parts list - proairproairllc.com/image/data/docs/promaster/09 000 421 install instr... · parts...

of 44

PRODUCT: DODGE PROMASTER MAX SYSTEM 530 / 560

RELEASE DATE: 02/24/15

REVISION DATE: 02/24/15

PART NUMBER: 09 000 421 B

Parts List 30’ 01 000 319 Wire,12 Ga Red w/White Stripe 7 02 000 653 Linestake, 2.5" Vinyl Coated

35’ 01 000 335 Wire,12 Ga Red 2 02 000 656 Bolt,7/16-14 x 4 1/2 Zinc Plate

30’ 01 000 421 Wire,6 Ga. Red (Max. Lgth @ 60 2 02 000 666 Spacer,3/4 x 1/2 x 1.25"Steel

1 01 000 504 Switch, Press Hi/Lo 28&385 psi 6’ 04 000 010 Tube, Convo 1"

1 01 000 615 Brkr,80 Amp Circuit Waterproof 16’ 04 000 019 Hose, Drain 1/2" Nil Braid

1 01 000 632 Switch, Rocker 11 Rear Mode 2 05 000 017 Ell,1/2 drain

1 01 000 633 Switch, Rocker 11 Rear Blower 1 05 000 020 Wye,5/8 OD Wtr Plastic

1 01 000 639 Module,7 Circuit Ground Signal 2 05 000 502 Ell,90 #6 FOR x 6 CF

15’ 01 000 713 Wire, 14 Ga, Blue 1 05 000 504 Ell,90 #8 FOR x 8 CF

3 01 000 771 Relay, 12v 50/30 Amp 1 05 000 521 Strt,#6 MOR x 6 CF

8 02 000 015 Linestake,2" 1 05 000 523 Strt,#10 MOR x 10 CF

6 02 000 021 Clamp,Dr Hose 7/8 1 05 000 547 Splice,#8CF x 8CFw/16mm SV

1 02 000 022 Linestake,1" 1 05 000 551 Splice,#10CF x 10CF w/13mm SV

37” 02 000 023 Trim, Lock 1 05 000 631 Ell,90 #8 FOR x 6 CF

48 02 000 052 Wire tie, 14 x 3/16 1 05 000 658 Booster Pump, MP w/Strt Nipples

1 02 000 054 Grommet,3" hose 1 05 000 712 Drier, Receiver w1/4 SP & HPRV

42 02 000 074 Screw,14x1 Hex Wshr Tek Zinc 1 05 000 852 Valve, Wtr Elec 2-Port 12v

4 02 000 075 Screw,10x3/4 hex wshr tek zinc 1 06 000 763 Brkt,Drier Bottle 3" Dia.

20 02 000 098 Linestake,1" Double 2 06 001 383 Brkt,526/530 Mtg NV Rear

4 02 000 105 Bolt,5/16-18 x 3 1/2 hex 2 06 001 487 Plate, Sprt 170" Ext EZ5 Mtg

1 02 000 132 Linestake,2" twisted ends 1 06 001 595 Plate, 13’DPM Switch

8 02 000 218 Washer,7/16 SAE flat zinc 2 06 001 607 Brkt,526/530 Adj Mtg DPM

14 02 000 243 Nut,5/16-18 Nylon Lock 2 06 001 610 Wmnt Brkt, 526/530 Mtg DPM Fon

32 02 000 264 Washer,5/16 Flat SS 1 06 001 658 Brkt, Water Valve Mnt

2 02 000 279 Nut,7/16-14 Nylon Lock 1 08 000 017 Tape, Prestite, Refrigerant

14 02 000 281 Bolt,5/16-18 x 1 Grade 5 SS 2 08 000 124 Sleeve, Fire Protective 2" I.D.

