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Sprinter
Standard
Legend
1 Vancouver VAC unit Assembly
2 Refrigerant Valve
Special Tools
– Hole saw kit
– Refrigerant recovery and recharging machine
DOC P/N 5013424A
KIT P/N 5013423A
Vancouver
2
1
Printed in USA
Webasto Thermo & Comfort N.A., Inc.
Sprinter
2006 - 2018 - 3.0 Liter
170" wheelbase
For kit number 5013423A
Special instructions for these models
Part locations may differ slightly dependent
on the vehicle-specific configuration.
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Summary of Contents for Webasto Sprinter Vancouver Standard
- Page 1 Legend 1 Vancouver VAC unit Assembly 2 Refrigerant Valve Special Tools – Hole saw kit – Refrigerant recovery and recharging machine DOC P/N 5013424A KIT P/N 5013423A Printed in USA Webasto Thermo & Comfort N.A., Inc.
- Page 3 – 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.
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Page 4: Table Of Contents
Sprinter Vancouver Table of Contents Kit Contents for 5012611 ..........5 Introduction . -
Page 5: Kit Contents For 5012611
Vancouver Sprinter Kit Contents for 5012423 Item Part Number Description Quantity Number VANCOUVER ASSEMBLY 12V W-THERMO- 5012085B STAT 62U003AA093A EVAPORATOR COVER 6290321660B DIFFUSER 5013424A INSTALLATION MANUAL 620681053RA 2-WAY SOLENOID VALVE 12V 5012221A BRACKET - ADAPTER VANCOUVER 5011082C WARRANTY STATEMENT 5011556A INSULATION HOSE ID 0.875IN X 6FT LONG 5012882A WIRE HARNESS ADAPTER NEO 1 5500 MM... - Page 6 Vancouver Sprinter 5013213A HOSE REFRIGERANT SIZE -6 X 11M LONG 5013167A HOSE REFRIGERANT SIZE -10 X 11 METERS 5012587A VAC WIRE HARNESS T-STAT or LP 8600mm WIRE HARNESS BLOWER NEO 5500- 5012876A 8100MM VAC WIRE HARNESS SOLENOID VALVE 5012430A 9000mm 5012816A BRACKET - NEO CONTROLLER 5012812B...
- Page 7 Sprinter Vancouver 5011195B FITTING REFRIG STR-06MTHD TO -06H FITTING REFRIGERANTSTR -10THD - 5011045B 10HOSE 5011002B FITTING REFRIGERANT 90 -6CONN -6HOSE 5011005B FITTING REFRIGERANT 90 -12THD -10HOSE 62A031060A TIE-IN ADAPTER 5013072A BAG - CABLE TIES AND EDGE TRIM 5011938A EDGE TRIM 0.125 X 0.5in. 2 feet 5001085A CABLE TIE - HEAVY DUTY BLACK...
- Page 8 Vancouver Sprinter 5001322A NUT - M6-1 SERRATED 5011929A SCREW SELF-DRILLING PAN HD 10X1.5Inch 629069011A TEE DRAIN HOSE 12MM OD 5011493A RIVET NUT HEAVY DUTY ALUM M8 X 1.25 5011487A SCREW SELF DIRLLING 0.25 X 1 INCH 5011593A SCREW 4.2 X 16MM SELF DRILLING BLACK 902713Z WASHER FLAT 0.3125 x 0.75 x 0.062 5000534A...
- Page 9 Sprinter Vancouver Notes...
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Page 10: 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 11: 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 12: 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 13: General References
Sprinter Vancouver 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. • Replace hose clamps as necessary. Hose clamps should be inspected before re-use. Look for damage to the screw and to the band due to fatigue, corrosion, or improper installation. - Page 14 Vancouver Sprinter 1. Mark and drill the four mounting holes for the Vancouver mounting bracket (10). Insert the four rivet nuts (39). Mount the Vancouver bracket using four bolts and washers (35, 42). 2. Install the lower bracket (6) to the Vancouver unit (1) using four M6 bolts (45).
- Page 15 Sprinter Vancouver NOTE: The arrow on the bottom of the refrigerant valve indicates the direction of refrigerant flow. 4. Using two self tapping screws (40), mount the refrigerant valve bracket to the vehicle. Mount the valve to the bracket using the included machine screw.
