INSTALLATION INSTRUCTIONS FOR Plumbing/Electrical NV, Max, Plumbing... · INSTALLATION INSTRUCTIONS...

INSTALLATION INSTRUCTIONS

FOR

Plumbing/Electrical

For Nissan NV / Max System / 552 Evaporator

Corporate Headquarters ProAir, LLC

28731 County Road 6; Elkhart, IN 46514

Phone: (574) 264-5494; Toll Free: 800-338-8544; Fax: (574) 264-2194

LLC Rev A 08/13 of 52

TABLE OF CONTENTS Page

Preparation Notes ..…………………………………………………………. 3

Parts List………………………………………………………………………….. 6

Instructions …………………………………………………………………..… 8

Parts Illustrations …………………………………………………………… 46

Diagrams ……………………………………………………………………….. 50


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, 1” double, 2” twisted,

1” Quad and 5/8”. These are secured with self-tapping screws (02 000 074, 02 000 075) to the

vehicle. These screws will require a screw gun/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, especially

areas where heat is generated.

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 (02 000 074) 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, 1/2” drain and #6, #8 and #10 refrigerant.


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.


Please read the following notes before beginning installation:

Parts Numbers for parts will usually 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 (09 000 046) and record your kit number on it. Also as

you unpack your Condenser and Evaporator you need to note the serial numbers for these units 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 in and two out and the angle port out

should be directed away from the in 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).


PARTS LIST

Item # Part # Qty Description 1 01 000 012 1 Harness, 15 Amp Power Relay 2 01 000 130 1 Breaker, 30 Amp Circuit 3 01 000 136 4 Relay, 40 Amp 4 01 000 239 1 Harness, 20 Amp Power Relay 5 01 000 319 1 Wire, 12 Gauge Red w/White Stripe 6 01 000 352 1 Harness, Wire Condenser 7 01 000 400 1 Harness, Evaporator 8 01 000 412 1 Wire, 6 Gauge Red 9 01 000 632 1 Switch, Rocker 11 Nissan Rear-Mode 10 01 000 633 1 Switch, Rocker 11 Nissan Rear-Blower 11 01 000 634 1 Harness, 11 Nissan Mode/Blower Switch 12 01 000 644 1 Harness, Water Valve Electric 2-Port 13 02 000 015 12 Linestake, 2” 14 02 000 021 9 Clamp, Drain Hose 7/8 15 02 000 023 1 Trim Lock, 2/3’ 16 02 000 052 30 Wire Tie, 14 x 3/16 17 02 000 053 4 Grommet, 1” Hose, 1 1/4” OD 18 02 000 074 21 Screw, 14x1 Hex Washer Tek Zinc 19 02 000 261 1 Plate, Fitting Mounting 20 02 000 262 1 Bolt, 10mm-1.5x55 BHX 21 02 000 263 1 Washer, 10mm Split Lock Zinc 22 02 000 390 10 Clamp, #10 Heater Hose 23 04 000 019 1 Hose, Drain 1/2” Nylon Braid 24 04 000 025 1 Hose, 5/8 ID OEM Spec-Bulk 25 04 000 053 1 Hose, 5/16” Refrigerant #4890 Redu Barrier CF, 23’ 26 04 000 054 1 Hose, 13/32” Refrigerant #4890 Redu 27 04 000 055 1 Hose, 1/2” Refrigerant #4890 Redu Barrier CF, 18’ 28 05 000 010 1 Tee, 1/2" Drain 29 05 000 017 2 Ell, 1/2” Drain 30 05 000 020 2 Wye, 5/8 OD Water, Plastic 31 05 000 050 4 Splice, 5/8 Heater Hose 32 05 000 414 1 Manifold, #8 Compressor 33 05 000 415 1 Manifold, #10 Compressor 34 05 000 479 1 Straight, #6 FOR x 6CF 35 05 000 502 1 Ell, 90 #6 FOR x 6 CF 36 05 000 504 3 Ell #8 FOR x 8 CF 37 05 000 507 1 Ell 90 #10 FOR x 10 CF 38 05 000 527 1 Ell, 90 #6 MOR x 6CF 39 05 000 529 1 Ell, 90 #10 MOR x10 CF 40 05 000 547 1 Splice, #8CF x 8CF w/16mm SV


41 05 000 551 1 Splice #10CF x 10CF w 13mm SV 42 05 000 971 2 Valve, Kazoo 3/4” ID x 10’ 43 08 000 017 1 Tape, Prestite Refrigerant 44 08 000 124 1 Sleeve, Fire Protective 45 09 000 035 1 Label, Refrigerant Capacity-Blank 46 09 000 037 1 Label, Anti-Freeze Mix 47 09 000 046 1 Label, Door Jamb 48 09 000 145 1 Card, Information Warranty Registration


INSTALLATION INSTRUCTIONS

These instructions assume that the Evaporator, Condenser, Booster Pump, Water Valve, Drier and Compressor

have been mounted (covered in other instruction files). It is advisable that you read through these instructions

completely before beginning a step-by-step installation.

