Webasto ProMaster Ibiza Manual
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Webasto ProMaster Ibiza Manual

Webasto ProMaster Ibiza Manual

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ProMaster
Standard
3
Legend
1 Ibiza HVAC unit Assembly
2 Refrigerant Valve and Coolant Valve
3 Coolant Pump
Special Tools
– Hose-clamping pliers
– Hole saw kit
– Refrigerant recovery and recharging machine
DOC P/N 5012950B
KIT P/N 5012949
Ibiza
Ram ProMaster
2015 - 2016 3.6 Liter
136" wheelbase
Single sliding door only
For kit number 5012949
1
2
Special instructions for these models
Part locations may differ slightly dependent
on the vehicle-specific configuration.
Printed in USA
Webasto Thermo & Comfort N.A., Inc.

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Summary of Contents for Webasto ProMaster Ibiza

  • Page 1 1 Ibiza HVAC unit Assembly 2 Refrigerant Valve and Coolant Valve 3 Coolant Pump Special Tools – Hose-clamping pliers – Hole saw kit – Refrigerant recovery and recharging machine DOC P/N 5012950B KIT P/N 5012949 Printed in USA Webasto Thermo & Comfort N.A., Inc.

  • Page 2: Table Of Contents

    – 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.

  • Page 3: Kit Contents

    Ibiza Ram ProMaster Kit Contents for Kit # 5012949 Item Part Number Description Quantity Number PPC201065A TXV MOUNTING PLATE OUTER 5011430A BRACKET PUMP PROMASTER 5011428A CAP SCREW SOCKET HD M6-1 12mm SS 9027035A BAG BRACKET U4847econ FOR TP50E 5001322A NUT HEX FLANGE SERRATED M6-1 6H 8.8 ZP 5013547A COUPLER REDUCER 0.75 X 0.625 FITTING 45 REFRIGERANT -12CONN -...
  • Page 4 Ram ProMaster Ibiza BLOWER HARNESS NEO 4000-7000 5012877A 152560Z FEDERRING DIN128-A6-PHRF 5011861A SPRING CLAMP 22MM SPRING CLAMP 27MM 5011862A 901100Z HOSE HEATER 0.75 ID GATES BLUE STRIPE 3.5 meters 10.5 901073Z HOSE-HEATER 5/8 INCH ID RUBBER meters 5011487A SCREW SELF DIRLLING 0.25 X 1 INCH REFRIGERANT HOSE BURGAFLEX H-06- 5011164A 6.5 meters...
  • Page 5 Ibiza Ram ProMaster 5011482A BRACKET MOUNTING SIDE RH-IBIZA BRACKET MOUNTING SIDE LH-IBIZA 5011481A SCREW PAN HD 10-16ST x 1 SELF DRILL- 902006Z 5011614A AC T BLOCK KIT PROMASTER INSTALLATION MANUAL - PROMASTER 5012950 IBIZA 5011506A HOSE DRAIN ID 0.4375 INCH 3 meters 629069011A RACCORDO SCARICO COND.D.12 A T...
  • Page 6 Ram ProMaster Ibiza 5011082B WARRANTY STATEMENT AC 1317523A SP CIRCULATION PUMP U4840 12V STD 5010321A COOLANT PUMP HARNESS 4500 5012880A ADAPTER HARNESS NEO 2 5012952A T-STAT JUMPER FOR NO VALVE BRACKET CONTROL HEAD NEO 2 BASIC 5012817A 5012813B CONTROLLER NEO 2 HVAC 6241258A WATER VALVE WEATHER PROOF COOLANT VALVE HARNESS EXTENSION...
  • Page 7 Ibiza Ram ProMaster 5001085A CABLE TIE - HEAVY DUTY 620406A CABLE TIE 11 IN BLACK...

  • Page 9: Introduction

    Failure to properly flush, purge, or pressure test a system for leaks can result in serious injury 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 ®...

  • Page 10: Scope

    Location of the Webasto provided components, wiring and control devices are important for proper operation. Failure to comply with the installation instructions provided may result in poor operation or damage to the Webasto unit, the vehi- cle, or vehicle components.

  • Page 11: Safety

    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.

  • Page 12: General References

    Ram ProMaster Ibiza General References • Bare body parts, around drilled holes for example, must be treated with an anti-corrosive coating. • Secure hoses, cables and wiring harnesses with cable ties and fit protective hoses around them at chafing points. •...
  • Page 13 Ibiza Ram ProMaster 1. Utilizing four existing holes, install the Ibiza HVAC unit mounting brackets (22, 23) using four M6 bolts and nuts (20, 5). 2. Install the Ibiza HVAC unit (10). 3. Using the supplied 35 mm P-clip, install the coolant valve using an existing hole (17, 21, 40).
  • Page 14 Ram ProMaster Ibiza 4. Drill ¼ 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 bracket. NOTE: Components pictured may be slightly different than found in some kits.

