AIRTECH II / TIE-IN

INSTALLATION INSTRUCTIONS
FOR
AIRTECH II / TIE-IN
For Nissan NV
Corporate Headquarters ProAir, LLC
28731 County Road 6; Elkhart, IN 46514
Phone: (574) 264-5494; Toll Free: 800-338-8544; Fax: (574) 264-2194
TABLE OF CONTENTS
Page
Preparation Notes …………………………………………………………… 3
Parts List …………………………………………………………………………. 6
Instructions …………………………………………………………………….. 8
Parts Illustrations …………………………………………………………… 37
Diagrams ……………………………………………………………………….. 40
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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 and 2” twisted. These
are secured with self-tapping screws 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 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.
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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.
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Please read the following notes before beginning installation:
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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 Evaporator you need to note the serial number for this unit 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 inlet port and two oulett ports and the
angle outlet port should be directed away from the inlet 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).
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PARTS LIST
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Item #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Part #
01 000 011
01 000 087
01 000 136
01 000 239
01 000 412
01 000 632
01 000 633
01 000 634
01 000 644
02 000 015
02 000 018
02 000 021
02 000 023
02 000 052
02 000 053
02 000 074
02 000 189
02 000 232
02 000 235
02 000 264
02 000 390
02 000 490
02 000 500
02 000 608
04 000 007
04 000 025
04 000 053
04 000 055
05 000 020
05 000 047
05 000 479
05 000 502
05 000 507
05 000 852
05 001 001
05 001 002
08 000 017
08 000 124
08 000 163
08 000 209
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Qty
1
1
2
1
1
1
1
1
1
6
1
1
1
20
4
16
5
1
2
1
10
1
2
1
1
1
1
1
2
1
1
1
2
1
1
1
1
1
2
2
Description
Harness, Wire 23’ 3-Speed
Harness, Resistor, AirTech/Mini Max
Relay, 40 Amp
Harness, 20 Amp Power Relay
Wire, 6 Gauge Red
Switch, Rocker 11 Nissan Rear-Mode
Switch, Rocker 11 Nissan Rear-Blower
Harness, 11 Nissan Mode/Blower Switch
Harness, Water Valve Electric 2-Port
Linestake, 2”
Washer, Lock 8mm
Clamp, Drain Hose 7/8
Trim Lock, 2/3’
Wire Tie, 14” x 3/16”
Grommet, 1” Hose, 1 1/4” OD
Screw, 14x1 Hex Washer Tek Zinc
Washer, Lock 6mm
Bolt, 8mm – 1.25 x 75 Hex Head
Wire Tie, 14” Stainless Steel
Washer, 5/16 Flat Stainless Steel
Clamp, #10 Heater Hose
Washer, 6mm
Spacer, 13/32” x 23/32” SRB Rubber
Bolt, 6mm-1.0x60mm Zinc Part Th
Hose, 1/2" ID Drain
Hose, 5/8 ID OEM Spec-Bulk
Hose, 5/16” Refrigerant #4890 Redu Barrier CF, 23’
Hose, 1/2” Refrigerant #4890 Redu Barrier CF, 18’
Wye, 5/8 OD Water, Plastic
Valve, Kazoo 5/8” ID
Straight Splice (Service Port), #6 FOR x 6 CF
Ell, 90 #6 FOR x CF
Ell, 90 #10 FOR x 10 CF
Valve, Water, Electric 2-Port
Fitting, Block, Liquid Tie-In 11 Nissan
Fitting, Block, Suction Tie-In 11 Nissan
Tape, Prestite, Refrigerant
Sleeve, Fire Protective, 2” I.D.
O-Ring, Slimline #12
O-Ring, #6 (006.8MG) CV23
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41
42
43
44
45
09 000 035
09 000 037
09 000 046
09 000 145
66 000 257
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1
1
1
1
1
Label, Refrigerant Capacity, Blank
Label, Anti-Freeze Mix
Label, Door Jamb
Card, Information, Warranty Registration
Evaporator, AirTech II
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INSTALLATION INSTRUCTIONS
It is advisable that you read through these instructions completely before beginning a step-by-step
installation.
