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Related Manuals for Classic AutoAir 1971-1973 Mustang A/C system
Summary of Contents for Classic AutoAir 1971-1973 Mustang A/C system
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Page 1: Installation Manual
Installation Manual 1971-1973 Mustang © DOCUMENT #1-2028 ©2013 ClassicAutoAir / 2-1vs.b... - Page 3 Congratulations... You have just purchased the highest quality, best performing A/C system ever designed for your Classic Vehicle. 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 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 A Basic A/C Overview 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 Control & Operating Instructions Your new Perfect Fit-Elite system offers complete comfort capabilities in virtually every driving condition. This includes temperature control in all of the modes. This system also provides the ability to blend the air between Face, Heat, and Defrost modes simultaneously. To illustrate the various ways you can adjust the airflow direction and temperature - we’ve provided these handy illustrations and chart to show exactly how you can adjust your Perfect Fit-Elite for maximum comfort...
- Page 7 Remove Glovebox, Console (optional), Facia, 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). Disconnect the electrical harness from the assembly. Also remove attachment screw located in front of the air inlet (see figure 4). FIGURE 1 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. Cleaning the parts before you need to reinstall them is a good idea too. FIGURE 3 FIGURE 2 FIGURE 4 www.classicautoair.com • 866.435.7801...
- Page 8 Remove all 4 nuts around blower (as indicated by arrows to right, on passenger side of firewall). Cut wires at firewall. Next, remove the OEM defrost duct and set aside for later modification. DRAIN COOLANT FROM RADIATOR and store safely to reuse or recycle accordingly.
- Page 9 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. Pressure Switch (engine compartment) Ground Ground Ground Thermostat OEM Power Supply Wire Harness - Power Supply Blower Switch Plug...
- Page 10 Remove The Heater Control Head From The Dash. 1) There are four OEM screws that hold your control head to the dash. Remove and retain these screws. Remove the control head assembly (see figure 7). 2) Remove the OEM blower switch knob. Retain the screw, you will use it again shortly.
- Page 11 Preparing the TEMP EZ Cable Integrator for installation: First place a cable clip over the end of the Integrator (see figure A). Press it firmly into place Figure A (using needle-nose pliers is recommended). Figure B Hook loop end of integrator wire over the end of the control head lever, see figure B.
- Page 13 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. Two 1/4 - #20 x 5/8" Bolts Evaporator Support Bracket Fresh Air Inlet Block Off Four #10 - 16 x 3/4"...
- Page 14 Locate the original wiring harness that supplied power to the original heater motor. Measure 4” from harness and cut 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).
- Page 15 Locate the Fresh Air inlet block off. Install over hole in inlet cowl as shown on the passenger side (see figure 17A). Attach with three #10 - 16 x 3/4" Tek Screws. Locate the mounting tab location as shown and attach the 1/4" 20 J-clip supplied (see figure 17B).
- Page 16 Installing the complete evaporator unit under the dash will go much easier with the help of a friend. One person can take the unit within the car and “roll” up and under the dash while the other person can be ready at the firewall area with DASH one of the 1/4"...
- Page 17 The second 1/4 - #20 x 5/8" bolt attaches the blower motor mounting bracket in the same location as the original heater mounting in front of the Air Inlet. The blower support bracket will have an additional hole behind the 1/4 - #20 x 5/8"...
- Page 18 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. Clear Plastic Drain Tube Electronic Water Control Valve Two 1 1/4" Cap Plugs Six Worm Gear Clamps Refrigerant Tape Two #10 - 16 x 3/4"...
- Page 19 In Bag Kit C you’ll find the firewall block off. Install this over the hose connections coming thru the firewall within the engine compartment. Attach with two #10 - 16 x 3/4" Tek screws Water valve hose connects to this connection (see figure 25).
- Page 20 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. The ECU will be found in it’s own box Five #10 - 16 x 3/4" Tek Screws Yellow Orange Blue...
- Page 21 We’ve included enough wire length to allow you to mount the ECU in a variety of places. It is very important that you mount this in a place where it will stay dry INSTALL (2) CAP PLUGS OVER HOLES. and that vibration is at a minimum. Also make sure that where ever you mount it SLOT ONE FOR THE CABLE.
