INSTALLATION INSTRUCTIONS FOR Plumbing/Electrical · Plumbing and electrical wiring often run in parallel so installation involves some switching ba ck and forth between plumbing

INSTALLATION INSTRUCTIONS

FOR

Plumbing/Electrical For Nissan NV / Super Tie-In / 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 Page 2 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 and 02 000 075) 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 3 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 (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, 7/8” 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 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 01 000 130 1 Breaker, 30 Amp Circuit 2 01 000 136 4 Relay, 40 Amp 3 01 000 239 1 Harness, 20 Amp Power Relay 4 01 000 319 1 Wire, 12 Gauge Red w/White Stripe 5 01 000 352 1 Harness, Wire Condenser 6 01 000 400 1 Harness, Evaporator 7 01 000 412 1 Wire, 6 Gauge Red 8 01 000 632 1 Switch, Rocker 11 Nissan Rear-Mode 9 01 000 633 1 Switch, Rocker 11 Nissan Rear-Blower 10 01 000 634 1 Harness, 11 Nissan Mode/Blower Switch 11 01 000 644 1 Harness, Water Valve Electric 2-Port 12 02 000 015 12 Linestake, 2” 13 02 000 018 2 Washer, Lock 8mm 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 02 000 129 1 Nut, 8mm-1.25 Hex 20 02 000 170 1 Bolt, 8mm, 1.25 x 55 21 02 000 189 5 Washer, Lock 6mm 22 02 000 232 1 Bolt, 8mm – 1.25 x 75 Hex Head 23 02 000 235 3 Cable Tie, 14” Stainless Steel 24 02 000 264 1 Washer, 5/16 Flat Stainless Steel 25 02 000 390 2 Clamp, #10 Heater Hose 26 02 000 490 1 Washer, 6mm 27 02 000 608 1 Bolt, 6mm-1.0x60mm Zinc Part Th 28 04 000 019 1 Hose, Drain ½” Nylon Braid 29 04 000 025 1 Hose, 5/8 ID OEM Spec-Bulk 30 04 000 053 1 Hose, 5/16” Refrigerant #4890 Redu Barrier CF, 23’ 31 04 000 054 1 Hose, 13/32” Refrigerant #4890 Redu 32 04 000 055 1 Hose, 1/2” Refrigerant #4890 Redu Barrier CF, 18’ 33 05 000 010 1 Tee, 1/2" Drain 34 05 000 017 2 Ell, ½” Drain 35 05 000 020 2 Wye, 5/8 OD Water, Plastic 36 05 000 050 4 Splice, 5/8 Heater Hose 37 05 000 479 1 Straight Splice (Service Port), #8 FOR x 8 CF 38 05 000 502 1 Ell, 90 #6 FOR x CF 39 05 000 504 3 Ell, 90 #8 FOR x 8 CF 40 05 000 507 1 Ell, 90 #10 FOR x 10 CF


41 05 000 515 3 Ell, 90 #6 FOR x 8 CF 42 05 000 527 1 Ell, 90 #6 MOR x 6 CF 43 05 000 529 1 Ell, 90 #10 MOR x 10 CF 44 05 000 655 1 Block, Discharge Ford Slim Line 45 05 000 671 1 Fitting, Condenser Ford Slime Line #8 46 05 000 971 1 Valve, Kazoo 3/4” ID x 10’ 47 05 001 001 1 Fitting, Block, Liquid Tie-In 11 Nissan 48 05 001 002 1 Fitting, Block, Suction Tie-In 11 Nissan 49 08 000 017 1 Tape, Prestite Refrigerant 50 08 000 124 1 Sleeve, Fire Protective 51 08 000 158 1 Washer, Sealing, 07 Ford Slim Line 52 08 000 159 1 O-Ring, 07 Ford Slim Line Discharge 53 08 000 163 2 O-Ring, Slim Line #12 54 08 000 209 2 O-Ring, #6 (006.8MG) CV23 55 09 000 035 1 Label, Refrigerant Capacity-Blank 56 09 000 037 1 Label, Anti-Freeze Mix 57 09 000 046 1 Label, Door Jamb 58 09 000 145 1 Card, Information Warranty Registration


INSTALLATION INSTRUCTIONS

These instructions assume that the Evaporator, Condenser, Booster Pump, Water Valve and Drier 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 ProAir Super Tie-In System is a supplemental Air Conditioning/Heating system for the Nissan NV. The Super

Tie-In system is an independent system with its own Evaporator and Condenser but “ties-in” to the OEM system,

using the OEM Compressor to drive its components. The heating side of the ProAir System “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 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 0400)(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

Floor Side Wall


3. 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. 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. 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 to minimize condensation (Figure 7).

