INSTALLATION INSTRUCTIONS FOR AIRTECH II / TIE-IN. For Nissan NV

Transcription

1 INSTALLATION INSTRUCTIONS FOR AIRTECH II / TIE-IN For Nissan NV Corporate Headquarters ProAir, LLC County Road 6; Elkhart, IN Phone: (574) ; Toll Free: ; Fax: (574)

2 TABLE OF CONTENTS Page Preparation Notes 3 Parts List. 6 Instructions.. 8 Parts Illustrations 37 Diagrams.. 40 LLC Rev A 08/13 Page 2 of 43

3 PREPARATION NOTES THE FOLLOWING ARE SUPPLIED IN YOUR KIT FOR GENERAL USE THROUGHOUT THE INSTALLATION: Vinyl Clad linestakes. These are used to attach hoses and wiring harnesses to the vehicle or other structure. There may be various types and sizes including 1, 2, 3, 2 double and 2 twisted. These are secured with self-tapping screws to the vehicle or other structure. These screws will require a screwgun/power screwdriver for installation. Tie Wraps (also called cable ties, cable wraps, wire ties, zip ties). These are used to secure bundles of hoses or wiring harnesses together. They are NOT used to secure hoses and wiring to the vehicle. These are 14 plastic. There are also stainless steel 14 tie wraps supplied for securing the fire protective sleeve to the refrigerant hoses/heater hoses that run near OEM equipment. Hose Clamps (wormgear clamps) used on hoses, #10 and 7/8 Wire Loom (Convoluted Tube). This comes in 1/4, 1/2, 3/4, and 1 sizes and is used to protect wiring and hoses at various points in the vehicle. It is easily cut to length. Trim Lock. Used to trim metal openings and edges. Various specialty hardware including grommets, plates, spacers and shims. Various general hardware including screws, bolts, washers, lock washers and nuts. Self-Tapping 14 x 1 screws ( ) are used frequently. Plumbing fittings including nipples, wyes, ells, splices, manifolds and O rings. Electrical wiring of various sizes and lengths including wiring harnesses. Hoses 5/8 heater, 7/8 drain and #6, #8 and #10 refrigerant. LLC Rev A 08/13 Page 3 of 43

4 IN ADDITION TO AN ASSORTMENT OF GENERAL TOOLS AND SUPPLIES, THE CUSTOMER WILL NEED THE FOLLOWING: Silicone Seal (as applied by a caulk gun) for sealing access holes and providing some protection for hoses in various places. Mineral Oil for use on the O rings associated with each refrigerant hose fitting and the drier connections. Refrigerant Fittings Crimp Tool. If you do not have this tool, take a fitting from your kit with you to your local auto supply store for help in obtaining a tool. An assortment of different size eyelet lugs (terminal rings) for wiring use. These are attached to bare wire and crimped. The lugs are then attached to screw terminals on devices and boards or attached to the vehicle chassis with self-tapping screws. An assortment of butt splices. These are used to join bare wires to make connections. They are crimped. Once crimped they should be weather proofed. If you use Perma-Seal Butt Connectors you can simply use a heat gun or torch to shrink the cover around the connection to seal it. If you use standard butt connectors, you will need to slip a piece of shrink tubing (customer supplied) over one wire, do your crimp, slide the shrink tubing over the connection and heat/seal with a torch or heat gun. LLC Rev A 08/13 Page 4 of 43

