Webasto Transit Vancouver Wagon Manual Download

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Transit

Vancouver

VAC Kit Vancouver Transit Wagon

Legend

1 Vancouver VAC Unit Assembly
2 Condenser Assembly

Special Tools

– Oetiker pliers
– Rivnut installation tool
– Hole saw kit
– Refrigerant recovery and recharging machine
– Weather-Pack/Metri-Pack crimping tool 12085270

Ford Transit

2015 - Present 3.5 Liter

148” Wheelbase - High-roof - Wagon body
For kit 5012603

Special instructions for these models

Part locations may differ slightly dependent on
the vehicle-specific configuration.

DOC P/N 5012631B KIT P/N 5012603 Printed in USA Webasto N.A., Inc.

Summary of Contents for Transit Vancouver Wagon

Page 1: ... 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 Wagon body For kit 5012603 Special instructions for these models Part locations may differ slightly dependent on the vehicle specific configuration DOC P N 5012631B KIT P N 5012603 Printed in USA Webasto N A Inc ...

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 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: ...Warnings Cautions and Notes 12 1 6 Safety 13 1 7 Legal Provisions for Installation 13 1 8 Prohibition on Venting 13 Vehicle preparation 14 General References 14 Preparation 14 Kit Component Installation 16 A C Hose Crimping 20 Hose Installation 22 Electrical and Hose Installation 26 Refrigerant System Diagram 28 Basic Board Layout 29 Extreme Board Layout 30 Initial Start 37 Wiring Diagram Basic 38...

Page 4: ...62U00025459 UNDER CHASSIS CONDENSER 1 3 5010279 BOLT HEX M6 1 6G X 16 8 8 ZP DIN 933 8 4 5012085 VAC KIT VANCOUVER 12V W THERMO STAT 1 5 62017067 FILTER DRYER R134A 1 6 62036025 SUPPORT FILTER 1 7 5001321 BOLT M6 1 0 x 20 11 8 5011771 LABEL REFRIGERANT CHARGE R134A 2 7LBS 1 9 21499 P Clip 1 10 152560 FEDERRING DIN128 A6 PHRF 1 ...

Page 5: ... 5012221 BRACKET ADAPTER VANCOUVER 1 15 629070001 ANTI COND TAPE M9ROL 1 METER 16 5011428 CAP SCREW SOCKET HD M6 1 12mm SS 1 17 902006 SCREW PAN HD 10 16ST x 1 SELF DRILLING 12 18 5001085 CABLE TIE HEAVY DUTY BLACK 20 19 5011594 THREADED PLATE M8X1 25 3 20 5000534 SCREW PAN T20 M4 2 1 4 STx19 TYPE AB SS 4 21 5001322 NUT HEX FLANGE SERRATED M6 1 6H 8 8 ZP 15 ...

Page 6: ...RIG 45 10THD TO 10H 1 26 5011002 FITTING REFRIGERANT 90 6CONN 6HOSE 1 27 PPC201065 TXV MOUNTING PLATE OUTER 1 28 5011164 REFRIGERANT HOSE BURGAFLEX H 06 3090 R 6 METERS 29 62U003AA020 AIR DUCT 4 GRIGLIE D67 NERO 1 30 5011008 FITTING REFRIGERANT 90 06THD 06HOSE 3 31 5011244 SPLICER IN LINE 10HOSE WITH PORT 1 32 629069011 RACCORDO SCARICO COND D 12 A T 1 ...

Page 7: ...SE WITH PORT 1 36 5011165 REFRIGERANT HOSE BURGAFLEX H 08 3090 R 8 METERS 37 5011010 FITTING REFRIGERANT 90 08THD 08HOSE 1 38 5012631B MANUAL INSTALL VANCOUVER TRANSIT EXR 1 39 5011029 FITTING REFRIGERANT 45 08THD 08HOSE 1 40 147729 M4 SCREW 6 41 5012013 M4 NUT 6 42 905163 BOLT HEX M8 1 25 6G x 25 8 8 ZP DIN933 7 43 902713 WASHER FLAT 0 3125 x 0 75 x 0 062 ZP 7 ...

