PRESSURE SWITCH INSTALLATION .............................................................................................. 24

J.

WIRING HARNESS INSTALLATION .................................................................................................. 25

K.

VPG: PARAMETER SETTING............................................................................................................ 26

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PROCEDURE

DANGER
Park vehicle safely, apply parking brake, stop engine. Prior to working on the vehicle, set the ignition
switch to the OFF position and trip the main circuit breakers equipped with a trip button. On Commuter
type vehicles, set the battery master switch (master cut-out) to the OFF position.
Lock out & Tag out (LOTO) must be performed during set-up, maintenance or repair activities. Refer to
your local procedure for detailed information regarding the control of hazardous energy.

A. COMPRESSOR DOOR UPPER HINGE REPLACEMENT
1.

Fully open the vehicle compressor door (rear, curb side of vehicle Figure 1).

FIGURE 1: VEHICLE COMPRESSOR DOOR

2.
Support the door at its lower edge without applying upward pressure. A scissor jack (or equivalent
lifting equipment) and a V shaped wood block are recommended (Figure 2).

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FIGURE 2: SUPPORTING THE DOOR

3.
Unscrew and remove both parts of the upper hinge (4X M6 bolts at frame and door). Discard all
parts and hardware (Figure 3; Figure 4).

FIGURE 3: UPPER HINGE REMOVAL VEHICLE SIDE

4.

FIGURE 4 UPPER HINGE REMOVAL DOOR SIDE

Install the new upper hinge (parts 280504, 280549 & 280610 in kit Figure 5) making sure that:

New M6 bolts and washers (5000310 & 5001833) are used at the upper (vehicle structure)
mounting points (Figure 5).
-

New M6 bolts (502622 & 5001833) are used at the door mounting points (Figure 5).

-

A new plastic bushing 284607 is installed at the pivot point (Figure 6).

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The door is fully supported by the lower hinge and not slightly lifted-up by the lift table so there is
no gap between parts at the lower pivot point (Figure 7).
-

There is no gap between the upper and lower part at the pivot point of the upper hinge (Figure 8).

The four M6 bolts are torqued to 68 lb-in (apply blue Loctite 242 or equivalent medium strength
thread locker on all fastener threads (Figure 9).

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FIGURE 5: NEW UPPER HINGE

FIGURE 6: BUSHING

FIGURE 7: LOWER HINGE SUPPORT

FIGURE 8: NO GAP – UPPER HINGE

FIGURE 9: TIGHTENING TORQUE- UPPER HINGE ; APPLY
THREAD LOCKER

B. ROLLER SUPPORT ADDITION ON COMPRESSOR DOOR
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C. COMPRESSOR DOOR LOWER HINGE REPLACEMENT
1.

Support door by the lower edge.

2.

Unscrew, remove & discard the vehicle structure part of the condenser door lower hinge (3X M6 bolts
Figure 10)

FIGURE 10: HINGE PART TO BE REMOVED (COMPRESSOR DOOR)

3.

Remove the two rivnuts (two vertical holes) by drilling them using a 3/8in drill bit (Figure 11).

FIGURE 11: LOWER HINGE RIVNUTS

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4.
-

Loosen the battery tray to allow the installation of the reinforcing plate.
Support the battery tray using a hydraulic bottle jack or other suitable equipment (Figure 12).

FIGURE 12: SUPPORTED BATTERY TRAY

-

Loosen the three front bolts (Figure 13)

FIGURE 13: FRONT BATTERY TRAY BOLTS

-

Loosen the three bolts underneath the battery tray (Figure 14).

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FIGURE 14: BATTERY TRAY BOLT (3X UNDERSIDE)

5.

Move the battery tray back approximately 1/4in (7mm) to make room for the reinforcing plate and
shims.

6.

Position the 7770484 reinforcing plate so it covers all 3 hinge holes at the back of the structure (slide
the top right corner between the frame and the battery tray (Figure 15).

FIGURE 15: 7770484 PLATE POSITIONNED OVER HOLES

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8.

Mark the center of the lower M6 bolt on the plate using a sharpie (Figure 16).

FIGURE 16 : MARKING THE PLATE WITH A SHARPIE PEN

9.

Remove the plate and drill the marked position using a 1/4in drill bit.

10.

Reposition the drilled plate on the vehicle and secure with one of the supplied bolt/nut (5001815,
502854) (Figure 17).

FIGURE 17 7770484 PLATE POSITIONNED FOR DRILLING

11.

Drill the two remaining holes using a 1/4in drill bit.

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12.

Install the new stainless steel lower hinge 2810294 making sure that:

-

Mounting surfaces are cleaned from old undercoating using emery cloth or sandpaper (expose primed
frame surfaces – not bare metal).

-

New plastic bushing 284607 and washer 502723 are installed at the pivot point (Figure 18).

-

Door is fully supported by the top hinge, not the lift table (no gap at the top pivot point) (Figure 19).

-

New M6 bolts, nuts, locks & washers (5001815, 502854, 502570 & 430406) are used to secure the
lower hinge at the vehicle structure point (Figure 20).

