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Webasto 5011764, Manual, Page: 2 / 36

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Webasto 5011764 Manual Download Page 2

– Installation and repair of Webasto heating and cooling systems requires special 

Webasto training, technical information, special tools and special equipment. 

– NEVER attempt to install or repair Webasto heating or cooling system unless you 

have the proper certifications, technical skills, tools, and equipment required to 
properly complete the necessary procedures.

– ALWAYS carefully follow Webasto installation and repair instructions and heed all 

WARNINGS. 

– Webasto rejects any liability for problems and damage caused by the system being 

installed by untrained personnel. 

Summary of Contents for 5011764

Page 1: ...y and recharge machine Riv Nut installation tool 1 2 3 Mercedes Sprinter 2015 2018 3 0 Liter 170 Wheelbase High Roof For kit 5011764 Special instructions for these models Part locations may differ slightly dependent on the vehicle model Due to vehicle build variations it may be necessary to utilize an A C compressor manifold with downward facing ports DOC P N 5011864B KIT P N 5011764 Printed in US...

Page 2: ...or repair Webasto heating or cooling system unless you have the proper certifications technical skills tools and equipment required to properly complete the necessary procedures ALWAYS carefully follow Webasto installation and repair instructions and heed all WARNINGS Webasto rejects any liability for problems and damage caused by the system being installed by untrained personnel ...

Page 3: ...ngs Cautions and Notes 6 1 6 Safety 7 1 7 Legal Provisions for Installation 7 1 8 Prohibition on Venting 7 Preparation 8 Kiev Bracket Installation 8 General References 8 Kit Components 10 Condenser Installation 12 A C Hose Crimping 15 A C Hose Installation 17 Coolant Hose Installation 19 Wiring Installation 21 Kiev Condenser Installation 28 Drain Hoses and Misc 30 A C System Charge 31 Charge the s...

Page 4: ...SE BURGAFLEX H 06 3090 R 46FT 5011165 REFRIGERANT HOSE BURGAFLEX H 08 3090 R 12FT 5011506 HOSE DRAIN ID 0 4375 INCH 12FT 5011863 BRACKET FUEL TANK SPRINTER 1 5011556 INSULATION HOSE ID 0 875IN X 6FT LONG 1 629070001 ANTI COND TAPE M9ROL OE 1M 5011814 WIRE HARNESS SPRINTER KIEV MCP EXTREME 1 147729 L SCHR DIN7985 M4X12 4 8 H A3G 6 5012013 NUT NYLOCK M4 0 7 6H 5 ZP 6 5011493 RIVET NUT HEAVY DUTY ALU...

Page 5: ...r R134a M M D76 H173 Z222 1 62036025 Support filter D76 1 62U00025459 E vent Underchassis Condenser HTC 14 kW 1 62043400 Pressure switch 0 35OFF 2 1ON YP 23111 1 62043118 Pressure Switch 3 Level Siceb Conn Intgr 1 62A04054 man Control AC with temperature 12V 1 620406 CABLE TIE 11 INCH BLACK 25 5011082 WARRANTY STATEMENT AC 1 5011864B MANUAL INSTALL KIEV SPRINTER ECK UBC 1 5010740 LABEL SERIAL NUMB...

Page 6: ...or death from explosion fire or contact with acid saturated refrigerant or oil mists Webasto recommends that the system be serviced using a flush and purge station such as a Robinair unit or similar equipment designed for R134a refrigerant systems Follow these precautions when flushing purging a system or pressure testing a system for leaks Use flushing products according to the manufacturer s ins...

Page 7: ...4 Applicability of Manual These non binding installation instructions apply to the make model listed on the front cover of this installation manual Due to optional equipment there may be build variations between this installation manual and the vehicle you are work ing on Technical modifications that differ from the instructions set forth exclude all liability claims Acknowledged engi neering conv...

