Installation Manual © 1971-1973 Mustang DOCUMENT #1-2028 ©2012 ClassicAutoAir / 3.12vs.a CAA 2028 Installation.
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).
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. If your vehicle has been or is being modified, some procedures will need to be adjusted to fit your particular application. A basic cleaning of the engine compartment and interior before beginning will make things go more smoothly.
5 A Basic A/C Overview OUTSIDE AIR Evaporator with Blower Fan 1 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. 2 Compressor The compressor pumps and circulates the refrigerant through the system. 3 Condenser The condenser is a heat exchanger mounted at the front of the vehicle.
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.
7 INTERIOR COMPARTMENT 9LTV]L .
8 Remove all 4 nuts around blower (as indicated by arrows to right, on passenger side of firewall). Also disconnect the electrical connector from the blower motor. Cut wires at grommet in 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. Cut heater hose approximately 1” from firewall.
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 ECU Thermostat OEM Power Supply Fan Plug &DEOH ,QWHJUDWRUV :LUH +DUQHVV 3RZHU 6XSSO\ Blower Switch Connection Relay )DFHSODWH 6WLFNHU %ORZHU 6ZLWFK .
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. Remove the control cables and the original blower switch and set aside (these will not be reused, see figure 8).
11 Attaching our exclusive cables to the control head is accomplished in three easy 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). Step 3) push the integrator wire ends over the ends of the levers (see figure 13).
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. 7ZR [ %ROWV (YDSRUDWRU 6XSSRUW %UDFNHW 2QH )UHVK $LU ,QOHW %ORFN 2II )RXU [ 7HN 6FUHZV 2QH 0DOH 6SDGH &RQQHFWRU 'HIURVW +HDW 'XFW $VVHPEO\ 2QH - &OLS )RXU [ 3KLOOLSV 6FUHZV 2QH :DVKHU Illustrations NOT shown actual size WWW CLASSICAUTOAIR COM s 866.435.7801 CAA 2028 Installation.
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” insulated male spade connector. Within the OEM fuse box upgrade the factory HEATER fuse with a 20 amp fuse (VERY IMPORTANT).
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). Install a Fresh Air inlet block off over the vent opening at the drivers-side in the same way, using the four OEM nuts. A Remove evaporator unit from box and place on a flat work surface.
15 DASH FIREWALL 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 one of the 1/4" - #20 x 5/8" bolts to secure the unit in place (see figure 20). Now the unit will be easy to level and secure. Leveling the unit is very important to insure proper drainage of condensation.
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" Bolts. Install a #10 - 16 x 3/4" Tek screw through this hole and into the cowling (see figure 22). Locate in the Hardware Sack Kit the Evaporator Mounting Bracket and attach to evaporator unit using two #10 - 10 x 5/8" Phillips screws.
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. &OHDU 3ODVWLF 'UDLQ 7XEH (OHFWURQLF :DWHU &RQWURO 9DOYH 7ZR &DS 3OXJV 6L[ :RUP *HDU &ODPSV 7ZR [ 7HN 6FUHZV 5HIULJHUDQW 7DSH )LUHZDOO %ORFN 2II Illustrations NOT shown actual size WWW CLASSICAUTOAIR COM s 866.435.7801 CAA 2028 Installation.
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... so seal carefully and thoroughly.
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. CONT WATER VALVE The ECU will be found in it’s own box ROL LOOR FACE/F ST DEFRO POWER )LYH [ 7HN 6FUHZV
20 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 and that vibration is at a minimum. Also make sure that where ever you mount it does not interfere with any moving controls or cables. We recommend mounting it just above the right hand side of the main unit using the included tek-screws. IMPORTANT! DON’T MOUNT THE ECU PERMANENTLY JUST YET.