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 engine) (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 one of the ells (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 just run 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. You can also “flip” this layout to the driver side. As shown you will need one (1) ell 05 000

017, one (1) tee 05 000 010, four (4) pieces of hose (04 000 019) 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). Secure the bundle to the side wall with linestakes and to itself with tie wraps (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 and30 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 INSTALLATION

19. In the area under the vehicle where the Condenser, Condenser Relay, 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 to the angle port of the wye following 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

Set aside the Evaporator inlet hose (liquid line, #6 hose) and the outlet hose (suction line, #10 hose)

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).

Attach fitting 05 000 515 to #8 hose (04 000 054)(long enough to run to the engine compartment), connect

to the Drier outlet and set aside.

Attach fitting 05 000 504 to #8 hose (04 000 054)(long enough to run to the engine compartment), connect

to the Condenser inlet and set aside.

Remember to apply mineral oil to the gaskets before inserting in 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)(Figure 48), and

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

Condenser Relay harness-Remove the Pressure Switch socket as it is not used in this installation. Cut Blue wire at point “X” (Figure 49) and discard the socket. Wire noted as “1” in Figure 49 is not used.

Red wire on Condenser harness is not used.

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

Butt splice to Blue wire on Condenser harness

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

Butt splice to Black wire on Condenser harness

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

Ground 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

X

Pressure Switch


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. Route the seven (7) hoses (3 heater hoses, 4 refrigerant hoses), three (3) wire harnesses (Evaporator,

Condenser, Water Valve) and Booster Pump wire (set aside items) to the engine compartment area noted in

Figure 52.

HOSES/HARNESSES/WIRE ROUTING

HOSE/HARNESS COMES FROM ROUTES TO ENGINE COMPARTMENT DEVICE

#10 Refrigerant Hose Evaporator Out Driver side Suction Tie-In Fitting

#8 Refrigerant Hose Condenser In Driver side Discharge Block

#8 Refrigerant Hose Drier Out Driver side Condenser Fitting

#6 Refrigerant Hose Evaporator In Passenger Side near Radiator Liquid Tie-In Fitting

Heater Hose (Red) Booster Pump In Passenger Side near Heater lines Engine Out

Heater Hose (Orange) Booster Pump Out (Angle Port on Wye)

Passenger Side near Heater lines OEM Heater Core In

Heater Hose Evaporator Out Driver Side Angle Port on Wye (Radiator In)

Water Valve harness Water Valve Will route into the passenger compartment through a hole in the firewall (to be created later)

Condenser harness Condenser Relay Will route into the passenger compartment through a hole in the firewall (to be created later)

Evaporator harness Evaporator Will route into the passenger compartment through a hole in the firewall (to be created later)

Wire Booster Pump Power In Will route into the passenger compartment through a hole in the firewall (to be created later)

Figure 52


23. A fire resistant sleeve (08 000 124) and two (2) stainless steel wire ties (02 000 235) are provided to protect

the hoses which might route near OEM equipment that generates heat near the engine compartment (Figure

53). Slip the hoses inside the sleeve and secure the sleeve to the hoses with the tie wraps and position

appropriately to keep hoses away from heat. Figure 54 shows the sleeve in place.

24. Once the hoses/harnesses/wire are routed, secure them to the underbody cross members as is appropriate

using linestakes and tie wraps (Figures 55 and 56).

f

Figure 54 Figure 53

Figure 55

Figure 56


ENGINE COMPARTMENT

COOLING

EVACUATE (DISCHARGE) THE OEM A/C SYSTEM BEFORE PROCEEDING!!!

25. A Super Tie-In System involves first separating the OEM fitting on the hard line connecting the OEM

Compressor Discharge line with the OEM Condenser.

26. Locate the OEM Condenser inlet junction fitting on the driver side of the engine compartment near the OEM

Condenser (Figure 57). Remove the bolt to separate the two parts (Figure 58).