4 02 000 381 Washer,1/4 Flat SS 1 09 000 246 Install Instr,07LWB Sprt Brkts

7 02 000 390 Clamp,#10 Worm gear HtrHose5/8" 1 31 000 034 Frkg,Cond 110 Sprinter LWB

3 02 000 395 Screw,10x3/4 hex wshr type AB 1 40 000 460 Schm,Wire ProMaster 530 & 435

2 02 000 416 Bolt,7/16-14 x 5 1/2 2 60 001 523 Valve, Kazoo 3/4" ID x 3"

7 02 000 462 Screw,10 x 3/4 Phil Pan Blk 1 62 000 274 Hose Assy,5/8 OEM Htr x 25.00

2 02 000 490 Washer,6mm 1 66 000 188 Frigiking, 530 c/o Free-blow

2 02 000 521 Bolt,6mm -1.0 x 25mm grade 8.8 15’ 540-008 Harn, Wire Cond. Grey ACT

2 02 000 621 Nut,6mm - 1.0 Nylon Lock

ENG000F Rel 09/12

of 44





1. Mark the center of the roof as shown.

2. From that center mark, measure 8-7/8” to each side and place another mark.

3. From each of the marks in step 2, measure 1-1/4” to each side and place two more marks.

4. Attach 06 001 610 bracket to 06 001 607 bracket with (2) 02 000 281 bolts, (4) 02 000 264 washers, (2) 02 000 243 lock-nut.

*Build (2) bracket assemblies.

ENG000F Rel 09/12

1

4

2

3 3

of 44





5. Attach a 06 001 383 bracket to the end of the brackets from step #4 with a 02 000 281 bolt, (2) 02 000 264 washers and 02 000 243

lock-nut.

*Have the “L” bracket on each of the (2) assemblies going in opposite directions of the other as shown.

6. Hold the bracket assemblies up to the marks on the van from step #1, mark the holes on the back as shown.

ENG000F Rel 09/12

5

6

of 44





7. Drill all the holes out to 1/2”

*Be careful drilling the holes in the far back to not go through the exterior sheet metal.

8. Attach the brackets to the roof as shown. Use (2) 02 000 105 bolts, (4) 02 000 264 washers, (2) 02 000 243 lock nuts on the front

of each bracket.

ENG000F Rel 09/12

7

8

of 44





9. Attach the rear of the brackets with (2) 02 000 281 bolts, (2) 02 000 264 washers and a 06 001 487 bracket on each bracket

assembly.

10. Remove the cover from 66 000 188 evaporator. Install the evaporator to the roof brackets with (4) 02 000 281 bolts,

(8) 02 000 264 washers, (4) 02 000 243 lock-nuts.

ENG000F Rel 09/12

9

10

of 44





11. Remove the plastic panels from the passenger rear corner of the vehicle.

12. Cut a 2.5” hole in the passenger rear corner as shown.

ENG000F Rel 09/12

11

12

of 44





13. Cut a 02 000 054 grommet as shown. Place it in the 2.5” hole and secure with (3) 02 000 395 screws.

14. Cut a 3” hole in the passenger-side back corner.

ENG000F Rel 09/12

13

14

of 44





15. Cut 02 000 023 trim-lock to 9”. Heat it, and then place it in the 3” hole under the vehicle.

16. Place 02 000 023 trim-lock around the hole in the top corner of the passenger side.

ENG000F Rel 09/12

15

16

of 44





17. Place 4” 02 000 023 trim lock as shown.

18. Place 02 000 023 trim-lock around the bottom hole as shown.

ENG000F Rel 09/12

17

18

of 44





19. Attach 01 000 504 pressure switch to 05 000 712 drier. Secure drier to frame with 06 000 763 bracket and (2) 02 000 075 screws.

*Drier is located on the passenger side in front of the leaf-spring support beam.

20. Measure 9.75” from the side frame rail and place a mark. Measure another 3.5” from that spot and make another mark.

Make sure that your marks are level and drill (2) holes with a 15/32” drill bit. Go all the way through both sides of the beam.

