Installation Manual © 1971-1973 Mustang DOCUMENT #1-2028 ©2013 ClassicAutoAir / 2-1vs.
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).
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.
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. Heat drawn out of the interior of 4 the car is expelled here.
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.
INTERIOR COMPARTMENT 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.
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. Cut heater hose approximately 1” from firewall.
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 Cable Integrators Wire Harness Power Supply Blower Switch Connection Relay Faceplate Sticker Blower Switch Knob Blower Switch Bracket Blower Switch Two #6 - 20x3/8" Screws NOTE: Illustrations NOT shown actual size Two - Cable Clips www.classicautoair.
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).
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 (using needle-nose pliers is recommended). Figure A Figure B Hook loop end of integrator wire over the end of the control head lever, see figure B. Using the OEM screw mount the integrator to the control head pedestal as shown in figure D. Make sure orientation is correct, using figure C as a guide.
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 One Male Spade Connector Defrost/Heat Duct Assembly One J-Clip Four #10 - 16 x 3/4" Tek Screws Four #10 - 10 x 5/8" Phillips Screws One 1/2" Washer Illustrations NOT shown actual size www.classicautoair.com • 866.435.
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). 4" Locate the bottom left mounting hole in the firewall that attached the original heater motor.
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). 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 18).
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.
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 Bag Kit B the Evaporator Mounting Bracket and attach to evaporator unit using two #10 - 10 x 5/8" Phillips screws.
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 Firewall Block Off Two #10 - 16 x 3/4" Tek Screws Refrigerant Tape Illustrations NOT shown actual size www.classicautoair.com • 866.435.
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 (see figure 25). TIP: This would be a good time to “jump” ahead a bit, and remove the ORANGE cable from Bag Kit D and route it thru the block off plate (it will be plugged into the electronic water valve).
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 ST LOOR POWER DEFRO FACE/F Five #10 - 16 x 3/4" Tek Screws Yellow Orange Blue Wire Harness System Illustrations NOT shown actual size www.classicautoair.com • 866.435.
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.
Orang eH arn e Wiring Diagram/Overview To 12V Power Supply ss Electronic Water Valve Re d /W hite Compressor Wi re r G Wh Pressure Switch Ground Wire ite Blower Switch res Wi e Blu ess arn H n ee ECU Servo for Defrost Ducts Relay Blu eW ire Thermostat ire W Red Wire ness 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
Temporarily reconnect the car battery at this time. You will need a full 12 volts to complete the calibration. WELCOME TO EZ CALIBRATION... 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.
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 Defrost Adaptor PN#2-1028-1 Bag F Bag G Two Louver Adaptors PN#2-1028-3 Center Dash Vent PN#1-1028-2 To Center Louver Two Duct Hoses, 2" I.D. Capped (unused) To Drivers Side Louver Two Duct Hoses, 2" I.D. Face/Duct Assembly To Passenger Side Louver Four Zip-Ties Four Zip-Ties Four #10 - 10 x 5/8” Screws Two Duct Hoses 2" I.D.
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). The face/duct assembly comes s-clips pre-installed which allow you to install it onto the evaporator unit quickly and securely (see figure 30). FIGURE 29 FIGURE 30 www.classicautoair.com • 866.435.
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.
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. Route to the face/duct asembly on the evaporator.
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).
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 Upper PN# 0022-100 Right Condenser Upper PN# 0046-50 Left Condenser Lower PN# 0022-101 Right Condenser Lower PN# PN# 0046-51 Drier Bracket Drier Liquid Tube Drier to Evaporator Condenser PN# 11-1043 Discharge Tube Core Support Spacer 3/8” Four Zip-Ties #10 1 Three Refrigerant Hoses ose Four #14 - 16 x 3/4" Tek Screws ti o S uc # Bag of
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).
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.
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.
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.
PREP PAGE New A/C System Preparation... A MUST READ! 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. Centerline of the Oil Plug 90˚ 90˚ 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.
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.
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.
OEM HOLE Lower Right OEM Heater Hose Hole DRILL 9/32’ HOLE CUT 4” DIAMETER HOLE IF YOU PRINTED THIS MANUAL PLEASE READ THIS...