27. On the top hard line (Discharge from Compressor), install Discharge Block 05 000 655 by removing the O-

Ring on the OEM line and inserting O-Ring 08 000 159 supplied with your kit. Join the hard line to the Discharge

Block, inserting seal 08 000 158 between the two parts. Bolt together using the OEM bolt, washer and nut. On

the bottom hard line (OEM Condenser Inlet), install the Condenser fitting 05 000 671 by inserting the O-Ring on

the Condenser fitting line’s groove. Join the Condenser fitting to the bottom hard line, inserting the seal

between the two parts. Bolt together using bolt 02 000 170, lock washer 02 000 018, and nut 02 000 129. Figure

59 illustrates the assembly.

Remember to apply mineral oil to the O-Rings before inserting into the fittings.

Seal Condenser

Fitting

Figure 59

Discharge

Block

O-Ring

From ProAir Drier

To ProAir Condenser

Figure 57 Figure 58

Remove


28. Install the hoses to these two (2) fittings. Cut the hose coming from the ProAir Condenser inlet to proper

length and attach a 05 000 504 fitting. Connect fitting to the Discharge Block (OEM Compressor Discharge port).

Cut the hose coming from the ProAir Drier outlet to proper length and attach a 05 000 504 fitting. Connect

fitting to the Condenser Fitting (OEM Condenser inlet port).


29. The Super Tie-In System next includes taking the OEM Condenser 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).

30. Disconnect the OEM hard refrigerant line (suction) located to the driver side in the engine compartment by

removing and discarding the OEM bolt (Figure 60). Separate the line and insert the Suction Tie-In fitting (05 001

002) and bolt into place with bolt 02 000 232. Slide lock washer 02 000 018 and washer 02 000 264 on the bolt

before installing (Figure 63). Before inserting the tie-in, install two (2) O-Rings (08 000 209.) One slips on the

groove on the fitting (Figure 62). The other slips on a similar groove on the OEM line. That line will have an O-

Ring in place when the line is broken. Remove and discard it and install the new one supplied with the kit (Figure

62).


Cut to length the refrigerant hose coming from the ProAir Evaporator (outlet) and install fitting 05 000 502.

Connect the hose to the Suction Tie-In fitting (Figure 61).

Remove/Discard Bolt

Figure 60

Tie-In

Fitting

Figure 62 Figure 63

Groove

Figure 61

Evaporator Out


31. Disconnect the OEM hard refrigerant line (liquid) located to the passenger side in the engine compartment

(near the radiator, Figure 64) by removing and discarding the OEM bolt. Separate the line and insert ProAir

Liquid Tie-In fitting 05 001 001 (Figure 65). Secure the fitting with bolt 02 000 608. Slide lock washer 02 000 189

and washer 02 000 490 on the bolt before installing (Figure 67). Before inserting the tie-in, install two (2) O-

Rings (08 000 163). One slips on the groove on the fitting (Figure 66). The other slips on a similar groove on the

OEM line. That line will have an O-Ring in place when the line is broken. Remove and discard it and install the

new one supplied with the kit (Figure 66).


Cut to length the refrigerant hose running from the ProAir Evaporator (inlet) and install fitting 05 000 507.

Connect the hose to the Liquid Tie-In fitting (Figure 65).

Figure 64

Figure 67 Figure 66

Figure 65

Remove/Discard Bolt

Tie-In Fitting

Groove


HEATING

32. 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 lines on the

firewall on the passenger side (Figure 68). The line 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 line (Figure 69). Do this procedure with a

cool engine to prevent injury. Cut the line 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 70). Splice the short

hose going to the Heater inlet to the hose (Orange tape) coming from the wye angle port following the Booster

Pump outlet (Figure 71). Remove the vise grips.

Figure 68

Figure 70

Figure 71

Figure 69

Heater Lines Vise Grips

Splice Splice


33. Follow the Return hose to the driver side (Figure 72) and repeat the process of clamping off the hose. Cut

the hose and insert a wye (05 000 020)(Figure 73). 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 72

Figure 73

To Radiator

From Heater Core

Wye


ELECTRICAL

OVERVIEW

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

30 Amp Breaker (connected to the battery)(01 000 130), Figure 74

Four (4) relays connected to wire harnesses (two of those have fuses attached), Figure 75

Evaporator harness running from the Evaporator at the back of the vehicle, Figure 76

Condenser harness running from the Condenser Relay (mounted near the Condenser), Figure 76

Water Valve harness running from the Water Valve, Figure 76

Booster Pump Power In wire

Two (2) switches: Mode (A/C or Heat) , Blower (Fan Speed-High, Med, or Low), Figure 77

