, best performing A/C system ever designed for your Corvette. To obtain the high level of performance and dependability our systems are known for, please pay close attention to the following instructions. Our installation steps and procedures are derived from a long history of research and development and the combined experience achieved thru thousands of successful installations (and feedback from customers like you).
  • Page 4 PAGE Check List, Pre- Installation: Before beginning the installation check the shipping box for the correct components. YOUR BOXED UNIT INCLUDES A LIST OF MAJOR COMPONENTS AND A LIST OF BAGGED PARTS. We have a 5 stage check process to make sure you have everything you’ll need.

  • Page 5: High Pressure Switch

    PAGE A Basic Overview of Automotive A/C..OUTSIDE AIR Evaporator with Blower Fan In order to remove the heat from the air in the vehicle, the A/C evaporator allows the refrigerant to absorb the heat from the air passing over it. The blower fan moves cool air out into the car interior.
  • Page 6 PAGE Control & Operating Instructions Your new Perfect Fit-Elite system offers complete comfort capabilities in virtually O F F FAN SWITCH every driving condition. This includes The FAN switch works like the OEM switch, temperature control in all of the modes. This D A S H C O L D the far left position is OFF (all power to the...
  • Page 7 PAGE Remove Glovebox, Console (optional) Radio and Bezel, and set them aside for reinstall later (see figure 1). The removal of the Original Heater Assembly can be accomplished by disconnecting three control cables. One is attached to the Heat/Defrost door (see figure 2). One is attached to the Temperature door, and one is attached to the Vent / Heat door (see figure 3).
  • Page 8 Interior Preparation PAGE Disconnect the electrical harness at the resistor block (see Figure 5). Remove the (4) screws that hold the console control assembly. Remove the “Vent” knobs using an allen wrench. Retain knobs. Remove the console cover. Retain all original hardware. (you will need the bezel later).
  • Page 9 Interior Preparation PAGE DISCONNECT BATTERY. (BATTERY IS LOCATED INSIDE THE CAR BEHIND THE DRIVERS Remove the (3) screws that hold the center bezel in place. Retain bezel screws. Red Stripped Factory A/C Cars Vacuum When removing controls make certain to plug any open vacuum source.
  • Page 10 Interior Preparation PAGE On the passenger side of the instrument panel. Locate and remove the (5) screws that attach the cover to the car. Retain all original hardware. www.classicautoair.com • 866.435.7801...
  • Page 11 OEM Heater and Defrost System Removal PAGE Moving to the engine compartment: In order to remove your heater assembly it is necessary to remove the heater case housing first. Located on the engine side of the firewall, remove six (6) bolts around the perimeter of the heater case housing (see Figure 7).
  • Page 12 OEM Heater and Defrost System Removal, continued PAGE You should now be able to remove the heater assembly located behind the dash area. Rotate upward being careful not to drain any coolant left in the heater coil. www.classicautoair.com • 866.435.7801...