- Page 22 Wiring Diagram/Overview To 12V Power Supply Electronic Water Valve Compressor Blower Switch Pressure Switch Ground Ground Cable Integrators Servo for Face/Floor Ducts Thermostat Relay Servo for Defrost Ducts Evaporator Ground REMINDER: BE SURE THAT THE WIRING HARNESS DOES NOT INTERFERE WITH THE OPERATION OF ANY CONTROLS. www.classicautoair.com •...
- Page 23 Temporarily reconnect the car battery at this time. You will need a full 12 volts to complete the calibration. CALIBRATION WELCOME TO Follow these directions carefully and your unit will be calibrated in just a few minutes. Before we boxed and shipped your unit, we tested and calibrated it to factory specifications to make sure it is capable of operating at maximum efficiency. However, the unit must still be calibrated to your specific vehicle and controls.
- Page 24 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 Defrost Adaptor Two Louver Adaptors PN#2-1028-1 Center Dash Vent PN#2-1028-3...
- Page 25 Bag Kit E. Attach the included defrost adaptor to the OEM duct assembly. Pre-installed S-Clips will hold it in place (trim flange as needed). Attach flex hoses to the adapter and route to the assembly on the top of the evaporator (see figure 29).
- Page 26 Attach louver adaptors to the back side of OEM louvers, both sides. S-Clips will hold them in place. Route supplied flex hoses as shown below. Take your time and route them so they don’t become kinked or torn. During installation of the hoses be aware of the eventual movement of the wiper arm components.
- Page 27 Bag Kit G: Installing the center louver vent requires some cutting to the upper pocket slot in the center dash area. Your goal is to open the back enough to insert the included center louver unit into the hole and then attach the flex hose. Once the hole is the right size, insert the new center louver and attach the flex hose using ty-wraps to secure.
- Page 28 You can reinstall the glove box, radio, bezel, facia and the console at this time. This completes the interior portion of the PERFECT FIT-ELITE installation process. This is a good time to make a final check that all the controls still move freely and that nothing is loose or hanging down.
- Page 29 THESE ARE THE PARTS YOU WILL NEED FOR THE ENGINE COMPARTMENT INSTALLATION You’ll find all of these parts within the main box Liquid Tube Left Condenser Right Condenser Upper Upper PN# 0022-100 PN# 0046-50 Drier Bracket Drier Left Condenser Right Condenser Condenser Lower Lower...
- Page 30 ENGINE COMPARTMENT INSTRUCTIONS FIRST THING: IF YOU HAVE NOT DONE SO ALREADY, DISCONNECT THE BATTERY. During the next steps you’ll be installing the condenser, drier, and 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, and latch support assembly (see figure 33).
- Page 31 DRIER AND CONDENSER PREPARATION. You can perform most of the following steps on a clean flat surface like a workbench. Lay the condenser down so that both hose connections are on the right side (the larger connection will be on top). We’ve provided four brackets, 2 upper and 2 lowers, each designed to mounted to the correct side of the condenser.
- Page 32 Screw the high-pressure switch into the port at the top of the drier. Plug in harness. Just to the left of the hole that you will route the tubes thru the support is a dimple (see illustration to the right). Drill a 3/16” hole thru the dimple, and mount the included tube support spacer.
- Page 33 Time to install the compressor kit. Included in your box is 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. C O M P L E T C O M...
- Page 34 PREP PAGE New A/C System Preparation... A MUST READ! Please read thru these procedures before completing this new A/C system charging operation. Centerline of the Oil Plug A licensed A/C technician should be utilized for these procedures to insure that your new system will perform at it’s peak, and that your compressor will 90˚...
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Page 35: Troubleshooting Guide
TROUBLESHOOTING GUIDE TEST CONDITIONS USED TO DETERMINE SYSTEM OPERATION have a more pronounced affect on the unit’s cooling ability. Installing the valve improperly (such as having the flow reversed) will also allow water to flow through, thus inhibiting (THESE TEST CONDITIONS WILL SIMULATE THE AFFECT OF cooling. - Page 36 Trouble Shooting Your Classic Auto Air A/C System PROBLEM: system is not cooling properly If the paper is held in place you are at least getting some air flow. If the high side decreases during test 2 & 3 then your condenser is not getting enough air which is ISSUE: cold at idle, warmer when raising engine RPM’s causing your system to not cool properly.
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