The ProAir Tie-In System is a supplemental Air Conditioning/Heating system for the Nissan NV. The Tie-In system
has its own Evaporator but “ties in” to the OEM system using its Compressor and Condenser to drive the A/C side
of the system. The heating side “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 AirTech II Evaporator (66 000 257) is to be mounted to the floor of the vehicle, installed on the rear side
of the rear wheel well on the driver side. Figure 1 shows the location (X) while Figure 2 shows a finished
installation.
X
Figure 1
Figure 2
2. A drain stub is located on the bottom of the unit (Figure 3) Place the unit in the vehicle in the location noted
in Figure 1 (X) and mark the location for a hole in the floor of the vehicle for the drain. Drill a hole slightly larger
than the drain stub. Figure 2 shows a finished installation. However, the Evaporator will not be mounted until
the hoses are run.
Drain Stub
Figure 3
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3. 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 (01 000 011)(Figure 4). 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 4 Inset). Take the bundle
inside the vehicle.
Figure 4
4. 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. This can be obtained at a local auto supply store (Figure 5).
 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 6).
Figure 5
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Figure 6
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5. Attach the refrigerant hoses to the AirTech II Evaporator. Remove the plastic caps on the refrigerant ports.
Install fitting 05 000 479 (straight) on the #6 hose and attach to the top port (liquid)(Figure 7). Install fitting 05
000 507 (90 degree) on the #10 hose and attach to the bottom port (suction)(Figure 7). After installation, wrap
the connections with Prestite tape 08 000 017 to minimize condensation (Figure 8).
Remember to apply mineral oil to the gaskets before inserting in the fittings.
Liquid Port
Prestite Tape
Suction Port
Figure 7
Figure 8
6. Prepare to install the two heater hoses. Remove the black plugs from the heat lines (Figure 9), observing the
warning tag (Figure 10).
Plugs
Figure 9
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Figure 10
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7. Attach the two (2) heater hoses to the heating ports. Connect the hose with Red tape to the bottom port,
Evaporator inlet (coolant from engine). Connect the other hose to the top port, Evaporator outlet (coolant to
engine)(Figure 11). Secure the hoses with clamps (02 000 390)(Figure 12).
Figure 11
Figure 12
8. Mount the Evaporator to the floor of the vehicle. Insert two (2) spacers (02 000 500) under the tabs and
secure with two self-tapping screws (02 000 074). (Figures 13 and 14).
Figure 13
Screws
Figure 14
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9. Connect the drain hose. Figure 15 shows the drain stub extending through the hole previously created in the
floor of the vehicle. Insert hose 04 000 007 (Figure 16) onto the drain stub (Figure 16). Insert kazoo valve 05 000
047 (Figure 16) over the hose. Slip clamp 02 000 021 (Figure 16) over the kazoo valve and secure the valve/hose
assembly to the drain stub (Figure 17).
Kazoo Valve
Drain Stub
Hose
Figure 15
Figure 16
Figure 17
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10. Prepare the Evaporator wiring. Connect the Mini Harness Assembly 01 000 087 (Figure 18) to the
Evaporator. One end has two (2) plugs. Connect the plug with two (2) wires to the blower motor pigtail on the
Evaporator (Figure 19).
Figure 19
Figure 18
11. Connect the second plug to the side panel of the Evaporator (three spade connections)(Figure 20).
Figure 20
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12. Mate the connector on the Mini harness with the connector on the Evaporator harness (Figure 21). Attach
the ground wire on the Mini Harness to the chassis with a self-tapping screw (Figure 22). Figure 23 shows the
completed wiring on the Evaporator end.
Figure 21
Figure 22
Evaporator Harness
Mini Harness
Figure 23
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13. Gather the refrigerant hoses (2), heater hoses (2), and Evaporator harness into a bundle and route them
over the wheel well (to the front side)(Figure 24). Secure the bundle with linestakes (02 000 015) to the inner
side wall of the vehicle (Figure 25). Use tie wraps (02 000 052) to keep the bundle together between linestakes
(Figure 25).
