INSTALL INSTRUCTIONS KK-S-HVAC SPRINTER VAN REAR HVAC SYSTEM

Transcription

1 INSTALL INSTRUCTIONS KK-S-HVAC SPRINTER VAN REAR HVAC SYSTEM TOOLS REQUIRED: Aeroquip (#FT1357) Pliers A/C Refrigerant Charging machine Refrigerant Hose Cutter Open-end wrench set (up to 1 ¼ ) 3 ½ hole saw or Jig Saw AC / HEAT FITTINGS AND PARTS: Power drill and drill bits Standard and Metric Socket set Ratcheting wrench Impact Wrench Wiring Tools QTY: DESCRIPTION: PART #: 1 AC/Heat Blower / Evaporator PRM AC/Heat Unit Mounting Strap FPM Under Body Condenser PRM Under Body Condenser Bracket Kit KKM Filter - Dryer PRM97425 NOTE: The Compressor fittings supplied attach to a Sanden compressor with one (1) 8FO high side and one (1) 10FO low side aftermarket style connectors. If another compressor is used with different connections, adaptor fittings are the responsibility of the installer. ** It is recommended to order the OEM 2 nd compressor system option from the Sprinter Dealer. OEM / Dealer installation of these optional parts is also recommended** AOC Refrigerant Hose Fittings and Parts 1 8 FO x 10 Hs 90ˌ Compressor Out / Hi PRM Hs x 10 Hs HCP High Charge Port Splice PRM FO x 10 Hs 90ˌ w/ 7/16 swp Condenser In PRM FO x 8 Hs 90 Condenser Out PRM High Pressure switch (** with Black wires) PRM FO x 8 Hs 90 Filter-Dryer In/Out PRM FO x 8 Hs straight Evaporator In PRM FO x 12 Hs 90ˌ w/7/16 swp Evaporator Out PRM Low Pressure switch (** with Blue wires) PRM Hs x 12 Hs LCP Low Charge Port Splice PRM FO x 12 Hs 90ˌ Compressor In / Low PRM ft. # 8 AOC Hose PRM ft. # 10 AOC Hose PRM ft. # 12 AOC Hose PRM # 8 AOC Hose Clamp Assembly (Black) PRM # 10 AOC Hose Clamp Assembly (Pink) PRM # 12 AOC Hose Clamp Assembly (Gray) PRM KK-S-HVAC-2_INST_4-14

2 AC / HEAT FITTINGS AND PARTS continued: 2 Heat Fitting Y PRM Heater Control Valve PRM ft (2-20 ft. pieces) - Heater Hose PRM Steel Hose Clamps (9/16 to 1 1/16 ) PRM Vacuum Solenoid 12v DC PRM /16 Vacuum T PRM ft Vacuum Hose 5/32 ID PRM ft ½ Clear Drain Hose PRM Vent cover / hose adaptor KKM Plenum w/ (4) 2 ½ Outlets PRM ft 2 ½ dia hose (12, 12, 17, 17 ft lengths) PRM Hose Clamps 3 GSM to 3 Adjustable Hose Clamps GSM Metal Clamp GSM ½ Rubber Coated Metal Clamp GSM Heavy Duty Black Wire Tie GSM Rubber Edge Molding (1/8 x 9/16 ) PRM97622 ELECTRICAL PARTS: 1 Under Dash Bracket with (2) switch cutout C-UDB-2 3 Label for Switch C-LABEL-S 1 On/Off/On Rocker Switch C-SW-2 2 On/Off Rocker Switch C-SW ga. Dark Blue (20ft.) PRM97902DKBL 1 14ga. Black (5ft.) PRM97902B 1 16ga. Yellow (5ft.) PRM ga. Black (12 ft.) PRM97902B 1 12ga. Orange (12 ft.) PRM97903O 1 12ga. Red (12 ft.) PRM97903R 1 12ga. Yellow (12 ft.) PRM97903Y 1 1 Plastic Grommet GSM prong Relay GSM ga. Butt Connector GSM ga. Butt Connector GSM ga. Female Connector GSM ga. Female Connector GSM ga. Male Connector GSM ga. #10 Ring Terminal GSM ga. ¼ Ring Terminal GSM ga. 5/16 Ring Terminal GSM Fuse Holder GSM amp Fuse GSM amp Fuse GSM KK-S-HVAC-2_INST_4-14

