PRODUCT: DODGE PROMASTER MAX SYSTEM 530 / 560 RELEASE DATE: 02/24/15 REVISION DATE: 02/24/15 PART NUMBER: B

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1 Parts List Wire,12 Ga Red w/white Stripe Linestake, 2.5" Vinyl Coated Wire,12 Ga Red Bolt,7/16-14 x 4 1/2 Zinc Plate Wire,6 Ga. Red (Max Spacer,3/4 x 1/2 x 1.25"Steel Switch, Press Hi/Lo 28&385 psi Tube, Convo 1" Brkr,80 Amp Circuit Waterproof Hose, Drain 1/2" Nil Braid Switch, Rocker 11 Rear Mode Ell,1/2 drain Switch, Rocker 11 Rear Blower Wye,5/8 OD Wtr Plastic Module,7 Circuit Ground Signal Ell,90 #6 FOR x 6 CF Wire, 14 Ga, Blue Ell,90 #8 FOR x 8 CF Relay, 12v 50/30 Amp Strt,#6 MOR x 6 CF Linestake,2" Strt,#10 MOR x 10 CF Clamp,Dr Hose 7/ Splice,#8CF x 8CFw/16mm SV Linestake,1" Splice,#10CF x 10CF w/13mm SV Trim, Lock Ell,90 #8 FOR x 6 CF Wire tie, 14 x 3/ Booster Pump, MP w/strt Nipples Grommet,3" hose Drier, Receiver w1/4 SP & HPRV Screw,14x1 Hex Wshr Tek Zinc Valve, Wtr Elec 2-Port 12v Screw,10x3/4 hex wshr tek zinc Brkt,Drier Bottle 3" Dia Linestake,1" Double Brkt,526/530 Mtg NV Rear Bolt,5/16-18 x 3 1/2 hex Plate, Sprt 170" Ext EZ5 Mtg Linestake,2" twisted ends Plate, 13 DPM Switch Washer,7/16 SAE flat zinc Brkt,526/530 Adj Mtg DPM Nut,5/16-18 Nylon Lock Wmnt Brkt, 526/530 Mtg DPM Fon Washer,5/16 Flat SS Brkt, Water Valve Mnt Nut,7/16-14 Nylon Lock Tape, Prestite, Refrigerant Bolt,5/16-18 x 1 Grade 5 SS Sleeve, Fire Protective 2" I.D Washer,1/4 Flat SS Install Instr,07LWB Sprt Brkts Clamp,#10 Worm gear HtrHose5/8" Frkg,Cond 110 Sprinter LWB Screw,10x3/4 hex wshr type AB Schm,Wire ProMaster 530 & Bolt,7/16-14 x 5 1/ Valve, Kazoo 3/4" ID x 3" Screw,10 x 3/4 Phil Pan Blk Hose Assy,5/8 OEM Htr x Washer,6mm Frigiking, 530 c/o Free-blow Bolt,6mm -1.0 x 25mm grade Harn, Wire Cond. Grey ACT Nut,6mm Nylon Lock Page 1 of 44

2 Mark the center of the roof as shown. 2. From that center mark, measure 8-7/8 to each side and place another mark. 3. From each of the marks in step 2, measure 1-1/4 to each side and place two more marks Attach bracket to bracket with (2) bolts, (4) washers, (2) lock-nut. *Build (2) bracket assemblies. Page 2 of 44

3 5. Attach a bracket to the end of the brackets from step #4 with a bolt, (2) washers and lock-nut. *Have the L bracket on each of the (2) assemblies going in opposite directions of the other as shown Hold the bracket assemblies up to the marks on the van from step #1, mark the holes on the back as shown. Page 3 of 44

4 7 7. Drill all the holes out to 1/2 *Be careful drilling the holes in the far back to not go through the exterior sheet metal Attach the brackets to the roof as shown. Use (2) bolts, (4) washers, (2) lock nuts on the front of each bracket. Page 4 of 44

5 9 9. Attach the rear of the brackets with (2) bolts, (2) washers and a bracket on each bracket assembly. 10. Remove the cover from evaporator. Install the evaporator to the roof brackets with (4) bolts, (8) washers, (4) lock-nuts. 10 Page 5 of 44

6 Remove the plastic panels from the passenger rear corner of the vehicle Cut a 2.5 hole in the passenger rear corner as shown. Page 6 of 44

