Webasto Ford Transit Manual

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Table of Contents

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London

Transit

Extreme Climate

Chassis-Mounted Condenser

Legend

1 London HVAC Unit Assembly

2 Coolant Valve

3 Coolant Pump

Special Tools

– Oetiker pliers (Webasto P/N 5012954A)

– Rivnut installation tool

– Hole saw kit

– Refrigerant recovery and recharging machine

– Weather-Pack/Metri-Pack crimping tool 12085270

DOC P/N 5013295A

KIT P/N 5013292A

Printed in USA

Webasto N.A., Inc.

Ford Transit

2015 - 2019

3.5 and 3.7 Liter Engines

148" wheelbase - All Roof Heights

For kit 5013292A

Special instructions for these models

Part locations may differ slightly dependent on

the vehicle-specific configuration.

Table of Contents

Summary of Contents for Webasto Ford Transit

Page 1 Legend 1 London HVAC Unit Assembly 2 Coolant Valve 3 Coolant Pump Special Tools – Oetiker pliers (Webasto P/N 5012954A) – Rivnut installation tool – Hole saw kit – Refrigerant recovery and recharging machine – Weather-Pack/Metri-Pack crimping tool 12085270 DOC P/N 5013295A...
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.
Page 3: Table Of Contents
Ford Transit London Table of Contents Kit Co ntents Kit Contents with Part Numbers ........4 INTRODUCTION .
Page 4: Kit Contents With Part Numbers
London Ford Transit Kit Contents Item Part Number Description Quantity Number HVAC KIT LONDON 12V W-THERMO- 5011500A STAT 5011595A BRACKET - TRANSIT LONDON 62U00025459C CONDENSER - UNDERCHASSIS 5011825A BRACKET RDR UBC TRANSIT 5011824A BRACKET - SUPPORT RL UBC TRANSIT BRACKET - SUPPORT CONDENSER -...
Page 5 Ford Transit London 62017067A FILTER / DRYER R134-A 62036025D BRACKET - FILTER / DRYER 9027035A BAG - BRACKET U4847 1317523A CIRCULATION PUMP - U4847 5012655A BRACKET KIT - RELAY BOARD RELAY BOARD HVAC EXTREME W/ 5012514A LABEL 5010740A LABEL - SERIAL NUMBER...
Page 6 London Ford Transit 5013213A HOSE - REFRIGERANT -6 X 11M 5013159A HOSE - REFRIGERANT -8 X 6M 5013168A HOSE - REFRIGERANT -10 X 14M HOSE HEATER 0.75 ID GATES BLUE STRIPE 5013225A 503221A HOSE HEATER 5/8 INCH ID 21M WIRE HARNESS - T-STAT or LOW PRESSURE...
Page 7 Ford Transit London WIRE HARNESS - BLOWER - 5500- 5012876A 8100mm 5012880A WIRE HARNESS - NEO ADAPTER 5010321A WIRE HARNESS - COOLANT PUMP 5012447A BATTERY CABLE - POWER 5012570A BATTERY CABLE - GROUND 5011556A INSULTATION HOSE 6241258A COOLANT VALVE 5013294A...
Page 8 London Ford Transit FITTING REFRIGERANT 90 -12TUBE-O - 5011005B 10HOSE 5011008B FITTING REFRIGERANT 90 -06THD -06HOSE 5011231B SPLICER IN LINE -08HOSE WITH PORT 5011030B FITTING REFRIGERANT 45 -10THD TO -10H 5011010B FITTING REFRIGERANT 90 -08THD -08HOSE 5011232B SPLICER IN LINE -10HOSE WITH PORT...
Page 9 Ford Transit London 62043118A LOW-PRESSURE / HIGH-PRESSURE SWITCH 5013293A BAG - HARDWARE PARTS 905163Z BOLT HEX M8-1.25 902713Z WASHER FLAT 0.3125 x 0.75 5011487A SCREW SELF DIRLLING 0.25 X 1 INCH 5001321A BOLT HFH M6-1.0 6g x 20 902006Z SCREW SELF DRILLING 10-16ST x 1...
Page 10 London Ford Transit PPC301028A P-CLIP WITH RUBBER 60DIA 50000039A SCREW SELF DRILLING 0.25-14ST X 1.5 5001301A RIVET NUT FLUSH M6-1.0 5013178 BAG - ELECTRICAL SMALL PARTS 5013291A BAG ATO FUSE 20AMP 2 PIECES 5013476A SCREW CROSS RECESS M4x14 5012013A NUT NYLOCK M4-0.7...
Page 11: 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 12: Scope
These non-binding installation instructions are intended to support trained or certified dealers, and personnel in the installa- tion of the Webasto London-series HVAC unit. Provided these instructions are followed properly and all options listed in the parts breakdown are installed, this system will provide supplemental heating and cooling.