3 PRM97474 Under Body Condenser KKM Condenser Brackets PRM97443 Evaporator PRM97476 Plenum PRM97410 Heater Y PRM97425 Filter-Dryer PRM97411 Heater Control Valve PRM97412 Vacuum Solenoid PRM97451 Vacuum Tee 3 KK-S-HVAC-2_INST_4-14

4 Driver side underbody condenser mount location Attach mount brackets to condenser with 5/16 x 1 HHCS. Determine position of unit. (fan s angled toward center of van) Hold in position and mark bracket locations. Remove brackets from condenser and place where previously outlined. Mark mount hole locations to be drilled. Drill 3/8 diameter holes completely through floor. (3 per bracket) Attach brackets to floor with 5/16 x 2 bolts washers and nuts. Bolt condenser back onto brackets. Run all necessary wiring. Run wiring to evaporator / blower unit. (approximately 24 behind driver seat Connect wire to green OEM compressor clutch wire. Run wire to condenser relay. 4 KK-S-HVAC-2_INST_4-14

5 OEM 12 volt power source can be found under passenger side seat. Locate heater hose connection 1. (near fire wall) Position Y as shown. Install Y, hose clamps and new 20 foot heater hose. Carefully run hose to driver side and down to frame area. Locate auxiliary (spare) OEM tee at lower passenger side engine compartment. Clamp off OEM hose to prevent leakage during installation. Attach shut off valve with 20 foot hose to OEM auxiliary hose. Run vacuum hose to vacuum solenoid. Carefully run hose to driver side and down to frame area. Use Clamps and wire ties to Carefully run heater hoses along frame back to the under Passenger side fender area -Mount vacuum solenoid -Add Tee to OEM vacuum source 5 -Connect vacuum hose to solenoid KK-S-HVAC-2_INST_4-14 -Connect vacuum hose from solenoid to shut off valve -Attach wiring to solenoid (per diagram) body condenser.

6 Connect refrigerant hoses to the OEM second compressor (MFG SANDEN). Note: OEM compressor s are subject to change, so the supplied fittings may not match. Dealer or local AC fitting supplier recommended if necessary. Carefully run heater hoses along frame back to the under body condenser. Install refrigerant charging ports in a convenient / protected location under body. View of hoses running to condenser. Cut approximately a 4 round hole in the floor for running hoses up to the evaporator / blower. Mount Filter/ dryer and connect AC/Heat hoses as per plumbing diagram. Mount evaporator to floor with See Kwik Kit instructions for driver strap bracket. side wall / bench installation. Run duct hoses from evaporator / Note: Prior to complete install, You blower to ceiling. 6 Connect duct may want to place wall assembly in KK-S-HVAC-2_INST_4-14 hoses to ceiling adaptors when insert is installed van to confirm evaporator positioning. Add Coolant and Refrigerant back into the system. (See info next page) Test AC/Heat system. Install cover when complete.

7 - Add original amount of refrigerant back into AC system plus an additional lbs for aftermarket system. (Total lbs maximum) NOTE: The vehicle should have a label under hood showing the amount of refrigerant needed for the OEM system. - Add 2 to 2.5 ounces of refrigerant oil. - Add original coolant back into system, plus approximately 1 gallon of new coolant. - Turn vehicle engine on, check for leaks and test. - Road test vehicle. This will help eliminate air that still may be in the coolant lines. NOTE: The Compressor fittings supplied attach to a Sanden compressor with one (1) 8FO high side and one (1) 10FO low side aftermarket style connectors. It is recommended to order the OEM 2 nd compressor option from the Sprinter Dealer. OEM / Dealer installation of these optional parts is also recommended. If another compressor is used with different connections, adaptor fittings are the responsibility of the installer. 7 KK-S-HVAC-2_INST_4-14

8 8 KK-S-HVAC-2_INST_4-14

9 Note: Aeroquip (#FT1357) can be purchased through your local Aeroquip or Automotive parts dealer. #12 Cage & Clip Fittings Notice the slight modification to the cage portion of the Fitting. This is only an alignment for the fitting and will not affect the installation. 9 KK-S-HVAC-2_INST_4-14

10 10 KK-S-HVAC-2_INST_4-14

11 11 KK-S-HVAC-2_INST_4-14

12 12 KK-S-HVAC-2_INST_4-14