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Webasto Transit Vancouver Extended Body, Manual, Page: 2 / 40

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2

Vancouver

Ford Transit

– 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 Transit Vancouver Extended Body

Page 1: ...aw kit Refrigerant recovery and recharging machine Weather Pack Metri Pack crimping tool 12085270 1 2 Ford Transit 2015 Present 3 5 Liter 148 Wheelbase High roof Extended body For kit 5012697 Special...

Page 2: ...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 care...

Page 3: ...ility of Manual 12 1 5 Meaning of Warnings Cautions and Notes 12 1 6 Safety 13 1 7 Legal Provisions for Installation 13 1 8 Prohibition on Venting 13 Vehicle and kit preparation 14 General References...

Page 4: ...00025459C UNDER CHASSIS CONDENSER 1 3 5010279A BOLT HEX M6 1 6G X 16 8 8 ZP DIN 933 8 4 5012085B VAC KIT VANCOUVER 12V W THERMO STAT 1 5 62017067A FILTER DRYER R134A 1 6 62036025D SUPPORT FILTER 1 7 5...

Page 5: ...12221A BRACKET ADAPTER VANCOUVER 1 15 629070001A ANTI COND TAPE M9ROL 1 METER 16 5011428A CAP SCREW SOCKET HD M6 1 12mm SS 1 17 902006 SCREW PAN HD 10 16ST x 1 SELF DRILLING 12 18 5001085A CABLE TIE H...

Page 6: ...45 10THD TO 10H 1 26 5011002B FITTING REFRIGERANT 90 6CONN 6HOSE 1 27 PPC201065A TXV MOUNTING PLATE OUTER 1 28 5011164A REFRIGERANT HOSE BURGAFLEX H 06 3090 R 7 METERS 29 62U003AA020B AIR DUCT 4 GRIG...

Page 7: ...WITH PORT 1 36 5011165A REFRIGERANT HOSE BURGAFLEX H 08 3090 R 9 METERS 37 5011010B FITTING REFRIGERANT 90 08THD 08HOSE 1 38 5012698B MANUAL INSTALL VANCOUVER TRANSIT EXR 1 39 5011029B FITTING REFRIG...

Page 8: ...DRILLING BLACK 4 48 5011082C WARRANTY STATEMENT AC 1 49 5011232B SPLICER IN LINE 10HOSE WITH PORT 1 50 5012015A WASHER FLAT M6x18x1 6 ZP DIN933 8 51 5011487A SCREW SELF DIRLLING 0 25 X 1 INCH 1 52 50...

Page 9: ...011592A RUBBER GROMMIT 2 INCH 1 58 5012577A AC CONTROL HARNESS SWITCH 1 59 5012448A BATTERY POSITIVE CABLE 6AWG 1 60 5012009A JUMPER GROUND 1 61 5012572A JUMPER BOARD TO BOARD 1 62 5012571A JUMPER POS...

Page 10: ...ransit Vancouver 10 66 5012643A COMPRESSOR HARNESS 1 67 5012586A LP SWITCH HARNESS 2 68 5012113A CONTROL HEAD ASSY AC TRANSIT 1 69 5012420A BLOWER HARNESS 1 70 689184 M5 NUT 1 71 5012652A FUSE 70 AMP...

Page 11: ...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 e...

Page 12: ...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 variat...

Page 13: ...quiring the removal of refrigerants be serviced by a certified technician under Section 608 of the Clean Air Act and that all refrigerant be reclaimed and recycled Vehicle operation must not be impair...

Page 14: ...ed with anti corrosive coating Secure hoses cables and wiring harnesses with cable ties and fit protective hoses around them at chafing points Fit edge protectors heat sleeve grommet split loom etc to...

Page 15: ...sting holes on the condenser 2 to 4mm 2 Install the condenser reinforcement brackets 11 12 on the condenser using 6 M4 bolts and nuts 40 41 3 Install the Vancouver top bracket 14 to the Vancouver unit...

Page 16: ...ERRATED M6 1 6H 8 8 ZP 11 3 5010279 BOLT HEX M6 1 6G X 16 8 8 ZP DIN 933 8 21 5001322 NUT HEX FLANGE SERRATED M6 1 6H 8 8 ZP 8 50 5012015 WASHER FLAT M6x18x1 6 ZP DIN933 8 55 5011493 RIVET NUT HEAVY D...