-

The stainless reinforcing plate (7770484) is installed at the backside of the frame (plate must be installed
between the frame and the battery tray floor (Figure 22).

-

Door is adjusted properly. There should be an even (parallel) gap of at least 0.080” (2mm) at the top of
the door and a 0.177”+/- 0.060” (4.5 +/-1.5 mm) gap between the door and the vehicle rear fender (see
step 17 below for final adjustment details).

-

All bolts are torqued to 84 lb-in (apply blue Loctite 243 or equivalent medium strength thread locker on
all fastener threads & apply a stripe of tamper proof indicator paint (torque seal) to the bolt heads (Figure
21).

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FIGURE 18: WASHER & BUSHING POSITION

FIGURE 19: UPPER SUPPORT- NO GAP ALLOWED

FIGURE 20: LOWER HINGE COMPONENTS

FIGURE 21: TIGHTENING TORQUE

FIGURE 22: REINFORCMENT PLATE INSTALLED

13.

Remove the battery tray bolt one by one to apply blue Loctite 243 or equivalent medium strength
thread locker to the threads (do all 6 bolts).

14.

Tighten the screw halfway.

15.

Insert a 030082 shim between the tray and the frame at all bolt location and tighten the bolts (Figure
23 & Figure 24).

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FIGURE 23: SHIM LOCATION

FIGURE 24 INSTALLED 030082 SHIM

16.

Re-Torque the 6 bolts to 47 lb-ft & apply a stripe of tamper proof indicator paint (torque seal) to the
bolt heads.

17.

Remove door support installed at step 2 and open and close the door several times to make sure it
is working properly, check door top and side adjustments. There should be an even (parallel) gap of
at least 0.080” (2mm) at the top of the door and a 0.177”+/- 0.060” (4.5 +/-1.5 mm) gap between the
door and the vehicle rear fender (Figure 25).

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FIGURE 25: COMPRESSOR DOOR HORIZONTAL & VERTICAL GAPS

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NOTE
If gap is out of spec the compressor door may be adjusted for proper fit by untightening hinge bolts:

18.

-

Loosen the bolts holding the hinges to the vehicle structure to shift the door horizontally LEFT
or RIGHT.

-

Loosen the bolts holding the hinges to the door frame to shift the door vertically UP or DOWN.

-

If upper hinges must be readjusted, re-torque the upper fasteners to 68lb-in

Make sure that there is a stripe of tamper proof indicator paint (torque seal) on all hinges bolt heads.

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D. CONDENSER RELOCATION OVERVIEW
•

The old road side condenser coil is removed and discarded.

•

Hose from filter dryer to front evaporator pipe is discarded.

•

Hoses to and from old condenser are discarded.

•

Hose from compressor to service valve is discarded.

•

Keep the filter dryer, associated piping and accessories.

•

Keep wiring, remove cable ties. Relocate.

•

Keep the service valve and associated piping.

•

Compressor location remains the same.

See image below for a representation of the final arrangement.

FIGURE 26: OVERVIEW FROM F-5740 SHOWN

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E. CONDENSER RELOCATION AND PREPARATION
19.

Reclaim all refrigerant from system. Proceed with best practices.

20.

On 454037 shroud assembly, install cable and hose management accessories shown on Figure 27

FIGURE 27: 454037 PRE-ASSEMBLY

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F. CONDENSER INSTALLATION
21.

Install new condenser, electric fan and accessories inside compressor door.

FIGURE 28: NEW CONDENSER, FAN AND ACCESSORIES

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G. A/C HOSE INSTALLATION
22.

Route hoses as shown using hardware below. Use 504751 dual saddle swivel type cable tie mount
as required to prevent rubbing.

FIGURE 29: A/C HOSE ROUTING

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H. FILTER DRYER INSTALLATION
23.
24.

Remove filter dryer from original location on vehicle. Disconnect hoses.
Keep the complete arrangement: filter dryer and associated piping, service valve piping and pressure
switch, including the assembly’s mounting bracket and mounting hardware.

FIGURE 30

25.

Mount the new filter dryer post 454035 to battery box frame using M10 x 25 screw 502655 5001758
M10 Stover nut and existing hardware on battery box frame

FIGURE 31: INSTALL FILTER DRYER POST

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27.
28.
29.

Mount reserved filter dryer bracket to new post with reserved M8 hardware. Two types of bracket are
present depending on VIN.
From E-5459 to E-5739 adjust position to fit and drill 8mm (5/16”) holes.
From F-5740, use existing holes.

FIGURE 32: FILTER DRYER BRACKET ON POST

I. PRESSURE SWITCH INSTALLATION
30.

Add a pressure switch 950270, Tee fitting, Schrader valve and connector sharing the same pressure
measuring point as the existing pressure transducer.

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J. WIRING HARNESS INSTALLATION

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K. VPG: PARAMETER SETTING

PARTS / WASTE DISPOSAL
Discard waste according to applicable environmental regulations (Municipal/State[Prov.]/ Federal)

Writer: FL