PRODUCT: Install Instructions, MV-1 C/O Std, With Aux Fan RELEASE DATE: 2/28/14 REVISION DATE: 9/30/2014 PART NUMBER: Rev C

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Julia Parsons
5 years ago
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Parts List (1) 01 000 027 Switch, 4 Position Blower (1) 04 000 007 Hose, 1/2 ID Drain, 6 (1) 01 000 087 Harn, Resistor (1) 04 000 078 Tube, Convo 1/2 x 24 (2) 01 000 136 Relay, 40 Amp (1) 04 000 015

1 Parts List (1) Switch, 4 Position Blower (1) Hose, 1/2 ID Drain, 6 (1) Harn, Resistor (1) Tube, Convo 1/2 x 24 (2) Relay, 40 Amp (1) Hose, Duct 3 x 48 Flex (1) Tap, Fuse ATM Mini (1) Tee, Block Assy #10 (1) Harness, Power With Fuse MV-1 (1) Tee, Block Assy #6 (1) Harness, Relay MV-1 (1) Plate, Unit Mount MV-1 Std (1) Harn, Relay Cond Fan/PS MV-1 (1) Brkt, Hose Clamp A (1) Harn,Wire 25.5 MV-1 (1) Brkt, Hose Clamp B (1) Knob, Fan w/screw (1) Brkt, Hose Clamp C (1) Trim Lock, 32 Long (1) Brkt, Hose Clamp D (4) Screw,10x1/2 Truss Hd Phil Bl (1) Cover, Duct Hose MV-1 (5) Screw, 8x1/2 Black Self Drilling (1) Adpt, MM to 3 (3) Screw, 8x1 1/4hex wshr zinc tek (1) Foam,1/8 x 4 x 24 Roll (24) Wiretie, 14 x 3/16 (1) Faceplate, Round, 3 Speed (2) Grommet, 1" hose, 1 1/4" OD (1) Install Inst, 14 MV-1 Std, With (1) Grommet, 1/2" ID 5/8" OD (1) Switch,Press Trimary 606w/Conn (16) Screw, 14x1 Hex Wshr Tek Zinc (1) Pusher Fan MV-1 (23) Screw, 10x3/4 hex wshr tek zinc (1) Cover Assy, MV-1 Std (1) Nut, 7/16-28 Pn'l zinc (1) Shroud Assy, MV-1 (2) Nut,7/16-14 Nylon Lock (1) Grommet, Assy Hose MV-1 (1) Washer,1/4 Flat SS (1) Hose Assy, #10 RBx23 MV-1 (3) Plug, 5/8 Plastic Cap (1) Hose Assy, #6 RB x 23 MV-1 (2) Nut, 5mm hex zinc (1) Valve kazoo 5/8" ID x 3" (16) Linestake,3/4" Double (1) O-ring Kit, 4 #6, 4 #10 & Tape (6) Screw, 8x3/4 Truss Gray (1) Warranty Packet (1) Power Pak, Evaporater c/o Page 1 of 52

2 1 1. Drivers side rear: Remove the tool kits and two bottom fasteners Passenger side rear: Remove the two bottom fasteners. Page 2 of 52

3 3 3. Install the (2) fasteners from the passenger side; into the driver s side Install the fastener with the strap in the hole furthest from the back door on the passenger side. Install the fastener with the loop to the other hole. Page 3 of 52

Install 06 001 644 bracket as shown, secure in place with four 02 000 075 #10

4 5 5. Secure the (2) tool kits to the passenger side with the Velcro strap /4 6. Install bracket as shown, secure in place with four #10 x ¾ self-drilling screws. The back edge of the bracket should be 3 1/4 from the screw. The bracket should be flush with the side wall. Page 4 of 52

5 7 7. Drill a 7/8 hole even with the edge of bracket and on top of hump in carpet On left side of van, inside just behind rear wheel well right below hump in wall carpet cut out a 6 x 9 hole in sidewall. Page 5 of 52