Figure 24
Figure 25
Linestake
Tie Wrap
14. Drill four (4) holes in the floor of the vehicle on the front side of the wheel well for the hoses to exit the
passenger compartment to the underside of the vehicle. Install grommets (02 000 053) in the holes. The
Evaporator harness exits the vehicle in the hole with the #6 refrigerant hose. Figure 26 shows the holes in the
floor of the vehicle while Figure 27 shows the finished installation. Figure 28 shows dimensions for drilling.
Figure 26
Figure 27
Grommets
13.5”
11.5”
9.5”
7.5”
Wall
1.00” from
wall
Wheel
Well
Figure 28
1.25” Holes
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15. Drill a hole in the inner side wall under the vehicle to allow the hoses between the side walls to exit to the
underside of the vehicle. Figures 29 and 30 show the hoses exiting the wall cavity to the underside. Trim the
hole with Trim Lock (02 000 023) to protect the hoses and harness (Figure 31). Figure 32 shows the dimensions
for drilling the hole.
Figure 30
Figure 29
Side Wall
Side Wall
Trim Lock
Figure 31
Floor
Wheel
Well
6.50”
16.00”
Figure 32
2.500” Hole
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16. 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.
Figure 33
Under Side of Floor
Figure 34
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REAR COMPARTMENT TO MID-BODY INSTALLATION
17. With the four (4) hoses and Evaporator harness now under the vehicle, determine a path to the engine
compartment. At some point along that path, cut the heater hose (marked with Red tape) for the Evaporator
inlet and insert the Water Valve 05 000 852 in the path. Mount the Water Valve to a cross member on the
underside of the vehicle using two (2) self-tapping screws (02 000 074)(Figure 35). Secure the heater hose to the
Water Valve inlet and outlet with clamps (02 000 390). An arrow on the Water Valve indicates the direction of
water flow (Figure 36). The Water Valve inlet fluid comes from the engine and flows to the Evaporator.
To Evaporator
(Water Valve Out)
(
Figure 35
From Wye In Engine
Compartment
Figure 36
18. Connect the Water Valve harness (01 000 644) plug to the Water Valve (Figure 37) and set aside the other
end (has relay socket, fuse, and Pink wire/spade connector on it)(Figure 38).
Figure 37
Pink Wire
Figure 38
Fuse
Relay Socket
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19. Route the hoses and Evaporator harness the remainder of the way to the engine compartment. Attach the
bundle appropriately to cross members with linestakes and wire ties between linestakes (Figures 39 and 40).
Care should be taken to not disturb any OEM equipment.
Figure 39
Figure 40
20. As the bundle enters the engine compartment, it needs to be protected from any heat generated by the
engine. A fire resistant sleeve (08 000 124) and two (2) stainless steel wire ties (02 000 235) are provided to
protect the hoses (Figure 41). Slip the hoses inside the sleeve and position appropriately to keep hoses away
from heat. Secure sleeve to hoses/harness with the ties. Figure 42 shows the sleeve in place.
Figure 41
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Figure 42
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ENGINE COMPARTMENT
COOLING
A Tie-In System involves taking the OEM Drier 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).
EVACUATE (DISCHARGE) THE OEM A/C SYSTEM BEFORE PROCEEDING!!!
21. Disconnect the OEM hard refrigerant line (suction) located to the driver side in the engine compartment
by removing and discarding the OEM bolt (Figure 43). 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 46). But before inserting the tie-in, install two (2) O-Rings (08 000 209). One O-Ring
slips on the groove on the fitting (Figure 45). The other O-Ring slips on a similar groove on the OEM line. The
OEM line will have an O-Ring in place when the line is broken. Remove and discard it. Install the O-Ring supplied
with the kit (Figure 45).
Attach fitting 05 000 507 to the refrigerant hose (#10) coming from the ProAir Evaporator (outlet) and
connect to the Suction Tie-In. (Figure 44).
Remember to apply mineral oil to all O-Rings before inserting in the fittings.
