INSTALL INSTRUCTIONS PT-A-401 HVAC UNIT for 2003-2018 CHEVROLET/GMC VAN (For 2007 ALL WHITE Prisoner Transport Inserts ONLY) Not Recommended for diesel engine application because of lack of space needed for ac fittings. Warning do not attempt to install A/C units unless you are experienced with servicing A/C systems! TOOLS REQUIRED: Crimping tool A/C Recovery Unit Wrench set up to 1 ¼ 4 Hole saw ½ Power drill 3/8 Drive Socket set 3/8 Drive Ratcheting wrench ½ Impact gun PARTS AND HARDWARE: QTY DESCRIPTION PART# 25 15 Wire ties GSM20036 2 ft. 1/8 x 9/16 Black Gimp PRM97622 6 2 HVAC Hose Clamp GSM20040 2 Heater Hose 45 Y fitting PRM97410 1 Water N/C Heater control valve PRM97411 1 Vacuum Solenoid 12volt PRM97412 6 ft. Vacuum Hose 5/32 PRM97418 1 Vacuum T fitting PRM97451 10 1 Adjustable steel heater hose clamp PRM97421 24ft. #6 AC Hose High Side PRM97413 24ft. #10 AC Hose Low Side PRM97414 48ft. 5/8 Heater hose PRM97415 1 Low Side T Block fitting PRM97447 1 High Side T Block fitting PRM97448 1 #10FO x #10BL Straight AC fitting PRM97404 1 #10FO x #10BL 90 AC fitting PRM97416 2 # 6FO x #6BL 90 AC Fitting PRM97405 2ft. HVAC Unit drain hose PRM97449 1 On/Off rocker switch C-SW-1 1 On/Off/On rocker switch C-SW-2 1 HVAC Unit PRM97484 1 HVAC unit L mount bracket CM93061-7 2 2 ½ Y Duct Connectors PRM97483 12 3 Hose Clamps GSM20045 32 2 ½ Air Duct Hose (32 foot length) PRM97475 4 Ceiling Vent Cover Brackets KKM0403-001 2 8mm-1.25 x 65mm HHCS GSM33728 2 5/16 Flat washer GSM31146 1
INSTALLATION: 1. REAR EVAPORATOR MOUNTING: A. Position rear AC/Heat evaporator blower behind wheel well on driver side. Note: Install prior to transport insert. This photo shows rear bulkhead position. D B. Mark location for drain hose and cut ¾ hole with hole saw. Note: Silicone hole from underneath when mounting is complete. C. Drill 1/8 and screw down floor mount bracket with #10 x ¾ sheet metal screw. D. Drill ¼ hole and bolt upper bracket to inner body sheet metal with ¼ x ¾ hex bolt. B C 2. AIR DUCT HOSE INSTALLATION: (This step is done PRIOR to transport insert installation) A. Attach duct hoses to evaporator blower and run to ceiling. B. Note: Photo 3 shows complete duct hose assembly. A C. Duct hoses should be temporarily attached to ceiling in approximate location of ceiling vents. Hoses to be pulled through ceiling holes when ceiling is installed. D. Attach vent to ceiling with #10 x ¾ Phillips flat head sheet metal screws 2
3. CUT NECESSARY HOLES: Always check under floor for obstructions (Re. Hoses or harnesses). Determine location on vehicles floor to drill hole. Hole must be forward of driver side wheel well. Cut 4 hole on driver side floor of van. Apply rubber edge molding provided around drilled hole. Note: Hole in floor of van will need to be sealed with silicon when installation is complete 4. ROUTE HOSES: Start under hood of van and route all AC and Heat hoses to HVAC Unit through previously cut hole. Avoid running hoses on or around sharp edges. (Use supplied edge molding if necessary) Route AC/Heat unit hoses through hole in floor of van. At this time focus on HVAC connections under hood of van. Note: Do not tie hoses to brake lines, fuel lines or exhaust pipes. Tie or bolt to frame rail. 5. HEATER HOSES AND COMPONENTS: (Refer to Plumbing Diagram) Drain coolant from system. Locate heater hoses coming from factory heater core. Determine flow of water through factory system. Heater Hose Connections at Engine Note: Proper flow is necessary to acquire optimal performance of HVAC unit. With system drained, cut input hose to Heater Core. Attach Heater Y to ends of cut hose with 45 portion of Y going with flow of water through system. Attach supplied 2 ft. section of Heater hose onto remaining part of Heater Y Other side of 2 ft. section of Heater Hose will then go to Heater control valve. 3
