Webasto Transit Vancouver Extended Body Manual
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Webasto Transit Vancouver Extended Body Manual

Webasto Transit Vancouver Extended Body Manual

Vac kit ford transit 2015 - present 3.5 liter
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Transit
Vancouver
VAC Kit Vancouver Transit
Extended Body
Legend
1 Vancouver VAC Unit Assembly
2 Condenser Assembly
Special Tools
– Oetiker pliers
– Rivnut installation tool
– Hole saw kit
– Refrigerant recovery and recharging machine
– Weather-Pack/Metri-Pack crimping tool 12085270
DOC P/N 5012698B
1
2
KIT P/N 5012697
Ford Transit
2015 - Present 3.5 Liter
148" Wheelbase - High-roof - Extended body
For kit 5012697
Special instructions for these models
Part locations may differ slightly dependent on
the vehicle-specific configuration.
Printed in USA
Webasto N.A., Inc.

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Summary of Contents for Webasto Transit Vancouver Extended Body

  • Page 1 1 Vancouver VAC Unit Assembly 2 Condenser Assembly Special Tools – Oetiker pliers – Rivnut installation tool – Hole saw kit – Refrigerant recovery and recharging machine – Weather-Pack/Metri-Pack crimping tool 12085270 DOC P/N 5012698B KIT P/N 5012697 Printed in USA Webasto N.A., Inc.
  • 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

    Table of Contents Kit Contents with Part Numbers ..........4 INTRODUCTION .

  • Page 4: Kit Contents With Part Numbers

    Vancouver Ford Transit Kit Contents Item Part Number Description Quantity Number 5011605B BRACKET LONDON REAR MOUNT TRANSIT 62U00025459C UNDER CHASSIS CONDENSER 5010279A BOLT HEX M6-1 6G X 16 8.8 ZP DIN 933 VAC KIT VANCOUVER 12V W-THERMO- 5012085B STAT 62017067A FILTER DRYER R134A 62036025D SUPPORT - FILTER...
  • Page 5 Ford Transit Vancouver 5011741A BRACKET ANGLE CONDENSER REAR 5011706A BRACKET ANGLE CONDENSER FRONT 5011761A BAG COMPRESSOR CLUTCH CONNECTOR 5012221A BRACKET ADAPTER VANCOUVER 629070001A ANTI COND TAPE M9ROL 1 METER 5011428A CAP SCREW SOCKET HD M6-1 12mm SS SCREW PAN HD 10-16ST x 1 SELF 902006 DRILLING 5001085A...
  • Page 6 Vancouver Ford Transit 5011984A BRACKET UNDERBODY RH 5011606A BRACKET UNDERBODY LH 620406 CABLE TIE 11 INCH BLACK 5011030B FITTING REFRIG 45 -10THD TO -10H 5011002B FITTING REFRIGERANT 90 -6CONN -6HOSE PPC201065A TXV MOUNTING PLATE OUTER REFRIGERANT HOSE BURGAFLEX H-06- 5011164A 7 METERS 3090-R 62U003AA020B...
  • Page 7 Ford Transit Vancouver 6233268A BAG PRESSURE SWITCH 035OFF-21ON REFRIGERANT HOSE BURGAFLEX H-10- 5011166A 3090-R METERS 5011231B SPLICER IN LINE -08HOSE WITH PORT REFRIGERANT HOSE BURGAFLEX H-08- 5011165A 9 METERS 3090-R 5011010B FITTING REFRIGERANT 90 -08THD -08HOSE MANUAL INSTALL VANCOUVER TRANSIT 5012698B 5011029B FITTING REFRIGERANT 45 -08THD -08HOSE...
  • Page 8 Vancouver Ford Transit 5012513A BASIC BOARD 5012514A EXTREME BOARD 5012655A BOARD BRACKET KIT 5011593A SCREW 4.2 X 16MM SELF DRILLING BLACK 5011082C WARRANTY STATEMENT AC 5011232B SPLICER IN LINE -10HOSE WITH PORT 5012015A WASHER FLAT M6x18x1.6 ZP DIN933 5011487A SCREW SELF DIRLLING 0.25 X 1 INCH 5011005B FITTING REFRIGERANT 90 -12THD -10HOSE PRESSURE SWITCH 3 LEVEL SICEB CONN...
  • Page 9 Ford Transit Vancouver 5011493A RIVET NUT HEAVY DUTY m8 5000413A HEAT SLEEVE - ORANGE 1 METER 5011592A RUBBER GROMMIT - 2 INCH 5012577A AC CONTROL HARNESS - SWITCH 5012448A BATTERY POSITIVE CABLE 6AWG 5012009A JUMPER - GROUND 5012572A JUMPER - BOARD TO BOARD 5012571A JUMPER - POSITIVE 5012570A...
  • Page 10 Ford Transit Vancouver 5012643A COMPRESSOR HARNESS 5012586A LP SWITCH HARNESS 5012113A CONTROL HEAD ASSY AC TRANSIT 5012420A BLOWER HARNESS 689184 M5 NUT 5012652A FUSE - 70 AMP MIDI...