  • Page 13: Control Box

    Control Box PAGE THESE ARE THE PARTS YOU WILL FIND IN CONTROL BOX You will use all of these parts and hardware during the next series of installation steps. DASH COLD D.E.R. Controller, 1968-74 Corvette PN #16-3053 Illustrations NOT shown actual size www.classicautoair.com •...
  • Page 14 BAG KIT B PAGE 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. One #6 - 20x3/8" Screws One Air Inlet Block Off Two 1/4 - #20 x 5/8"...
  • Page 15 Air Block Off PAGE www.classicautoair.com • 866.435.7801...
  • Page 16 Familiarize yourself with the Evaporator Actuator Motor Hose Connection Thermostat Liquid Pressure Hose Connection Dash Hose Connections Defrost Hose Connections Defrost Hose Connections Expansion Valve Actuator Motor Heater Hose Connections Thermostat Blower Motor Heater Air Dumps www.classicautoair.com • 866.435.7801...
  • Page 17 DO NOT USE CALIBRATION KEY WITHOUT TECH SUPPORT DASH COLD Locate main wiring harness from Bag Kit Locate Yellow, Orange wiring harness from Bag Kit Locate the Controls Acquire a 12V Battery (NOT a battery charger) CLASSIC AUTO AIR Page 17...
  • Page 18 WIRING PREP • Wiring Preparation Steps 1 & 2 Click! Click! Connect Yellow Harness into Defrost/Heat Servo Motor Connect Orange Harness into water valve CLASSIC AUTO AIR Page 18...
  • Page 19 Click! Connect Yellow Harness into Face/Floor Port on ECU Connect Orange Harness into Water Valve Port on ECU DO NOT USE Click! DASH COLD From your D.E.R., Connect Green Harness into Control Port on ECU CLASSIC AUTO AIR Page 19...
  • Page 20 Connect red tagged power harness to POWER port on ECU. Connect both BLUE leads into thermostat Connect ground. (either lead into either terminal) 12V Power (20 amp fuse) Grd - Grd - Grd - (White lead is to be connected to compressor) CLASSIC AUTO AIR Page 20...
  • Page 21 Move MODE knob to BLEND Move MODE knob to DEFROST Move MODE knob to DASH Move TEMP knob to COLD AIR OUT OF ALL VENTS AIR OUT OF DASH VENTS AIR OUT OF FLOOR/DEFROST VENTS (50/50) CLASSIC AUTO AIR Page 21...
  • Page 22 GET THE CORRECT OUTCOME, PLEASE CALL OPEN CLOSED TECH SUPPORT BEFORE INSTALLING INTO VEHICLE. 1(866)435-7801 You will be able to see through water valve passage You will NOT be able to see through water valve passage CLASSIC AUTO AIR Page 22...
  • Page 23 Firewall/ Cowl Prep. PAGE Locate on the passenger kick panel the inlet collar. THIS IS FROM INSIDE THE COWL AREA! Factory A/C Cars Remove condenser assembly, a/c hoses, compressor unit, and V.I.R. assembly. Carefully cut the collar off flush Locate the inlet block off and with the firewall.
  • Page 24 PAGE Locate the radio support bracket. Remove the screw and attach the left evaporator support bracket to this bracket location using the original screw or locate (1) ¼-20 x 5/8” hex head screw and nut from Bag Kit B. Locate (1) #8 x 3/8 pan head screw. Holding the evaporator level attach the blower support brace to the blower using the #8 screw and a power screw LEVEL...
  • Page 25 PAGE DASH COLD Illustrations NOT shown actual size www.classicautoair.com • 866.435.7801...
  • Page 26 BAG KIT C PAGE THESE ARE THE PARTS YOU WILL FIND IN BAG KIT C You will use all of these parts and hardware during the next series of installation steps. Calibration Key DO NOT USE WITHOUT TECH SUPPORT Five #10 - 16 x 3/4" Tek Screws Pressure Switch (engine compartment) Yellow...
  • Page 27 Bench Calibration Steps 1 and 2 PAGE Click! Click! Connect Yellow Harness into Defrost/Heat Servo Motor Connect Orange Harness into water valve www.classicautoair.com • 866.435.7801...
  • Page 28 PAGE Click! Click! Connect Yellow Harness into Face/Floor Port on ECU Connect Orange Harness into Water Valve Port on ECU DO NOT USE Click! DASH COLD From your D.E.R., Connect Green Harness into Control Port on ECU www.classicautoair.com • 866.435.7801...
  • Page 29 PAGE Click! Grd - Connect corresponding Fan Switch Connect corresponding fan motor harness. Connect ground. harness to the Bower Switch on Controls Connect ground. Connect Power lead to 12V. Click! Connect red tagged power harness to POWER port on ECU. Connect both BLUE leads into thermostat Connect ground.
  • Page 30 BAG KIT D PAGE THESE ARE THE PARTS YOU WILL FIND IN BAG KIT D You will use all of these parts and hardware during the next series of installation steps. Clear Plastic Drain Tube Electronic Water Control Valve PN#16-1023 Six Worm Gear Clamps Refrigerant Tape Six 1/4 - #20 x 1"...
  • Page 31 Firewall/ Engine Compartment PAGE There are two sets of nuts on two of the hose connections coming through the firewall. In order to install block off plate you will need to remove one nut from both of the hose connections. www.classicautoair.com •...
  • Page 32 Firewall/ Engine Compartment PAGE In Bag Kit D you’ll find the firewall block off. Install this over the hose connections coming through the firewall within the engine compartment. Attach Block off to Rear Mounting Bracket using (2) 1/4-20 x 1” Bolts Install nuts to both hose connections on the outside of block off plate.
  • Page 33 Firewall/ Engine Compartment PAGE In Bag Kit D you’ll find the firewall block off. Install this over the hose connections coming through the firewall within the engine compartment. Attach Block off to Rear Mounting Bracket using (2) 1/4-20 x 1” Bolts and 1/4 -20 nuts This will be easier with a buddy...
  • Page 34 Firewall/ Engine Compartment PAGE TIP: Route ORANGE cable through the block off plate (it will be plugged into the electronic water valve). The loose white wire from main power harness can be fed through the same hole (as shown below). Orange Harness White Wire...
  • Page 35 PAGE IMPORTANT NOTICE: PROPER INSTALLATION OF WATER VALVE MUST Your water valve be installed per these instructions!... (If not, your system will not work properly. lower heater tube connection on firewall will be routed to the water connection on intake manifold using 5/8”...
  • Page 36 BAG KITS E,F,G PAGE THESE ARE THE PARTS YOU WILL FIND IN BAG KITS E, F, and G You will use all of these parts and hardware during the next series of installation steps. Bag E Bag F Bag G Center Dash Vent Assembly Ball Louver Adapters PN# 2-1053-1...