Page 8: ...quiring the removal of refrigerants be serviced by a certified technician under section 609 of the Clean Air Act and that all refrigerant be reclaimed and recycled Vehicle operation must not be impaired due to any Webasto installed components All power circuits must be fused with an appropriate fuse or circuit breaker 1 8 Prohibition on Venting Section 609 of the Clean Air Act prohibits individual...

Page 9: ...ve the driver s seat Remove the driver and passenger side step well trim Remove the left and right hand b pillar trim 1 Install the A C compressor and A C manifold per the manufacturer s instructions 2 Cut the tie strap from the wiring boot located near the battery box NOTE Exercise caution when working around impact sensors NOTE Passenger side shown driver s side similar 3 Remove the foam block b...

Page 10: ...lation 4 Temporarily install the Kiev mounting brackets and spacers on the Kiev HVAC unit 5 Have an assistant hold the Kiev HVAC unit in position and mark the four mounting holes 6 Drill four 1 2 in 13 mm holes and install the M8 threaded inserts ...

Page 11: ...rily installing the headliner mark and cut the holes for the evaporator assembly mounts X4 and the hose and harness pass through X1 The hose and harness pass through hole should be above the Kiev unit so it is concealed by the trim panel that may be used Remove the headliner Kit Components 9 Fabricate a bracket and install the coolant valve in the upper left corner of the vehicle ...

Page 12: ...de of the vehicle in front of the right rear tire NOTE The location is not critical Be sure there is no interference between the cool ant pump and any other components 11 Drill a 1 4 in 7 mm hole in the transmission support cross member on the left side 12 Install a short length of 3 4 in hose and a 3 4 in to 5 8 in reducer on the output side of the coolant pump Torque all hose clamps to 40 in lbs...

Page 13: ...Mercedes Sprinter Kiev 13 Mount the coolant pump to the cross member Condenser Installation 14 Drill the six holes in the condenser to 4 mm 15 Install the condenser reinforcement brackets on the condenser ...

Page 14: ...ndenser is not critical The condenser must be far enough away or protected from exhaust heat and any moving components 17 Hold the condenser assembly in the desired installation location and mark the inner mounting points Drill a 9 mm hole and install the M8 threaded inserts 18 Mount the condenser using the inner brackets ...

Page 15: ...cedes Sprinter Kiev 19 Hold the condenser in place and mark the outer mounting points Drill a 13 mm hole and install the M8 threaded inserts 20 Install the condenser and tighten all the fasteners at this time ...

Page 16: ...with making A C hoses A Using blade type hose cutters cut the hose in one cut The cut edge must be clean and flush B Place two properly sized clips in the clip holder The clips should both be facing the same direction for ease of assembly C Slide the hose in the clip holder until the cut edge of the hose is against the small opening in the clip holder ...

Page 17: ...17 Mercedes Sprinter Kiev D Lubricate the fitting with PAG oil and insert the fitting until the shoulder of the fitting is touching the clip holder E Using Oetiker pliers crimp the clips closed ...

Page 18: ...ation NOTE The following diagram is intended to show hose sizes and basic connections only Refer to the individual steps for additional information NOTE Route hoses in a location manner that protects them from heat moving parts pinch points etc ...

Page 19: ...90 degree service fitting route the 12 A C hose from the A C compressor through the hole in the passenger side step well along the roof line to the area where the Kiev unit will be located Leave enough hose to connect to the Kiev unit 23 Using the 8 90 degree service port route the 8 A C hose from the A C compressor to the condenser ...

Page 20: ... the 8 straight fitting route the high pressure hose from the A C compressor to the 8 fitting on the condenser Coolant Hose Installation NOTE This is a parallel connection Do not restrict or obstruct coolant flow 26 Install two T fittings in the heater core return hose as shown in the diagram Torque all hose clamps to 40 in lbs 5 4 5 Nm 5 ...

Page 21: ...om the adapter installed on the coolant pump through the hole in the driver s side step well and along the roof line to the area where the Kiev will be mounted Leave enough hose to connect to the Kiev unit 29 Route the 5 8 in coolant hose from the return T fitting through the hole in the driver s side step well to the outlet side of the coolant valve ...

