Webasto ProMaster Vancouver Standard Manual
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Webasto ProMaster Vancouver Standard Manual

Webasto ProMaster Vancouver Standard Manual

Ram promaster 2015 - present
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ProMaster
Standard
1
Legend
1 Vancouver VAC unit Assembly/Refrigerant Valve
Special Tools
– Burgaflex crimping pliers (Webasto P/N 5012954A)
– Hole saw kit
– Refrigerant recovery and recharging machine
– Right-angle drill
DOC P/N 5013003B
KIT P/N 5013004A
Vancouver
Printed in USA
Webasto Thermo & Comfort N.A., Inc.
Ram ProMaster
2015 - Present
All wheelbases
Single sliding door only
For kit number 5013004A
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 ProMaster Vancouver Standard

  • Page 1 Part locations may differ slightly dependent on the vehicle-specific configuration. Legend 1 Vancouver VAC unit Assembly/Refrigerant Valve Special Tools – Burgaflex crimping pliers (Webasto P/N 5012954A) – Hole saw kit – Refrigerant recovery and recharging machine – Right-angle drill DOC P/N 5013003B...
  • 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.

  • Page 4: Table Of Contents

    ........... . . 36 Webasto Limited Non-Transferable Warranty...

  • Page 5: Kit Contents With Part Numbers

    Ram ProMaster Vancouver Item Part Number Description Quantity Number 620681053R 2-WAY SOLENOID VALVE 12V 5011556A INSULATION HOSE ID 0.875IN X 6FT LONG 5012081A BRACKET VANCOUVER PROMASTER LEFT BRACKET VANCOUVER PROMASTER 5012082A RIGHT 5011082C WARRANTY STATEMENT AC INSTALL MANUAL VANCOUVER 5013003A PROMASTER FM VAC ASSY VANCOUVER 12V W-THERMO- 5012085B...
  • Page 6 Vancouver Ram ProMaster 5011511A MOUNTING PLATE LONDON PROMASTER 5011506A HOSE DRAIN ID 0.4375 INCH 3.5 M 5012812B CONTROLLER - NEO 1 HVAC WIRE HARNESS SOLENOID VALVE 5012430 9000mm 5012882A WIRE HARNESS ADAPTER NEO 1 5500MM HVAC WIRE HARNESS T-STAT or LP 5012587A 8600mm WIRE HARNESS BLOWER NEO 4000-...
  • Page 7 Ram ProMaster Vancouver 620406 CABLE TIE - 11 INCH 5013147A BAG - AC SMALL PARTS PROMASTER FITTING 45 REFRIGERANT -12CONN - 5011026A 10HOSE 5011028A FITTING REFRIGERANT 45 -06THD -06HOSE 5011023A FITTING REFRIGERANT 45 -6CONN -6HOSE FITTING REFRIGERANT 45 -06MTHD - 5011202A 06HOSE 5011030A...
  • Page 8 Vancouver Ram ProMaster 5013075A BAG -AC T-BLOCK PROMASTER AND TRANSIT 5011384A AC T BLOCK KIT PROMASTER 5001054A BOLT - m8 X 1.25 X 60 5013074A BAG - WASHERS SLIMLINE 5013149A BAG - HARDWARE PARTS VANCOUVER PROMASTER 5011593A SCREWS - BLACK 902006A SCREW - PAN HEAD - SELF TAPPING 5011487A...

  • 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

    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 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

    Vancouver Ram ProMaster 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 Ram ProMaster Vancouver 5. Center the Vancouver unit on the package tray and mark where the package tray interferes with the brackets. NOTE: The Vancouver unit is shown installed for clarity. 6. Trim notches into the package tray to allow the Vancouver brackets to pass through.
  • Page 14 Vancouver Ram ProMaster 8. Insert the two threaded plates (11) through the access holes into the roof brace, one on each side of the vehicle. 9. Set the Vancouver in place. Do not install the fasteners at this time. 10.Drill a 2 in. (51mm) hole approximately 2.5 in (64 mm) behind the B-pillar and 2.5 in (64 mm) inboard of the left side of the vehicle.
  • Page 15 Ram ProMaster Vancouver NOTE: The upper and lower holes will not line up vertically. 11. Drill a 2 in (51 mm) hole in the chassis near the filler neck. Install edge protector (21) after protecting the cut edge from corrosion. 12.Trim the fuel filler shield as shown.

  • Page 16: Electrical Connections

    Vancouver Ram ProMaster NOTE: The location shown is not the only location where edge trim is necessary. 14. To prevent chaffing, install edge trim (21) to the portions of the body where wiring or hoses may rub. Electrical Connections Required parts for electrical connections: Item Part Number Description...
  • Page 17 Ram ProMaster Vancouver Refer to this graphic for electrical connections as needed. Ground 12V constant power NEO controller connections (*see below) Refrigerant valve or compressor Extreme board jumper Thermostat 12V Ignition on Blower ON signal wire Blower connector at Neo controller Blower connector at evaporator Blue Black...
  • Page 18 Vancouver Ram ProMaster NOTE: This step applies to front-mounted controllers only. 15.Remove the driver’s side knee-bolster. NOTE: This step applies to front-mounted controllers only. 16. Remove the coin holder from the dashboard, below and to the left of the steering wheel. NOTE: This step applies to front-mounted controllers only.
  • Page 19 Ram ProMaster Vancouver 18.Insert the blue wire labeled AC BLOWER ON from the NEO adapter harness (15) into cavity C of the blower harness X1 connector (17). 19. Connect the NEO adapter harness and the blower harness to the control panel (13). Mount the controller to the controller bracket.
  • Page 20 Vancouver Ram ProMaster NOTE: This step applies to front-mounted controllers only. 21.Connect the thermostat (16) and refrigerant valve harnesses (14) to the NEO adapter harness. Mount the NEO 1 assembly to the dashboard. 22. Bundle any unused connectors to the wiring harness and rout the wiring harness down the driver’s side a-pillar (20, 22).
  • Page 21 Ram ProMaster Vancouver 24. Route the wiring harnesses along the step- well and past the b-pillar. Route the power and ground connections to the battery box. Connect the power and ground connections to the battery. 25. Route the wiring harnesses up the b-pillar. Connect the blower-motor electrical connector.