21 Orang eH arn e Wiring Diagram/Overview To 12V Power Supply Re Electronic Water Valve d /W ss hite Compressor Wi re r G Wh Pressure Switch Ground Wire ite Blower Switch r Ha n ee s ire W e Blu s nes ECU Relay Servo for Defrost Ducts Blu eW ire Thermostat Red Wire ness ire W Blu e Servo for Face/Floor Ducts Blue Har ss r ne Yello w H a Cable Integrators Ground Evaporator Bl ue W ire Ground REMINDER: BE SURE THAT THE WIRING HARNESS DOES NOT INTERFERE WITH THE OPERATION OF
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. This is an easy process that will only take a few minutes. TEMP As you follow thru these steps you’ll be able to hear the motors working on your unit.
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.
24 Bag Kit E. Locate defrost duct from the heater box to base of the defrost distribution plenum. Use sharp box knife and carefully trim duct assembly flush with flange as shown below. Attach the included defrost adaptor to the duct assembly. Pre-installed S-Clips will hold it in place. Attach flex hoses to the adapter and route to the assembly on the top of the evaporator (see figure 29).
25 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. TECH TIPS During installation of the hoses be aware of the eventual movement of the wiper arm components. Also, the process for installing the center louver vent will require a small amount of cutting. This is outlined on the next page.
26 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. Use a hole drill bit and open it up a bit at a time (see below). Use the new center louver as a guide to see when you’ve cut-away enough material. Once the hole is the right size, insert the new center louver and attach the flex hose using ty-wraps to secure.
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. The interior of your car should look pretty much the same as before you started (or better).
28 THESE ARE THE PARTS YOU WILL NEED FOR THE ENGINE COMPARTMENT INSTALLATION You’ll find all of these parts within the main box /LTXLG 7XEH /HIW &RQGHQVHU 8SSHU 31 5LJKW &RQGHQVHU 8SSHU 31 /HIW &RQGHQVHU /RZHU 31 5LJKW &RQGHQVHU /RZHU 31 31 'ULHU %UDFNHW 'ULHU /LTXLG 7XEH 'ULHU WR (YDSRUDWRU &RQGHQVHU 31 'LVFKDUJH 7XEH &RUH 6XSSRUW 6SDFHU µ R V H Q + WL R XF )RXU =LS 7LHV )RXU [ 7HN 6FUHZV 6SOLFH DQG %XOOHW
29 ENGINE COMPARTMENT INSTRUCTIONS ENGINE COMPARTMENT 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).
30 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.
31 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. Locate the Liquid Tube, and the Discharge Tube. Using (1) #6 o-ring and a few drops of mineral oil attach liquid tube to drier and pass through the opening in the radiator core support.
32 rS de Fe n CO COMMPLETE PRES KIT SOR tru ts 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. FIGURE 37 1) Attach the #8 Discharge Hose (13/32") to the connection coming thru the core support and route to the compressor.
33 New A/C System Preparation 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. 1) Your radiator/cooling system is an integral part of your new system. Please insure that you have a 50/50 mix of distilled water and antifreeze.
34 Trouble Shooting Your Classic Auto Air A/C System PROBLEM: system is not cooling properly ISSUE: cold at idle, warmer when raising engine RPM’s Make sure the Water Valve is positioned correctly The water valve is a directional valve and should be installed with the arrow pointing towards the water pump, it should be connected to the heater hose that runs from the heater core to the water pump.
35 TROUBLESHOOTING GUIDE TEST CONDITIONS USED TO DETERMINE SYSTEM OPERATION (THESE TEST CONDITIONS WILL SIMULATE THE AFFECT OF DRIVING THE VEHICLE AND GIVE THE TECHNICIAN THE THREE CRITICAL READINGS THAT THEY WILL NEED TO DIAGNOSE ANY POTENTIAL PROBLEMS). B. CONNECT GAUGES OR SERVICE EQUIPMENT TO HIGH/LOW CHARGING PORTS. C. PLACE BLOWER FAN SWITCH ON MEDIUM. D. CLOSE ALL DOORS AND WINDOWS ON VEHICLE. E. PLACE SHOP FAN IN FRONT OF CONDENSER. F. RUN ENGINE IDLE UP TO 1500 RPM.
CAA 2028 Installation.