Figure 74

Figure 77

Figure 76

Figure 75

Evaporator Harness

Water Valve Harness

Condenser Harness

Booster Pump Wire


35. Figure 78 illustrates the components.

Switch

Relay

(Cool)

#2

Power

(Ignition)

Relay

#1

Switch

Relay

(Heat)

#3

Water

Valve

Relay

#4

Fuse

20

Amp

SUPER TIE-IN SYSTEM

Fuse

5

Amp

30

Amp

Breaker

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 the AUX side

Wiring To Passenger Compartment

Battery

Ignition

Evaporator Harness

Condenser Harness

Water Valve Harness

Booster Pump Power In

Figure 78


PREPARATION

36. Physical location of the four (4) 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 79 shows the passenger

compartment area where the units would be installed (glove box removed) while Figure 80 shows an area where

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

Note: Installing the 30 Amp Breaker in the engine department 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.

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

panel (Figure 81) just snaps in. The glove box requires removal of seven (7) screws, three (3) on the bottom

(Figure 82) and four (4) screws exposed when the unit is opened (Figure 83). Set the glove box aside (Figure 84).

Figure 79

Figure 80

Side Panel

Glove Box

Remove

Figure 81 Figure 82


38. Find locations for all the relays and the 30 Amp Breaker. Figure 85 shows the general layout:

#1, OEM switch panel, Figure 85

#2, Relay #1 (Ignition, Power), Relay #4 (Water Valve) and the 30 Amp Breaker, Figure 86

#3, Relay #2 and Relay #3 (Switch Relays), Figure 87

#4, Hole (in firewall) for the wiring to route between the engine and passenger compartments, Figure 88

1

2

3 4

Figure 86 Figure 85

Figure 84

Remove

Figure 87

Figure 88

Figure 83


INSTALLATION

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

compartment (Figures 89 and 90). The hole must be big enough to allow passage of the ignition wire, battery

wire, Booster Pump wire and three wiring 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.

40. 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 91).

Figure 89

Figure 91

Figure 90


41. Attach four (4) relays (01 000 136) to relay harnesses (Figure 92). Number/label them as noted below

(Figure 93). (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 Relays), connect to harness 01 000 634

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

attached)

42. 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 94, 95, 96 and 97).

Power, Water Valve Relays,

Breaker

Relays

Screws

Figure 92

Figure 95

Figure 94

Figure 93


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

compartment (Figure 98).

Switch Relays

Breaker

Ignition Wire

Figure 97 Figure 96

Figure 98


44. Remove the OEM switch plate from the dash (Figure 99) 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 100).

45. Note the numbering of the terminals on the rear of the switches (Figure 101). This information will be used

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

46. Connect the wiring in the passenger compartment by following Figures 102, 103 and 106. Relay wiring is

noted on Figure 102. Figure 103 includes the wiring from the harnesses/wire from the engine compartment.

Figure 106 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

Blower

1 4

2 5

3 6

66

Mode

1 4

2 5

3 6

66

Figure 101 – Rear View

Figure 99


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 102


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

Red wire Not used

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 #3, 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 to Terminal 4

Terminal 3 Connect with long Blue wire of Relay #2 harness (Switch Relay #1, A/C, Signal In)

Terminal 4 Connect other end of White/Orange jumper wire to Terminal 2

Terminal 5 Connect with Red wire of Relay#3 (Switch Relay #2, Heat, Power In)

Terminal 6 Connect with long Pink wire on Relay #3 (Switch Relay #2, Heat, Signal In)

BLOWER SWITCH (Spade Connections)

Terminal 1 Connect with Evaporator harness Yellow wire

Terminal 2 Connect one end of White/Orange jumper wire to Terminal 4

Terminal 3 Connect with Evaporator harness Red wire

Terminal 4 Connect other end of White/Orange jumper wire to Terminal 2

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

Terminal 6 Connect with Evaporator harness Orange wire

Figure 103


47. Figures 104 and 105 illustrate the wiring on the back of the switches. Figure 105 shows the jumper referred

to in Figure 103.