Page 13: Safety
608 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 14 London Ford Transit Parts needed for the installation of the London HVAC Unit and related components: Item Part Number Description Quantity Number 5011594A THREADED PLATE M8X1.25 5011595A BRACKET - TRANSIT LONDON 905163Z BOLT HEX M8-1.25 5011500A HVAC KIT LONDON 12V W-THERMOSTAT...
Page 15: Vehicle And Kit Preparation
Ford Transit General References • The locations of the components outlined in the manual are for reference only. If alternate locations re used the wiring harness cannot be extended. • Bare sheet metal, for example around drilled holes, must be treated with anti-corrosive coating.
Page 16 London Ford Transit 4. Mount the coolant valve (39) near the left- rear wheel using a p-clip (63) and an M6 bolt and nut (59, 57, 61). NOTE: Alternate method: drill two 2-inch holes in the location shown and install edge trim to protect against chaffing.
Page 17 Ford Transit London NOTE: Alternate method: drill two 2-inch holes in the location shown and install edge trim to protect against chaffing. 7. Drill two 1 3/4 inch (45 millimeters) holes in front of the left-rear wheel, similar to previously done. Install edge protection around the cut hole and protect against chaffing.
Page 18 London Ford Transit 10. Install the filter/dryer in the filter/dryer mounting clamp (11, 12). Loosely install the trinary switch (55) in the filter/dryer. 11.Install the filter/dryer assembly and the filter/ dryer bracket (4, 59). Use the existing threaded holes in the chassis to mount the bracket (56) Tighten the trinary switch.
Page 19 Ford Transit London NOTE: The condenser is installed on the left side of the vehicle next to the fuel tank. 13. Hold the condenser in place and mark the four mounting hole locations. NOTE: In some cases you will only have to drill three holes.
Page 20: Electrical Installation
London Ford Transit Electrical Installation Refer to this graphic for electrical connections as needed. Battery 12V power Thermostat Ignition ON 12V power Compressor Battery ground Heat switch (NEO 3 only - goes to blower pin C) # Blower motor connection at evaporator assembly...
Page 21: Extreme Board Layout
Ford Transit London Extreme Board Layout...
Page 22 London Ford Transit Parts required for electrical installation: Item Part Number Description Quantity Number 5012813A CONTROLLER - NEO 2 HVAC 5010321A WIRE HARNESS - COOLANT PUMP 5012948A WIRE HARNESS - HEATER CONTROL EXTENSION SEALED 5012876A WIRE HARNESS - BLOWER - 5500-8100mm...
Page 23 Ford Transit London 17.Drill a 1.25 inch (32 mm) hole in the rear of the left foam panel, approximately centered between the two indents. 18.Route the following harnesses from the area above the rear-view mirror through the hole and down the b-pillar: •...
Page 24 London Ford Transit 20.Connect the blower harness and NEO adapter harness to the NEO controller. Install the dome light bezel on the package tray. NOTE: Refer to the diagram earlier in this manual for more information 21.Connect the following connectors to the NEO controller adapter harness: •...
Page 25 Ford Transit London 22. Install the control panel and install the dome light bezel. Secure wiring harnesses as necessary (20). 23. Route the power portion of the blower harness and the NEO adapter harness under the flooring toward the battery compartment.
Page 26 London Ford Transit 25. Connect the ground wires to a good ground point. Route and secure the wiring to prevent chaffing. Do not connect the power wire at this time. 26. Connect the extreme board harness to the extreme board.