  • Page 22: A/C Hose Installation

    Vancouver Ram ProMaster 27.Reassemble the connector and insert the locking screw. A/C Hose Installation NOTE: If you are unfamiliar with A/C hose crimping, refer to the steps on pages 26 and 27. NOTE: Lubricate all fitting o-rings with PAG oil prior to assembly. Parts required for hose installation: Item Part Number...

  • Page 23: Hvac System Diagram

    Vancouver Ram ProMaster Refer to the diagram below for a general overview of the system. NOTE: Not all kits will utilize the heating portions of this diagram. HVAC System Diagram...
  • Page 24 Vancouver Ram ProMaster 28.Place the refrigerant valve bracket (1) against the left wall of the package tray, positioning it as far forward as the tapered channel will allow. The single mounting hole should face the Vancouver unit. 29. Attach the mounting bracket to the package tray using two #6 pan-head screws (36).
  • Page 25 Ram ProMaster Vancouver NOTE: The arrow on the bottom of the valve indicates the direction of flow. The arrow must face forward. 31. Install the refrigerant valve using the screw supplied with the valve. 32.Remove the nut and stud from the factory TXV.

  • Page 26: A/C Hose Crimping

    Vancouver Ram ProMaster 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. 34. Using blade-type hose cutters, cut the hose in one cut. The cut edge must be clean and flush. 35.
  • Page 27 Ram ProMaster Vancouver 37. Lubricate the fitting with PAG oil and insert the fitting until the shoulder of the fitting is touching the clip holder. 38.Using Oetiker pliers, crimp the clips closed. (Webasto P/N 5012954A) 39.Connect the thermostat electrical connector.
  • Page 28 Vancouver Ram ProMaster 40. Route the hoses through the hole in the floor. Using the 45º fitting (23), connect the #10 hose to the Vancouver unit. Loosely install the TXV mounting (29, 30, 31) plate at this time. NOTE: Both fittings are shown connected to the TXV for clarity only.
  • Page 29 Ram ProMaster Vancouver 43.Tighten the TXV mounting plate. 44. Install the Vancouver assembly using (A) two 1” self-tapping screws (37) and (B) two M6 bolts (38). NOTE: Lubricate the supplied O-rings with PAG oil before installation. 45. Install the magnetic coil on the refrigerant valve.
  • Page 30 Vancouver Ram ProMaster Notes...

  • Page 31: Drain Tube Installation

    Ram ProMaster Vancouver Drain Tube Installation Required parts for drain tube installation: Item Part Number Description Quantity Number 5011506A HOSE DRAIN ID 0.4375 INCH As needed 5001085A CABLE TIE - HEAVY DUTY BLACK As needed 620406 CABLE TIE - 11 INCH As needed 62U003AA020B AOR DUCT 4 GRIGLE D67 NERO...
  • Page 32 Vancouver Ram ProMaster 48.Drill a 5/8 in (16 mm) hole in two of the A- pillar trim stanchions as shown. 49. Drill a 5/8 in (16 mm) hole in the floor in the area indicated. Paint the cut edge to protect against corrosion.
  • Page 33 Ram ProMaster Vancouver WARNING: Be sure to route the drain hose in a way that will not interfere with airbag deployment. 51. Route the drain hose through the holes drilled in the A-pillar trim, then route the drain hose through the hole drilled in the body. 52.
  • Page 34 Vancouver Ram ProMaster 54. Cut the drain hoses approximately 1.5 in (38 mm) below the body at a 45º angle away from the direction of travel. Rout the left drain hose along the A/C hoses through the hole in the floor. Secure and trim the hose 1.5 in (38 mm) below the body at a 45º...

  • Page 35: Initial Start

    Ram ProMaster Vancouver Initial Start Required parts for the initial start: Item Part Number Description Quantity Number 5011627A LABEL REFRIGERANT CHARGE LABEL R134A 2.1 LBS 901406Z FUSE MINI 10 AMP RED 58. Recharge the vehicle per the manufacturer’s procedures using the chart below. Item Type Quantity...

  • Page 36: Wiring Diagram

    Ram ProMaster Vancouver Wiring Diagram...
  • Page 37 Ram ProMaster Vancouver Notes...

  • Page 38: Webasto Limited Non-Transferable Warranty

    Ram ProMaster Vancouver...
  • Page 40 Webasto Thermo & Comfort N.A., Inc. Technical Assistance Hotline USA: (800) 555-4518 Canada: (800) 667-8900 www.webasto.us Org.10/2018 Rev. 10/2020 P/N 5013003B www.techwebasto.com...

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Ram promaster 2015

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