Remove/Discard Bolt
Evaporator Out
Tie-In
Fitting
Figure 44
Figure 43
Groove
Figure 46
Figure 45
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22. Disconnect the OEM hard refrigerant line (liquid) located to the passenger side in the engine compartment
(near the radiator) by removing and discarding the OEM bolt (Figure 47). Separate the line and insert ProAir
Liquid Tie-In fitting 05 001 001. 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 50). But before inserting the tie-in, install two (2) O-Rings (08 000
163). One O-Ring slips on the groove on the fitting (Figure 49). The other O-Ring slips on a similar groove on the
OEM line. The OEM line will have an O-Ring in place when the line is broken. Remove and discard it. Install the
new O-Ring supplied with the kit (Figure 49).
Attach fitting 05 000 502 to the refrigerant hose (#6) running from the ProAir Evaporator (inlet) and connect
to the Liquid Tie-In (Figure 48).
Remember to apply mineral oil to all O-Rings before inserting in the fittings.
Tie-In
Fitting
Evaporator In
Remove/Discard Bolt
Figure 48
Figure 47
Groove
Figure 49
Figure 50
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HEATING
23. The Tie-In to the heating system is accomplished by inserting a wye in both the OEM Heater Push (inlet) line
and the OEM Heater Return (outlet) line. Locate the OEM Heater lines on the firewall on the passenger side
(Figure 51). The line on the passenger side is typically the Push line (but verify this for your vehicle). Use vise
grips or some other kind of tool to clamp off the line (Figure 52). Do this procedure with a cool engine to prevent
injury. Cut the line and insert the wye (05 000 020) and connect the two hose ends to the inline ports of the wye
(Figure 52) and clamp (02 000 390). Make sure the angle port on the wye is pointing in the direction of water
flow.
Heater Lines
Wye
Vise Grips
Figure 51
Figure 52
24. Connect the Water Valve inlet hose (marked with the Red tape) to the angle port on the wye (Figure 53) and
clamp. Remove the vise grips.
Figure 53
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25. Follow the Return hose to the driver side (Figure 54) and repeat the process of clamping off the hose, cutting
the hose, and inserting a wye. Connect the cut ends to the inline ports of the wye and clamp. Connect the
Evaporator outlet (return) line to the angle port on the wye and clamp (Figure 55). Remove the vise grips.
From OEM Evaporator
To Radiator
Figure 55
Figure 54
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ELECTRICAL
OVERVIEW
26. The electrical system requires the interconnection of the following:
 Four (4) relays connected to wire harnesses (two of those have fuses attached), Figure 56
 Evaporator harness running from the Evaporator at the back of the vehicle, Figure 57
 Water Valve Harness running from the Water Valve, Figure 57
 Two (2) switches: Mode (A/C or Heat) , Blower (Fan Speed-High, Med, or Low), Figure 58
Water Valve Harness
Evaporator Harness
Figure 56
Figure 57
Figure 58
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27. Figure 59 illustrates the components.
TIE-IN SYSTEM
Power
Fuse
20 Amp
(Ignition)
Relay
#1
Switch
Relay
(Cool)
#2
Switch
Relay
(Heat)
#3
Fuse
5 Amp
Water
Valve
Relay
#4
Wiring To Passenger Compartment
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

Battery
Ignition
Evaporator Harness
Water Valve Harness
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Figure 59
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PREPARATION
28. Physical location of the four (4) relays 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 60 shows the passenger compartment area where the
units would be installed (glove box removed) while Figure 61 shows an area where they could be installed in the
engine compartment on the firewall.
These instructions will illustrate installation of all relays in the passenger compartment.
Figure 60
Figure 61
29. Remove the side panel and the glove box in the passenger compartment on the passenger side. The side
panel (Figure 62) just snaps in. The glove box requires removal of seven (7) screws, three (3) on the bottom
(Figure 63) and four (4) screws exposed when the unit is opened (Figure 64). Set the glove box aside (Figure 65).
