INSTALL INSTRUCTIONS KK-S-HVAC-2 2007-2014 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 PRM97443 1 AC/Heat Unit Mounting Strap FPM99115 1 Under Body Condenser PRM97474 1 Under Body Condenser Bracket Kit KKM002129 1 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 PRM97515 1 10 Hs x 10 Hs HCP High Charge Port Splice PRM97516 1 8 FO x 10 Hs 90ˌ w/ 7/16 swp Condenser In PRM97517 1 8 FO x 8 Hs 90 Condenser Out PRM97523 1 High Pressure switch (** with Black wires) PRM97550 2 6 FO x 8 Hs 90 Filter-Dryer In/Out PRM97518 1 6 FO x 8 Hs straight Evaporator In PRM97519 1 10 FO x 12 Hs 90ˌ w/7/16 swp Evaporator Out PRM97520 1 Low Pressure switch (** with Blue wires) PRM97551 1 12 Hs x 12 Hs LCP Low Charge Port Splice PRM97521 1 12 FO x 12 Hs 90ˌ Compressor In / Low PRM97522 10 ft. # 8 AOC Hose PRM97530 20 ft. # 10 AOC Hose PRM97531 20 ft. # 12 AOC Hose PRM97488 4 # 8 AOC Hose Clamp Assembly (Black) PRM97540 4 # 10 AOC Hose Clamp Assembly (Pink) PRM97541 4 # 12 AOC Hose Clamp Assembly (Gray) PRM97487 1 KK-S-HVAC-2_INST_4-14
AC / HEAT FITTINGS AND PARTS continued: 2 Heat Fitting Y PRM97410 1 Heater Control Valve PRM97411 40 ft (2-20 ft. pieces) - Heater Hose PRM97415 10 Steel Hose Clamps (9/16 to 1 1/16 ) PRM97421 1 Vacuum Solenoid 12v DC PRM97412 1 3/16 Vacuum T PRM97451 10 ft Vacuum Hose 5/32 ID PRM97418 4 ft ½ Clear Drain Hose PRM97449 4 Vent cover / hose adaptor KKM0403-001 1 Plenum w/ (4) 2 ½ Outlets PRM97476 58 ft 2 ½ dia hose (12, 12, 17, 17 ft lengths) PRM97475 8 Hose Clamps 3 GSM20045 4 2 to 3 Adjustable Hose Clamps GSM20049 6 2 Metal Clamp GSM20040 5 1 ½ Rubber Coated Metal Clamp GSM20044 15 15 Heavy Duty Black Wire Tie GSM20037 2 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-1 1 14ga. Dark Blue (20ft.) PRM97902DKBL 1 14ga. Black (5ft.) PRM97902B 1 16ga. Yellow (5ft.) PRM97901 1 14ga. 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 GSM20007 3 4 prong Relay GSM20700 3 16-14ga. Butt Connector GSM20208 3 12-10ga. Butt Connector GSM20209 12 16-14ga. Female Connector GSM20224 6 12-10ga. Female Connector GSM20228 1 16-14ga. Male Connector GSM20225 4 16-14ga. #10 Ring Terminal GSM20256 1 16-14ga. ¼ Ring Terminal GSM20257 1 12-10ga. 5/16 Ring Terminal GSM20264 2 Fuse Holder GSM20153 1 15 amp Fuse GSM20117 1 20 amp Fuse GSM20118 2 KK-S-HVAC-2_INST_4-14
PRM97474 Under Body Condenser KKM002129 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
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
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.
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.
- Add original amount of refrigerant back into AC system plus an additional 2-2.5 lbs for aftermarket system. (Total 4-4.5 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
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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
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