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Webasto London, Installation Manual

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Webasto London Installation Manual Download Page 8

ProMaster 

 

London 

8 

 

Item 

Number 

Part Number 

Description 

Qty 

 

21 

901073Z 

HOSE - HEATER 5/8 INCH ID RUBBER 

9.5 MT 

 

22 

5012120A 

BLEEDER VALVE 16mm OD 

1 

 

23 

5012117A 

TEE COOLANT 16-20 PLASTIC BLACK KALORI 

2 

 

24 

9027035A 

BAG BRACKET U4847econ FOR TP50E 

1 

 

25 

1317523A 

CIRCULATION PUMP U4840 12V STD 

1 

 

26 

620681053RA 

2-WAY SOLENOID VALVE 12V 

1 

 

27 

62U003AA020B  AIR DUCT OUTLET GRILL 

1 

 

28 

5011627A 

LABEL - REFRIGERANT CHARGE R134a 2.1LBS 

1 

 

29 

5010740A 

LABEL - SERIAL NUMBER 

2 

 

30 

5011506A 

HOSE DRAIN ID 0.4375 INCH 

11.5 

FT 

 

Summary of Contents for London

Page 1: ...2015 2019 Ram ProMaster London Installation Manual Tie In System 3 6 L Pentastar All Wheelbases High Roof Single Sliding Door Only For Kit number 5012987 Org 6 2018 Rev 03 2021 P N 5012988B ...

Page 2: ...5 Applicability of Manual 4 1 6 Meaning of Warnings Cautions and Notes 5 1 7 Safety 5 1 8 Legal Provisions for Installation 5 1 9 Prohibition on Venting 5 2 KIT CONTENTS FOR KIT 5012987 6 3 VEHICLE AND KIT PREPARATION 12 4 PARTS REQUIRED FOR UNIT INSTALLATION 13 5 PARTS REQUIRED FOR WIRING INSTALLATION 20 6 PARTS REQUIRED FOR HOSE INSTALLATION 27 7 INITIAL START 38 8 WIRING DIAGRAM 39 ...

Page 3: ... 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 in...

Page 4: ...se instructions are followed properly and all options listed in the parts breakdown are installed this system will provide supplemental heating and cooling 1 5 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 t...

Page 5: ...he relevant operating safety instructions must be observed at all times 1 8 Legal Provisions for Installation EPA regulations stipulate that all vehicles requiring 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 A...

Page 6: ...M 0 125 X 0 5 INCH 2FT 1 3 620406Z CABLE TIE 11 INCH BLACK 30 4 5011487A SCREW SELF DIRLLING 0 25 X 1 INCH 8 5 902005Z NUT NYLOC 6 32 UNC ZP 2 6 902004Z SCREW PAN HEAD 6 32 UNC X 0 5 ZP 2 7 5001321A BOLT HFH M6 1 0 6g x 20 8 8 ZP CLEAR 10 8 902006Z SCREW PAN HD 10 16ST x 1 SELF DRILLING 6 9 5011511A MOUNTING PLATE LONDON PROMASTER 2 10 21499A TUBE CLAMP 1 ...

Page 7: ...TTING REFRIGERANT 45 06THD 06HOSE 1 14 5011026A FITTING 45 REFRIGERANT 12CONN 10HOSE 1 15 5011023A FITTING REFRIGERANT 45 6CONN 6HOSE 1 16 152560Z FEDERRING DIN128 A6 PHRF 1 17 5011428A CAP SCREW SOCKET HD M6 1 12mm SS 1 18 PPC201065A TXV MOUNTING PLATE OUTER 1 19 5011166A REFRIGERANT HOSE BURGAFLEX H 10 3090 R 25 FT 20 5011164A REFRIGERANT HOSE BURGAFLEX H 06 3090 R 25 FT ...