5 Please read the following notes before beginning installation: Parts Numbers for parts will be noted the first time the parts are referred to in the instructions only. Plumbing and electrical wiring often run in parallel so installation involves some switching back and forth between plumbing and electrical. Diagrams are provided at the end of these instructions, illustrating the air conditioning path, the heating path and the wiring runs for the installation. You may follow them as you read these instructions. Pictures of all the parts noted on the Parts List are included at the end of the instructions. Using the zoom tool (+ symbol) allows you to magnify pictures (assuming you are viewing this document on a computer and not as a printout). This may provide some additional clarification on some pictures. Also, if you print these instructions, note that several items are in color so a color copy is best. When installing refrigerant lines, if you install one end but do not immediately install the other end, cover that end with a cap or tape (electrical) to keep out contaminates. As you unpack your kit, locate the install label ( ) and record your kit number on it. Also, as you unpack your Evaporator you need to note the serial number for this unit on the label as well. (Note: You will need these numbers if you ever have to call ProAir for service). Remove the air cleaner before beginning installation. Reinstall after system installation. When installing a wye plumbing fitting, note that there is one inlet port and two oulett ports and the angle outlet port should be directed away from the inlet port as shown below. GENERAL RULE: AVOID CONTACT AS MUCH AS POSSIBLE WITH OEM EQUIPMENT AS YOU PROCEED WITH THE INSTALL (KEEP ITEMS YOU INSTALL AWAY FROM ORIGINAL EQUIPMENT COMPONENTS). LLC Rev A 08/13 Page 5 of 43

6 PARTS LIST Item # Part # Qty Description Harness, Wire 23 3-Speed Harness, Resistor, AirTech/Mini Max Relay, 40 Amp Harness, 20 Amp Power Relay Wire, 6 Gauge Red Switch, Rocker 11 Nissan Rear-Mode Switch, Rocker 11 Nissan Rear-Blower Harness, 11 Nissan Mode/Blower Switch Harness, Water Valve Electric 2-Port Linestake, Washer, Lock 8mm Clamp, Drain Hose 7/ Trim Lock, 2/ Wire Tie, 14 x 3/ Grommet, 1 Hose, 1 1/4 OD Screw, 14x1 Hex Washer Tek Zinc Washer, Lock 6mm Bolt, 8mm 1.25 x 75 Hex Head Wire Tie, 14 Stainless Steel Washer, 5/16 Flat Stainless Steel Clamp, #10 Heater Hose Washer, 6mm Spacer, 13/32 x 23/32 SRB Rubber Bolt, 6mm-1.0x60mm Zinc Part Th Hose, 1/2" ID Drain Hose, 5/8 ID OEM Spec-Bulk Hose, 5/16 Refrigerant #4890 Redu Barrier CF, Hose, 1/2 Refrigerant #4890 Redu Barrier CF, Wye, 5/8 OD Water, Plastic Valve, Kazoo 5/8 ID Straight Splice (Service Port), #6 FOR x 6 CF Ell, 90 #6 FOR x CF Ell, 90 #10 FOR x 10 CF Valve, Water, Electric 2-Port Fitting, Block, Liquid Tie-In 11 Nissan Fitting, Block, Suction Tie-In 11 Nissan Tape, Prestite, Refrigerant Sleeve, Fire Protective, 2 I.D O-Ring, Slimline # O-Ring, #6 (006.8MG) CV23 LLC Rev A 08/13 Page 6 of 43

7 Label, Refrigerant Capacity, Blank Label, Anti-Freeze Mix Label, Door Jamb Card, Information, Warranty Registration Evaporator, AirTech II LLC Rev A 08/13 Page 7 of 43

8 INSTALLATION INSTRUCTIONS It is advisable that you read through these instructions completely before beginning a step-by-step installation. The ProAir Tie-In System is a supplemental Air Conditioning/Heating system for the Nissan NV. The Tie-In system has its own Evaporator but ties in to the OEM system using its Compressor and Condenser to drive the A/C side of the system. The heating side ties in to the OEM system, using the same heated water from the engine that the OEM system does. Diagrams 1 and 2 at the end of these instructions show A/C and Heating Flow. REAR COMPARTMENT TO MID-BODY INSTALLATION (EVAPORATOR, HOSES, AND HARNESS) 1. The AirTech II Evaporator ( ) is to be mounted to the floor of the vehicle, installed on the rear side of the rear wheel well on the driver side. Figure 1 shows the location (X) while Figure 2 shows a finished installation. X Figure 1 Figure 2 2. A drain stub is located on the bottom of the unit (Figure 3) Place the unit in the vehicle in the location noted in Figure 1 (X) and mark the location for a hole in the floor of the vehicle for the drain. Drill a hole slightly larger than the drain stub. Figure 2 shows a finished installation. However, the Evaporator will not be mounted until the hoses are run. Drain Stub Figure 3 LLC Rev A 08/13 Page 8 of 43