7 Cut a grommet as shown. Place it in the 2.5 hole and secure with (3) screws Cut a 3 hole in the passenger-side back corner. Page 7 of 44

8 Cut trim-lock to 9. Heat it, and then place it in the 3 hole under the vehicle Place trim-lock around the hole in the top corner of the passenger side. Page 8 of 44

9 Place trim lock as shown Place trim-lock around the bottom hole as shown. Page 9 of 44

10 Attach pressure switch to drier. Secure drier to frame with bracket and (2) screws. *Drier is located on the passenger side in front of the leaf-spring support beam Measure 9.75 from the side frame rail and place a mark. Measure another 3.5 from that spot and make another mark. Make sure that your marks are level and drill (2) holes with a 15/32 drill bit. Go all the way through both sides of the beam. Page 10 of 44

11 Measure 10 from the side frame-rail and place a mark. Then measure another 3.5 over and place another mark. Drill these holes with a 15/32 drill bit. Go all the way through both sides of the beam. *Notice that this is one cross-beam behind the larger muffler *Reference photo for steps Page 11 of 44

12 Assemble condenser to instructions. Have a second person help hold the condenser up if necessary. The connection fittings should be toward the front of the vehicle Attach the front end of the condenser with (2) bolts, (4) washers, (2) lock-nuts. Page 12 of 44

13 Attach the rear side of the condenser with (2) bolts, (4) washers, (2) spacers, (2) lock-nuts Install the booster pump to the drivers-side frame rail with (4) screws, (4) washers. *Note: The booster pump is in line with the cross-beam that goes over the middle of the condenser. Page 13 of 44

14 Attach metal plate to water valve with (2) bolts, (2) washers, (2) lock-nuts Attach water valve assembly with (4) screws to the cross-beam on the drivers-side of the parking brake cable connector. Page 14 of 44

15 Lay the hoses and harnesses out. Mark the hoses accordingly: Red: Push from engine Orange: From Booster Pump to Dash Black: From Rear heater back to engine Run the hoses and harnesses up through the 3 hole in that back corner. Page 15 of 44

16 Run AC hoses and harness up back corner Route the hoses out the top hole and towards the evaporator. Page 16 of 44

17 Crimp a fitting to the #6 Hose. Crimp a fitting to the #10 hose. Place O-rings on the fittings and lubricate them with mineral oil. Attach fittings to expansion block Wrap the fittings and expansion block with prestite tape. Plug in the wire harness and secure with a tie-wrap. Plug the blue wires into the thermostat. Page 17 of 44

18 Secure the AC hoses and wire harness with a linestake and a screw Attach a linestake as shown in the top back corner with a screw. Page 18 of 44

19 Secure the hoses with a linestake and a screw Secure the hoses with a linestake and a screw. Page 19 of 44

20 Run drain hose down the back corner as shown. Attach a elbow and another 4 piece of drain hose. Secure the hoses to the elbow with (2) clamps and then use (1) clamp to attach the hose to the evaporator Secure the drain hose going down the back corner with (3) tie-wraps as shown. Page 20 of 44

21 Run another drain hose down the other back corner. Attach a elbow and a 4 piece of drain hose with (2) clamps. Attach the hose to the evaporator with another clamp. Remove black plastic covers if necessary and secure with (2) tie-wraps Route drain hoses out the back square grommets under the rear bumper, attach (2) kazoo valves to the ends with (2) tie-wraps. Page 21 of 44

22 Replace plastic covers on both sides Secure the hoses & harnesses coming out of the bottom 3 hole with a linestake a screw and (3) tie-wraps. Page 22 of 44

23 Secure the Red/Black heater hoses & wire harness with (6) tie-wraps as shown. *These hoses will be routed up the back corner with the A/C lines if a 560 unit is being installed Place (2) linestakes on the heat hoses as shown. Place (2) linestakes on the AC hoses as shown. Secure the linestakes to the frame with (2) screws. Place (2) tie-wraps between the linestakes. Page 23 of 44

24 Place (2) linestakes as shown with (2) screws. 71. Wrap the heat hoses with (2) tie-wraps and the n wrap the heat hoses to the AC hoses with another tie-wrap Place (2) tie-wraps. Page 24 of 44