Page 8: ...2117A TEE COOLANT 16 20 PLASTIC BLACK KALORI 2 24 9027035A BAG BRACKET U4847econ FOR TP50E 1 25 1317523A CIRCULATION PUMP U4840 12V STD 1 26 620681053RA 2 WAY SOLENOID VALVE 12V 1 27 62U003AA020B AIR DUCT OUTLET GRILL 1 28 5011627A LABEL REFRIGERANT CHARGE R134a 2 1LBS 1 29 5010740A LABEL SERIAL NUMBER 2 30 5011506A HOSE DRAIN ID 0 4375 INCH 11 5 FT ...

Page 9: ...BLACK 5 33 5011556A INSULATION HOSE ID 0 875IN X 6FT LONG 1 34 5001085A CABLE TIE HEAVY DUTY BLACK 11 35 PPC301028A P CLIP WITH RUBBER 60DIA X 12 7 2 36 5012587A HVAC HARNESS THERMOSTAT 1 37 5011932A PLUG FUSE ATM APM MINI ADD A CIRCUIT 1 38 901406Z FUSE MINI 10 AMP RED 1 39 5011939A EDGE TRIM 0 250X0 5INCH 1FT 1 40 5011479A BRACKET MOUNTING SIDE LONDON 2 ...

Page 10: ...5011430A BRACKET PUMP PROMASTER 1 44 5011614A AC T BLOCK KIT PROMASTER 1 45 901100Z HOSE HEATER 0 75 ID GATES BLUE STRIPE 2 5 MT 46 5013547A CONNECTING UNION 17 20 PLASTIC KALORI 1 47 5012988B INSTALL MANUAL LONDON PROMASTER 1 48 5012948A COOLANT VALVE HARNESS EXTENSION SEALED 1 49 6241258B WATER VALVE WEATHER PROOF 1 50 5012813B CONTROLER NEO 2 HVAC 1 ...

Page 11: ...012805A PROMASTER NEO CONTROL BRACKET 1 52 5012880A ADAPTER HARNESS NEO 2 1 53 5010321A COOLANT PUMP HARNESS 4500 1 54 5012877A BLOWER HARNESS NEO 4000 7000 1 55 5011861A SPRING CLAMP 22MM 12 56 5011862A SPRING CLAMP 27MM 4 57 5012430A HVAC HARNESS SOLENOID VALVE 1 ...

Page 12: ...40 5011479A BRACKET MOUNTING SIDE LONDON 2 1 5011500A HVAC KIT LONDON 12V W THERMOSTAT 1 8 902006Z SCREW PAN HD 10 16ST x 1 SELF DRILLING 2 41 5011480A BRACKET MOTOR SUPPORT LONDON 1 KIT PREPARATION NOTE Some pre production parts are pictured in this document This does not impact the function NOTE For clarity not all bolts and washers are shown 1 Remove the eight bolts from the side of the London ...

Page 13: ...00Z HOSE HEATER 0 75 ID GATES BLUE STRIPE As Needed 46 5013547A CONNECTING PIE 17 20 PLASTIC KALORI 1 56 5011862A SPRING CLAMP 27MM 2 24 9027035A BAG BRACKET U4847econ FOR TP50E 1 25 1317523A SP CIRCULATION PUMP U4840 12V STD 1 43 5011430A BRACKET PUMP PROMASTER 1 31 5001322A NUT HEX FLANGE SERRATED M6 1 6H 8 8 ZP 1 49 6241258B WATER VALVE WEATHER PROOF 1 10 21499A TUBE CLAMP D_b_d 1 39 5011939A E...

Page 14: ...dges of the floor pan Protect the edge against corrosion and install edge trim protection in both holes 2 5 Trim 2 of foam from the left side foam block as shown 6 Drill a 2 inch 51 millimeters hole along the centerline about 8 1 2 inches 216 millimeters from the back wall of the package tray ...

Page 15: ...e supplied overhead brace 42 using M6 bolts 7 and existing threaded holes 8 Install the upper mounting plates 9 in the channel above the package tray 9 Install the London HVAC unit in place using two M6 bolts 7 into the upper mounting plates ...