9 3. Stretch out the two 5/8 heater hoses ( ), the #6 ( ) and #10 ( ) refrigerant hoses, and the Evaporator harness ( )(Figure 4). Mark one of the heater hoses with Red electrical tape (or in some other way) at intervals to designate it as the Evaporator inlet hose (Figure 4 Inset). Take the bundle inside the vehicle. Figure 4 4. Before beginning installation of the refrigerant hoses observe the following: A green gasket is supplied for each refrigerant hose fitting and mineral oil must be applied to the gasket before insertion in the fitting. This can be obtained at a local auto supply store (Figure 5). On the hose connection end, a special crimp tool must be used to crimp the rings. That tool must be obtained at a local auto supply store (Figure 6). Figure 5 Figure 6 LLC Rev A 08/13 Page 9 of 43

10 5. Attach the refrigerant hoses to the AirTech II Evaporator. Remove the plastic caps on the refrigerant ports. Install fitting (straight) on the #6 hose and attach to the top port (liquid)(figure 7). Install fitting (90 degree) on the #10 hose and attach to the bottom port (suction)(figure 7). After installation, wrap the connections with Prestite tape to minimize condensation (Figure 8). Remember to apply mineral oil to the gaskets before inserting in the fittings. Liquid Port Suction Port Prestite Tape Figure 7 Figure 8 6. Prepare to install the two heater hoses. Remove the black plugs from the heat lines (Figure 9), observing the warning tag (Figure 10). Plugs Figure 9 Figure 10 LLC Rev A 08/13 Page 10 of 43

11 7. Attach the two (2) heater hoses to the heating ports. Connect the hose with Red tape to the bottom port, Evaporator inlet (coolant from engine). Connect the other hose to the top port, Evaporator outlet (coolant to engine)(figure 11). Secure the hoses with clamps ( )(Figure 12). Figure 11 Figure Mount the Evaporator to the floor of the vehicle. Insert two (2) spacers ( ) under the tabs and secure with two self-tapping screws ( ). (Figures 13 and 14). Figure 13 Screws Figure 14 LLC Rev A 08/13 Page 11 of 43

12 9. Connect the drain hose. Figure 15 shows the drain stub extending through the hole previously created in the floor of the vehicle. Insert hose (Figure 16) onto the drain stub (Figure 16). Insert kazoo valve (Figure 16) over the hose. Slip clamp (Figure 16) over the kazoo valve and secure the valve/hose assembly to the drain stub (Figure 17). Drain Stub Hose Kazoo Valve Figure 15 Figure 16 Figure 17 LLC Rev A 08/13 Page 12 of 43

13 10. Prepare the Evaporator wiring. Connect the Mini Harness Assembly (Figure 18) to the Evaporator. One end has two (2) plugs. Connect the plug with two (2) wires to the blower motor pigtail on the Evaporator (Figure 19). Figure 18 Figure Connect the second plug to the side panel of the Evaporator (three spade connections)(figure 20). Figure 20 LLC Rev A 08/13 Page 13 of 43

14 12. Mate the connector on the Mini harness with the connector on the Evaporator harness (Figure 21). Attach the ground wire on the Mini Harness to the chassis with a self-tapping screw (Figure 22). Figure 23 shows the completed wiring on the Evaporator end. Evaporator Harness Figure 21 Figure 22 Mini Harness Figure 23 LLC Rev A 08/13 Page 14 of 43

15 13. Gather the refrigerant hoses (2), heater hoses (2), and Evaporator harness into a bundle and route them over the wheel well (to the front side)(figure 24). Secure the bundle with linestakes ( ) to the inner side wall of the vehicle (Figure 25). Use tie wraps ( ) to keep the bundle together between linestakes (Figure 25). Figure 24 Figure 25 Linestake Tie Wrap 14. Drill four (4) holes in the floor of the vehicle on the front side of the wheel well for the hoses to exit the passenger compartment to the underside of the vehicle. Install grommets ( ) in the holes. The Evaporator harness exits the vehicle in the hole with the #6 refrigerant hose. Figure 26 shows the holes in the floor of the vehicle while Figure 27 shows the finished installation. Figure 28 shows dimensions for drilling. Figure 26 Figure 27 Grommets Wall Wheel Well Holes 1.00 from wall Figure 28 LLC Rev A 08/13 Page 15 of 43