The Pro-Air Max System is a supplemental Air Conditioning/Heating system for the Nissan NV. The Max System is

an independent system with its own Evaporator, Condenser, Compressor and associated plumbing and electrical

components. The Compressor is driven by the OEM engine as is the OEM A/C system. The heating side of the

ProAir System does “tie 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 552 Evaporator plumbing/electrical installation begins with the creation of holes for the Evaporator drain

hoses. Drill with a hole saw a 1 1/4” hole in each corner of the rear of the vehicle between the inner and outer

side walls. Insert grommet 02 000 053 in each hole (Figure 1). Drill another 1 1/4” hole in the inner side wall

under the vehicle on each side for the drain hose to exit (Figure 2). Trim with Trim Lock (02 000 023).These holes

must not interfere with any OEM equipment. It is possible to only use one drain hose in which case only one

hole is needed (See pages 13-14).

2. Stretch out the two 5/8” heater hoses (04 000 025), the #6 (04 000 053) and #10 (04 000 055) refrigerant

hoses, and the Evaporator harness (01 000 400)(Figure 3). 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 3 Inset). Take the bundle

inside the vehicle.

Figure 1 Figure 2

Figure 3

Side Wall Floor


3. Before beginning installation of the refrigerant hoses observe the following:

There is a green gasket supplied for each refrigerant hose fitting and mineral oil must be applied to the

gasket before insertion in the fitting. Mineral oil can be obtained at a local auto supply store (Figure 4).

On the hose connection end, a special crimp tool must be used to crimp the rings and that tool must be

obtained at a local auto supply store (Figure 5).

4. Install the refrigerant hoses. The refrigerant ports are on the left side of the Evaporator as viewed from the

rear of the vehicle. Install fitting 05 000 529 on the #10 hose and attach on the bottom (suction) port (Figure 6).

Install fitting 05 000 527 on the #6 hose and attach on the top (liquid) port (Figure 6). Secure the fittings and

wrap them with Prestite tape (08 000 017)(Figure 7) to minimize condensation.

Remember to apply mineral oil to the gaskets before inserting them into the fittings.

Figure 4 Figure 5

Figure 6 Figure 7

Suction Port

Liquid Port Prestite Tape


5. Install the heater hoses. Remove the black plugs from the heat lines (Figure 8), observing the warning tag

(Figure 9).

6. Install the heater hoses to the Evaporator heating ports (on the right side). Attach the hose with Red tape to

the bottom port, Evaporator inlet (coolant from engine) and the other hose to the top port, Evaporator outlet

(coolant to radiator)(Figure 10). Secure these lines to the Evaporator with clamps (02 000 390).

Figure 10

Figure 8 Figure 9

Plugs


7. Connect the two (2) Evaporator pigtails (already attached to the Evaporator, 01 000 154) to the Evaporator

harness 01 000 400 (Figure 11). The Evaporator harness has one end with two plugs which mates with the

pigtails. Ground the two (2) Black wires from the Evaporator pigtails to the vehicle chassis. Connect the two (2)

Blue wires with spade lugs on the Evaporator harness to the Freeze Up Thermostat mounted on the Evaporator

(Figure 12). They can be connected in any order.

8. Gather the refrigerant hoses (2), heater hoses (2), and Evaporator harness into a bundle. Secure the bundle

with linestakes (02 000 015) attached to the driver side inner side wall of the vehicle with self-tapping screws

(02 000 074)(Figures 13 and 14). Secure the bundle together between linestakes with tie wraps (02 000

052)(Figure 13). Route the bundle to the floor of the vehicle.

Figure 11

Figure 12

Evaporator Pigtails

Grounds

Evaporator Harness

Figure 13 Figure 14

Linestake

Tie Wrap


9. Prepare the drain hoses by taking the bulk drain hose (may be clear or nylon braided)(04 000 019) and cutting

off two (2) 2 1/2” pieces and then cutting the remainder in half. Insert each 2 1/2” piece into an ell (05 000 017)

and secure with a clamp (02 000 021)(Figure 15). Attach the two longer length hoses to the ells with clamps.

Insert the remaining end of the 2 1/2” pieces into the drain ports on each side of the Evaporator and secure with

clamps (Figure 16).

10. Route the passenger side drain hose between the inner and outer side walls (Figure 17) and bring it through

the access hole on the inner side wall under the vehicle (Figure 19). Leave about 6” exposed under the vehicle

(cut off any excess) and attach a kazoo valve (05 000 971) and secure with a tie wrap. Route the driver side hose

to the side and parallel with the hose/harness bundle (Figure 18) and out the hole created previously to exit

under the vehicle. Secure the hose to the other hoses with tie wraps. Leave about 6” exposed under the vehicle

(cut off any excess) and attach a kazoo valve and secure with a tie wrap (Figure 19).

