INSTALLATION INSTRUCTIONS PT-A-402 - HEAT/AC STANDARD KIT 2007-2014 FORD E-SERIES VANS with Gas engine (To be used with 2007 and newer Prisoner Transport Inserts ONLY) Warning do not attempt to install A/C units unless you are experienced with servicing A/C systems! TOOLS REQUIRED: Crimping tool 3 ½ Hole saw 3/8 Drive Socket set A/C Recovery Unit ½ Power drill 3/8 Drive Ratcheting wrench Wrench set up to 1 ¼ ½ Impact gun PT-A-402 PARTS AND HARDWARE: QTY DESCRIPTION PART# 10 Wire ties GSM20036 5 Wire ties GSM20037 2 ft. 1/8 x 9/16 Black Gimp PRM97622 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 Box of Hose clamps PRM97421 20ft. #6 AC Hose High Side PRM97413 20ft. #10 AC Hose Low Side PRM97414 40ft. 5/8 Heater hose PRM97415 1 #10FO x #10BL 90 AC fitting PRM97416 2 # 6FO x #6BL 90 AC Fitting PRM97405 1 #10FO x #10BL straight AC fitting PRM97404 1 High and Low side T AC fittings PRM97498 2ft. HVAC Unit drain hose PRM97449 1 On/Off rocker switch C-SW-1 1 On/Off/On rocker switch C-SW-2 2 Switch Label (HI-LOW and REAR AC HEAT) C-LABEL-S 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
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. A B. Note: Photo 3 shows complete duct hose assembly. 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. 2
Attach duct hose to KKM0403-001 ceiling vents with 3 inch hose clamps Attach KKM0403-001 vents to ceiling with #10 x 3/4" Phillips flat head sheet metal screws. 3
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: a. Start under hood of Van and route all AC and Heat hoses going to HVAC Unit and through previously cut hole. b. If installing Auxiliary powered condenser it is recommended to run the (2) 15ft. sections of AC hose at this time. Be sure to mark both sides of one of the hoses in order to differentiate hoses. c. Also route the 20ft. 10ga. Red and 10ga. Black harness with ½ Loom along with the Auxiliary Condenser hoses. d. Avoid running hoses on or around sharp edges. (Use supplied edge molding if necessary) e. Route AC/Heat unit hoses through hole in floor of Van. f. Route Auxiliary condenser hoses down driver side of vehicle. g. 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. 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. 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. 4
Secure with Adjustable Steel Hose Clamps. 6. HEATER CONTROL VACUUM SWITCH: Locate OEM vacuum line. 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 near Heater Control Valve. Attach Vacuum hose to top inlet of Vacuum Solenoid. Secure with supplied 4 Wire Tie. 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) Be sure to include O-Rings as needed. Separate Low side connection near OEM evaporator. Insert supplied Low Side T fitting. Attach #10 AC hose to remaining portion of T. Be sure all connections are tightly secure. 8. HIGH SIDE AIR CONDITIONING: (Refer to Plumbing Diagram) Be sure to include O-Rings as needed. Separate High side AC connection located between OEM condenser and battery. Crimp on High Side T fitting to 15-foot section of #6 AC hose going to HVAC unit. Insert High Side T fitting inline with separated OEM High Side AC line. a. Wire tie and/or clamp all hoses away from moving components and hot surfaces. 9. AC / HEAT UNIT: (Refer to Plumbing and wiring Diagrams) a. Wire tie supplied ½ Clear Drain Hose to plastic drain cap on HVAC Unit. b. Route Clear Drain Hose to hole in floor of Van. Cut to length and wire tie. c. Wire AC / Heat Unit. From Unit wires are as follows: Orange - High Fan Yellow Low Fan Black Ground Red Not used (Cap off) d. Connect wires, loom, and run to area where switching will be installed. e. Cut AC and Heat hoses to length. f. Crimp #10FO x #10BL 90 AC fitting to 20-foot Section of #10 Low Side AC hose. g. Attach to HVAC unit. h. Crimp #6FO x #6BL 90 AC fitting to 20-foot section of #6 High Side AC hose. i. Attach to HVAC unit. j. Attach Heater hose to HVAC unit using adjustable steel hose clamps. k. Silicone hole in floor of Van. l. Attach HVAC unit and Hose cover to vehicle using #10 Sheet metal screws. 10. Recharge system with 3.5 to 4 lbs refrigerant and 2 ounces refrigerant oil. 5
HVAC Unit PRM97484 Wiring Kit HS-WK-3 Vacuum Hose PRM97418 Vacuum Tee PRM97451 Heater Tees PRM97410 #8MIO x #8BL 90AC fitting PRM97492 #6FO x #6BL 90 AC fitting PRM97405 #6MO x #6BL 90 AC fitting PRM97478 6
#8FO x #6BL 90 AC Fitting PRM97479 #10-90 Degree PRM97416 High Side T Fitting (Gas only) PRM97498 Low Side T Fitting (Gas only) PRM97498 ***Note: Part number PRM97498 is a Kit that includes both fittings and the longer bolts required 2 ½ Hose Clamp GSM20040 7
HEAT DIAGRAM FORD VANS 45 Heater T 8
AIR CONDITIONING DIAGRAM FORD VAN GAS ONLY 9
REAR AC / HEAT WIRING DIAGRAM 10