Glove Box
Side Panel
Remove
Figure 62
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Figure 63
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Figure 64
Remove
Figure 65
30. Find locations for all the relays. Figure 66 shows the general layout:
 #1, OEM switch panel, Figure 66
 #2, Relay #1 (Ignition) and Relay #4 (Water Valve), Figure 67
 #3, Relay #2 and Relay #3 (Switch Relays), Figure 68
 #4, Hole (in firewall) for the wiring to route between the engine and passenger compartments, Figure 69
2
1
3
4
Figure 66
Figure 67
Figure 69
Figure 68
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INSTALLATION
31. Drill a hole in the firewall to allow wires to route between the engine compartment and the passenger
compartment (Figures 70 and 71). The hole must be big enough to allow passage of the ignition wire, battery
wire, and two wiring harnesses (Evaporator and Water Valve). Trim the hole with Trim Lock (behind the
insulation). Route the Evaporator and Water Valve harnesses through the hole in the firewall into the passenger
compartment.
Figure 70
Figure 71
32. Install an eyelet lug on one end of the 6 gauge wire 01 000 412. Route the other end through the hole in the
firewall into the passenger compartment (Figure 72). This end is to be butt spliced to the fuse wires on Relays #1
and #4 later.
Figure 72
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33. Attach four (4) relays (01 000 136) to relay harnesses (Figure 73). Number/label them as noted below
(Figure 74). (Numbering will be referred to throughout the instructions).
 Relay #1, Power (Ignition), 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)
Figure 73
Figure 74
34. Mount the relays/fuses in the locations selected. Use self-tapping screws (02 000 074) to attach to OEM
compartment (Figures 75, 76, and 77). Route the Relay #1 (Power, Ignition) Orange wire (Signal In) through the
firewall hole into the engine compartment (Figure 78).
Screws
Power and Water Valve Relays
Figure 76
Relays
Figure 75
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Ignition Wire
Switch Relays
Figure 77
Figure 78
35. Remove the OEM switch plate from the dash (Figure 79) 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 80).
Figure 80
Figure 79
36. Note the numbering of the terminals on the rear of the switches (Figure 81). This information will be used
when connecting the wiring to the switches. The connections are spade terminals:
Blower
1
4
Mode
1
4
2
5
2
5
3
66
6
3
66
6
Figure 81 – Rear View
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37. Connect the wiring in the passenger compartment by following Figures 82, 83 and 86. Relay wiring is noted
on Figure 82. Figure 83 includes the wiring from the harnesses/wire from the engine compartment. Figure 86
notes wiring involving the relays and will include some wiring already completed 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 82
RELAY WIRING
Relay 01 000 136
Plugs into Harnesses 01 000 012,
01 000 239, 01 000 334,
01 000 634, 001 000 644
Power Relay
Relay with tab side down looking on end:
1 – Power Out / Red or Red/White Stripe
2 – Ground / Black
2
3 – Signal In / Orange, Blue or Pink
4 – Power In / Red
5 – Power In / Red (not always used)
LLC
Grnd
Pwr In
1
5
3
Sig In
Pwr Out
Relay Schematic
4
Rev A 08/13
Page 31 of 43
Figure 83
WIRING HARNESSES, SWITCHES WIRING
Yellow wire
Red wire
Orange wire
Relay socket
Red wire/Fuse
Pink wire
Black wire
EVAPORATOR HARNESS, 01 000 011
Connect to Blower Switch, Terminal #1
Connect to Blower Switch, Terminal #3
Connect to Blower Switch, Terminal #6
WATER VALVE HARNESS, 01 000 644
Connect to Relay #4
Butt splice to 6 gauge Red wire going to the battery in the engine compartment
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
Ground to vehicle chassis
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 4
Connect one end of White/Orange jumper wire here, other end to Terminal 2
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 2
Connect one end of White/Orange jumper wire here, other end to Terminal 4
Terminal 3
Connect Evaporator harness Red wire here
Terminal 4
Connect one end of White/Orange jumper wire here, other end to Terminal 2
Terminal 5
Connect Red/White Stripe wire of Relay #2 here (Switch Relay #1, Power Out)
Terminal 6
Connect Evaporator harness Orange wire here
38. Figures 84 and 85 illustrate the wiring on the back of the switches. Figure 85 shows the jumper referred to in
Figure 83.