Figure 16 Figure 15

Figure 17

Figure 18


11. An alternative installation is to run only one drain hose (but the recommended installation is two (2) drain

hoses). In this configuration, one (1) ell is replaced with a tee (Figure 21). Figure 20 shows the layout for a run to

the passenger side. This layout can be “flipped” to route to the driver side. The parts needed are one (1) ell 05

000 017, one (1) tee 05 000 010, four (4) pieces of hose (04 000 025) cut to the appropriate lengths and seven

(7) clamps (02 000 021). Figures 22 and 23 show a finished installation.

EVAPORATOR

Figure 19

Drain

Hose

Ell Hose Tee Hose run to

under vehicle

Figure 21

Figure 20

Side Wall


Figure 22 Figure 23

Tee

Tee


12. Route the hose/harness bundle on the floor along the side wall and over the wheel well to its front side

(Figure 24). Tie wrap the bundle and secure to the side wall with linestakes (Figure 25).

13. On the front side of the wheel well, drill four (4) holes in the floor of the vehicle for the hoses to exit the

passenger compartment to the underside of the vehicle. Install grommets (02 000 053) in the holes. Figure 26

shows the holes in the floor of the vehicle while Figure 27 shows the finished installation. Note the Evaporator

harness routes out the same hole with the #6 refrigerant hose. Figure 28 shows dimensions for drilling.

13.5”

11.5”

9.5”

7.5”

Wall

Wheel

Well

1.00” from

wall

1.25” Holes

Figure 24

Figure 27 Figure 26

Figure 25

Figure 28

Linestake

Tie Wrap

Grommets


14. Drill a hole in the inner side wall to allow the hoses/harness between the side walls to exit to the underside

of the vehicle. Figures 29 and 30 show the hoses/harness exiting the wall cavity to the underside. Trim the hole

with Trim Lock (02 000 023) to protect the hoses/harness (Figure 31). Figure 32 shows the dimensions for drilling

the hole.

Floor

6.50”

16.00”

2.500” Hole

Wheel

Well

Figure 32

Figure 29

Figure 31

Figure 30

Side Wall

Trim Lock

Side Wall


15. 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.

16. There are a couple of other options to consider. One is to route the hoses completely under the vehicle. The

drain hose hole on the driver side must be made large enough to accommodate the hose/harness bundle

coming off the Evaporator. Figure 35 shows the hole inside the vehicle while Figure 36 shows the hole under the

vehicle.

Figure 33

Figure 34

Figure 35

Figure 36

Under Side of Floor

Floor

Under Side of Floor


17. In this installation, the under body of the vehicle must be examined to determine precise routing to avoid

interference with OEM components. Figures 37, 38, 39, and 40, show examples of routing under the vehicle.

Figure 40

Figure 37

Figure 39

Figure 38


18. Another option is to notch out two holes in the inner side wall on the driver side as noted by letters “A” and

“B” in Figure 41. The bundle can be routed between the side walls as indicated by the arrows. The horizontal

seam has access holes behind it to allow routing from top to bottom. The bundle exits the side wall cavity and

routes to the floor where holes have previously been drilled. The hoses can be “boxed-in” (as depicted by a

transparent box) to protect the hoses and to provide a more aesthetic look.

A

B

Figure 41


MID-BODY COMPONENTS

19. In the area under the vehicle where the Condenser, Booster Pump, Water Valve and Drier are located

perform the following:

HEATING

Cut the Evaporator inlet hose (marked with Red tape) to the appropriate length and attach to the Water

Valve outlet (Figure 42).

Attach the remainder of the hose to the Booster Pump inlet and set aside.

Set aside the Evaporator outlet hose.

A third heater hose (04 000 025) is supplied in the kit. Mark that hose with Orange electrical tape applied at

intervals (or in some other way) and attach it to the angle port of the wye of the Booster Pump outlet

(Figure 43) and set aside.

Note: Secure all these hose connections with clamps (02 000 390).

Figure 42

Figure 43

From Booster Pump

(Water Valve In)

To Evaporator

(Water Valve Out)

(

To Heater Core In

From Engine

To Evaporator

Wye


COOLING

Cut an appropriate length of #6 hose to run from the Condenser outlet to the Drier inlet. Install fitting 05

000 479 on the Condenser outlet hose end and fitting 05 000 502 on the Drier inlet hose end (Figure 44) and

connect to the units (Figure 45).

Cut the Evaporator inlet hose (liquid port, #6 hose) to an appropriate length, attach fitting 05 000 502 and

connect to the Drier outlet.

Set aside the Evaporator outlet hose (suction port, #10 hose).

Attach fitting 05 000 504 to the #8 hose (04 000 054), connect to the Condenser inlet and set aside.

Remember to apply mineral oil to the gaskets before inserting into the fittings.