ENG000F Rel 09/12

19

20

of 44





21. Measure 10” from the side frame-rail and place a mark. Then measure another 3.5” over and place another mark.

Drill these holes with a 15/32” drill bit. Go all the way through both sides of the beam.

*Notice that this is one cross-beam behind the larger muffler.

22. *Reference photo for steps 20-21.

ENG000F Rel 09/12

21

22

of 44





23. Assemble condenser to 09 000 246 instructions. Have a second person help hold the 31 000 034 condenser up if necessary. The

connection fittings should be toward the front of the vehicle.

24. Attach the front end of the condenser with (2) 02 000 656 4.5” bolts, (4) 02 000 218 washers, (2) 02 000 279 lock-nuts.

ENG000F Rel 09/12

23

24

of 44





25. Attach the rear side of the condenser with (2) 02 000 416 5.5” bolts, (4) 02 000 218 washers, (2) 02 000 666 1.25” spacers,

(2) 02 000 279 lock-nuts.

26. Install the 05 000 658 booster pump to the drivers-side frame rail with (4) 02 000 074 screws, (4) 02 000 381 washers.

*Note: The booster pump is in line with the cross-beam that goes over the middle of the condenser.

ENG000F Rel 09/12

25

26

of 44





27. Attach 06 001 658 metal plate to 05 000 852 water valve with (2) 02 000 521 bolts, (2) 02 000 490 washers,

(2) 02 000 621 lock-nuts.

28. Attach water valve assembly with (4) 02 000 074 screws to the cross-beam on the drivers-side of the parking brake cable

connector.

ENG000F Rel 09/12

27

28

of 44





29. Lay the hoses and harnesses out. Mark the hoses accordingly:

Red: Push from engine

Orange: From Booster Pump to Dash

Black: From Rear heater back to engine.

30. Run the hoses and harnesses up through the 3” hole in that back corner.

ENG000F Rel 09/12

29

30

of 44





31. Run AC hoses and harness up back corner.

55. Route the hoses out the top hole and towards the evaporator.

ENG000F Rel 09/12

31

55

of 44





56. Crimp a 05 000 521 fitting to the #6 Hose. Crimp a 05 000 523 fitting to the #10 hose. Place O-rings on the fittings and

lubricate them with mineral oil. Attach fittings to expansion block.

57. Wrap the fittings and expansion block with 08 000 017 prestite tape. Plug in the 01 000 011 wire harness and secure with

a 02 000 052 tie-wrap. Plug the blue wires into the thermostat.

ENG000F Rel 09/12

56

57

of 44





58. Secure the AC hoses and wire harness with a 02 000 098 linestake and a 02 000 074 screw.

59. Attach a 02 000 098 linestake as shown in the top back corner with a 02 000 074 screw.

ENG000F Rel 09/12

58

59

of 44





60. Secure the hoses with a 02 000 098 linestake and a 02 000 074 screw.

61. Secure the hoses with a 02 000 098 linestake and a 02 000 074 screw.

ENG000F Rel 09/12

60

61

of 44





62. Run 04 000 019 drain hose down the back corner as shown. Attach a 05 000 017 elbow and another 4” piece of drain hose.

Secure the hoses to the elbow with (2) 02 000 021 clamps and then use (1) 02 000 021 clamp to attach the hose to the evaporator.

63. Secure the drain hose going down the back corner with (3) 02 000 052 tie-wraps as shown.

ENG000F Rel 09/12

62

63

of 44





64. Run another 04 000 019 drain hose down the other back corner. Attach a 05 000 017 elbow and a 4” piece of drain hose with

(2) 02 000 021 clamps. Attach the hose to the evaporator with another 02 000 021 clamp.

Remove black plastic covers if necessary and secure with (2) 02 000 052 tie-wraps.

65. Route drain hoses out the back square grommets under the rear bumper, attach (2) 60 001 523 kazoo valves to the ends with (2)

02 000 052 tie-wraps.