Page 27 Ford Transit London 28. Drill a 1 3/4 in. (45 mm) hole in the body cavity behind the driver’s seat. Paint the cut edge to protect against corrosion and install edge trim to protect the wires (20). 29. Route the following harnesses through the hole in the floor: •...
Page 28 London Ford Transit NOTE: Be sure to connect the thermostat connector to the brass terminals on the thermostat. 31.Connect the blower motor connector and the thermostat connector. Connect the blower harness ground connector to one of the London mounting bolts.
Page 29 Ford Transit London 34. Route the A/C compressor harness to the engine compartment. Using the supplied connector and the proper crimping tool, connect the A/C compressor electrical connector.
Page 30: A/C Hose Crimping
London Ford Transit 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.
Page 31 Ford Transit London 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 5012954A).
Page 32: Hose Installation
London Ford Transit Hose Installation Refer to the diagram below for a general overview of the system. NOTE: Not all kits will utilize the heating portions of this diagram.
Page 33 Ford Transit London NOTE: When working with constant-tension band clamps, always use tools designed for them. Using slip-joint, tongue-and-groove, or other types of pliers will compromise the integrity of the clamps. Failure to do so can cause leaks, damaging the vehicle.
Page 34: A/C Hose Installation
London Ford Transit A/C Hose Installation NOTE: Before cutting any hoses ensure there is enough hose for proper routing and securing of the hose. 35. Using a #6 90º fitting, route a high-pressure A/C hose from the evaporator through the hole drilled in the floor (51, 22, 52).
Page 35 Ford Transit London 38.Using a #10 45º fitting (47), route the low- pressure A/C hose from the service fitting to the A/C compressor. 39.Using a #8 45º fitting (42, 23) route the high- pressure hose from the compressor to the area of the condenser.
Page 36 London Ford Transit 41. Using the #6 180º fitting (50), connect the filter/dryer output port. 42.Using a #6 45º and a #6 90º fitting (41, 45, 22), connect the filter/dryer input port to the condenser outlet port. 43. Using the #8 90º fitting (48), connect the hose from the service port to the condenser assembly.
Page 37: Heater Hose Installation
Ford Transit London Heater Hose installation. 44.Using a short length of hose, install a bleeder valve to the return (upper) port on the London HVAC unit (26, 73, 77). 45. Route the coolant hose from the bleeder valve to the coolant valve inlet (upper) port (73).
Page 38 London Ford Transit NOTE: The following step applies only to vehicles with factory up-fitter ports. NOTE: When using the factory up-fitter ports, two 3/4” to 5/8” reducers are used. 47. Connect the return and supply hoses to the appropriate up-fitter ports (73).
Page 39 Ford Transit London NOTE: Do not secure the drain hose to the other hoses at the roof level. The drain hose must be lower than the London HVAC unit. 50. Connect the drain hose to the London HVAC unit. Tie both sides together with a “T” fitting (64).
Page 40: Initial Start
Ford Transit Initial Start Parts needed for initial start: Item Part Number Description Quantity Number 5010740A LABEL - SERIAL NUMBER 6290321660B DIFFUSER 5011593A SCREW SELF DRILLING - BLACK 62U003AA093A COVER - EVAPORATOR 5011556A INSULTATION HOSE 5011771A LABEL - REFRIGERANT CHARGE...
Page 41: Wiring Diagram
Ford Transit Wiring Diagram NEO 2 Extreme Kit...
Page 42: Extreme Board
Ford Transit Extreme Board...
Page 43 Ford Transit NEO 1 and NEO 2 Controller Templates...
Page 44 Webasto Product N.A., Inc. Technical Assistance Hotline USA: (800) 555-4518 Canada: (800) 667-8900 www.webasto.us Org.: 10/2019 Rev.: 01/2021 www.techwebasto.com...