WIRING

Connect the Water Valve harness (01 000 644) plug to the Water Valve (Figure 46) and set aside the other

end (has relay socket, fuse, and Pink wire/spade connector on it)(Figure 47).

Figure 44

Figure 45

Figure 46 Figure 47 Pink Wire

Fuse

Relay Socket


20. Connect the Condenser harness (01 000 352), Condenser Relay harness (01 000 199), and Condenser pigtail

(attached to Condenser, 31 000 078) as follows:

Condenser Relay harness-Blue wire attached to Pressure Switch socket, Figure 49, 1

Butt splices to Red wire on Condenser harness

Condenser Relay harness –Blue wire coming off relay socket, Figure 49, 2

Butt splices to Blue wire on Condenser harness

Condenser Relay harness, Red/White Stripe Wire, Figure 49, 3

Butt splices to Black wire on Condenser harness

Condenser Relay harness, Black wire with eyelet lug, Figure 49, 4

Grounds to chassis with self-tapping screw

Condenser Relay harness, plugs (2), Figure 50 Join to plugs (2) on Condenser pigtail

Set the Condenser harness aside.

4

3

2 1

Figure 49

Figure 50

Figure 48


21. Butt splice a piece of Red/White Stripe wire (01 000 319, Figure 51) long enough to route to the engine

compartment, through a hole in the firewall (to be created later) into the passenger compartment to the

Booster Bump Red wire, Power In. Set the unconnected end aside.

Figure 51


HOSE/HARNESS ROUTING

22. Gather together the hoses/harnesses/wiring that have been “set aside” (three (3) heater hoses, two (2)

refrigerant hoses, three (3) wiring harnesses, and one (1) Booster Pump wire). Route them to the middle of the

vehicle. The five (5) hoses break away from the bundle just to the driver side of the passenger side exhaust pipe

to route to the front of the vehicle while the wiring harnesses/wire route to the passenger side wall of the

vehicle (Figure 52).

23. Route the wire harnesses to the inside of the front passenger side wheel well and up into the engine

compartment (Figure 53). The harnesses can be tie wrapped to an OEM harness that follows a portion of that

same path (Figure 54).

Figure 42

Hoses

Harnesses/

Wire

Figure 52

Figure 54

Figure 53

Wheel

Well


24. Once the hoses make the turn to route to the front of the vehicle, splice the service ports into the hoses

(Figure 55). Fitting 05 000 547 is spliced into the #8 hose while fitting 05 000 551 is spliced into the #10 hose.

Measure the amount of fire protective sleeve (08 000 124) needed to run from the service ports to the

Compressor. The hoses will route inside the sleeve (for heat protection) between the passenger side exhaust

pipe and the transmission fluid pan/engine oil pan to the Compressor (Figure 56). Cut the sleeve and slip the five

(5) hoses inside the sleeve and route to the Compressor. Run the heater hoses up into the engine compartment

(to be installed later).

I

25. The bundle should be attached appropriately to cross members with linestakes and tie wraps between

linestakes (Figures 57 and 58). Care should be taken to not disturb any OEM equipment.

f

Figure 57

Figure 55

Figure 58

Figure 56

Exhaust Pan

To Compressor


ENGINE COMPARTMENT

COOLING

26. The Compressor (05 000 432) has been previously mounted using BSI instructions. Install the manifolds on

the unit before attaching the refrigerant hoses. Remove and discard the plate and mounting bolt on the back

side of the Compressor (Figure 59). The suction and discharge ports are now exposed (Figure 60). Install the

suction manifold (05 000 415) on the port marked “S” (to the driver side) and the discharge manifold (05 000

414) on the port marked “D” (to the passenger side).

Note the gasket (Figure 60 inset) inserted between the manifold and Compressor port. This gasket is not treated

with mineral oil.

27. Secure the manifolds to the ports with mounting plate (02 000 261) attached to the Compressor using bolt

02 000 262 and lock washer 02 000 263 (between the bolt head and plate) (Figure 61).

Discard

Figure 59

Figure 60

Suction Manifold Discharge Manifold

Old Plate

New Plate

Figure 61


Figure 62 shows one manifold installed while Figure 63 illustrates both manifolds installed on the mounted

Compressor. Note that the manifolds are installed facing down.

28. Connect the refrigerant hoses to the Compressor by first cutting them to proper length.

Install fitting 05 000 504 on the #8 hose and attach it to the discharge port of the Compressor (passenger

side)(Figure 64). Install fitting 05 000 507 on the #10 hose and connect it to the suction port of the Compressor

(driver side)(Figure 64).