Heater Control Valve has an arrow displaying direction of flow. Secure 2 ft. section onto top inlet of Heater Control Valve using Adjustable Steel Hose Clamps. Secure 1 st - 20 ft. section of Heater Hose to outlet of Heater Control Valve using adjustable steel hose clamps. Cut output hose from heater core. Attach Heater Y to ends of cut hose with 45 portion of Y going with flow of water through system. Attach 2 nd - 20 ft. section of Heater Hose to 45 portion of Y. Secure with Adjustable Steel Hose Clamps. 6. HEATER CONTROL VACUUM SWITCH: Locate OEM vacuum. Cut line and insert Vacuum T Re-attach cut Vacuum hose to sides of Vacuum T. Attach supplied Vacuum hose to bottom of Vacuum T. Mount Vacuum Solenoid in area shown in photo. Attach Vacuum hose to top inlet of Vacuum Solenoid. Secure with supplied 4 Wire Ties. Attach cut portion of Vacuum Hose to Vacuum Solenoid and route to Heater control Valve. Secure each end with 4 Wire Ties. Vacuum Solenoid has (2) ¼ spade terminals. One end needs to be grounded. The other end runs through supplied switch. Use 14ga Dark Blue as power out to the Vacuum Solenoid. (10amps) 7. LOW SIDE AIR CONDITIONING: (Refer to Plumbing Diagram) Separate Low side AC connection near OEM evaporator. Insert supplied Low Side T block fitting (PRM97447) between the separated fittings and reattach using metric bolt and washer. Crimp #10FO x #10BL 90 AC fitting onto #10 Low Side AC hose and attach to Low Side T block fitting previously installed. Be sure all connections are tightly secure. 4
Low Side T Block AC fitting connection with #10FO x #10BL 90 AC fitting High Side T Block AC fitting connection with #6FO x #6BL 90 AC fitting 5
8. HIGH SIDE AIR CONDITIONING: (Refer to Plumbing Diagram) Separate High side AC connection near OEM evaporator. Insert High Side T Block fitting (PRM97448) between separated fittings and reattach using metric Bolt and washer. Crimp #6FO x #6BL 90 AC fitting onto #6 High Side AC hose and attach to High Side T block fitting previously installed. Be sure all connections are tightly secure. 9. AC / HEAT UNIT: (Refer to Plumbing Diagram) Attach 2 ½ black duct hoses to plenum w/ (4) 2 ½ outlets located on HVAC unit using 2 ½ adjustable steel hose clamps. Route 2 ½ black duct hoses up driver sidewall of van in the area between the rear wheel well and the gas fill. Individually wire tie hoses in the corner of the vans wall and ceiling using 15 supplied wire ties being sure to fully stretch hoses. Wire tie supplied ½ Clear Drain Hose to plastic drain cap on HVAC Unit. Route hoses into HVAC access on driver side bench of Insert. Route Clear Drain Hose to hole in floor of Van. Cut to length and wire tie under vehicle. Wire AC / Heat Unit. Wires are as follows: Orange - High Fan Yellow Low Fan Black Ground Red Not used (Cap off) Connect wires, loom, and run to area where switching will be installed. Cut AC and Heat hoses to length. Crimp #10FO x #10BL Straight AC fitting to 18-foot Section of #10 Low Side AC hose. Attach to HVAC unit. Crimp #6FO x #6BL 90 AC fitting to 18-foot section of #6 High Side AC hose. Attach to HVAC unit. Attach Heater hoses to HVAC unit using adjustable steel hose clamps. Center unit in access cutout and flush to lip in bench. Screw HVAC unit strap to floor of van using #10 x ¾ sheet metal screws. Silicone hole in floor of Van. 10. Recharge system with 3.5 to 4 lbs refrigerant and 2 ounces refrigerant oil. Vacuum Hose PRM97418 Vacuum Tee PRM97451 Heater Tees PRM97410 6
Wiring Kit HS-WS3 2 ½ Hose Clamp GSM20040 HVAC Unit PRM97484 Heater Control Valve PRM97411 Vacuum Solenoid PRM97412 Drain Hose PRM97449 #6FO x #6BL 90 AC fitting PRM97405 #10-90 Degree PRM97416 7
#6FO x #6BL Straight AC Fitting PRM97403 #10FO x #10BL Straight AC Fitting PRM97404 High Side T Block PRM97448 Low Side T Block PRM97447 8
HEAT DIAGRAM CHEVROLET VANS 45 Heater Y 9
AIR CONDITIONING DIAGRAM CHEVROLET VANS 10
REAR AC / HEAT WIRING DIAGRAM 11