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

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1 INSTALLATION INSTRUCTIONS KK-F-HVAC/KK-FD-HVAC - HEAT/AC STANDARD KIT KK-F-MAX-AIR - HEAT/AC UPGRADE KIT FORD E-SERIES VANS 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 3 ½ Hole saw ½ Power drill 3/8 Drive Socket set 3/8 Drive Ratcheting wrench ½ Impact gun KK-F-HVAC/KK-FD-HVAC PARTS AND HARDWARE: QTY DESCRIPTION PART# 20 Wire ties GSM ft. 1/8 x 9/16 Black Gimp PRM 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 Box of Hose clamps PRM ft. #6 AC Hose High Side PRM ft. #10 AC Hose Low Side PRM ft. Heater core hose PRM Low Side T fitting (12MOx12FOx10MO) 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-WK-3 2 Evaporator mounting brackets KKM HVAC Unit PRM97443 Diesel Only: 1 High side Suction Block fitting (8FOx8MIOx6SB) PRM ½ ft. #6 Hose (w/ fittings) PRM #8 FO x #6 BL 90 AC fitting PRM #6 BL 3-way Universal T Fitting PRM97431 Gas Only 1

2 1 6FO x 6MO x 6BL High Side T fitting PRM97409 KK-F-MAX AIR Optional Auxiliary Underbody Powered Condenser 1 Auxiliary Underbody Powered Condenser PRM Auxiliary Powered Condenser Mounting brackets / /16-18 x 4 Hex Head Bolts GSM /16-18 x 1 Hex Head Bolts GSM /16 Flat Washers GSM /16 Nylock Nuts GSM30017 Diesel only Optional Auxiliary Powered Condenser 2 15-foot sections of #8 AC hose PRM #8FO x #8BL Straight AC fitting PRM #6FO x #8BL Straight AC fitting PRM #8MIO x #8BL 90 AC fitting PRM #8FO x #8BL 90 AC fitting PRM97493 Gas only Optional Auxiliary Powered Condenser 2 15-foot sections of #6 AC hose PRM #8FO x #6BL Straight AC fitting PRM #6FO x #6BL Straight AC fitting PRM #6FO x #6BL 90 AC fitting PRM #6MIO x #6BL 90 AC fitting PRM97478 Auxiliary Powered Condenser Wire Kit 20 ft. 10ga. Red 20 ft. 10ga. Black 5 ft. 16ga. Yellow 5 ft. 16ga. Black 1 40-amp. Breaker 1 40-amp 4-prong Relay Butt Connectors ga #10 Ring Terminal Female spade Terminals 2

3 INSTALLATION: 1. CUT NECESSARY HOLES: Mount HVAC unit to front side of Front partition using mounting brackets and ¼ hardware provided. Note: If installing a double or triple compartment Kwik Kit you must mount the HVAC Ductwork with hoses to HVAC unit at this time. With unit mounted, place HVAC unit cover and hose cover to determine location of hole to be drilled into floor of Van. (To route hoses) Drill or Cut a 3 hole. Apply rubber edge molding provided around drilled or cut holes. Note: Hole in floor of van needs to be sealed with silicon. Attach ductwork to HVAC unit prior to mounting to Kwik Kit Assembly mounts to front partition of Kwik Kit Attaches through side of HVAC unit 3

4 2. ROUTE HOSES: Start under hood of Van and route all AC and Heat hoses going to HVAC Unit and through previously cut hole. 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. Also route the 20ft. 10ga. Red and 10ga. Black harness with ½ Loom along with the Auxiliary Condenser hoses. 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. Route Auxiliary condenser hoses down driver side of vehicle. 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. 3. 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 - 15 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 - 15 ft. section of Heater Hose to 45 portion of Y. Secure with Adjustable Steel Hose Clamps. 4. 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. 4

5 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) 5. 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. 6. HIGH SIDE AIR CONDITIONING: (Refer to Plumbing Diagram) DIESEL ONLY Be sure to include O-Rings as needed. Remove OEM High side AC line that runs from OEM evaporator and Condenser. At OEM condenser insert supplied High Side T Block. Replace high side AC line with supplied (2 ½)-foot section of #6 AC hose, and attached fittings. Both ends get #8 FO x #6 BL 90 AC fitting (PRM97479). In a suitable area on this line install a #6 BL 3-way Universal T Fitting (PRM97431). If installing Auxiliary powered condenser do not hook up the end going to the OEM condenser this will be attached to one of the #8 AC hoses for the Auxiliary powered condenser. Attach the other #8 AC hose needs to be attached to the previously installed High Side T block. Crimp on the 15-foot section of #6 High Side A/C hose to the remaining portion of T fitting from the previously replaced High Side AC line. If not installing Auxiliary Powered Condenser simply crimp on 15-foot section of #6 AC hose to the T fitting located on the replaced High Side AC line. GAS ONLY 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. If installing Auxiliary Powered Condenser, interrupt system at the High Side T fitting just installed. Crimp a #6MIO x #6BL 90 AC fitting to (1 of 2) 15-foot sections of #6 AC hose going to Auxiliary Powered Condenser. Attach to #6FO side of High Side T fitting installed. Crimp a #6FO x #6BL 90 AC fitting to remaining 15-foot section of #6 AC hose going to Auxiliary Powered Condenser. Attach to OEM #6MIO fitting/ac line just removed from High Side T fitting. Wire tie and/or clamp all hoses away from moving components and hot surfaces. 5

