Webasto 5011764 Manual
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Webasto 5011764 Manual

Webasto 5011764 Manual

Mercedes sprinter kiev 2015 - 2018 3.0 liter 170” wheelbase high roof underbody condenser
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Sprinter
Extreme Climate - Underbody Condenser
Legend
1 Kiev HVAC assembly
2 Coolant pump
3 Condenser assembly
Special Tools
– Oetiker pliers
– Weather-Pack/Metric-Pack crimping pliers
– Hole saw kit
– Refrigerant recovery and recharge machine
– Riv-Nut installation tool
DOC P/N 5011864B
KIT P/N 5011764
Kiev
2
3
1
Printed in USA
Webasto N.A., Inc.
Mercedes Sprinter
2015 - 2018 3.0 Liter
170" Wheelbase
High Roof
For kit #5011764
Special instructions for these models
Part locations may differ slightly dependent
on the vehicle model.
Due to vehicle build variations, it may be
necessary to utilize an A/C compressor
manifold with downward-facing ports.

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Summary of Contents for Webasto 5011764

  • Page 1 Extreme Climate - Underbody Condenser Mercedes Sprinter 2015 - 2018 3.0 Liter 170” Wheelbase High Roof For kit #5011764 Special instructions for these models Part locations may differ slightly dependent on the vehicle model. Due to vehicle build variations, it may be necessary to utilize an A/C compressor manifold with downward-facing ports.
  • 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

    Mercedes Sprinter Kiev Table of Contents INTRODUCTION ..........5 1.0 General Service and Safety Precautions .
  • Page 4 Kiev Mercedes Sprinter Kit Contents Kit Contents for Kit #5011764 Part Number Description Quantity 62U003CF051E Kit HVAC KIEV 12V 629069011 RACCORDO SCARICO COND.D.12 A T 9027035 BAG BRACKET U4847econ FOR TP50E 1317523 SP CIRCULATION PUMP U4840 12V STD 1320143 CONNECTING PIE 17/20, PLASTIC 5011505 BLEEDER VALVE COOLANT 0.625 COPPER...
  • Page 5 Mercedes Sprinter 667607 NUT KEP M8-1.25 6H ZP 5011741 BRACKET ANGLE CONDENSER RH 5011706 BRACKET ANGLE CONDENSER LH 5011765 BRACKET CONDENSER LH FRONT 5011766 BRACKET CONDENSER RH FRONT 5011767 BRACKET CONDENSER LH REAR 5011768 BRACKET CONDENSER RH REAR 905163 BOLT HEX M8-1.25 6G x 25 8.8 ZP DIN933 5011487 SCREW SELF DIRLLING 0.25 X 1 INCH 902006...

  • Page 6: 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 7: 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 8: 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 9: Preparation

    Mercedes Sprinter General References • Bare body parts, for example around drilled holes, must be treated with anti-corrosive coating. • Secure hoses, cables and wiring harnesses and fit protective hoses around them at chafing points. • Fit edge protectors (opened fuel hose, grommet, split-loom, etc.) to sharp edges. NOTE: Due to vehicle build variations, it may be necessary to utilize an A/C compressor manifold with downward-facing ports.

  • Page 10: Kiev Bracket Installation

    Kiev Mercedes Sprinter Kiev Bracket Installation 4. Temporarily install the Kiev mounting brackets and spacers on the Kiev HVAC unit. 5. Have an assistant hold the Kiev HVAC unit in position and mark the four mounting holes. 6. Drill four 1/2 in (13 mm) holes and install the M8 threaded inserts.

  • Page 11: Kit Components

    Mercedes Sprinter Kiev 7. Install the Kiev evaporator assembly. After verifying the positioning, remove the Kiev evaporator, leaving the brackets and spacers in place. 8. After temporarily installing the headliner, mark and cut the holes for the evaporator assembly mounts (X4) and the hose and harness pass-through (X1).
  • Page 12 Kiev Mercedes Sprinter NOTE: Lubricate the o-ring with PAG oil before installing the high-pressure switch. 10. Install the high-pressure switch into the receiver/dryer. Install the receiver/dryer on the right side of the vehicle in front of the right- rear tire. NOTE: The location is not critical.

  • Page 13: Condenser Installation

    Mercedes Sprinter Kiev 13. Mount the coolant pump to the cross- member. Condenser Installation 14. Drill the six holes in the condenser to 4 mm. 15. Install the condenser reinforcement brackets on the condenser.
  • Page 14 Kiev Mercedes Sprinter 16. Loosely install the condenser brackets on the condenser assembly. NOTE: The location of the condenser is not critical. The condenser must be far enough away, or protected from exhaust heat and any moving components. 17. Hold the condenser assembly in the desired installation location and mark the inner mounting points.
  • Page 15 Mercedes Sprinter Kiev 19. Hold the condenser in place and mark the outer mounting points. Drill a 13 mm hole and install the M8 threaded inserts. 20. Install the condenser and tighten all the fasteners at this time.

  • Page 16: A/C Hose Crimping

    Kiev Mercedes Sprinter 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 17 Mercedes Sprinter Kiev 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.