Page 22: ...gh hose to connect to the Kiev unit Wiring Installation 31 Unbolt the driver s seat base from the vehicle and raise the seat enough to pass the following harness legs into the area under the driver s seat Relay bar Fuse block Positive cable Negative cable Engine ON signal wire Re install the driver s seat base 32 Attach the relay bar under the driver s seat ...

Page 23: ...ock under the driver s seat 34 Pass the power cable through the boot under the driver s seat NOTE Due to vehicle build variations this image may not be representative 35 Attach the ground cable to an appropriate ground point under the driver s seat ...

Page 24: ... 5 amp fuse and fuse holder connect the pink wire to an ignition switched circuit under the driver s seat 37 Pass the following harness legs through the hole drilled in the driver s step well Coolant pump A C compressor Condenser fans High pressure switch 38 Route the rest of the wiring up the b pillar securing as necessary ...

Page 25: ...lock at the top of the driver s side b pillar 40 Route the control harness above the driver s door and windshield to the area above the rear view mirror 41 Route the wiring harness along the roof line to the area where the Kiev unit will be mounted ...

Page 26: ...tative 43 Cut the connector s off the compressor if necessary The connector housing and pin s that are supplied with the wiring harness will be used 44 Route the A C compressor harness to the compressor Using the supplied connector connect the compressor Connect the compressor ground wire to a suitable ground if equipped ...

Page 27: ... the red power cable to the 12V power lug next to the battery box 46 Connect the coolant pump electrical connector 47 Insert the pins in the connectors for the condenser fans Refer to the wiring diagram in this manual for more information ...

Page 28: ...onnect the electrical connectors for the condenser fans 49 Insert the pins in the high pressure switch housing Refer to the wiring diagram in this manual for more information 50 Connect the high pressure switch electrical connector ...

Page 29: ...stallation was used in this example 51 Trim the headliner as indicated After connecting the electrical connector install the controller and all headliner sections Kiev Condenser Installation 52 Guide the hoses and wiring through the hole in the headliner and install the headliner 53 Install the Kiev unit ...

Page 30: ...splice fitting and the low pressure switch make a low pressure switch hose 55 Connect the low pressure hose and using a 6 45º fitting the high pressure hose to the Kiev TXV using the TXV plate Connect the low pressure switch electrical connector 56 Using the bleeder valve and a short section of coolant hose connect the supply and return hoses to the Kiev unit ...

Page 31: ...8 Using the provided T fitting connect both drain hoses at the right side of the Kiev unit NOTE The drain hose should always run down hill from the Kiev unit NOTE Drain hose shown for clarity 59 Drill a 3 4 in 19 mm hole in the headliner about 6 in 153 mm from the rear and 8 in 203 mm from the bottom of the headliner ...

Page 32: ... Drill a 3 4 in 19mm hole in the lower body panel and route the drain hose from the Kiev unit through the headliner to the exterior of the vehicle 61 Cut the drain hose about 1 in 24 mm past the hole The hole should be cut at a 45º angle away from the direction of travel ...

Page 33: ...air from the system 65 After all the air has been removed from the system fill the reservoir to the proper level 66 While monitoring the system for leaks allow the vehicle to idle until the engine reaches normal operating temperature 67 Allow the vehicle to cool to a safe level 68 Re torque all hose clamps to 40 in lbs 5 4 5 Nm 5 and inspect for leaks 69 Pressure test the coolant system per the ma...

Page 34: ...34 Kiev Mercedes Sprinter Wiring Diagram ...

Page 35: ...35 Kiev Mercedes Sprinter Wiring Diagram cont d ...

Page 36: ...Webasto Product N A Inc Technical Assistance Hotline USA 800 555 4518 Canada 800 667 8900 www webasto us www techwebasto com Org 11 2016 Rev 08 2019 P N 5011864B ...

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