16 15. Drill a hole in the inner side wall under the vehicle to allow the hoses between the side walls to exit to the underside of the vehicle. Figures 29 and 30 show the hoses exiting the wall cavity to the underside. Trim the hole with Trim Lock ( ) to protect the hoses and harness (Figure 31). Figure 32 shows the dimensions for drilling the hole. Figure 29 Figure 30 Side Wall Side Wall Figure 31 Trim Lock Floor Wheel Well Figure Hole LLC Rev A 08/13 Page 16 of 43

17 16. The method of drilling four (4) holes between the two side walls provides for a more compact installation as the hoses are close to the wall in the passenger compartment. An alternative method is to drill one large hole for all four hoses and the Evaporator harness to route through. This hole would be drilled in the floor and would not be inside the wall cavity. Figure 33 shows the hole inside the vehicle and Figure 34 shows it under the vehicle. A large grommet could be inserted in the hole or use Trim Lock to provide protection for the hoses/harness. The hoses can be covered with a box for protection and aesthetics. Figure 33 shows a transparent image of such an installation. Figure 33 Under Side of Floor Figure 34 LLC Rev A 08/13 Page 17 of 43

18 REAR COMPARTMENT TO MID-BODY INSTALLATION 17. With the four (4) hoses and Evaporator harness now under the vehicle, determine a path to the engine compartment. At some point along that path, cut the heater hose (marked with Red tape) for the Evaporator inlet and insert the Water Valve in the path. Mount the Water Valve to a cross member on the underside of the vehicle using two (2) self-tapping screws ( )(Figure 35). Secure the heater hose to the Water Valve inlet and outlet with clamps ( ). An arrow on the Water Valve indicates the direction of water flow (Figure 36). The Water Valve inlet fluid comes from the engine and flows to the Evaporator. Figure 35 To Evaporator (Water Valve Out) From Wye In Engine Compartment Figure Connect the Water Valve harness ( ) plug to the Water Valve (Figure 37) and set aside the other end (has relay socket, fuse, and Pink wire/spade connector on it)(figure 38). Figure 37 Figure 38 Pink Wire Fuse Relay Socket LLC Rev A 08/13 Page 18 of 43

19 19. Route the hoses and Evaporator harness the remainder of the way to the engine compartment. Attach the bundle appropriately to cross members with linestakes and wire ties between linestakes (Figures 39 and 40). Care should be taken to not disturb any OEM equipment. Figure 39 Figure As the bundle enters the engine compartment, it needs to be protected from any heat generated by the engine. A fire resistant sleeve ( ) and two (2) stainless steel wire ties ( ) are provided to protect the hoses (Figure 41). Slip the hoses inside the sleeve and position appropriately to keep hoses away from heat. Secure sleeve to hoses/harness with the ties. Figure 42 shows the sleeve in place. Figure 41 Figure 42 LLC Rev A 08/13 Page 19 of 43

20 ENGINE COMPARTMENT COOLING A Tie-In System involves taking the OEM Drier outlet to a ProAir Liquid Tie-In fitting which sends the liquid refrigerant to both the OEM Evaporator and the ProAir Evaporator. The outputs from both Evaporators are tied together in a ProAir Suction Tie-In fitting which connects to the Compressor Suction port (See Diagram 1 at the end of these instructions). EVACUATE (DISCHARGE) THE OEM A/C SYSTEM BEFORE PROCEEDING!!! 21. Disconnect the OEM hard refrigerant line (suction) located to the driver side in the engine compartment by removing and discarding the OEM bolt (Figure 43). Separate the line and insert the Suction Tie-In fitting ( ) and bolt into place with bolt Slide lock washer and washer on the bolt before installing (Figure 46). But before inserting the tie-in, install two (2) O-Rings ( ). One O-Ring slips on the groove on the fitting (Figure 45). The other O-Ring slips on a similar groove on the OEM line. The OEM line will have an O-Ring in place when the line is broken. Remove and discard it. Install the O-Ring supplied with the kit (Figure 45). Attach fitting to the refrigerant hose (#10) coming from the ProAir Evaporator (outlet) and connect to the Suction Tie-In. (Figure 44). Remember to apply mineral oil to all O-Rings before inserting in the fittings. Remove/Discard Bolt Evaporator Out Tie-In Fitting Figure 43 Figure 44 Groove Figure 45 Figure 46 LLC Rev A 08/13 Page 20 of 43