  • 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

    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 13: Safety

    Section 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: Vehicle And Kit Preparation

    Ford Transit Vancouver General References NOTE: Due to production variation, some images in this manual may not represent the vehicle you are working on. • Bare sheet metal, for example around drilled holes, must be treated with anti-corrosive coating. • Secure hoses, cables and wiring harnesses with cable ties and fit protective hoses around them at chafing points.
  • Page 15 1. Expand the 6 existing holes on the condenser (2) to 4mm. 2. Install the condenser reinforcement brackets (11,12) on the condenser using 6 M4 bolts and nuts (40,41). 3. Install the Vancouver top bracket (14) to the Vancouver unit (4) using 4 bolts (7).

  • Page 16: Kit Component Installation

    Parts Required for Kit Component Installation Item Part Number Description Quantity Number 5011594 THREADED PLATE M8X1.25 905163 BOLT HEX M8-1.25 6G x 25 8.8 ZP DIN933 902713 WASHER FLAT 0.3125 x 0.75 x 0.062 ZP 5012567 BRACKET LONDON TRANSIT WAGON 5001321 BOLT HEX M6-1.0X20 5001322...
  • Page 17 Ford Transit Vancouver 4. Insert the three threaded plates (19) into the support ribs as shown. 5. Using three M8 bolts (42) and washers (43) in the front and two M6 bolts (7) and nuts (21) in the rear, install the upper bracket (1) to the vehicle.
  • Page 18 Vancouver Ford Transit 7. Drill 2 existing holes to 0.5 in. (13 mm) and install two threaded inserts (55). 8. Install the condenser mounting brackets (22, 23) using 4 M8 bolts (42) and washers (43). Two existing holes will be used, as well as the threaded inserts.
  • Page 19 Ford Transit Vancouver 10. Mount the filter/dryer (5, 6) to the condenser mount bracket using two M6 bolts and nuts (7, 21). 53) to the filter/ 11. Mount the pressure switch ( dryer. NOTE: The location of this hole is not critical, but it must avoid the factory-equipped rear HVAC module, if equipped.

  • Page 20: A/C Hose Crimping

    Vancouver 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. B.
  • Page 21 Ford Transit Vancouver D. Lubricate the fitting with PAG oil and insert the fit- ting until the shoulder of the fitting is touching the clip holder. E. Using Oetiker pliers, crimp the clips closed.