  • Page 18: A/C Hose Installation

    Kiev Mercedes Sprinter A/C Hose Installation NOTE: The following diagram is intended to show hose sizes and basic connections only. Refer to the individual steps for additional information. NOTE: Route hoses in a location/manner that protects them from heat, moving parts, pinch-points, etc.
  • Page 19 Mercedes Sprinter Kiev 21. Route the A/C hoses into the engine compartment. Use the provided heat sleeve as needed. 22.Using the #12 90 degree service fitting, route the #12 A/C hose from the A/C compressor through the hole in the passenger side step- well, along the roof-line, to the area where the Kiev unit will be located.

  • Page 20: Coolant Hose Installation

    Kiev Mercedes Sprinter 24. Using a #6 90º fitting, route the #6 A/C hose from the condenser to the inlet side of the receiver/dryer. 25. Using the #8 straight fitting, route the high- pressure hose from the A/C compressor to the #8 fitting on the condenser.
  • Page 21 Mercedes Sprinter Kiev 27. Route 3/4 in. coolant hose from the supply “T” fitting to the inlet side of the coolant pump. 28. Route 5/8 in. coolant hose from the adapter installed on the coolant pump, through the hole in the driver’s side step-well, and along the roof-line, to the area where the Kiev will be mounted.

  • Page 22: Wiring Installation

    Kiev Mercedes Sprinter 30. Route the 5/8 in. coolant hose from the inlet side of the coolant valve to the area where the Kiev unit will be located. Leave enough hose to connect to the Kiev unit. Wiring Installation 31. Unbolt the driver’s seat base from the vehicle and raise the seat enough to pass the following harness legs into the area under the driver’s seat:...
  • Page 23 Mercedes Sprinter Kiev 33. Mount the fuse block under the driver’s seat. 34. Pass the power cable through the boot under the driver’s seat. NOTE: Due to vehicle build variations, this image may not be representative. 35. Attach the ground cable to an appropriate ground point under the driver’s seat.
  • Page 24 Kiev Mercedes Sprinter NOTE: Due to vehicle build variations, this image may not be representative. 36. Using the supplied 7.5 amp fuse and fuse holder, connect the pink wire to an ignition- switched circuit under the driver’s seat. 37. Pass the following harness legs through the hole drilled in the driver’s step well: •...
  • Page 25 Mercedes Sprinter Kiev 39. Remove the foam block at the top of the driver’s side b-pillar. 40. Route the control harness above the driver’s door and windshield to the area above the rear-view mirror. 41. Route the wiring harness along the roof line to the area where the Kiev unit will be mounted.
  • Page 26 Kiev Mercedes Sprinter 42. Connect the coolant valve electrical connector. NOTE: This A/C compressor may not be representative. 43. Cut the connector(s) off the compressor if necessary. The connector housing and pin(s) that are supplied with the wiring harness will be used.
  • Page 27 Mercedes Sprinter Kiev 45. Connect the red power cable to the 12V power lug next to the battery box. 46. Connect the coolant pump electrical connector. 47. Insert the pins in the connectors for the condenser fans. Refer to the wiring diagram in this manual for more information.
  • Page 28 Kiev Mercedes Sprinter 48. Connect the electrical connectors for the condenser fans. 49. Insert the pins in the high-pressure switch housing. Refer to the wiring diagram in this manual for more information. 50. Connect the high-pressure switch electrical connector.

  • Page 29: Kiev Condenser Installation

    Mercedes Sprinter Kiev NOTE: The controller can be installed in any preferred location. A headliner installation was used in this example. 51. Trim the headliner as indicated. After connecting the electrical connector, install the controller and all headliner sections. Kiev Condenser Installation 52.
  • Page 30 Kiev Mercedes Sprinter NOTE: Use PAG oil to lubricate the o-ring before assembly. 54. Using a short section of #12 hose, a 45º #12 fitting, the low-pressure switch splice fitting, and the low-pressure switch, make a low- pressure switch hose. 55.

  • Page 31: Drain Hoses And Misc

    Mercedes Sprinter Kiev 57. Connect the blower motor (1) and thermostat (2) electrical connectors. Drain Hoses and Misc. 58. Using the provided “T” fitting, connect both drain hoses at the right side of the Kiev unit. NOTE: The drain hose should always run down-hill from the Kiev unit.
  • Page 32 Mercedes Sprinter Kiev NOTE: Headliner shown removed for clarity. 60. Drill a 3/4 in (19mm) hole in the lower body panel and route the drain hose from the Kiev unit, through the headliner, to the exterior of the vehicle. 61. Cut the drain hose about 1 in. (24 mm) past the hole.

  • Page 33: A/C System Charge

    Mercedes Sprinter Kiev A/C System Charge Charge the system using the chart below: Coolant System: 62. Start the engine and monitor the coolant level, add as necessary. Follow the vehicle manufacturer’s recommendation for coolant type. NOTE: The A/C button must be OFF for the pump to activate. 63.

  • Page 34: Wiring Diagram

    Kiev Mercedes Sprinter Wiring Diagram...
  • Page 35 Kiev Mercedes Sprinter Wiring Diagram (cont’d)
  • Page 36 Webasto Product N.A., Inc. Technical Assistance Hotline USA: (800) 555-4518 Canada: (800) 667-8900 www.webasto.us Org.11/2016 Rev. 08/2019 P/N 5011864B www.techwebasto.com...

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