Page 17: ...into the support ribs as shown 5 Using three M8 bolts 42 and washers 43 in the front and two M6 bolts 7 and nuts 21 in the rear install the upper bracket 1 to the vehicle 6 Mount the Vancouver assembl...

Page 18: ...mm and install two threaded inserts 55 8 Install the condenser mounting brackets 22 23 using 4 M8 bolts 42 and washers 43 Two existing holes will be used as well as the threaded inserts 9 Install the...

Page 19: ...h 53 to the filter dryer NOTE The location of this hole is not critical but it must avoid the factory equipped rear HVAC module if equipped 12 Drill a 2 in 51 mm hole approximately 2 5 in 64 mm from t...

Page 20: ...ith 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 th...

Page 21: ...Ford Transit Vancouver 21 D Lubricate the fitting with PAG oil and insert the fit ting until the shoulder of the fitting is touching the clip holder E Using Oetiker pliers crimp the clips closed...

Page 22: ...LEEVE ORANGE 1 39 5011029 FITTING REFRIGERANT 45 08THD 08HOSE 1 25 5011030 FITTING REFRIG 45 10THD TO 10H 1 18 5001085 CABLE TIE HEAVY DUTY BLACK As needed 24 620406 CABLE TIE 11 INCH BLACK As needed...

Page 23: ...t to the input port on the filter dryer 14 Connect a 6 90 fitting 30 to the output on the filter dryer and route the hose 28 through the hole drilled in the floor 15 Using a 8 90 fitting 37 route A C...

Page 24: ...stall the heat protective sleeve 56 over both hoses to protect against heat 17 Using a 8 and a 10 45 fitting 39 25 attach the A C hoses to the A C compressor NOTE Install the service fittings with fit...

Page 25: ...he area where the Vancouver unit 18 24 20 Install the pressure switch 33 on the low pressure hose using the splice fitting 31 Crimp enough hose on the inlet side of the switch to connect to the evapor...

Page 26: ...te NOTE Trim the drain hose at a 45 angle away from the direction of travel 23 Using the drain t 32 and the drain hose 4 connect the two drain ports together Route the drain hose through the headliner...

Page 27: ...012448 BATTERY POSITIVE CABLE 6AWG 1 60 5012009 JUMPER GROUND 1 61 5012572 JUMPER BOARD TO BOARD 1 62 5012571 JUMPER POSITIVE 1 13 5011761 BAG COMPRESSOR CLUTCH CONNECTOR 1 60 5012009 JUMPER GROUND 1...

Page 28: ...ay not be used in this installation Note The refrigerant valve compressor connector can be plugged in two different ways Be sure the power wire is on the correct terminal Refer to the wiring diagram f...

Page 29: ...29 Ford Transit Vancouver Extreme Board Layout...

Page 30: ...n air bags using self tapping screws 25 Replace one of the 60 amp fuses with the supplied 70 amp fuse 71 Reinstall the power distribution center at this time NOTE Due to vehicle variances some con nec...

Page 31: ...y 28 Route the control harness to the area above the rear view mirror NOTE The wiring must be routed above and behind the air bags 29 Route the control and positive wiring harnesses along the roof lin...

Page 32: ...switch 64 and A C compressor 66 from the electrical boards down the e pillar and through the hole in the floor 31 Connect the following harnesses to the electrical boards and to the Vancouver unit LP...

Page 33: ...connectors 34 Route the A C compressor harness to the engine compartment Using the supplied connector 13 and the proper crimping tool connect the A C compressor electrical connector 35 Secure the wir...

Page 34: ...r clarity Do not install the dome light at this time 37 Connect the wiring connector and install the control panel 68 using four screws 20 38 Make the following connections at the basic and electrical...

Page 35: ...ll interior panels and components that were removed unless otherwise instructed in this manual NOTE This step is optional Install the appearance cover 54 using self tapping screws 17 Item Number Part...

Page 36: ...36 Ford Transit Wiring Diagram Basic...

Page 37: ...Ford Transit 37 Wiring Diagram Extreme Components...

Page 38: ...38 Ford Transit...

Page 39: ...Ford Transit Vancouver 39...

Page 40: ...Webasto Product N A Inc Technical Assistance Hotline USA 800 555 4518 Canada 800 667 8900 www webasto us www techwebasto com Org 1 2018 Rev 01 2021...

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