Figure 62

Figure 63

Figure 64

Suction

Discharge

Driver Side


HEATING

29. The Tie-In to the heating system is accomplished by interrupting both the OEM Heater Push (inlet) line and

the OEM Heater Return (outlet) line and splicing in the ProAir System. Locate the OEM Heater hoses on the

firewall on the passenger side (Figure 65). The hose on the passenger side is usually the Push line but verify for

your vehicle. Use vise grips or some other kind of tool to clamp off the hose (Figure 66). Perform this procedure

with a cool engine to prevent injury. Cut the hose and insert a splice (05 000 050) joining the hose coming from

the engine to the hose (Red tape) coming from the Booster Pump inlet. Clamp the splice (Figure 67). Splice the

short hose going to the Heater Push (inlet) line to the hose (Orange tape) coming from the wye angle port

following the Booster Pump outlet (Figure 68). Remove the vise grips.

Figure 65

Figure 67

Figure 68

Figure 66 Vise Grips

Linestake

Heater Lines

Splice

Splice


30. Follow the Return hose to the driver side (Figure 69) and repeat the process of clamping off the hose. Cut

the hose and insert a wye (05 000 020)(Figure 70). Connect the cut ends to the inline ports of the wye and

clamp. Connect the Evaporator outlet (return) hose to the angle port of the wye and clamp. Remove the vise

grips.

Figure 69

Figure 70

To Radiator

From Heater Core

Wye


ELECTRICAL

OVERVIEW

(Note: Diagram #3 at the end of these instructions shows electrical layout)

31. The electrical system requires the inter connection of the following:

30 Amp Breaker (connected to the battery)(01 000 130), Figure 71

Five (5) relays connected to wire harnesses (three of those have fuses attached), Figure 72

Evaporator harness running from the Evaporator at the back of the vehicle, Figure 73

Condenser harness running from the Condenser Relay (mounted near the Condenser), Figure 73

Water Valve harness running from the Water Valve, Figure 73

Booster Pump Power In wire, Figure 73

Clutch/Compressor Power In wire

Two (2) switches: Mode (A/C or Heat) , Blower (Fan Speed-High, Med, or Low), Figure 74

Figure 71

Figure 74 Figure 73

Figure 72

Evaporator Harness

Water Valve Harness

Condenser Harness

Booster Pump Wire


32. Figure 75 illustrates the components.

Wiring To Passenger Compartment

Battery

Ignition

Evaporator Harness

Water Valve Harness

Condenser Harness

Booster Pump Power In

Clutch Power In

Switch

Relay

(Cool)

#2

Power

(Ignition)

Relay

#1

Switch

Relay

(Heat)

#3

Water

Valve

Relay

#4

Fuse

20

Amp

MAX SYSTEM

Fuse

5

Amp

Fuse

15

Amp

Clutch (Compressor)

Relay

#5

Breaker

30

Amp

BA

T

AU

X

Notes on 30 Amp Breaker:

Vehicle battery connects to BAT side

All Fuses connect to the BAT side

Condenser Relay (under Vehicle) Power In connects to AUX side

Figure 75


PREPARATION

33. Physical location of the five (5) relays and 30 Amp Breaker 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 76 shows the passenger

compartment area where the units would be installed (glove box removed) while Figure 77 shows an area where

they could be installed in the engine compartment on the firewall.

Note: Installing the 30 Amp Breaker in the engine compartment may result in it overheating so

installation in the passenger compartment is recommended. But when the breaker is installed in the

passenger compartment, make sure the two posts do not “short” (make connection). This will result in

failure of the system.

These instructions will illustrate installation of all relays/breaker in the passenger compartment.

34. Remove the side panel and the glove box in the passenger compartment on the passenger side. The side

panel (Figure 78) just snaps in. The glove box requires removal of seven (7) screws, three (3) on the bottom

(Figure 79) and four (4) screws exposed when the unit is opened (Figure 80). Set the glove box aside (Figure 81).

Figure 76

Figure 77

Side Panel

Glove Box

Remove

Figure 78 Figure 79


35. Find locations for all the relays and the 30 Amp Breaker. Figure 82 shows the general layout:

#1, OEM switch panel, Figure 82

#2, Relay #1 (Ignition/Power), Relay #4 (Water Valve), Relay #5 (Clutch/Compressor) and the 30 Amp

Breaker, Figure 83

#3, Relay #2 and Relay #3 (Switch Relays), Figure 84

#4, Hole (in firewall) for the wiring to route between the engine and passenger compartments, Figure 85

1

2

3 4

Figure 83 Figure 82

Figure 81

Remove

Figure 84

Figure 85

Figure 80


INSTALLATION

36. Drill a hole in the firewall to allow wires to route between the engine compartment and the passenger

compartment (Figures 86 and 87). The hole must be big enough to allow passage of the ignition wire, battery

wire, Booster Pump wire, Clutch/Compressor wire and three wire harnesses (Evaporator, Condenser, and Water

Valve). Trim the hole with Trim Lock (behind the insulation). Route the Evaporator, Condenser, and Water Valve

harnesses and the Booster Pump wire from the engine compartment through the hole in the firewall into the

passenger compartment.