  • Page 37: Installing Duct Work

    Installing Duct Work PAGE Insert the Center air distribution assembly across the top of the gauges. Route the 36” hose assembly across the bottom of the dash to the 90 deg hose adaptor before attaching to the ball. Locate the 2” flex duct, cut (2) pieces 8”, (1) piece 11”, and (1) 16” long. Attach to the evaporator and air distribution as shown.
  • Page 38 PAGE Locate the defrost hose adapter assembly. Insert the adapter into the inlet of the defrost diffuser. Make sure that the s-clips are all the way into the plastic. Locate the long defrost flex hose and attach to the left outlet on the back of the evaporator.
  • Page 39 Passenger Side Dash PAGE Locate the passenger side dash Remove the (3) pan head screws Attach the hose adapter over the cover, set the cover on the that hold the original hose ball louver and retain with the (2) bench face side down. adapter to the panel.
  • Page 40 Driver Side Fresh Air Duct PAGE Located on the driver’s side Remove the wing nut and retain. Locate the fresh air cover and above the kick panel is the fresh Remove and discard the duct. slide over the inlet flange. air duct.
  • Page 41 Driver Side Dash PAGE Locate the driver side dash Remove the (3) pan head screws Attach the hose adapter over the cover, set the cover on the that hold the original hose ball louver and retain with the (2) bench face side down. adapter to the panel.
  • Page 42 Center Bezel Trim PAGE Locate the original center bezel, Cut out the template and tape to and the trim template from the the center Bezel as shown. last page of the instructions.. Cut out the shaded area. www.classicautoair.com • 866.435.7801...
  • Page 43 Center Bezel Trim PAGE CAUTION: CUT CAREFULLY. Install new louver into the center dash bezel. CHECK THE LOUVER ASSEMBLY Factory A/C Cars FOR FIT. IT MAY BE NECESSARY TO FILE THE OPENING TO SIZE It is necessary to remove the shut off door. www.classicautoair.com •...
  • Page 44 FACTORY A/C CARS ONLY Center air distribution assembly Remove the foam seal. Locate center air distribution assembly. Modify the duct to clear factory Locate (1) 16” piece of open cell louver attaching screw. Cut off foam ans carefully wrap the flanges and cut notch in the duct as factory louver assembly.
  • Page 45 PAGE THESE ARE THE PARTS YOU WILL NEED FOR THE ENGINE COMPARTMENT INSTALLATION You’ll find all of these parts within the main box Drier Bracket Drier Splice and Bullet Connector Condenser PN#11-1042 (2) Short Condenser Bracket (2) Long Condenser Brackets PN#0088-50 PN#0088-51 Eight #10 - 20 x 1/4"...
  • Page 46 Condenser Mounting PAGE Locate the following components from the condenser kit. Condenser, (2) left side condenser mounting brackets, (2) right side condenser mounting brackets, condenser to bulkhead hose assembly, (1) #6 O-rings, and (8) #10 x #8 Large Fitting #6 Small Fitting Attach the condenser brackets using #10 screws to the 3rd hole ATTENTION: THIS IS A VIEW OF THE BACK OF THE CONDENSER...
  • Page 47 PAGE #8 Large Fitting Attach the condenser brackets using #10 screws to the 2nd hole #6 Small Fitting from the top, using th outer #10-20 x 1/4” HEX-HEAD Attach the condenser brackets #10 - 16 X 3/4” using #10 screws to the 3rd hole TEK SCREWS from the bottom, using th outer www.classicautoair.com •...
  • Page 48 PAGE Locate the height of the condenser to the radiator support as shown! www.classicautoair.com • 866.435.7801...
  • Page 49 PAGE Place condenser in front of the radiator and using the #14 self-drilling screws secure the mounting brackets. #10-20 x 1/4” HEX-HEAD #10 - 16 X 3/4” TEK SCREWS www.classicautoair.com • 866.435.7801...