9 9. Cut 16 of 02 000 023 Trim Lock and install

Slide 04 000 007 drain hose over 66 000 016

6 9 9. Cut 16 of Trim Lock and install around edge of hole Slide drain hose over evaporator unit drain. 11. Slide kazoo valve over end of drain hose. Page 6 of 52

7 From underneath van behind left rear wheel remove plug or tape from factory hole. 13. Drill a 1 ¼ hole beside factory hole and apply primer to bare metal Run the 90 degree fitting on #6 A/C hose and harness up the factory hole, grommet, and out hole in the sidewall. 15. Run #10 A/C hose up the 1 ¼ hole and out hole in sidewall. Page 7 of 52

8 Slide both hoses and wire harness into grommet assembly, secure in place with four #10 x ¾ screws Place evaporator on mounting bracket making sure that drain tube goes through hole drilled in step 7, secure in place with four , 10 x ¾ screws. 18. Attach wire harness to blower motor wire and resister. Page 8 of 52

PRODUCT: Install Instructions, MV-1 C/O CNG, With Aux Fan 20 19

Place 08 000 009 #6 o-ring on fitting, apply mineral oil to

Attach 62 000 885 #10 A/C hose to evaporator.

o-ring and threads then torque to 21-27 foot pounds. 21 21.

9 PRODUCT: Install Instructions, MV-1 C/O CNG, With Aux Fan Attach #6 A/C hose to evaporator. Place #6 o-ring on fitting, apply mineral oil to o-ring and threads then torque to foot pounds. 20. Attach #10 A/C hose to evaporator. Place #10 o-ring on fitting apply mineral oil to o-ring and threads then torque to foot pounds Secure ground wire to inner side wall with #10 x ¾ screw, place screw in line with spot welds. Page 9 of 52

10 Plug wire harness into harness on evaporator Tie hoses and wire harness together with a tie wrap. Page 10 of 52

11 Wrap all of the suction fittings so that no metal is showing and the liquid line needs to be taped up to the disc of expansion valve Seal hole in plastic hose grommet with silicone as shown Page 11 of 52

12 Place grommet around hose and wire insert into hole and secure with two , 10 x ¾ screws. 27. Place grommet around hose insert into hole and secure with two , 10 x ¾ screws Seal around harness and A/C hoses with silicon sealant. Page 12 of 52

13 Seal around harness and A/C hoses with silicon sealant Secure hoses and wire harness together with tie wrap. Page 13 of 52

stakes and (2) 02 000 118 7/16-nuts. 33 32 32.

14 Secure hoses and wire harness to bumper mount bracket studs with (2) line stakes and (2) /16-nuts Secure hoses and wire harness to rear cross-member with line stake and , 14 x 1 screw. 33. Half way between the line stakes, tie hoses and wire harness together with tie wrap. Page 14 of 52

linestakes and (2) 02 000 074, 14 x 1 screws. 35.

15 Secure hoses and wire harness to rear frame cross member with (2) linestakes and (2) , 14 x 1 screws. 35. Half way between the line stakes, tie hoses and wire harness together with (2) tie wraps Remove Right Rear fender well, Attach bracket to the frame behind the rear tire as shown with (2) screws. 37. Secure hoses and wire harness to bracket with line stake and , 14 x 1 screw. Page 15 of 52

38 40 39 38. Attach 06 001 651 bracket to the frame with (2) 02 000 074 screws.

Remove the nut from the top shock bolt, attach 06 001 652 bracket and then replace the nut. 40.

16 Attach bracket to the frame with (2) screws. *Should be able to use a long extension through the wheel. 39. Remove the nut from the top shock bolt, attach bracket and then replace the nut. 40. Secure hoses and wire harness to both brackets with (2) linestakes and (2) , 14 x 1 screws Attach bracket to the cross member as shown with (2) screws. 42. Secure hoses and wire harness to bracket with line stake and , 14 x 1 screw. 43. Half way between the line stakes tie hoses and wire harness together with tie wrap. 41 Page 16 of 52

17 Secure hoses and wire harness to frame with (3) linestakes and (3) , 14 x 1 screws. 45. Half way between the linestakes tie hoses and wire harness together with (3) tie wraps Secure hoses and wire harness to the body with (2) linestakes and (2) , 14 x 1 screws. 47. Half way between the line stakes tie hoses and wire harness together with (2) tie wraps. Page 17 of 52

above hoses. trim lock should be visible sides of the hoses. 49.

