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Dieselsite Kit and Explanationhttp://www.dieselsite.com/index.asp?PageAction=VIEWPROD&ProdID=21

Original reference info is from TheDieselStophttp://www.thedieselstop.com/forums/f26/pic-heater-bypass-valve-mod-installed-69644/

NAPA part number is 6601294O’Reilly part number is 74809

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FTE User Discussions and Mod Optionshttp://www.ford-trucks.com/forums/512209-wow-real-air-conditioning.html

NOTE: this mod only applies to the F-series trucks, and does NOT apply to the Excursions.

Here is an outstanding reference diagram provided by Izzy351 (Joe) of the Ford Ranger HVACsystem, which is nearly identical to that in our PSD’s. There are ACTUAL diagrams for thevacuum system for a 2002 7.3L PSD at the end of this document.

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General mod explanation and parts list.

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Installation TIPS….

New tubing routingDrill a hole (slightly smaller than the new tubing) through the firewall’s plastic/rubber grommetlocated above the carpet, upper right passenger side floor. Fish the tubing through and up towhere you need it. Might be helpful to sue a piece of looped string to pull the line up, and dropit down and use a coat hanger with a hook from inside the cab to pull the tubing inside the cab.

Where to mount the valve?The valve can go on either the heater core inlet or outlet. Once the flow is stopped on eitherside, the heat does not migrate into the heater core.

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There are several ways to configure the controls for this heater bypass valve:1. Manually (cheap, simple, has some convenience drawbacks2. ON for A/C, MAX A/C, Vent, and Bi-Level (prevents A/C from working with Defrost)3. ON for only MAX A/C4. A/C FLEX ULTIMATE option (sort of a combination of #2 and #3)

1. MANUAL Operation

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2. A/C, MAX A/C, Vent, and Bi-LevelThis is what Neal described in his initial procedure by way of tee-ing into the RED vacuum line.

3. MAX A/C only

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4. A/C FLEX ULTIMATE option

Here is a link to the Small Parts Inc. manual in-line shutoff valve.http://www.smallparts.com/Colder-Line-Shutoff-Valve-Tube/dp/B001DVZ6EA?ie=UTF8&qid=1246549321&pf_rd_r=0E8Y21ZEF1W6FBXZ6X49&pf_rd_p=467590031&pf_rd_i=0&sr=1-35&pf_rd_s=center-3&pf_rd_m=AIUBT5HP6PMAF&pf_rd_t=301

You can also use a 12v electronic solenoid vacuum shut-off valve, like the ones linked here….1) http://www.valvestore.com/prodinfo.asp?number=42702 ($32), normally closed, powered open2) http://www.hotrodair.com/index.cfm/page/ptype=product/product_id=172/category_id=23/home_i

d=2/mode=prod/prd172.htm (no price advertised - (877) 693-3200, part #92-0001)

One final option is to simply use a 3-way toggle switch valve with only the switch sticking through thedash.

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DIAGRAMS for 2002 7.3L F250 – Manual A/C System.

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DIAGRAMS for 2002 7.3L F250 - Manual A/C System, continued.

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DIAGRAMS for 2002 7.3L F250 – Electronic Automatic Temperature System.

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DIAGRAMS for 2002 7.3L F250 – Electronic Automatic Temperature System, continued.