21 22. Disconnect the OEM hard refrigerant line (liquid) located to the passenger side in the engine compartment (near the radiator) by removing and discarding the OEM bolt (Figure 47). Separate the line and insert ProAir Liquid Tie-In fitting Secure the fitting with bolt Slide lock washer and washer on the bolt before installing (Figure 50). But before inserting the tie-in, install two (2) O-Rings ( ). One O-Ring slips on the groove on the fitting (Figure 49). The other O-Ring slips on a similar groove on the OEM line. The OEM line will have an O-Ring in place when the line is broken. Remove and discard it. Install the new O-Ring supplied with the kit (Figure 49). Attach fitting to the refrigerant hose (#6) running from the ProAir Evaporator (inlet) and connect to the Liquid Tie-In (Figure 48). Remember to apply mineral oil to all O-Rings before inserting in the fittings. Tie-In Fitting Evaporator In Remove/Discard Bolt Figure 47 Figure 48 Groove Figure 49 Figure 50 LLC Rev A 08/13 Page 21 of 43

22 HEATING 23. The Tie-In to the heating system is accomplished by inserting a wye in both the OEM Heater Push (inlet) line and the OEM Heater Return (outlet) line. Locate the OEM Heater lines on the firewall on the passenger side (Figure 51). The line on the passenger side is typically the Push line (but verify this for your vehicle). Use vise grips or some other kind of tool to clamp off the line (Figure 52). Do this procedure with a cool engine to prevent injury. Cut the line and insert the wye ( ) and connect the two hose ends to the inline ports of the wye (Figure 52) and clamp ( ). Make sure the angle port on the wye is pointing in the direction of water flow. Heater Lines Wye Vise Grips Figure 51 Figure Connect the Water Valve inlet hose (marked with the Red tape) to the angle port on the wye (Figure 53) and clamp. Remove the vise grips. Figure 53 LLC Rev A 08/13 Page 22 of 43

23 25. Follow the Return hose to the driver side (Figure 54) and repeat the process of clamping off the hose, cutting the hose, and inserting a wye. Connect the cut ends to the inline ports of the wye and clamp. Connect the Evaporator outlet (return) line to the angle port on the wye and clamp (Figure 55). Remove the vise grips. From OEM Evaporator To Radiator Figure 54 Figure 55 LLC Rev A 08/13 Page 23 of 43

24 ELECTRICAL OVERVIEW 26. The electrical system requires the interconnection of the following: Four (4) relays connected to wire harnesses (two of those have fuses attached), Figure 56 Evaporator harness running from the Evaporator at the back of the vehicle, Figure 57 Water Valve Harness running from the Water Valve, Figure 57 Two (2) switches: Mode (A/C or Heat), Blower (Fan Speed-High, Med, or Low), Figure 58 Water Valve Harness Evaporator Harness Figure 56 Figure 57 Figure 58 LLC Rev A 08/13 Page 24 of 43

25 27. Figure 59 illustrates the components. TIE-IN SYSTEM Fuse 20 Amp Power (Ignition) Relay # 1 Switch Relay (Cool) #2 Switch Relay (Heat) #3 Fuse 5 Amp Water Valve Relay #4 Wiring To Passenger Compartment Battery Ignition Evaporator Harness Water Valve Harness Figure 59 LLC Rev A 08/13 Page 25 of 43