6 7. OPTIONAL AUXILIARY POWERED CONDENSOR: (Refer to Plumbing Diagram) Be sure to include O-Rings as needed. Mark both ends on (1 of 2) #6 or #8 AC hoses (gas or diesel) going to Auxiliary Powered condenser. Wire tie and clamp hoses together as necessary avoiding sharp edges. Mount the 40-amp breaker and 4-prong, 40-amp relay in a convenient location under the hood the van. Supply 12volts to the 40-amp breaker. This will provide power for the relay. 5ft. 16ga yellow wire supplied is used to trigger the relay. 16ga yellow wire and T-tap ties into OEM condenser wire. 5ft. 14ga black wire is ground for relay. The 10ga. Red and Black harness that was run earlier with the AC/ Heat hoses is power & ground for Auxiliary Powered condenser. Attach the 10ga Black wire to the ground stud on the battery. Attach the 10ga. Red wire to power out on the 4-prong relay. Loosely attach Auxiliary condenser brackets to Auxiliary condenser using (4) ¼-20 x ¾ Hex head bolts, lock washers, and flat washers. Note: Condenser will position between emergency brake cable and body of vehicle and must touch either. This is a tight fit and will require exact positioning. Emergency Brake Cable Inner Body Wall Position Auxiliary condenser and mark (4 of 6) mounting holes. Remove unit and drill holes. All (4) mounting holes will need 5/16 holes drilled. A pilot is recommended. The forward holes need to go though both sides of the channel. Loosely attach front bracket using (2) 5/16-18 x 4 bolts, washers and Nylock nuts. Loosely attach rear bracket using (2) 5/16-18 x 1 bolts, washers and Nylock nuts. Re-attach condenser. Tighten all hardware being sure to keep condenser off of both the body and brake cable. Crimp AC fittings to the respective hoses according to plumbing diagram. 6

7 Attach fittings and hoses to Auxiliary condenser. Cut connector and attach 10ga. Red and 10ga. Black to auxiliary condenser using yellow butt connectors. 8. AC / HEAT UNIT: (Refer to Plumbing Diagram) Wire tie supplied ½ Clear Drain Hose to plastic drain cap on HVAC Unit. Route Clear Drain Hose to hole in floor of Van. Cut to length and wire tie. Wire AC / Heat Unit. From 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 90 AC fitting to 15-foot Section of #10 Low Side AC hose. Attach to HVAC unit. Crimp #6FO x #6BL 90 AC fitting to 15-foot section of #6 High Side AC hose. Attach to HVAC unit. Attach Heater hose to HVAC unit using adjustable steel hose clamps. Silicone hole in floor of Van. Attach HVAC unit and Hose cover to vehicle using #10 Sheet metal screws. Wiring Kit HS-WK-3 2 ½ Hose Clamp GSM20040 Evaporator Mounting Brackets KKM99029 KKM

8 Vacuum Hose PRM97418 Vacuum Tee PRM97451 Heater Tees PRM97410 #8MIO x #8BL 90 AC fitting PRM97492 #6FO x #6BL 90 AC fitting PRM97405 #6MO x #6BL 90 AC fitting PRM97478 #8FO x #6BL 90 AC Fitting PRM97479 High Side T Fitting (Gas only) PRM97409 #6BL 3-way T fitting (Diesel only) PRM

9 #6FO x #8BL Straight AC fitting (Diesel only) PRM97494 High Side Suction Block fitting (Diesel only) PRM97496 #8FO x #8BL Straight AC fitting (Diesel only) PRM97429 Low Side Tee PRM97408 #10-90 Degree PRM

10 Drain System Mount HVAC unit 3 Hole Location FORD VAN GAS SPECIFIC INST. FORD VAN GAS SPECIFIC INSTRUCTIONS High Side T PRM97409 Low Side T PRM

11 FORD VAN DIESEL SPECIFIC INST. View looking into the engine compartment on the Passenger side of Ford Diesel Van View looking back towards Front of 2004 Ford Diesel Van Evaporator Low Side AC line High Side Suction Block fitting High Side T Block fitting Vacuum Line - Vacuum T - Vacuum Solenoid View behind Engine cover inside driver compartment 11

12 HEAT DIAGRAM FORD VANS 45 Heater T 12

13 AIR CONDITIONING DIAGRAM FORD VAN GAS ONLY 13

14 AIR CONDITIONING DIAGRAM - FORD VAN DIESEL ONLY SUCTION BLOCK 14

15 REAR AC / HEAT WIRING DIAGRAM 15

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