37. Install an eyelet lug on one end of the 6 gauge (Red) wire 01 000 412 and route that end from the engine

compartment through the hole into the passenger compartment (Figure 88). This is the Battery wire.

Figure 86

Figure 88

Figure 87


38. Attach five (5) relays (01 000 136) to relay harnesses (Figure 89). Number/label them as noted below (Figure

90). (Numbering will be referred to throughout the instructions).

Relay #1, Power (Ignition/Power), connects to harness 01 000 239 (20 Amp Fuse attached)

Relays #2 and #3 (Switch), connect to harness 01 000 634

Relay #4, Water Valve, connects to harness 01 000 644 (routed from engine compartment)( 5 Amp Fuse

attached)

Relay #5, Clutch/Compressor, connects to harness 01 000 012 (15 Amp Fuse attached)

39. Mount the relays/fuses and 30 Amp Breaker (01 000 130) in the locations selected. Use self-tapping screws

(02 000 074) to attach to OEM compartment (Figures 91, 92, 93 and 94).

Power, Water Valve, Clutch

Relays, Breaker

Relays

Screws

Figure 89

Figure 92

Figure 91

Figure 90


40. Route the Relay #1 (Power, Ignition) Orange wire (Signal In) through the firewall hole into the engine

compartment (Figure 95). Connect the Battery wire to the BAT terminal (copper colored) on the 30 Amp Breaker

(Figure 96).

Switch Relays

Breaker

Ignition Wire

Figure 94 Figure 93

Figure 95

Figure 95 Figure 96

Battery Wire


41. Remove the OEM switch plate from the dash (Figure 97) and insert the Rear Mode switch (Heat-A/C) 01 000

632 and the Rear Blower switch (Fan Speed-High, Med, Low) 01 000 633 into the plate. The Mode switch should

be on the left as viewed from the front (Figure 98).

42. Note the numbering of the terminals on the rear of the switches (Figure 99). This information will be used

when you connect wiring to the switches. The connections are spade terminals:

Figure 98

Blower

1 4

2 5

3 6

66

Mode

1 4

2 5

3 6

66

Figure 99 – Rear View

Figure 97


43. Butt splice a length of wire from bulk 01 000 319 (also used on Booster Pump) to the Compressor Power In

pigtail (Figure 100) and route through the hole in the firewall to the passenger compartment. It will be

connected later.

44. Connect the wiring in the passenger compartment by following Figures 101, 102 and 105. Relay wiring is

noted on Figure 101. Figure 102 includes the wiring from the harnesses/wire from the engine compartment.

Figure 103 notes wiring involving the relays and will include some wiring already completed (Condenser Relay to

Condenser) 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.

Figure 100


RELAY WIRING

Diagram 4

Relay 01 000 199 / 201

Condenser Relay

Relay with tab side down looking on end:

1 – Power In / Red-White

2 – Signal In / Blue

3 – Ground / Black

4 – Power Out / Red

1

2 3

4

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)

1

2 3

4

5

Relay 01 000 136

Plugs into Harnesses 01 000 012,

01 000 239, 01 000 334,

01 000 634, 001 000 644

Power Relay

Pwr Out Pwr In

Sig In Grnd

Relay Schematic

Figure 101


WIRING HARNESSES, BOOSTER PUMP WIRE, SWITCHES WIRING

EVAPORATOR HARNESS, 01 000 400 (Strip to Bare Wires)

Remove 3-wire plug (Yellow, Red, Orange wires) and spade connectors on two Blue wires)

Yellow wire Install female spade connector on wire and connect to Blower Switch, Terminal #1

Red wire Install female spade connector on wire and connect to Blower Switch, Terminal #3

Orange wire Install female spade connector on wire and connect to Blower Switch, Terminal #6

Blue wire (either one)

Butt splice to short Blue wire on Relay #2 harness (Switch Relay #1, A/C, Signal In) after removing spade connector on Relay wire

Blue wire (either one)

Butt splice to Condenser harness Blue wire

CONDENSER HARNESS, 01 000 352 (Bare Wire)

Black wire Install eyelet lug and attach to 30 Amp Breaker, AUX side

Blue wire Butt splice to Blue wire (either one) on Evaporator harness (Thermostat)

Red wire Butt splice to Orange wire on Relay #5 (Clutch, Signal In)

WATER VALVE HARNESS, 01 000 644

Relay socket Connect to Relay #4

Red wire/Fuse Connect eyelet lug to 30 Amp Breaker, BAT side

Pink wire Remove spade connector on this wire and the spade connector on the short Pink 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

BOOSTER PUMP WIRE, 01 000 319 (Bare Wire)

Butt splice Power wire, Red/White Stripe, to Pink wire on Water Valve harness and Pink wire on Relay #3 harness (Switch Relay #2, Heat, Signal In)

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 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 3 Connect Evaporator harness Red wire here


Terminal 5 Connect Red/White Stripe wire of Relay #2 here (Switch Relay #1, Power In)

Terminal 6 Connect Evaporator harness Orange wire here

Figure 102


45. Figures 103 and 104 illustrate the wiring on the back of the switches. Figure 103 shows the jumper referred

to in Figure 102.