ENG000F Rel 09/12

64

65

of 44





66 . Replace plastic covers on both sides.

67. Secure the hoses & harnesses coming out of the bottom 3” hole with a 02 000 015 linestake a 02 000 074 screw and

(3) 02 000 052 tie-wraps.

ENG000F Rel 09/12

66

67

of 44





68. Secure the Red/Black heater hoses & wire harness with (6) 02 000 052 tie-wraps as shown.

*These hoses will be routed up the back corner with the A/C lines if a 560 unit is being installed.

69. Place (2) 02 000 098 linestakes on the heat hoses as shown. Place (2) 02 000 015 linestakes on the AC hoses as shown.

Secure the linestakes to the frame with (2) 02 000 074 screws. Place (2) 02 000 052 tie-wraps between the linestakes.

ENG000F Rel 09/12

68

69

of 44





70. Place (2) 02 000 098 linestakes as shown with (2) 02 000 074 screws.

71. Wrap the heat hoses with (2) 02 000 052 tie-wraps and the n wrap the heat hoses to the AC hoses with another 02 000 052

tie-wrap.

72. Place (2) 02 000 052 tie-wraps.

ENG000F Rel 09/12

70

72

71

of 44





73. Cut the Red heat hose at the water valve and connect with (2) 02 000 390 clamps.

74. Attach a 02 000 022 linestake to the Red hose with a 02 000 074 screw as shown. Use a 02 000 052 tie-wrap to secure both hoses

and wire harness.

75. Attach the (2) blue wires to the pressure switch.

76. Attach a 05 000 502 fitting to the #6 hose going to the evaporator. Place O-ring / mineral oil and attach it to the drier as shown.

77. Attach a 05 000 502 fitting on the #6 hose that goes to the condenser. Place O-ring /mineral oil and attach it to the drier as

shown.

78. Secure hoses with (2) 02 000 052 hoses.

ENG000F Rel 09/12

73

75

74

76

77

78

of 44





79. Secure hoses / harness with 02 000 098 linestake and 02 000 074 screw.

80. Secure with 02 000 015 linestake and 02 000 052 tie-wrap.

81. Crimp a 05 000 631 fitting to the #6 hose going to the drier. Apply O-ring / mineral oil and connect it to the bottom coil tube.

Crimp a 05 000 504 fitting to the #8 hose. Apply O-ring / mineral oil and connect to the top coil tube.

ENG000F Rel 09/12

79

80

81

of 44





82. Place 08 000 124 heat sock over the hoses where they cross over the top of the exhaust.

Secure with (2) 02 000 015 linestakes and (2) 02 000 074 screws.

83. Plug in 01 000 644 water valve harness. Secure harness with 02 000 052 tie-wrap.

ENG000F Rel 09/12

82

83

of 44





84. Cut 6” off 62 000 274 hose and insert a 05 000 020 “wye” fitting. Insert the orange hose to the “Y” part of the fitting.

Secure all three pieces of hose with (3) 02 000 390 clamps. Use another 02 000 390 clamp to attach the hose assembly to

the booster pump.

85. Secure the hoses with (2) 02 000 098 linestakes, (2) 02 000 074 screws.

ENG000F Rel 09/12

84

85

of 44





86. Attach the inlet hose to the booster pump with a 02 000 390 clamp.

87. Secure hoses with a 02 000 098 linestake, 02 000 074 screw, and a 02 000 052 tie-wrap.

88. Secure hoses with 02 000 015 linestake 02 000 074 screw and 02 000 052 tie-wrap.

ENG000F Rel 09/12

86

88

87

of 44





89. Join AC hoses with the Heat hoses, route along the frame rail towards the front of the vehicle. Secure with 02 000 653 linestake

and a 02 000 074 screw.