  • Page 50: Water Pump

    PAGE O-RING O-RING O-RING Locate the receiver drier, hi / low pressure switch, liquid tube (bulkhead / drier), drier mounting bracket, and (2) #10 x.” tek screws. Attach to the inlet block off as shown using the liquid tube for location. Attach tube using (2) #6 O-rings and a few drops of mineral oil.
  • Page 51 PAGE Remove the passenger front wheel assembly and retain hardware. Locate the (2) templates from the installation The condenser tube assemblies will pass through the instructions. core support in front of the radiator and the core support behind the radiator. The picture above shows the tubes installed from behind the passenger wheel.
  • Page 52 PAGE Locate the Liquid Tube (1) #6 O-ring, the Discharge tube, and (1) #8 Insert the large tube through the Insert the smaller tube through the upper-drilled hole and attach to lower drilled hole and attach to the the top fitting on the condenser bottom fitting on the condenser using (1) #8 O-ring and a few using (1) #6 O-ring and a few drops...
  • Page 53 Connecting the Hoses Passenger Side Install the compressor kit. Included was a premium compressor kit with all the parts you’ll need to install the compressor. This kit includes instructions specifically written for your engine. Once you’ve installed the complete compressor kit, continue on to connecting the hoses.
  • Page 54 Connecting the Hoses Driver Side Install the compressor kit. Included was a premium compressor kit with all the parts you’ll need to install the compressor. This kit includes instructions specifically written for your engine. Once you’ve installed the complete compressor kit, continue on to connecting the hoses.
  • Page 55 PAGE New A/C System Preparation... A MUST READ! CENTERLINE OF THE OIL FILL BOLT Please read through these procedures before completing this new A/C system charging operation. A licensed A/C technician should be utilized for these procedures to ensure that your new system will perform at it’s peak, and that your compressor will not be damaged.
  • Page 56 PAGE Troubleshooting Guide Test conditions used to determine system operation: D. Internal freeze-up occurs when the system has too much moisture inside. The These test conditions will simulate the effect of driving the vehicle and give the technician the symptoms of internal freeze-up often surface after extended highway driving. The three critical readings that they will need to diagnose any potential problems.
  • Page 57 PAGE Troubleshooting Your Classic Auto Air A/C System Problem: system is not cooling properly Confirm the correct refrigerant charge is in the system. Issue: cold at idle. warmer when raising engine RPMs All of our systems should be charged with 1.5lbs (24oz) of R134a refrigerant only.If overcharged, you will need to evacuate the system and recharge with the correct Make sure the water valve is positioned correctly.

  • Page 58: Wiring Schematic

    Wiring Schematic MAIN POWER HARNESS / CONTROL HARNESS TO THERMOSTAT GRN (01) BLU (02) GRND - BLU (04) WHT (05) BLK (08) GRND - YEL (09) BLUE YELLOW ORG (11) ORANGE GREEN GRND - COMPRESSOR PWR RED/WHT (12) COMPRESSOR www.classicautoair.com • 866.435.7801...
  • Page 59 Wiring Schematic BLU (28) YEL / BLK (29) GRN / BLK (30) BRN (31) WHT / BLK (32) FACE / FLOOR BLU (33) YEL / BLK (34) GRN / BLK (35) BRN (36) WHT / BLK (37) DEFROST BLUE YELLOW BLK (38) GRN / BLK (39) BRN (40)
  • Page 61 IF YOU PRINTED THIS MANUAL PLEASE READ THIS... Just as a cautionary step, please measure this box and make sure it is 1” x 1”. Some copiers/printers may not print at 100% of actual size. REAR EDGE OF RADIATOR SUPPORT...
  • Page 63 BEND ALONG THIS LINE CUT OUT SHADED AREA IF YOU PRINTED THIS MANUAL PLEASE READ THIS... Just as a cautionary step, please measure this box and make sure it is 1” x 1”. Some copiers/printers may not print at 100% of actual size.