Figure 103

Figure 104

100

Jumper


NISSAN MAX WIRING / RELAYS

Relay Name Device Wire Color Harness Signal Connects To Connection

Power Fuse on Relay #1 Red 01 000 239 Power In 30 Amp Breaker, BAT Side Eyelet

Power Relay #1 Red 01 000 239 Power In Fuse on Relay #1, Power Out Loop

Power Relay #1 Red 01 000 239 Power Out Relay #2, Power In, Red Wire, 01 000 634 Spade

Power Relay #1 Orange 01 000 239 Signal In Ignition Terminal Block in Engine Compartment (To be installed later. Instructions will follow)

Bare Wire

Power Relay #1 Black 01 000 239 Ground Chassis* Eyelet

Switch Relay #2 Red 01 000 634 Power In Relay #1, Power Out, Red Wire (01 000 239) Spade

Switch Relay #2 Red/White 01 000 634 Power Out Blower Switch, Terminal #5 Spade

Switch Relay #2 Red/White 01 000 634 Power Out Relay #3, Power Out Loop

Switch Relay #2 Blue (long) 01 000 634 Signal In Mode Switch, Terminal #3, A/C Command Spade

Switch Relay #2 Blue (short) 01 000 634 Signal In Evaporator harness, Blue wire, 01 000 400 Butt Splice

Switch Relay #2 Black 01 000 634 Ground Relay #3, Ground Loop

Switch Relay #3 Red 01 000 634 Power In Mode Switch, Terminal 5 Spade

Switch Relay #3 Red/White 01 000 634 Power Out Relay #2, Power Out Loop

Switch Relay #3 Pink (short) 01 000 634 Signal In Relay #4, Signal In, Pink wire, 01 000 644 Butt Splice

Switch Relay #3 Pink (long) 01 000 634 Signal In Mode Switch, Terminal #6, Heat Command Spade

Switch Relay #3 Black 01 000 634 Ground Chassis* Eyelet

W Valve Fuse on Relay #4 Red 01 000 644 Power In 30 Amp Breaker, BAT Side Eyelet

W Valve Relay #4 Red 01 000 644 Power In Fuse on Relay #4, Power Out Loop

W Valve Relay #4 Red 01 000 644 Power In Water Valve, Loop Plug

W Valve Relay #4 Pink 01 000 644 Signal In Relay #3, Signal In, Pink wire, 01 000 634 Butt Splice

W Valve Relay #4 Purple 01 000 644 Power In Water Valve Plug

W Valve Relay #4 Black 01 000 644 Ground Water Valve Plug

W Valve Relay #4 Black 01 000 644 Power Out Relay #4, Ground Loop

W Valve Relay #4 Black 01 000 644 Ground Chassis* Eyelet

Clutch Fuse on Relay #5 Red 01 000 012 Power In 30 Amp Breaker, BAT Side Eyelet

Clutch Relay #5 Red 01 000 012 Power In Fuse on Relay #5, Power Out Loop

Clutch Relay #5 Red 01 000 012 Power Out Clutch, Compressor Butt Splice

Clutch Relay #5 Orange 01 000 012 Signal In Condenser harness, Red wire, 01 000 352 Butt Splice

Clutch Relay #5 Black 01 000 012 Ground Chassis* Eyelet

Condenser Condenser Relay Red/White 01 000 199 Power In Condenser harness, Black wire, 01 000 352 Butt Splice

Condenser Condenser Relay Blue 01 000 1999 Signal In Condenser harness, Blue wire, 01 000 352 Butt Splice

Condenser Condenser Relay Blue

Pressure Sw 01 000 199 Signal In Condenser harness, Red wire, 01 000 352 Butt Splice

Condenser Condenser Relay Red 01 000 199 Power Out Condenser Plug

Condenser Condenser Relay Black 01 000 199 Ground Condenser Plug

*All ground (black) wires that attach to the chassis can be butt spiced to a single wire that can then be grounded

to the chassis.

Figure 105


46. Reinstall the OEM panel into the vehicle as in Figures 106 and 107.

47. Reattach the side panel and the glove box.

48. 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 108) and create a notch for the wire to enter

the unit (Figure 109). Install a spade lug on the end of the wire and install in the position shown in Figure 110.

Reinstall the cover.

Figure 106

Figure 107

Figure 108

Figure 109

Ignition

Terminal

Notch


49. In the engine compartment, cut the 6 gauge (Red) wire coming from the 30 Amp Breaker in the passenger

compartment to length (terminates at the positive terminal on the battery)(Figure 111). Attach an eyelet lug to

the wire and secure to the positive terminal of the battery (Figure 112).

