5001851

NUT HEX SS NSS M6-1.0

4

5001931

NUT HEXF NYRT NX500 M8-1.25 CP 8

6

502692

NUT HEXF STO Z050 M8-1.25EX

4

502837

NUT HEXF STO N500 M8-1.25

2

504339

RIVET POP DOME SS OE 1/8 (0.25_0.375)

3

504379

RIVET POP DOME SS OE 3/16 (0.126_0.250)

2

504291

CLAMP HOSE LINER SS/CS 21-44

2

504324

CLAMP HOSE SS/CS 114-165

1

504229

CLAMP HOSE SS/CS 165-216

3

952627

CLAMP P STL ZP RUB 12.7 ID

1

952629

CLAMP P STL ZP RUB 15.9 ID

3

952631

CLAMP P STL ZP RUB 19 ID

1

Writer: JPHD

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504013

CABLE TIE MOUNT, BLACK 1/4"

2

509490

TWO WAY SADDLE MOUNTS, GREY

1

509815

FIR TREE MOUNTING (FT7 TYPE)

2

504016

CABLE TIE, NYLON BLK (LIGHT-HEAVY)

20

504637

CABLE TIE, NYLON BLK (STD)

40

504768

CABLE TIE, NYLON BLK DOUBLE LOOP

15

504061

GROMMET .4375X.6875X.0625X.3125X.9375

1

INSTRUCTION SHEET (EN)

1

IS-21089

NOTE
Material can be obtained through regular channels.

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SAFETY PRECAUTIONS
•

Eye protection should always be worn when working in a shop.

•

Rules for Personal Protection Equipment should always be respected. Wear your PPE
including but not limited to the following:

Safety
First!

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.

NOTE
Be aware before to start the project you must remove and relocate all converter appliance inside
compartment (ex.: heater, pressure washer… etc.)

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Table of contents

A. PART TO REMOVE ............................................................................................................................... 11
B. PART TO WELD ..................................................................................................................................... 15
C. AIR FILTER INSTALLATION.................................................................................................................. 31
D. COMPRESSOR DOOR MODIFICATION .............................................................................................. 38
E. CONDENSER INSTALLATION .............................................................................................................. 39
F. DRYER INSTALLATION ......................................................................................................................... 44
G. HOSE INSTALLATION........................................................................................................................... 46
H. HOSE FIXATION .................................................................................................................................... 48
I. POWER STEERING TANK INSTALLATION ........................................................................................... 51
J. WIRING HARNESS INSTALLATION ...................................................................................................... 52
K. VPG: PARAMETER SETTING ............................................................................................................... 55
Appendix A .................................................................................................................................................. 56

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A. PART TO REMOVE
1. Remove all appliances in the compartment,
all those systems need to be relocated in the
vehicle.

2. Remove air filter installation.

3. Reuse those parts from the old turbo pipe
connection:
-

Inlet hose 21659720

-

Clamp 504257

-

Clamp 504324

Writer: JPHD

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4. Reuse this part from the old turbo pipe:
-

Indicator, filter restriction 530161

5. Discard the rest of air intake (hose, pipe and
air filer and hardware).

Only vehicle with slide-out reinforcement
6. Drain power steering tank oil and remove it.

Writer: JPHD

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7. Recover refrigerant as required by local
authorities.
8. Remove the system.
9. Prevent moisture to get in the air condition
circuit Add plastic cap on all open fitting and
remove it when you ready to re-install.

10. Reuse the dryer assembly.
11. Replace filter dryer 950370.
12. Prevent moisture to get in the air condition
circuit Add plastic cap on all open fitting and
remove it when you ready to re-install.

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13. Discard the rest of condenser, hoses, and
hardware.

Only vehicle with slide-out reinforcement
14. If needed it, cut those tube of the structure.

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B. PART TO WELD
CAUTION
Disconnect all electronic modules to prevent any damage prior to welding.
Refer to MULTIPLEX MODULE DISCONNECTION PROCEDURE see maintenance manual section
00a for your vehicle
Welding setting see Appendix A

CAUTION
Welding should be performed by a qualified welder using the appropriate personal protection
equipment.
Install OSHA safe portable welding screens or curtains around the work area to protect bystanders.

For vehicle without slide-out reinforcement

1. Assemble bracket 2810648 (2x) to support
assembly 454764 using bolts 5001981 (2x),
washers 5001849 (4x), spacers 286716 (4x)
and nylon lock nuts 5001787 (2x).
2. Assemble angular 218982 to support
assembly 454764 using bolt 502862 lock
washer 500942, washer 500332.

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3. Fixe the assembly with clamps.

4. Tack weld bracket 2810648 and angular
218982 to the structure.

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5. Drill 7/16 hole using the frame as a guide.

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6. Remove support 454764, bolts 5001981
(2x), washers 5001849 (4x), spacers 286716
(4x) and nylon lock nuts 5001787 (2x) bolt
502862 lock washer 500942, washer 500332
to support assembly 454764 .

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7. Weld 2810648 (2X) see images below.

8. Weld 218982 see image.

Writer: JPHD

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9. Weld the nut 502609 on two face.

Only vehicle with slide-out reinforcement
1. Assemble bracket 2810648 (lower) and
bracket 2810658 (upper) to support
assembly 454764 using bolts 5001981 (2x),
washers 5001849 (4x), spacers 286716 (4x)
and nylon lock nuts 5001787 (2x).
2. Assemble angular 218942 to support
assembly 454764 using bolt 502862 lock
washer 500942, washer 500332 .

Writer: JPHD

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10. Fixe the assembly with clamps.

Writer: JPHD

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11. Tack weld brackets 2810648 and 2810658
and angular 218942 to the structure.

12. Drill 7/16 hole using the frame as a guide.

Writer: JPHD

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13. Remove support 454764, bolts 5001981
(2x), washers 5001849 (4x), spacers 286716
(4x) and nylon lock nuts 5001787 (2x) bolt
502862 lock washer 500942, washer 500332
to support assembly 454764 .

Writer: JPHD

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14. Weld brackets 2810658 and 2810648.

15. Weld 218942 see image.

Writer: JPHD

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16. Weld the nut 502609 on two face.

Weld section Air Filter and Air Dryer
1. If need it cut 218944 at marking position on
the part.

2. Weld the bracket 218944 full both end.

Writer: JPHD

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3. Assemble bracket 218943 to bracket
454892 using washer 500332 and nut
5001931.
4. Assemble bracket 454892 to bracket
454888 using washers 500332 (2x) and
nuts 5001931 (2x).
5. Assemble bracket 454893 to bracket
454888 using bolts 502780 (2x) and
washers 5001868 (2x).
6. Assemble bracket 218948 to bracket
454888 using washers 500332 (2x) and
nuts 5001931 (2x).

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7. Tack weld lower section of the assembly.

8. Tack weld lower section of the assembly.

Writer: JPHD

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9. Remove the assembly, nuts 5001931 (3x)
and washers 500332 (3x).

Writer: JPHD

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10. Weld 281948 full inside and outside.

11. Weld 281943 see image.

Writer: JPHD

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Only vehicle with slide-out reinforcement
12. Weld the new Support 218949 see image.

Writer: JPHD

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