  • Page 15: Wiring Installation

    Ibiza Ram ProMaster Wiring Installation Parts required for the wiring installation: Item Part Number Description Quantity Number 5011506A HOSE DRAIN ID 0.4375 INCH 629069011A RACCORDO SCARICO COND.D.12 A T 5012877A BLOWER HARNESS NEO 4000-7000 5012948A COOLANT VALVE HARNESS EXTENSION SEALED 5010321A COOLANT PUMP HARNESS 4500 5012880A...
  • Page 16 Ram ProMaster Ibiza 1. Using the supplied “T” fitting (28), route the drain hose (27) from the Ibiza HVAC unit to the body cavity. 2. Remove paint in the area that the ground will attach to the body. Attach the ground eyelet from the blower harness to clean, unpainted sheet-metal near the Ibiza unit.
  • Page 17 Ibiza Ram ProMaster NOTE:Hoses are shown connected to indi- cate how all hoses and wiring will be routed. NOTE: The thermostat connection is not used in this installation. 4. Connect the blower motor connector (11). Route the blower harness along the body to the area of the driver’s side b-pillar 5.
  • Page 18 Ram ProMaster Ibiza 7. Insert the blue wire labeled AC BLOWER ON from the NEO adapter harness (36) into cavity C of the blower harness X1 connector. 8. Connect the coolant pump and coolant valve harnesses to the NEO adapter harness. Install the thermostat jumper into the NEO adapter harness (37) 9.
  • Page 19 Ibiza Ram ProMaster 10. Find a suitable location for the control panel and cut the mounting panel as described. Install the mounting bezel (38, 24). 11. Connect the NEO adapter and blower harnesses to the controller (39). Install the controller and secure the wiring harness where appropriate.
  • Page 20 Ram ProMaster Ibiza 13. Connect the two pink wires to the add-a- circuit (30). 14. Make the following electrical connections: 1. Battery + 2. Battery ground...

  • Page 21: Hose Installation

    Ibiza Ram ProMaster Hose Installation NOTE: The order and priority of the steps presented in this manual are only a suggestion. Before begin- ning the installation, review this installation manual and determine if a different order would be more appropriate in your individual situation. Parts required for the hose installation: Item Part Number...

  • Page 22: A/C Hose Crimping

    Ram ProMaster Ibiza A/C Hose Crimping NOTE: The proper method for crimping A/C hoses is outlined below. Refer to these steps if you are unfamiliar 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.
  • Page 23 Ibiza Ram ProMaster 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. (Webasto P/N 5012954)
  • Page 24 Ram ProMaster Ibiza If you are unfamiliar with crimping A/C fittings, refer to the steps on the next two pages Refer to the diagram below for a general overview of the heat and a/c system.

  • Page 25: Heater Hoses

    Ibiza Ram ProMaster Heater Hoses NOTE: The location is not critical, the high- light shows the approximate location. NOTE: This hole should align with the pas- sage being used in step 23. 15Drill a 3 in. (76 mm) hole in front of the left- rear wheel.
  • Page 26 Ram ProMaster Ibiza 18.Cut the return hose near the coolant valve. Connect the coolant valve in-line as shown (13). Route the rest of the supply hose to the engine compartment. 19. Using the plastic tee fittings (19), spring clamps (13), and 5/8” hose (16), assemble the double tee assembly as shown.

  • Page 27: A/C Hoses

    Ibiza Ram ProMaster 21. Connect the 3/4” supply hose and the 5/8” return hose to the double tee assembly (13, 14). Route all hoses in a way that keeps them clear of any moving parts and protects from abrasion (44, 45). A/C Hoses NOTE: Lubricate o-rings and fittings with PAG oil during assembly.
  • Page 28 Ram ProMaster Ibiza 24.Remove the nut and stud from the factory TXV. Set the A/C manifold aside. NOTE: Clean the mating surfaces on the TXV, H-Block, and A/C manifold. NOTE: Lubricate the supplied O-rings with PAG oil before installation. 25.Using the supplied bolt, install the A/C manifold and the H-Block (25) to the TXV.

  • Page 29: Initial Start

    Ibiza Ram ProMaster 27. Install the add-a-circuit to an ignition ON circuit in the fuse panel. Initial Start NOTE:Due to production differences, fuse panels may not be identical to this image. NOTE: Be sure to connect the feed side of the fuse first. 28.Install the add-a-circuit to an ignition ON circuit position in the fuse panel, insert the fuse (29).

  • Page 30: Wiring Diagram

    Ibiza Ram ProMaster Wiring Diagram...
  • Page 31 Ram ProMaster Ibiza...
  • Page 32 Webasto Thermo & Comfort N.A., Inc. Technical Assistance Hotline USA: (800) 555-4518 Canada: (800) 667-8900 www.webasto.us Org.6/2018 Rev. 10/2020 www.techwebasto.com...

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