26 PREPARATION 28. Physical location of the four (4) relays must be determined. The Switch relays (Relays #2 and #3) should be installed inside the passenger compartment while the others may be installed in the passenger compartment (preferred method) or the engine compartment. Figure 60 shows the passenger compartment area where the units would be installed (glove box removed) while Figure 61 shows an area where they could be installed in the engine compartment on the firewall. These instructions will illustrate installation of all relays in the passenger compartment. Figure 60 Figure Remove the side panel and the glove box in the passenger compartment on the passenger side. The side panel (Figure 62) just snaps in. The glove box requires removal of seven (7) screws, three (3) on the bottom (Figure 63) and four (4) screws exposed when the unit is opened (Figure 64). Set the glove box aside (Figure 65). Glove Box Side Panel Remove Figure 62 Figure 63 LLC Rev A 08/13 Page 26 of 43

27 Figure 64 Remove Figure Find locations for all the relays. Figure 66 shows the general layout: #1, OEM switch panel, Figure 66 #2, Relay #1 (Ignition) and Relay #4 (Water Valve), Figure 67 #3, Relay #2 and Relay #3 (Switch Relays), Figure 68 #4, Hole (in firewall) for the wiring to route between the engine and passenger compartments, Figure Figure 66 Figure 67 Figure 69 Figure 68 LLC Rev A 08/13 Page 27 of 43

28 INSTALLATION 31. Drill a hole in the firewall to allow wires to route between the engine compartment and the passenger compartment (Figures 70 and 71). The hole must be big enough to allow passage of the ignition wire, battery wire, and two wiring harnesses (Evaporator and Water Valve). Trim the hole with Trim Lock (behind the insulation). Route the Evaporator and Water Valve harnesses through the hole in the firewall into the passenger compartment. Figure 70 Figure Install an eyelet lug on one end of the 6 gauge wire Route the other end through the hole in the firewall into the passenger compartment (Figure 72). This end is to be butt spliced to the fuse wires on Relays #1 and #4 later. Figure 72 LLC Rev A 08/13 Page 28 of 43

29 33. Attach four (4) relays ( ) to relay harnesses (Figure 73). Number/label them as noted below (Figure 74). (Numbering will be referred to throughout the instructions). Relay #1, Power (Ignition), connects to harness (20 Amp Fuse attached) Relays #2 and #3 (Switch Relays), connect to harness Relay #4, Water Valve, connects to harness (routed from engine compartment)( 5 Amp Fuse attached) Figure 73 Figure Mount the relays/fuses in the locations selected. Use self-tapping screws ( ) to attach to OEM compartment (Figures 75, 76, and 77). Route the Relay #1 (Power, Ignition) Orange wire (Signal In) through the firewall hole into the engine compartment (Figure 78). Power and Water Valve Relays Screws Figure 76 Relays Figure 75 LLC Rev A 08/13 Page 29 of 43

30 Ignition Wire Switch Relays Figure 77 Figure Remove the OEM switch plate from the dash (Figure 79) and insert the Rear Mode switch (Heat-A/C) and the Rear Blower switch (Fan Speed-High, Med, Low) into the plate. The Mode switch should be on the left as viewed from the front (Figure 80). Figure 80 Figure Note the numbering of the terminals on the rear of the switches (Figure 81). This information will be used when connecting the wiring to the switches. The connections are spade terminals: Blower Mode Figure 81 Rear View LLC Rev A 08/13 Page 30 of 43

31 37. Connect the wiring in the passenger compartment by following Figures 82, 83 and 86. Relay wiring is noted on Figure 82. Figure 83 includes the wiring from the harnesses/wire from the engine compartment. Figure 86 notes wiring involving the relays and will include some wiring already completed or wiring that does not need to be done (loops noted in the Connection column). There is some duplication in the instructions but this serves as system documentation. RELAY WIRING Figure 82 Relay Plugs into Harnesses , , , , Power Relay Grnd Sig In Relay with tab side down looking on end: 1 Power Out / Red or Red/White Stripe 2 Ground / Black 3 Signal In / Orange, Blue or Pink 4 Power In / Red 5 Power In / Red (not always used) Pwr In Relay Schematic Pwr Out LLC Rev A 08/13 Page 31 of 43