Figure 111

Figure 110

Figure 112


50. With the installation now complete, seal all holes with silicone seal. This includes holes created for

hoses/wiring harnesses to enter and exit the vehicle (Figure 113). This is to keep out moisture and contaminates.

Also apply silicone at any locations where hoses/harnesses come in contact with any vehicle structures,

especially OEM related components.

51. Add 2.50 to 2.75 pounds of R134A refrigerant and 4 ounces of PAG oil to the system (Figure 114).

52. Several informational labels are provided to document installation and provide those who service the system

with proper maintenance information. Those are:

Figure 113

Seal

Seal

09 000 035

This label notes the refrigerant

and PAG oil capacity of your

system. It should be applied

somewhere in the engine

compartment.

09 000 037

This label notes the anti-freeze

mixture ratio and should also be

applied in the engine

compartment.

09 000 046

This label provides information

as to date of installation and the

installer’s name. The serial

numbers for the Condenser and

Evaporator are noted here as

well as your kit number. It

should be attached to the driver

side door jamb.

Figure 114


01 000 633

01 000 400

01 000 239 01 000 136

01 000 352

01 000 644

01 000 632

02 000 021

01 000 634

01 000 412

01 000 319

01 000 130

02 000 023

02 000 015

02 000 052

PARTS


04 000 053

02 000 390

02 000 261 02 000 074

02 000 263

04 0000 055

04 000 025

05 000 017

04 000 054

04 000 019

02 000 262

02 000 053

05 000 020

05 0000 010

05 000 050


05 000 547

05 000 507

05 000 479 05 000 415

05 000 504

05 000 971

05 000 529

08 000 124

05 000 551

05 000 527

05 000 502

05 000 414

09 000 035

08 000 017

09 000 037


01 000 012 09 000 145

09 000 046


A/C FLOW – NISSAN NV, MAX (552 Evaporator)

OEM

Diagram 1

CONDENSER 31 000 078

In Out

COMPRESSOR

05 000 432

Discharge

Suction

05 000 504

Fitting

05 000 414

Manifold

#8 Hose

SERVICE PORT

05 000 547

EVAPORATOR 66 000 118

In

Out

DRIER 05 000 712

In Out

SERVICE PORT

05 000 551

05 000 415

Manifold

05 000 507

Fitting

05 000 504

Fitting

05 000 479

Fitting

05 000 502

Fitting 05 000 527

Fitting

05 000 502

Fitting

#8 Hose #6 Hose #6 Hose

#10 Hose #10 Hose

Notes:

Part Numbers for fittings for hoses connecting to devices are noted.

#6 Hose-5/16”=PN 04 000 053, #8 Hose=13/32”=PN 04 000 054, #10 Hose=1/2”=PN 04 000 055

Fittings require a special crimp tool.

Fittings come with a green gasket. Gasket should have mineral oil applied to it before installation.

Drain Hoses

04 000 019

05 000 529

Fitting


HEATING FLOW – 552 EVAPORATOR

Diagram 2

IN

HEATER CORE (Dash)

OUT

In PUMP Out

05 000 658

In

EVAPORATOR

66 000 118

Out

Out

From

Engine (Push Line)

To

Radiator (Return Line)

Notes:

Dotted lines above represent original (OEM) installed hose

Kit installed hose is 5/8” standard heater hose PN 04 000 025

In WATER VALVE Out

01 000 644

Wye

05 000 020

Splice

05 000 050

Splice

05 000 050

Wye

05 000 020

Heater Hose 5/8” Ell

05 000 110


Diagram 3

Mode Switch

Not Used 1

2

3

4

5

6

Blower Switch

1

2

3

4

5

6

Thermostat

Pressure Switch

Condenser Relay

Power In/Power Out

Signal In

Ground

Relay #5 (Clutch)

Signal In

Power In/Power Out

Ground

Relay #3 (SW #2)

Signal In

Power In/Power Out

Ground

Relay #2 (SW #1)

Signal In

Power In/Power Out

Ground

Relay #4 (W Valve)

Signal In

Power In/Power Out

Ground

Relay #1 (Ignition)

Signal In

Power In/Power Out

Ground

Booster Pump

Power In

Ground

Water Valve

Black

Red

Purple

5 Amp Fuse

20 Amp Fuse

Compressor

Power In

Ground

Condenser

Power In

Ground

Evaporator

Low

Med

High

AUX

BAT

30

Amp

Breaker

Ignition

15 Amp Fuse

NOTES:

Wire crosspoints do not represent connections. Wires that “T” are

butt spliced.

Ground wires can be individually grounded to the vehicle chassis or

can be daisy-shanied together in any fashion and then grounded.

Vehicle battery connects to the 30 Amp Circuit Breaker.

ELECTRICAL LAYOUT – NISSAN NV MAX SYSTEM

INSTALLATION INSTRUCTIONS FOR Plumbing/Electrical NV, Max, Plumbing... · INSTALLATION INSTRUCTIONS...

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