Figure 104

Figure 105

Jumper


NISSAN SUPER TIE-IN WIRING

Relay Name Device Wire Color Harness? Signal Connects To Connection

Power Fuse on Relay #1 Red Power In 30 Amp Breaker, Battery Side Eyelet

Power Relay #1 Red Power In Fuse on Relay #1, Power Out Loop

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

Power Relay #1 Orange 01 000 239 Signal In Ignition Terminal Block in Engine Compartment

Note: To be installed later Bare Wire

Power Relay #1 Black Ground Chassis Eyelet

Switch Relay #2 Red 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 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 Condenser Harness, Blue wire Butt Splice

Switch Relay #2 Black Ground Relay #3, Ground Loop

Switch Relay #3 Red 01 000 634 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 (01 000 644) Spade

Switch Relay #3 Pink (long) 01 000 634 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 30 Amp Breaker, Battery 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 Spade

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 Power Out Relay #4, Ground Loop

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

Condenser Condenser Relay Red/White 01 000 352 Power In Condenser Harness, Black wire which connects to 30 Amp Breaker, Aux Side

Eyelet

Condenser Condenser Relay Red Power Out Condenser Plug

Condenser Condenser Relay Blue 01 000 352 Signal In Condenser Harness, Blue wire which connects to Mode Switch, Terminal 3, Cool Command

Butt Splice

Condenser Condenser Relay Black Ground Condenser Plug

Note: All the 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 106


48. Reinstall the OEM panel into the vehicle as in Figures 107 and 108.

49. Reattach the side panel and the glove box.

50. 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 109) and create a notch for the wire to enter

the unit (Figure 110). Install a spade lug on the end of the wire and install in the position shown in Figure 111.

Reinstall the cover.

Figure 107

Figure 108

Figure 109

Figure 110

Ignition

Terminal

Notch


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

compartment to length (Figure 112)(terminates at the positive terminal on the battery). Attach an eyelet lug to

the wire and secure to the positive terminal of the battery ( Figure 113).

Figure 112

Figure 111

Figure 113


52. 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 114). This is to keep out moisture and contaminates.

Also apply silicone behind the water valve and any locations where hoses come in contact with any vehicle

structures especially OEM related components.

53. Refrigerant can now be added to the system at the rate of two (2) pounds over factory specifications (noted

on a label in the engine compartment or on the door jamb)(Figure 115). PAG oil is also added, 2-3 ounces.

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

with proper maintenance information. Those are:

Figure 114

Seal

Figure 115

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.


01 000 633

01 000 400

01 000 239 01 000 136

01 000 352

01 000 644

01 000 632

02 000 018

01 000 634

01 000 412

01 000 319

01 000 130

02 000 021

02 000 015

02 000 023

PARTS


02 000 264

02 000 189

02 000 074 002 000 053

02 000 170

02 000 490

01 000 538

02 000 235

04 000 019

02 000 390

02 000 232

02 000 129

02 000 052

04 000 025

02 000 608

04 000 053


05 000 504

05 000 050

05 000 010 04 000 055

05 000 020

05 000 515

05 000 502

05 000 529

05 000 507

05 000 479

05 000 017

04 000 054

05 000 655

05 000 527

05 000 671


08 000 209

08 000 158

05 001 002 05 001 001

08 000 124

09 000 037

08 000 163

09 000 145

09 000 035

08 000 159

08 000 017

05 000 971

09 000 046


A/C FLOW – NISSAN NV, SUPER TIE-IN (552 Evaporator)

OEM

Diagram 1

CONDENSER (ProAir)

In Out

31 000 078

Suction Tie-In/

O-Ring

(ProAir)

05 000 002

08 000 163

In

CONDENSER (OEM)

Out

Liquid Tie-In

O-Ring

(ProAir)

05 000 001

08 000 209

DRIER (ProAir)

In Out

05 000 712

EVAPORATOR (OEM)

Dash

Out In

EVAPORATOR (ProAir)

66 000 118

Out In

COMPRESSOR

(OEM)

Discharge

Suction

Condenser

Fitting/O-ring

(ProAir)

05 000 671

08 000 158

Discharge

Block/O-Ring

(ProAir)

05 000 655 08 000 159

05 000 515

Fitting

05 000 515

Fitting

05 000 502

Fitting

05 000 527

Fitting

05 000 529

Fitting

05 000 507

Fitting

#8 Hose

05 000 504

Fitting

05 000 504

Fitting

OEM

Accumulator

05 000 515

Fitting

05 000 504

Fitting

#8 Hose #8 Hose

#6 Hose #10 Hose

OEM

OEM

OEM

OEM OEM

OEM 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


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

Condenser Relay

Power In/Power Out

Signal In

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

Condenser

Power In

Ground

Evaporator

Low

Med

High

AUX

BAT

30

Amp

Breaker

Ignition

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 / SUPER TIE-IN

Documents

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