32 Figure 83 WIRING HARNESSES, SWITCHES WIRING EVAPORATOR HARNESS, Yellow wire Connect to Blower Switch, Terminal #1 Red wire Connect to Blower Switch, Terminal #3 Orange wire Connect to Blower Switch, Terminal #6 WATER VALVE HARNESS, Relay socket Connect to Relay #4 Red wire/fuse Butt splice to 6 gauge Red wire going to the battery in the engine compartment Remove spade connector on this wire and the spade connector on the short Pink Pink wire wire on Relay #3 harness (Switch Relay #2, Heat, Signal In). Butt splice these two wires together with the Red/White Stripe wire running from the Booster Pump Black wire Ground to vehicle chassis MODE SWITCH (Spade Connections) Terminal 1 Not Used Terminal 2 Connect one end of White/Orange jumper wire here, other end to Terminal 4 Terminal 3 Connect long Blue wire of Relay #2 harness here (Switch Relay #1, A/C, Signal In) Terminal 4 Connect one end of White/Orange jumper wire here, other end to Terminal 2 Terminal 5 Connect Red wire of Relay#3 here (Switch Relay #2, Heat, Power In) Terminal 6 Connect long Pink wire on Relay #3 here (Switch Relay #2, Heat, Signal In) BLOWER SWITCH (Spade Connections) Terminal 1 Connect Evaporator harness Yellow wire here Terminal 2 Connect one end of White/Orange jumper wire here, other end to Terminal 4 Terminal 3 Connect Evaporator harness Red wire here Terminal 4 Connect one end of White/Orange jumper wire here, other end to Terminal 2 Terminal 5 Connect Red/White Stripe wire of Relay #2 here (Switch Relay #1, Power Out) Terminal 6 Connect Evaporator harness Orange wire here 38. Figures 84 and 85 illustrate the wiring on the back of the switches. Figure 85 shows the jumper referred to in Figure 83. Figure 85 Jumper Figure 84 LLC Rev A 08/13 Page 32 of 43

33 TIE-IN WIRING Figure 86 Relay Name Device Wire Color Harness? Signal Connects To Connection Power Fuse on Relay #1 Red Power In Battery, Positive Terminal** Eyelet Power Relay #1 Red Power In Fuse on Relay #1, Power Out Loop Power Relay #1 Red Power Out Relay #2, Power In, Red Wire Spade Power Relay #1 Orange Signal In Ignition Terminal Block in Engine Compartment*** Bare Wire Power Relay #1 Black Ground Chassis* Eyelet Switch Relay #2 Red Power In Relay #1, Power Out, Red Wire ( ) Spade Switch Relay #2 Red/White Power Out Blower Switch, Terminal #5 Spade Switch Relay #2 Red/White Power Out Relay #3, Power Out Loop Switch Relay #2 Blue (long) Signal In Mode Switch, Terminal #3, A/C Command Spade Switch Relay #2 Blue (short) Signal In not used Spade Switch Relay #2 Black Ground Relay #3, Ground Loop Switch Relay #3 Red Power In Mode Switch, Terminal 5 Spade Switch Relay #3 Red/White Power Out Relay #2, Power Out Loop Switch Relay #3 Pink (short) Signal In Relay #4, Signal In, Pink Wire ( ) Spade Switch Relay #3 Pink (long) Signal In Mode Switch, Terminal #6, Heat Command Spade Switch Relay #3 Black Ground Chassis* Eyelet W Valve Fuse on Relay #4 Red Power In Battery Positive Terminal** Eyelet W Valve Relay #4 Red Power In Fuse on Relay #4, Power Out Loop W Valve Relay #4 Red Power In Water Valve, Loop Plug W Valve Relay #4 Pink Signal In Relay #3, Signal In, Pink Wire Spade W Valve Relay #4 Purple Power In Water Valve Plug W Valve Relay #4 Black Ground Water Valve Plug W Valve Relay #4 Black Power Out Relay #4, Ground Loop W Valve Relay #4 Black Ground Chassis* Eyelet *All the ground (Black) wires are to be attached to the chassis with a self-tapping screw. **These wires are butt spliced to the #6 wire running through the hole in the firewall to the battery. ***To be connected later. LLC Rev A 08/13 Page 33 of 43

