INSTALL INSTRUCTIONS KK-C-HVAC-1 HVAC UNIT CHEVROLET/GMC VANS FOR

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Frederica Cobb
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1 INSTALL INSTRUCTIONS KK-C-HVAC-1 HVAC UNIT CHEVROLET/GMC VANS FOR (For NEW 2007 ALL WHITE KWIK-KITS ONLY) 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# Wire ties GSM Wire Ties GSM ft. 1/8 x 9/16 Black Gimp PRM HVAC Hose Clamp GSM Heater Hose 45 Y fitting PRM Water N/C Heater control valve PRM Vacuum Solenoid 12volt PRM ft. Vacuum Hose 5/32 PRM Vacuum T fitting PRM Adjustable steel heater hose clamp PRM ft. #6 AC Hose High Side PRM ft. #10 AC Hose Low Side PRM ft. Heater hose PRM Low Side T Block fitting PRM High Side T Block fitting PRM #10FO x #10BL Straight AC fitting PRM #10FO x #10BL 90 AC fitting PRM # 6FO x #6BL 90 AC Fitting PRM ft. HVAC Unit drain hose PRM Wiring Kit w/ switching, connectors, relays HS-WS3 1 HVAC Unit PRM HVAC unit L mount bracket CM ½ Y Duct Connectors PRM Ceiling Vent Cover Bracket KKM Hose Clamps GSM ½ Air Duct Hose (10 foot length) PRM ½ Air Duct Hose (3 foot length) PRM

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#

2 INSTALLATION: 1. REAR EVAPORATOR MOUNTING: A. Position rear AC/Heat evaporator blower behind wheel well on driver side. Note: Install prior to Kwik-Kit. 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 Kwik-Kit 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. 2

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.

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: 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 break 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

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.

4 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

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.

5 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

6 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 Kwik-Kit. 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 PRM

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.

7 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 PRM

8 #6FO x #6BL Straight AC Fitting PRM97403 #10FO x #10BL Straight AC Fitting PRM97404 Low Side T Block PRM97447 High Side T Block PRM

9 HEAT DIAGRAM CHEVROLET VANS 45 Heater Y 9

10 AIR CONDITIONING DIAGRAM CHEVROLET VANS 10

11 REAR AC / HEAT WIRING DIAGRAM 11

TOOLS REQUIRED: Crimping tool A/C Recovery Unit Wrench set up to 1 ¼ 3 ½ Hole saw

TOOLS REQUIRED: Crimping tool A/C Recovery Unit Wrench set up to 1 ¼ 3 ½ Hole saw INSTALLATION INSTRUCTIONS KK-F-HVAC/KK-FD-HVAC - HEAT/AC STANDARD KIT KK-F-MAX-AIR - HEAT/AC UPGRADE KIT 1997-2009 FORD E-SERIES VANS Warning do not attempt to install A/C units unless you are experienced