Page 16: ...ProMaster London 16 10 Bolt the overhead brace in place 11 Using a inch X 1 inch self tapping bolt 4 attach the London lower bracket to the overhead brace ...

Page 17: ...drill a 1 4 inch 7 millimeters hole in the center of the raised rib Attach the coolant valve 49 to the tray using the 35 mm P clip 10 4 13 Place the refrigerant valve bracket 26 against the left wall of the package tray positioning it as far forward as the tapered channel will allow about 4 inches 102 millimeters The single valve mounting hole should face the right side of the vehicle ...

Page 18: ...ve discard NOTE There is an arrow on the bottom of the valve to indicate the direction of flow 15 Attach the mounting bracket to the package tray using two 6 pan head screws 6 and two nuts 5 Install the refrigerant valve with the arrow facing forward 16 Drill in 7 mm hole approximately 1 5 in 38 mm from the top and 0 5 in 13 mm from the left edge of the left side evaporative emissions canister bra...

Page 19: ...d pump mount 25 24 to the pump mounting bracket 43 using an M6 bolt and nut 7 31 18 Install the coolant pump assembly on to the evaporative emissions bracket 7 31 NOTE The location shown is not the only location where edge trim is necessary 19 To prevent chaffing install edge trim 39 to the portions of the body where wiring coolant or A C hoses may rub ...

Page 20: ...00 7000 1 53 5010321A COOLANT PUMP HARNESS 4500 1 48 5012948A COOLANT VALVE HARNESS EXTENSION SEALED 1 36 5012587A HVAC HARNESS THERMOSTAT 1 57 5012430A HVAC HARNESS SOLENOID VALVE 1 37 5011932A PLUG FUSE ATM APM MINI ADD A CIRCUIT 1 38 901406Z FUSE MINI 10 AMP RED 1 3 620406Z CABLE TIE 11 INCH BLACK As needed 33 5011556A INSULATION HOSE ID 0 875IN X 6FT LONG 2 27 62U003AA020B AIR DUCT 4 GRIGLIE D...

Page 21: ... holder from the dashboard below and to the left of the steering wheel 22 Cut the rear wall off of the coin holder to allow the wire harness to pass through 23 Mount the controller 50 51 in the coin holder using three self tapping screws 32 ...

Page 22: ...avity B of the blower harness X1 connector 54 25 Connect the coolant pump 53 coolant valve 48 thermostat 36 and refrigerant valve harnesses 57 to the NEO adapter harness Tape unused connectors to the harness 26 Install the control panel and route the wires through the dashboard to the driver s foot well ...

Page 23: ...e add a circuit 37 NOTE Due to production differences fuse panels may not be identical to this image 28 Install the add a circuit to an ignition ON circuit position in the fuse panel 38 29 Make the following electrical connections 1 Battery 2 Battery ground ...

Page 24: ...ute the refrigerant valve and coolant valve harnesses up the b pillar and onto the package shelf NOTE The refrigerant valve connector is not polarity sensitive 32 Remove the screw from the refrigerant valve connector and remove the connector plate Connect the appropriate wires to terminals 1 and 2 not the ground terminal ...

Page 25: ...ble the connector and insert the locking screw 34 Install the o ring and magnetic switch on the refrigerant valve The magnet should snap in place Connect the electrical connector 35 Connect the blower motor and thermostat connectors ...

Page 26: ...in the floor and connect the coolant pump Secure all hoses and harnesses at this time 38 Add foam insulation 33 to the exposed low pressure hose in the upper package tray area 39 Using the diffuser 27 as a template mark and pre drill the front of the London unit and attach the diffuser using two 4 2 X 16mm self tapping screws 32 ...