90. Attach 02 000 052 tie-wrap and a 02 000 653 linestake, 02 000 074 screw.

ENG000F Rel 09/12

89

90

of 44







ENG000F Rel 09/12

91

92

of 44






94. Secure with (3) 02 000 052 tie-wraps and (2) 02 000 653 linestakes, (2) 02 000 074 screws.

ENG000F Rel 09/12

93

94

of 44





95. Pass the hoses up over the front sub-frame and route the Heat hoses towards the top of the engine on the driver’s side and

route the two AC lines toward the driver’s side under the front bumper.

96. Secure all three hoses by removing the bolt from the top of the transmission and reinstall with a 02 000 015 linestake, 02 000 281

bolt, (2) 02 000 264 washers and a 02 000 243 lock-nut.

ENG000F Rel 09/12

95

96

of 44





97. Move the coolant reservoir over drill a hole in the corner of the metal plate and install a modified 02 000 132 linestake.

*Reattach coolant reservoir after installing linestake.

98. Route the hoses under coolant reservoir and attach as shown:

Red: Out from engine.

Orange: to Dash Heater

Black: Return back to engine.

ENG000F Rel 09/12

97

98

of 44





99. Cover the hoses with 04 000 010 convoluted tubing.

100. Secure the two AC hoses going over the driver’s side axle with (2) 02 000 098 linestakes and (2) 02 000 074 screws.

Place (2) 02 000 052 tie-wraps between the linestakes as shown.

ENG000F Rel 09/12

99

100

of 44





101. Crimp a 05 000 547 fitting to the #8 hose and a 05 000 551 fitting to the #10 hose.

102. Secure the hoses with a 02 000 098 linestake, 02 000 074 screw and (2) 02 000 052 tie-wraps.

103. Route the hoses across the front under the front bumper. Secure with (3) 02 000 098 linestakes, (3) 02 000 074 screws.

Place (3) 02 000 052 tie-wraps between the linestakes.

104. Push a piece of 08 000 124 heat-sock over the AC lines and secure it to the end with a 02 000 052 tie-wrap.

ENG000F Rel 09/12

101

103

102

104

of 44





105. Place O-rings and mineral oil on the fittings and connect to the compressor fittings.

Attach the Red clutch wire to the compressor.

106. Install 01 000 639 and (3) 01 000 771 relays to passenger side rear corner with (7) 02 000 462 screws.

Connect a 01 000 748 harness to the (3) relays.

ENG000F Rel 09/12

105

106

of 44





107. Follow schematic 40 000 460 for all wiring.

108. Attach ground wires to the vehicle as shown with a 02 000 075 screw.

*Screw needs to go through where the metal is doubled to prevent stripping or coming loose.

109. Secure harnesses with (2) 02 000 098 linestakes and (2) 02 000 074 screws.

ENG000F Rel 09/12

107

108

109

of 44





110. Remove fuse panel access cover and dash insert as shown.

111. Cut the back off of the part removed from the dash.

ENG000F Rel 09/12

110

111

of 44





112. Install 01 000 632 & 01 000 633 switches to 06 001 595 plate as shown.

113. Insert plate into modified part from the dash. Secure the parts together with (3) 02 000 075 screws.

ENG000F Rel 09/12

112

113

of 44





114. Wire the switches according to 40 000 460 schematic with 01 000 765 harness.

115. Reinstall switch assembly and fuse panel cover.

ENG000F Rel 09/12

114

115

of 44





116. Remove the cover at the bottom of the driver’s door. The ignition wire is blue / yellow-stripe.

117. Remove battery access cover on the floor in front of the driver’s seat. Install a 01 000 615 breaker in the battery box with

(2) 02 000 074 screws.

ENG000F Rel 09/12

116

117

of 44





118. Connect power wire to the battery.

119. Reinstall battery cover.

ENG000F Rel 09/12

118

119

parts list - proairproairllc.com/image/data/docs/promaster/09 000 421 install instr... · parts...

Documents