18 Remove front right fender liner (11) 7mm screws and place 6 of trim lock part number on body lip above hoses. trim lock should be visible sides of the hoses. 49. From outside of frame secure hoses and wire harness to body cross member with line stake and , 14 x 1 screw. *Keep hoses tucked above frame as much as possible to keep them from rubbing on the inner fender well. 50. Half way between the line stakes tie hoses and wire harness together with tie wrap Secure hoses and wire harness to the frame with linestake, washer, , 14 x 1 screw. Page 18 of 52

19 Page 19 of 52

53 54 52. Recover all of the refrigerant from the A/C system. 53.

Remove liquid line from expansion block, carefully bend line and install 05 000 193 #6 liquid tee fitting.

20 Recover all of the refrigerant from the A/C system. 53. Remove suction line from expansion block and slide towards front of van. 54. Remove liquid line from expansion block, carefully bend line and install #6 liquid tee fitting. Place #6 o-ring on fitting, apply mineral oil to o-ring and threads Position fitting so the MIO nut points to 10 o clock position then torque both nuts to foot pounds. Page 20 of 52

expansion block, slide factory suction line to tee and attach, position tee so that the MIO nut points straight up and

21 Place #10 o-ring on #10 suction tee apply mineral oil to o-ring and threads then attach tee to expansion block, slide factory suction line to tee and attach, position tee so that the MIO nut points straight up and then torque to foot pounds Place #6 o-ring on fitting of #6 A/C hose, apply mineral oil to o-ring and threads and attach to #6 tee, position switch port pointing forward then torque to foot pounds. Page 21 of 52

then attach to #10 tee, torque to 21-27 foot pounds. 59.

22 Place #10 o-ring on #10 A/C hose, apply mineral oil to o-ring and threads then attach to #10 tee, torque to foot pounds. 59. Secure A/C hoses to fender well with line stake and , 14 x 1 screw Remove cap from fitting and attach pressure switch, tighten to 7 foot pounds. Page 22 of 52

61 61. Remove cover and then remove fuse box cover. 62 62.

23 Remove cover and then remove fuse box cover On passenger side floor, drill a 5/8 hole next to factory drain. Page 23 of 52

24 Run harness coming from rear unit through hole Secure fuse holder of wire harness to fender well with x ¾ screw. Page 24 of 52

25 Insert long side of harness up to convoluted tubing, into hole drilled in step 65, secure harness with wire tie Place grommet around both harnesses and snap into hole. Page 25 of 52

Secure both harnesses with two 02 000 052 wire ties.

26 Run wires to center of dash, up behind the fuse box. 67. Secure both harnesses with two wire ties Cut trim lock to 10 long and slide over edge of metal beside fuse box. Page 26 of 52

connector of 01 000 702 relay harness, wire inserts into out most

27 Run red with white stripe wire into fuse box area and insert it into connector of relay harness, wire inserts into out most hole not the center hole Plug relay into harness and secure in place with x ¾ screw. Page 27 of 52

28 Secure ground wire from relay harness to metal with x ¾ screw Remove this 10-amp fuse. Page 28 of 52

29 Place fuse tap on fuse Replace fuse with the tap on right side. Page 29 of 52

30 Attach orange wire from relay harness to fuse tap Cut notch in fuse cover for the orange wire to exit. Page 30 of 52

31 Replace fuse box cover; make sure orange wire is in notch of cover Drill a 7/16 hole in dash for switch. 1 5/8 up from red line and a 1 ¼ over to the right of red line. Page 31 of 52

32 Red 79 Yellow Orange Red White 79. Attach wires to switch Insert switch into mounting hole, secure in place with faceplate and nut. Tighten and then push on knob. Page 32 of 52