Page 27: ...OSE BURGAFLEX H 10 3090 R As Needed 13 5011028A FITTING REFRIGERANT 45 06THD 06HOSE 1 21 901073Z HOSE HEATER 5 8 INCH ID RUBBER As Needed 22 5012120A BLEEDER VALVE 16mm OD 1 44 5011614A AC T BLOCK KIT PROMASTER 1 23 5012117A TEE COOLANT 16 20 PLASTIC BLACK KALORI 2 45 901100Z HOSE HEATER 0 75 ID GATES BLUE STRIPE As needed 55 5011861A SPRING CLAMP 22MM 12 56 5011862A SPRING CLAMP 27MM 2 3 620406Z ...

Page 28: ...ProMaster London 28 ...

Page 29: ...port on the London HVAC unit to the output port on the refrigerant valve 16 17 18 41 Using the 10 fitting 14 and hose 19 install a refrigerant hose from the London HVAC unit low pressure fitting through the hole in the floor Leave enough hose to reach the engine compartment Tighten the TXV mounting plate at this time NOTE Valve shown with no hoses connected for clarity 42 Fabricate and install a r...

Page 30: ...ve 21 22 55 connect the return top port of the London to the coolant valve as shown 44 Connect the 5 8 hose 21 55 to the supply port on the London Route the hose through the hole in the floor Trim the coolant hose leaving enough hose to reach the coolant pump installed earlier 45 Connect the return hose 21 55 to the inlet side of the coolant valve Route the hose through the hole in the floor ...

Page 31: ...ating surfaces on the TXV H Block and A C manifold NOTE Lubricate the supplied O rings with PAG oil before installation 47 Using the supplied bolt install the A C manifold and the H Block 44 to the TXV 48 Using the plastic tee fittings 23 spring clamps 55 and 5 8 hose 21 assemble the double tee assembly as shown ...

Page 32: ...mbly in the heater core return hose as shown in the diagram 56 50 Connect the coolant return hose from the coolant valve to the lower fitting on the T assembly 55 51 Connect the heater hose 45 to the upper fitting on the T assembly 56 Route the hose through the engine compartment to the area where the coolant pump is mounted ...

Page 33: ...London 33 52 Connect the 5 8 return hose to the inlet on the pump 56 Route the supply hose into the engine compartment 53 Connect the coolant supply hose to the pump inlet 56 54 Trim the fuel filler shield shown ...

Page 34: ... 34 35 56 Using the supplied fittings 44 connect the A C hoses to the tie in block Secure all hoses as necessary keeping them away from hot and or moving components 3 35 57 Connect drain hoses 30 to the London HVAC unit Route the left drain hose through the hole in the floor along with the other hoses ...

Page 35: ...move the passenger s side upper and lower A pillar trim panels 59 Route the right side drain hose down the right A pillar to the passenger s foot well 60 Drill a 5 8 in 16 mm hole in two of the a pillar trim stanchions as shown ...

Page 36: ... against corrosion WARNING Be sure to route the drain hose in a way that will not interfere with airbag deployment 62 Route the drain hose through the holes drilled in the A pillar Route the drain hose through the hole drilled in the body 63 Apply silicone sealant to the drain hose where it passes through the hole ...

Page 37: ...ProMaster London 37 64 Install the upper and lower A pillar trim 65 Cut both drain hoses approximately 1 1 2 in 38 mm below the body at a 45 angle away from the direction of travel ...

Page 38: ...he London blower on and request maximum heat a The coolant pump will turn on and coolant will begin to flow through the heat exchanger 70 Using both the bleeder valve on the London unit and the vehicle s coolant overflow cap release trapped air from the system a 71 After all the air has been removed from the system fill the reservoir to the proper level 72 While monitoring the system for leaks all...

Page 39: ...ProMaster London 39 8 Wiring Diagram ...

Page 40: ...Webasto Thermo Comfort N A Inc 15083 North Road Fenton MI 48430 USA Phone 810 593 6000 Fax 810 593 6001 Internet http www webasto us http www techwebasto com ...

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