25 Cut the Red heat hose at the water valve and connect with (2) clamps. 74. Attach a linestake to the Red hose with a screw as shown. Use a tie-wrap to secure both hoses and wire harness Attach the (2) blue wires to the pressure switch. 76. Attach a fitting to the #6 hose going to the evaporator. Place O-ring / mineral oil and attach it to the drier as shown. 77. Attach a fitting on the #6 hose that goes to the condenser. Place O-ring /mineral oil and attach it to the drier as shown. 78. Secure hoses with (2) hoses. Page 25 of 44

26 Secure hoses / harness with linestake and screw Secure with linestake and tie-wrap. 81. Crimp a fitting to the #6 hose going to the drier. Apply O-ring / mineral oil and connect it to the bottom coil tube. Crimp a fitting to the #8 hose. Apply O-ring / mineral oil and connect to the top coil tube. Page 26 of 44

27 Place heat sock over the hoses where they cross over the top of the exhaust. Secure with (2) linestakes and (2) screws Plug in water valve harness. Secure harness with tie-wrap. Page 27 of 44

28 Cut 6 off hose and insert a wye fitting. Insert the orange hose to the Y part of the fitting. Secure all three pieces of hose with (3) clamps. Use another clamp to attach the hose assembly to the booster pump Secure the hoses with (2) linestakes, (2) screws. Page 28 of 44

29 Attach the inlet hose to the booster pump with a clamp. 87. Secure hoses with a linestake, screw, and a tie-wrap Secure hoses with linestake screw and tie-wrap. Page 29 of 44

30 Join AC hoses with the Heat hoses, route along the frame rail towards the front of the vehicle. Secure with linestake and a screw Attach tie-wrap and a linestake, screw. Page 30 of 44

31 Attach tie-wrap and a linestake, screw Attach tie-wrap and a linestake, screw. Page 31 of 44

32 Attach tie-wrap and a linestake, screw Secure with (3) tie-wraps and (2) linestakes, (2) screws. Page 32 of 44

33 Pass the hoses up over the front sub-frame and route the Heat hoses towards the top of the engine on the driver s side and route the two AC lines toward the driver s side under the front bumper Secure all three hoses by removing the bolt from the top of the transmission and reinstall with a linestake, bolt, (2) washers and a lock-nut. Page 33 of 44

34 Move the coolant reservoir over drill a hole in the corner of the metal plate and install a modified linestake. *Reattach coolant reservoir after installing linestake Route the hoses under coolant reservoir and attach as shown: Red: Out from engine. Orange: to Dash Heater Black: Return back to engine. Page 34 of 44

35 Cover the hoses with convoluted tubing Secure the two AC hoses going over the driver s side axle with (2) linestakes and (2) screws. Place (2) tie-wraps between the linestakes as shown. Page 35 of 44

36 Crimp a fitting to the #8 hose and a fitting to the #10 hose Secure the hoses with a linestake, screw and (2) tie-wraps Route the hoses across the front under the front bumper. Secure with (3) linestakes, (3) screws. Place (3) tie-wraps between the linestakes Push a piece of heat-sock over the AC lines and secure it to the end with a tie-wrap. Page 36 of 44

37 Place O-rings and mineral oil on the fittings and connect to the compressor fittings. Attach the Red clutch wire to the compressor Install and (3) relays to passenger side rear corner with (7) screws. Connect a harness to the (3) relays. Page 37 of 44

38 Page 38 of 44

39 Follow schematic for all wiring Attach ground wires to the vehicle as shown with a screw. *Screw needs to go through where the metal is doubled to prevent stripping or coming loose Secure harnesses with (2) linestakes and (2) screws. Page 39 of 44

40 Remove fuse panel access cover and dash insert as shown Cut the back off of the part removed from the dash. Page 40 of 44

41 Install & switches to plate as shown Insert plate into modified part from the dash. Secure the parts together with (3) screws. Page 41 of 44

42 Wire the switches according to schematic with harness Reinstall switch assembly and fuse panel cover. Page 42 of 44

43 Remove the cover at the bottom of the driver s door. The ignition wire is blue / yellow-stripe Remove battery access cover on the floor in front of the driver s seat. Install a breaker in the battery box with (2) screws. Page 43 of 44

44 Connect power wire to the battery Reinstall battery cover. Page 44 of 44