33 Tie up harness with two wire ties Replace center dash cover. Page 33 of 52

34 Page 34 of 52

35 Remove 10 Push-Pins Remove (3) T20 Torx screws from each headlight bezel Page 35 of 52

36 Unplug the connector to the turn-signal bulb and remove the bezel from both front lights. 86. Remove the (3) push pins from the bottom center of the front bumper cover. 86 Page 36 of 52

37 Remove (2) 7mm screws from each side under the front bumper Remove the front (6) 7mm screws from the left front fender. Page 37 of 52

38 (Looking up into the fender) Remove (2) 10mm bolts that secure the front bumper cover to the fender, on each side of the vehicle (Looking up, at the back-side of the headlight assembly) Remove the nut from the stud with a 7mm socket Page 38 of 52

(May require some maneuvering / wiggling to get the top

39 Unplug the turn-signal / parking-light connector on each side of the bumper cover. 92. Have a 2 nd person assist removing the front cover. (May require some maneuvering / wiggling to get the top two 7mm studs out.) Remove (3) bolts with a 13mm socket. 94. Trim the off the plastic tabs at the yellow marks. Page 39 of 52

40 Install fan assembly so that the two holes line up and reattach the (2) longer 13mm bolts. 96. Reattach the shorter 13mm bolt in the center Plug Relay into harness. 98. Remove two 10mm bolts and reinstall with the relay/fuse harness as shown. Page 40 of 52

41 Route the long end of the harness up towards the pressure switch. Secure with (2) tie-wraps Plug the connector into the pressure switch. Page 41 of 52

42 Run the other end of the harness under the foam in the top corner by the condenser coil. Secure with (1) tie-wrap Route the harness/connector as shown and plug into the fan. Secure with (1) tie-wrap. Page 42 of 52

43 Connect the single red wire from the harness to the Positive (+) battery post as shown Have a second person assist replacing the front cover. - Get the top two threaded studs lined up and inserted into the fenders then replace the 7mm nut on each stud behind the headlights. Page 43 of 52

44 Replace the (2) 10mm bolts inside each fender Reconnect the side-marker light plug on the bumper (both sides). Page 44 of 52

107 107. Replace (2) 7mm screws on each side, under the front bumper.

45 Replace (2) 7mm screws on each side, under the front bumper Replace (3) push pins in the center under the front bumper. Page 45 of 52

109 109. Connect the headlight power plugs. 110 110.

46 Connect the headlight power plugs Attach each headlight bezel with (3) T20 torx screws. Page 46 of 52

47 Replace (10) push pins on the top edge of the front cover Replace (6) 7mm screws to the front left fender liner and reinstall the right fender liner with (11) 7mm screws. Page 47 of 52

48 Attach shroud with (3) screws Attach duct hose to the top shroud with (2) screws. Then attach a tie-wrap around the hose Attach the duct hose to the Power Pack with (2) screws. Then attach a tie-wrap around the hose. Page 48 of 52

116 116. Wrap 08 000 001 foam tape around unit outlet and duct hose to seal connections.

49 Wrap foam tape around unit outlet and duct hose to seal connections Set Cover Assy. over the Power Pack. Do not attach it yet. Page 49 of 52

and then attach with six 02 000 663 screws.

Attach the unit cover with three 02 000 024

50 Position cover over the duct hose and then attach with six screws Attach the unit cover with three screws along top Secure bottom of unit cover with one self-drilling screw in bottom. 120 Page 50 of 52

51 Put (3) plugs in the holes on the top shroud Attach power wire to positive battery cable. Page 51 of 52

52 Vacuum, leak check and charge A/C system with 2.75 pounds of 134a refrigerant and 2 ounces of pag oil Place ProAir Refrigerant Charge Label under the hood. Page 52 of 52

Warning Do not attempt to install A/C units unless you are experienced with servicing A/C systems!

Warning Do not attempt to install A/C units unless you are experienced with servicing A/C systems! TOOLS REQUIRED: INSTALLATION INSTRUCTIONS PT-A-406 Rear HVAC System for 2014-2018 RAM PROMASTER without OEM rear AC/Heat Prep Package Fittings ***This system can also be used for a Promaster van with the