  • Page 22: Hose Installation

    Ford Transit Parts required for Hose Installation Item Part Number Description Quantity Number 5011008 FITTING REFRIGERANT 90 -06THD -06HOSE 5011164 REFRIGERANT HOSE BURGAFLEX H-06-3090-R As needed 5011010 FITTING REFRIGERANT 90 -08THD -08HOSE 5011165 REFRIGERANT HOSE BURGAFLEX H-08-3090-R As needed 5011166 REFRIGERANT HOSE BURGAFLEX H-10-3090-R As needed 5000413...
  • Page 23 Ford Transit Vancouver 13. Using two #6 90º fittings (30) connect a high- pressure hose (28) from condenser output port to the input port on the filter/dryer. 14. Connect a #6 90º fitting (30) to the output on the filter/dryer and route the hose (28) through the hole drilled in the floor.
  • Page 24 Vancouver Ford Transit NOTE: Cover the ends of the hose with tape to prevent debris from entering the hose. 16.Route #10 A/C hose (34) from the area of the A/C compressor through the hole in the floor. Leave enough hose to connect to the evaporator assembly.
  • Page 25 Ford Transit Vancouver NOTE: Factory-equipped rear HVAC components shown. These may not be present. 19. Route the A/C hoses up the e-pillar to the area where the Vancouver unit (18, 24). 20. Install the pressure switch (33) on the low- pressure hose using the splice fitting (31).
  • Page 26 Vancouver Ford Transit 22.Using the #6 90º fitting (26), connect the high-pressure hose to the Vancouver assembly. Tighten the TXV plate. NOTE: Trim the drain hose at a 45º angle, away from the direction of travel. 23.Using the drain t (32) and the drain hose (4), connect the two drain ports together.

  • Page 27: Electrical Installation

    Ford Transit Vancouver Parts Required for Electrical Installation Item Part Number Description Quantity Number 5001085 CABLE TIE HEAVY DUTY BLACK As needed 620406 CABLE TIE 11 INCH BLACK As needed 5012655 BOARD BRACKET KIT 5012513 BASIC BOARD 5012514 EXTREME BOARD 5012652 FUSE - 70 AMP MIDI 5012577...

  • Page 28: Basic Board Layout

    Ford Transit Basic Board Layout Note: Some connections may not be used in this installation. Note: The refrigerant valve/compressor connector can be plugged in two different ways. Be sure the power wire is on the correct terminal. Refer to the wiring diagram for more information.

  • Page 29: Extreme Board Layout

    Ford Transit Vancouver Extreme Board Layout...
  • Page 30 Vancouver Ford Transit 24. Remove the factory HVAC duct, if applicable. Using the board bracket kits (46), install the basic and extreme circuit boards (44, 45) above the side-curtain air bags using self- tapping screws. 25. Replace one of the 60 amp fuses with the supplied 70 amp fuse (71).
  • Page 31 Ford Transit Vancouver 27. Connect the positive wire (59) to the fuse installed earlier and the basic board. NOTE: The package tray is shown installed for clarity. 28.Route the control harness to the area above the rear-view mirror. NOTE: The wiring must be routed above and behind the air bags.
  • Page 32 Vancouver Ford Transit 30. Route the wiring for the condenser fans (65), HP/LP switch (64), and A/C compressor (66) from the electrical boards, down the e-pillar and through the hole in the floor. 31. Connect the following harnesses to the electrical boards and to the Vancouver unit: •...
  • Page 33 Ford Transit Vancouver 33. Connect the condenser fan connectors. 34. Route the A/C compressor harness to the engine compartment. Using the supplied connector (13) and the proper crimping tool, connect the A/C compressor electrical connector. 35. Secure the wiring harness to protect against heat and chaffing (18, 24).
  • Page 34 Vancouver Ford Transit 36. Drill two 1 3/4 in (45 mm) holes in the map light housing as indicated. NOTE: The map light is shown installed for clarity. Do not install the dome light at this time. 37.Connect the wiring connector and install the control panel (68) using four screws (20).

  • Page 35: Initial Start

    Ford Transit Vancouver Initial Start Item Part Number Description Quantity Number 629070001 ANTI COND TAPE M9ROL As needed 5001085 CABLE TIE HEAVY DUTY BLACK As needed 620406 CABLE TIE 11 INCH BLACK As needed 62U003AA020 AIR DUCT 4 GRIGLIE D67 NERO 5011593 SCREW 4.2 X 16MM SELF DRILLING BLACK 5011771...

  • Page 36: Wiring Diagram - Basic

    Ford Transit Wiring Diagram - Basic...

  • Page 37: Wiring Diagram - Extreme Components

    Ford Transit Wiring Diagram - Extreme Components...
  • Page 38 Ford Transit...
  • Page 39 Ford Transit Vancouver...
  • Page 40 Webasto Product N.A., Inc. Technical Assistance Hotline USA: (800) 555-4518 Canada: (800) 667-8900 www.webasto.us Org.1/2018 Rev. 01/2021 www.techwebasto.com...

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