Summary of Contents for Classic AutoAir Mustang 1969
- Page 1 Installation Manual 1969-1970 Mustang © DOCUMENT #1-2027 ©2012 ClassicAutoAir / 2.12vs3...
- 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 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 5 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 6 Control & Operating Instructions PERFECT 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.
- Page 7 Remove Glovebox, Console (if equipped), 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).
- Page 8 Locate blower motor on the firewall (Passenger Side) in the engine compartment. Remove all 4 nuts around blower. Also disconnect the electrical connector from the blower motor (see figure 5A). Cut wires at grommet in firewall. DRAIN COOLANT FROM RADIATOR and store safely to reuse or recycle 1"...
- 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 three OEM screws that hold your control head to the dash, one on the lower side and two on the upper. Remove and retain these screws. Remove the control head assembly (see figure 7). 2) Remove the OEM blower switch knob.
- Page 11 Attaching our exclusive cables to the control head is accomplished in three easy FIGURE 11 steps: Step 1) slide the include cable clips over the ends of the of the EZ Integrators (as shown in figure 11) then, Step 2) attach the integrators to the OEM control head base with the OEM screw you removed earlier, overlapping the cable clamps (see figure 12).
- Page 12 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 One Fresh Air Inlet Block Off Four #10 - 16 x 3/4"...
- Page 13 Locate the original wiring harness that supplied power to the original heater motor (these wires were previously cut on the engine side of the firewall). Reaching thru the glove box opening pull these wires out of their grommet. Measure 4” from harness and cut both wires (see figure 15). On the OEM power supply wire attach a 1/4”...
- Page 14 Locate the Fresh Air inlet block off. Install over hole in inlet cowl as shown on the passenger side (see figure 18A). 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 18B).
- Page 15 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 16 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 17 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" Cap Plugs Six Worm Gear Clamps Refrigerant Tape Two #10 - 16 x 3/4"...
- Page 18 Water valve hose connects to this connection 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 (Figure 25). Seal around the tubes with the included refrigerant tape. This will keep unwanted moisture and debris from entering thru the firewall...
- Page 19 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 20 We’ve included enough wire length to allow you to mount the ECU in a variety INSTALL (2) of places. It is very important that you mount this in a place where it will stay dry 1” dia. CAP PLUGS OVER HOLES. and that vibration is at a minimum.
- Page 21 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 22 TEMPORARILY RECONNECT THE BATTERY AT THIS TIME. MODE YOU CAN NOW CALIBRATE YOUR UNIT. CALIBRATION: 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 23 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 Center Dash Vent Driver &...
- Page 24 Bag Kit E. In order to use your OEM defrost diffuser, you need to modify it slightly and attach our included defrost adapter. Remove the OEM diffuser and lay on a flat surface. From the top of the duct measure and mark 4” down from the top.
- Page 25 Bag Kit F: To install your new louver ball assemblies you’ll need to drill a hole on the drivers and passenger side lower dash. We’ve included templates for each side. Cut these templates out, tape to dash (they will align with the curvature of the lower dash), and cut a bit smaller than the center hole.
- Page 26 Bag Kit G: Installing the center louver vent requires some cutting to the dash pad. We’ve included a template for cutting the center louver hole. Use this template as shown below, but cut a bit smaller than the template hole and test fit/enlarge until you have a snug fit. Center Louver: In order for your new center louver fit to fit into the dash, the dash pad must be cut where the OEM louver would have been.
- Page 27 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 28 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 Condenser Brackets Drier Drier Bracket Condenser Splice and Pressure Switch Bullet Connector Four Zip-Ties Pressure Switch Harness Eight #10 - 20x5/8"...
- Page 29 ENGINE COMPARTMENT INSTRUCTIONS STEP ONE: IF YOU HAVE NOT DONE SO ALREADY, DISCONNECT THE BATTERY. STEP TWO: 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, horn(s), and latch support assembly (see figure 33).
- Page 30 STEP THREE: 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). The drier is conveniently mounted on the right hand You can easily find the side of the condenser.
- Page 31 STEP SIX: Your OEM radiator support was designed to support a A/C condenser and conveniently has two small indentations on the drivers side core support (see figure 38, aftermarket core supports may or may not have these indentations). Locate these two small indentations and drill a 1 3/8” hole thru each (be sure to check for any obstructions before drilling, and remove any sharp burrs from the drilling before continuing, see figure 34), then the area between the two holes will be easy to remove (example figure 35).
- Page 32 STEP EIGHT: 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 33 STEP TEN: Connect the pressure switch by first connecting one wire to the connection on the compressor, and the other wire will be routed along with the liquid hose along the underside of the fender supports and connected to the blue lead you put thru the firewall during the interior installation (for attachment route, see figure 37, on previous page).
- Page 34 New A/C System Preparation Centerline of the Oil Plug Please read thru these procedures before completing this new A/C system charging operation. 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 not be damaged. 90˚...
- Page 35 Trouble Shooting Your Classic Auto Air A/C System PROBLEM: system is not cooling properly With car still in idle and gages attached, pour water down the front of the condenser. What happens to the pressures? ISSUE: cold at idle, warmer when raising engine RPM’s If the paper is held in place you are at least getting some air flow.
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Page 36: 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 (THESE TEST CONDITIONS WILL SIMULATE THE AFFECT OF DRIVING THE VEHICLE AND through, thus inhibiting cooling. - Page 39 PASSENGER SIDE...