Figure 85
100
Jumper
Figure 84
LLC
Rev A 08/13
Page 32 of 43
Figure 86
TIE-IN WIRING
Relay Name
Power
Power
Power
Power
Power
Device
Fuse on Relay #1
Relay #1
Relay #1
Relay #1
Relay #1
Wire Color
Red
Red
Red
Orange
Black
Harness?
01 000 239
01 000 239
01 000 239
01 000 239
01 000 239
Signal
Power In
Power In
Power Out
Signal In
Ground
Connects To
Battery, Positive Terminal**
Fuse on Relay #1, Power Out
Relay #2, Power In, Red Wire
Ignition Terminal Block in Engine Compartment***
Chassis*
Switch
Switch
Switch
Switch
Switch
Switch
Relay #2
Relay #2
Relay #2
Relay #2
Relay #2
Relay #2
Switch
Switch
Switch
Switch
Switch
W Valve
W Valve
W Valve
W Valve
W Valve
W Valve
W Valve
W Valve
Connection
Eyelet
Loop
Spade
Bare Wire
Eyelet
Red
Red/White
Red/White
Blue (long)
Blue (short)
Black
01 000 634
01 000 634
01 000 634
01 000 634
01 000 634
01 000 634
Power In
Power Out
Power Out
Signal In
Signal In
Ground
Relay #1, Power Out, Red Wire (01 000 239)
Blower Switch, Terminal #5
Relay #3, Power Out
Mode Switch, Terminal #3, A/C Command
not used
Relay #3, Ground
Spade
Spade
Loop
Spade
Spade
Loop
Relay #3
Relay #3
Relay #3
Relay #3
Relay #3
Red
Red/White
Pink (short)
Pink (long)
Black
01 000 634
01 000 634
01 000 634
01 000 634
01 000 634
Power In
Power Out
Signal In
Signal In
Ground
Mode Switch, Terminal 5
Relay #2, Power Out
Relay #4, Signal In, Pink Wire (01 000 644)
Mode Switch, Terminal #6, Heat Command
Chassis*
Spade
Loop
Spade
Spade
Eyelet
Fuse on Relay #4
Relay #4
Relay #4
Relay #4
Relay #4
Relay #4
Relay #4
Relay #4
Red
Red
Red
Pink
Purple
Black
Black
Black
01 000 644
01 000 644
01 000 644
01 000 644
01 000 644
01 000 644
01 000 644
01 000 644
Power In
Power In
Power In
Signal In
Power In
Ground
Power Out
Ground
Battery Positive Terminal**
Fuse on Relay #4, Power Out
Water Valve, Loop
Relay #3, Signal In, Pink Wire
Water Valve
Water Valve
Relay #4, Ground
Chassis*
Eyelet
Loop
Plug
Spade
Plug
Plug
Loop
Eyelet
*All the ground (Black) wires are to be attached to the chassis with a self-tapping screw.
**These wires are butt spliced to the #6 wire running through the hole in the firewall to the battery.
***To be connected later.
LLC
Rev A 08/13
Page 33 of 43
39. Reinstall the OEM panel into the vehicle as in Figures 87 and 88.
Figure 87
Figure 88
40. Reattach the side panel and the glove box.
41. 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 89) and create a notch for the wire to enter the
unit (Figure 90). Install a spade lug on the end of the wire and install in the position shown in Figure 91. Reinstall
the cover.
Figure 89
Ignition
Terminal
Notch
Figure 90
LLC
Rev A 08/13
Page 34 of 43
Figure 91
42. In the engine compartment, attach the 6 gauge (Red) wire to the positive terminal of the battery (Figure 92).
Figure 92
LLC
Rev A 08/13
Page 35 of 43
43. To finish the install, use silicone to seal around all holes made in the vehicle including the Evaporator drain
hose hole, the refrigerant hoses/heater hoses/Evaporator harness bundle holes (in the floor and inner side wall
of the vehicle)(Figure 93), and the firewall hole. Also seal anywhere where hoses come up against OEM
equipment (if any).