- Page 16 Vancouver Sprinter NOTE: A headliner-installation is typical. The control head can be mounted in any accessi- ble location. NOTE: When cutting the hole for the control head, be sure the area behind the location is clear of obstructions before cutting the hole. 7.
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Page 17: Electrical Connections
Sprinter Electrical Connections Item Part Number Description Quantity Number 902006Z SCREW PAN HD 10-16ST x 1 SELF DRILLING 5012882A WIRE HARNESS ADAPTER NEO 1 5500 MM 5012876A WIRE HARNESS BLOWER NEO 5500-8100MM 5012587A VAC WIRE HARNESS T-STAT or LP 8600mm 5012430A VAC WIRE HARNESS SOLENOID VALVE 9000mm 5001085A... -
Page 18: Electrical Installation
Vancouver Sprinter Electrical Installation Refer to the image below for electrical connections as needed Ground 12V constant power NEO controller connections (*see below) Refrigerant valve Extreme board jumper (not used) Thermostat 12V Ignition on Blower ON signal wire Blower connector at Neo controller Blower connector at evaporator See Item #3 Above Blue... - Page 19 Sprinter Vancouver 8. Insert the blue wire labeled AC BLOWER ON from the NEO adapter harness (9) into cavity C of the blower harness X1 connector (14). NOTE: Refer to the graphic and table on the previous page for more information. 9.
- Page 20 Vancouver Sprinter 11.Connect the pink wires to an ignition source [1] using the fuse holder. Secure the fuse holders (34). NOTE: The refrigerant valve connector is not polarity sensitive. 12.Route the refrigerant valve wiring harness to the refrigerant valve. Remove the screw from the refrigerant valve connector and remove the connector plate.
- Page 21 Sprinter Vancouver NOTE: Be sure to connect the thermostat con- nectors to the thermostat, not the grounding tabs on the housing. 14.Route the blower and thermostat harnesses to the evaporator unit. Connect the thermistor and blower motor connections. Connect the ground eyelet to a good chassis ground.
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Page 22: Hose Installation
Hose Installation Sprinter Item No. Part Number Description Quantity 5011043B FITTING REFRIG STR -06THD TO -06H 5011195B FITTING REFRIG STR-06MTHD TO -06H 5011002B FITTING REFRIGERANT 90 -6CONN -6HOSE 5013213A HOSE REFRIGERANT SIZE -6 X 11M LONG As needed 5013071A BAG - TXV PLATE 5011005B FITTING REFRIGERANT 90 -12THD -10HOSE 5013167A... - Page 23 Vancouver Sprinter...
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Page 24: A/C Hose Crimping
Vancouver 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 25 Sprinter Vancouver 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 26 Vancouver Sprinter 15. Install the straight #6 fittings (21, 22) on the refrigerant valve. 16.Using the 90º fittings (24, 25), install the low- and high-pressure A/C hoses (11, 12) to the Vancouver assembly. After orienting the fittings, install the TXV plate (18). NOTE: The magnet will click into place when properly installed.
- Page 27 Sprinter Vancouver 18. Remove the stud and nut from the factory TXV. Set the manifold aside. NOTE: Lubricate the O-rings with PAG oil. 19. Clean all surfaces and install the tie-in fittings (27). NOTE: Lubricate the O-rings with PAG oil. 20.
- Page 28 Vancouver Sprinter 21. Using the drain tee (38) and the drain hose, connect the drains. Route the drain hose to the right or left D-Pillar. 22. Route the drain hose inside of the D-pillar. 23.Drill a 3/4 in (19 mm) hole in the body cavity and route the drain hose through the hole.
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Page 29: Initial Start
Sprinter Initial Start Item Part Number Description Quantity Number 5011556A INSULATION HOSE ID 0.875IN X 6FT LONG 5013253A ANTI-CONDENSATION TAPE As Needed 21499 TUBE CLAMP As Needed 5011487 SCREW SELF-DIRLLING - 0.25 X 1 in. As Needed 5001085A CABLE TIE - HEAVY DUTY BLACK As needed 620406Z CABLE TIE 11 IN.- BLACK... -
Page 30: Wiring Diagram
Sprinter Vancouver Wiring Diagram... - Page 31 Vancouver Sprinter NOTES...
- Page 32 Webasto Thermo & Comfort N.A., Inc. Technical Assistance Hotline USA: (800) 555-4518 Canada: (800) 667-8900 www.webasto.us Org.08/2019 Rev. 10/2020 www.techwebasto.com...
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