34 39. Reinstall the OEM panel into the vehicle as in Figures 87 and 88. Figure 87 Figure Reattach the side panel and the glove box. 41. The Orange wire (Signal In) on Relay #1 runs to the Ignition terminal compartment in the engine compartment adjacent to the battery. Remove the cover (Figure 89) and create a notch for the wire to enter the unit (Figure 90). Install a spade lug on the end of the wire and install in the position shown in Figure 91. Reinstall the cover. Figure 89 Ignition Terminal Notch Figure 90 LLC Rev A 08/13 Page 34 of 43

35 Figure In the engine compartment, attach the 6 gauge (Red) wire to the positive terminal of the battery (Figure 92). Figure 92 LLC Rev A 08/13 Page 35 of 43

36 43. To finish the install, use silicone to seal around all holes made in the vehicle including the Evaporator drain hose hole, the refrigerant hoses/heater hoses/evaporator harness bundle holes (in the floor and inner side wall of the vehicle)(figure 93), and the firewall hole. Also seal anywhere where hoses come up against OEM equipment (if any). 44. Remove the protective cover over the Evaporator Fan (Figure 94). Figure 93 Figure Refrigerant can now be added to the system at the rate of one (1) pound over factory specifications (noted on a label in the engine compartment or on the door jamb). No additional PAG oil over factory specs is needed. 46. Several informational labels are provided to document installation and provide those who service the system with proper maintenance information. Those are: This label should note the new refrigerant and PAG oil capacity of your system. It should be applied somewhere in the engine compartment This label notes the anti-freeze mixture ratio and should also be applied in the engine compartment This label provides information as to date of installation and the installer s name. The serial number for the Evaporator is noted here as well as your kit number. It should be attached to the driver side door jamb. LLC Rev A 08/13 Page 36 of 43

37 PARTS LLC Rev A 08/13 Page 37 of 43

38 LLC Rev A 08/13 Page 38 of 43

39 LLC Rev A 08/13 Page 39 of 43

40 A/C FLOW NISSAN NV, TIE-IN (AirTech II) Diagram 1 COMPRESSOR (OEM) CONDENSER (OEM) DRIER (OEM) Discharge OEM In Out OEM In Out OEM OEM Suction OEM Suction Tie-In/ O-Ring (ProAir) OEM EVAPORATOR (OEM) Out In OEM Liquid Tie-In/ O-Ring (ProAir) Fitting Fitting #10 Hose Fitting EVAPORATOR (ProAir) Out In Fitting #6 Hose Drain Hoses Notes: Part Numbers for fittings for hoses connecting to devices are noted. #6 Hose-5/16 =PN , #8 Hose=13/32 =PN , #10 Hose=1/2 =PN Fittings require a special crimp tool. Fittings come with a green gasket. Gasket should have mineral oil applied to it before installation. LLC Rev A 08/13 Page 40 of 43

41 Diagram 2 HEATING FLOW AIRTECH II EVAPORATOR In WATER VALVE Out In From Engine (Push Line) To Radiator (Return Line) Wye Wye IN OEM HEATER (Dash) OUT EVAPORATOR Out Notes: Dotted lines above represent original (OEM) installed hose Kit installed hose is 5/8 standard heater hose PN LLC Rev A 08/13 Page 41 of 43

42 Diagram 3 ELECTRICAL LAYOUT / TIE-IN SYSTEM Ignition 20 Amp Fuse Relay #1 (Ignition) Signal In Power In/Power Out Ground Mode Switch Not Used BAT Relay #2 (SW #1) Signal In Power In/Power Out Ground 5 Blower Switch Evaporator Low Med High Relay #3 (SW #2) 5 Amp Fuse Signal In Power In/Power Out Ground Relay #4 (W Valve) Signal In Power In/Power Out Ground Water Valve Black NOTES: Wire cross points do not represent connections. Wires that T are butt spliced. Ground wires can be individually grounded to the vehicle chassis or can be daisy-chained together in any fashion and then grounded.. Red Purple LLC Rev A 08/13 Page 42 of 43

43 CUSTOMER NOTES: LLC Rev A 08/13 Page 43 of 43