44. Remove the protective cover over the Evaporator Fan (Figure 94).
Figure 93
Figure 94
45. Refrigerant can now be added to the system at the rate of one (1) pound over factory specifications (noted
on a label in the engine compartment or on the door jamb). No additional PAG oil over factory specs is needed.
46. Several informational labels are provided to document installation and provide those who service the system
with proper maintenance information. Those are:
09 000 035
This label should note the
“new” refrigerant and PAG oil
capacity of your system. It
should be applied somewhere in
the engine compartment.
LLC
09 000 037
This label notes the anti-freeze
mixture ratio and should also be
applied in the engine
compartment.
Rev A 08/13
09 000 046
This label provides information
as to date of installation and the
installer’s name. The serial
number for the Evaporator is
noted here as well as your kit
number. It should be attached
to the driver side door jamb.
Page 36 of 43
PARTS
01 000 011
01 000 087
01 000 136
01 000 239
01 000 412
01 000 633
01 000 634
01 000 644
02 000 015
02 000 018
02 000 021
02 000 052
02 000 053
02 000 023
LLC
Rev A 08/13
01 000 632
Page 37 of 43
02 000 074
02 000 189
02 000 232
02 000 235
02 000 264
02 000 490
02 000 500
02 000 608
04 000 007
04 000 025
04 000 053
05 000 020
05 000 047
04 000 055
LLC
Rev A 08/13
02 000 390
Page 38 of 43
05 000 479
05 000 502
05 000 507
05 000 852
05 0001 001
05 001 002
08 000 017
08 000 124
08 000 163
08 000 209
08 000 035
08 000 037
08 000 046
08 000 145
66 000 257
LLC
Rev A 08/13
Page 39 of 43
Diagram 1
A/C FLOW – NISSAN NV, TIE-IN (AirTech II)
COMPRESSOR
(OEM)
Discharge
DRIER
(OEM)
CONDENSER
(OEM)
OEM
In
OEM
Out
In
OEM
Out
OEM
Suction
OEM
EVAPORATOR
(OEM)
Suction Tie-In/
O-Ring
(ProAir)
05 000 002
08 000 163
OEM
Out
OEM
In
Liquid Tie-In/
O-Ring
(ProAir)
05 000 001
08 000 209
05 000 502
Fitting
05 000 507
Fitting
#10 Hose
05 000 507
Fitting
EVAPORATOR
(ProAir)
66 000 257
Out
In
#6 Hose
05 000 479
Fitting
Drain Hoses
04 000 007
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.
LLC
Rev A 08/13
Page 40 of 43
Diagram 2
HEATING FLOW – AIRTECH II EVAPORATOR
In WATER VALVE Out
01 000 644
From
Engine
Wye
05 000 020
IN
OEM HEATER
(Dash)
(Push Line)
To
Radiator
(Return Line)
In
Wye
05 000 020
EVAPORATOR
66 000 257
OUT
Out
Out
Notes:
 Dotted lines above represent original (OEM) installed hose
 Kit installed hose is 5/8” standard heater hose PN 04 000 025
LLC
Rev A 08/13
Page 41 of 43
Diagram 3
ELECTRICAL LAYOUT / TIE-IN SYSTEM
Relay #1 (Ignition)
Ignition
20 Amp Fuse
Signal In
Power In/Power Out
Ground
Mode Switch
Not Used
1
2
3
4
5
6
BAT
Blower Switch
1
2
3
4
Relay #2 (SW #1)
Signal In
Power In/Power Out
Ground
Evaporator
Low
Med
5
6
High
Relay #3 (SW #2)
Signal In
Power In/Power Out
Ground
Relay #4 (W Valve)
Signal In
Power In/Power Out
Ground
5 Amp Fuse
Red
Purple
NOTES:

Wire cross points do not represent connections. Wires that “T” are
butt spliced.

Ground wires can be individually grounded to the vehicle chassis or
can be daisy-chained together in any fashion and then grounded..
LLC
Water Valve
Black
Rev A 08/13
Page 42 of 43
CUSTOMER NOTES:
LLC
Rev A 08/13
Page 43 of 43