Page 8: ...LF DRILLING BLACK 4 48 5011082 WARRANTY STATEMENT AC 1 49 5011232 SPLICER IN LINE 10HOSE WITH PORT 1 50 5012015 WASHER FLAT M6x18x1 6 ZP DIN933 8 51 5011487 SCREW SELF DIRLLING 0 25 X 1 INCH 1 52 5011005 FITTING REFRIGERANT 90 12THD 10HOSE 1 53 62043118 PRESSURE SWITCH 3 LEVEL SICEB CONN INTGR 1 54 62U003AA093 LONDON COVER MODULE AIR 1 1 ...

Page 9: ...57 5011592 RUBBER GROMMIT 2 INCH 1 58 5012577 AC CONTROL HARNESS SWITCH 1 59 5012448 BATTERY POSITIVE CABLE 6AWG 1 60 5012009 JUMPER GROUND 1 61 5012572 JUMPER BOARD TO BOARD 1 62 5012571 JUMPER POSITIVE 1 63 5012570 GND EXTREME BOARD 1 64 5012429 LP HP SWITCH HARNESS 1 65 5012584 CONDENSER HARNESS 2 ...

Page 10: ...d Transit Vancouver 10 66 5012643 COMPRESSOR HARNESS 1 67 5012586 LP SWITCH HARNESS 2 68 5012630 CONTROL HEAD ASSY AC TRANSIT 1 69 5012420 BLOWER HARNESS 1 70 689184 M5 NUT 1 71 5012652 FUSE 70 AMP MIDI 1 ...

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 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 12: ...1 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 co...

Page 13: ...equiring 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 individua...

Page 14: ...e treated 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 sharp edges as necessary Some components shown in this manual may be pre production parts and may not be representative of current production parts Parts Required for Preparation Item Number P...

Page 15: ...isting 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 4 using 4 bolts 7 ...

Page 16: ... TRANSIT WAGON 1 19 5011594 THREADED PLATE M8X1 25 3 55 5011493 RIVET NUT HEAVY DUTY m8 2 22 5011984 BRACKET UNDERBODY RH 1 23 5011606 BRACKET UNDERBODY LH 1 43 902713 WASHER FLAT 0 3125 x 0 75 x 0 062 ZP 4 7 5001321 BOLT HEX M6 1 0X20 6 21 5001322 NUT HEX FLANGE SERRATED M6 1 6H 8 8 ZP 2 5 62017067 FILTER DRYER R134A 1 6 62036025 SUPPORT FILTER 1 53 62043118 PRESSURE SWITCH 3 LEVEL SICEB CONN INT...

Page 17: ...Place the 3 threaded plates 19 in the locations as shown 5 Using 3 M8 bolts 42 install the upper evaporator bracket 1 6 Hold the rear headliner section in place Mark and slot the headliner to clear the upper bracket mounting tabs ...

Page 18: ...rator trim piece Cut a piece of hardboard lauan or similar that will be above the headliner to mount the air handler trim to The board should be slightly larger than the Vancouver trim piece 8 Drill 2 existing holes to 0 5 in 13 mm and install two threaded inserts 55 9 Install the condenser mounting brackets 22 23 using 4 M8 bolts 42 and washers 43 ...

Page 19: ...r 10 Install the condenser assembly to the condenser bracket using 4 M6 bolts 7 11 Mount the filter dryer 5 6 to the condenser mount bracket using two M6 bolts and nuts 7 21 12 Mount the pressure switch 53 to the filter dryer ...

Page 20: ...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 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: ... H 08 3090 R As needed 34 5011166 REFRIGERANT HOSE BURGAFLEX H 10 3090 R As needed 56 500413 HEAT SLEEVE ORANGE 1 30 5011008 FITTING REFRIGERANT 90 06THD 06HOSE 3 37 5011010 FITTING REFRIGERANT 90 08THD 08HOSE 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 9 2...

Page 23: ...ide wall and approximately 3 5 in 89 mm from the chassis outrigger Protect the cut edge against corrosion and chaffing and install a grommit 57 14 Using two 6 90º fittings 30 connect a high pressure hose 28 from condenser output port to the input port on the filter dryer 15 Connect a 6 90º fitting 30 to the output on the filter dryer and route the hose 28 through the hole drilled in the floor ...

Page 24: ...Cover the ends of the hose with tape to prevent debris from entering the hose 17 Route 10 A C hose 34 from the area of the A C compressor through the hole in the floor Leave enough hose to connect to the evaporator assembly Install the heat protective sleeve 56 over both hoses to protect against heat 18 Using a 8 and a 10 45º fitting 39 25 attach the A C hoses to the A C compressor ...

Page 25: ...nt the service caps retaining water 19 Route and secure the A C hoses along the chassis 18 24 9 51 In a location that provides service access cut the A C hoses and install the two service ports 35 49 20 Route the A C hoses past the rear HVAC blower up the e pillar to the area where the Vancouver unit will be installed 18 24 ...

Page 26: ... AMP MIDI 1 61 5012572 JUMPER GROUND 1 60 5012009 JUMPER POWER 1 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 26 5011002 FITTING REFRIGERANT 90 6CONN 6HOSE 1 52 5011005 FITTING REFRIGERANT 90 12THD 10HOSE 1 31 5011244 SPLICER IN LINE 10HOSE WITH PORT 1 26 5011002 FITTING REFRIGERANT 90 6CONN 6HOSE ...

Page 27: ...Ford Transit 27 This page intentionally left blank ...

Page 28: ...28 Vancouver Ford Transit Refrigerant System Diagram ...

Page 29: ...29 Ford Transit Note Some connections may not be used in this installation Basic Board Layout ...

Page 30: ...30 Ford Transit Extreme Board Layout ...

Page 31: ...oards 44 45 above the side curtain air bags using self tapping screws 22 Replace one of the 60 amp fuses with the supplied 70 amp fuse 71 Reinstall the power distribution center at this time 23 Connect the positive wire to the fuse installed earlier Connect the ground wire to a good ground point Route and secure the wiring to prevent chaffing ...

Page 32: ...pictured 24 Connect the controller harness 58 and route it along the roof line to the area above the rear view mirror Connect the pink wire to a 12V ignition on circuit at the open connector in the battery compartment 25 Use jumpers 60 62 connect the BATT and GND terminals on the basic board to the same terminals on the extreme board Connect the jumper harness 61 from board to board Route the wiri...

Page 33: ...nd the wiring through the pass through cut into the headliner and reinforcement board Install the Vancouver unit using eight bolts nuts and washers 3 21 50 27 Using the 6 90º fitting 26 connect the high pressure hose to the Vancouver assembly 28 Install the low pressure hose on the Vancouver assembly using the 10 90º fitting and pressure switch splice 52 31 Install the TXV mounting plate 27 16 10 ...

Page 34: ...tch a 30 Using the drain T 32 and the drain hose 4 connect the two drain ports together Route the drain hose through the headliner down the body in the right rear corner and through an existing hole in the body 31 Trim the drain tube 1 2 inches 25 50 mm below the bumper cover at a 45º angle away from the direction of travel a ...

Page 35: ... the filter dryer connector 33 Connect the condenser fan 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 ...

Page 36: ...ancouver Ford Transit 35 Remove the storage compartment insert Plug in and install the control panel 68 in the overhead storage bin 36 Secure the wiring harness to protect against heat and chaffing 18 24 17 ...

Page 37: ...hat were removed unless otherwise instructed in this manual NOTE This step is optional 44 Install the appearance cover 54 using self tapping screws 17 Item Number Part Number Description Quantity 15 629070001 ANTI COND TAPE M9ROL As needed 18 5001085 CABLE TIE HEAVY DUTY BLACK As needed 24 620406 CABLE TIE 11 INCH BLACK As needed 29 62U003AA020 AIR DUCT 4 GRIGLIE D67 NERO 1 47 5011593 SCREW 4 2 X ...

Page 38: ...38 Ford Transit Wiring Diagram Basic ...

Page 39: ...Ford Transit 39 Wiring Diagram Extreme Components ...

Page 40: ...40 Ford Transit ...

Page 41: ...te the nearest Webasto authorized dealer for warranty service visit http www webasto com or call 800 860 7866 in USA 800 667 8900 in Canada a Limitations Webasto specifically excludes and limits warranty from the following Normal wear of service parts filters and fuses are not covered Removal and replacement of Air Conditioning System Damage to product in transit All claims must be filed with carr...

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Page 44: ...Webasto Product N A Inc Technical Assistance Hotline USA 800 555 4518 Canada 800 667 8900 www webasto us www techwebasto com Org 08 2017 Rev 08 2018 ...

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