Webasto Transit Vancouver Wagon Manual
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Webasto Transit Vancouver Wagon Manual

Webasto Transit Vancouver Wagon Manual

Vac kit ford transit 2015 - present 3.5 liter
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Transit
Vancouver
VAC Kit Vancouver Transit Wagon
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 5012631B
1
2
KIT P/N 5012603
Ford Transit
2015 - Present 3.5 Liter
148" Wheelbase - High-roof - Wagon body
For kit 5012603
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 Wagon

  • 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 5012631B KIT P/N 5012603 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 ............. . . 4 INTRODUCTION .

  • Page 4: Kit Contents

    Vancouver Ford Transit Kit Contents Item Part Number Description Quantity Number 5012567 BRACKET LONDON TRANSIT WAGON 62U00025459 UNDER CHASSIS CONDENSER 5010279 BOLT HEX M6-1 6G X 16 8.8 ZP DIN 933 VAC KIT VANCOUVER 12V W-THERMO- 5012085 STAT 62017067 FILTER DRYER R134A 62036025 SUPPORT - FILTER 5001321...
  • Page 5 Ford Transit Vancouver 5011741 BRACKET ANGLE CONDENSER REAR 5011706 BRACKET ANGLE CONDENSER FRONT 5011761 BAG COMPRESSOR CLUTCH CONNECTOR 5012221 BRACKET ADAPTER VANCOUVER 629070001 ANTI COND TAPE M9ROL 1 METER 5011428 CAP SCREW SOCKET HD M6-1 12mm SS SCREW PAN HD 10-16ST x 1 SELF 902006 DRILLING 5001085...
  • Page 6 Vancouver Ford Transit 5011984 BRACKET UNDERBODY RH 5011606 BRACKET UNDERBODY LH 620406 CABLE TIE 11 INCH BLACK 5011030 FITTING REFRIG 45 -10THD TO -10H 5011002 FITTING REFRIGERANT 90 -6CONN -6HOSE PPC201065 TXV MOUNTING PLATE OUTER REFRIGERANT HOSE BURGAFLEX H-06- 5011164 6 METERS 3090-R 62U003AA020...
  • Page 7 Ford Transit Vancouver 6233268 BAG PRESSURE SWITCH 035OFF-21ON REFRIGERANT HOSE BURGAFLEX H-10- 5011166 3090-R METERS 5011231 SPLICER IN LINE -08HOSE WITH PORT REFRIGERANT HOSE BURGAFLEX H-08- 5011165 8 METERS 3090-R 5011010 FITTING REFRIGERANT 90 -08THD -08HOSE MANUAL INSTALL VANCOUVER TRANSIT 5012631B 5011029 FITTING REFRIGERANT 45 -08THD -08HOSE...
  • Page 8 Vancouver Ford Transit 5012513 BASIC BOARD 5012514 EXTREME BOARD 5012655 BOARD BRACKET KIT 5011593 SCREW 4.2 X 16MM SELF DRILLING BLACK 5011082 WARRANTY STATEMENT AC 5011232 SPLICER IN LINE -10HOSE WITH PORT 5012015 WASHER FLAT M6x18x1.6 ZP DIN933 5011487 SCREW SELF DIRLLING 0.25 X 1 INCH 5011005 FITTING REFRIGERANT 90 -12THD -10HOSE PRESSURE SWITCH 3 LEVEL SICEB CONN...
  • Page 9 Ford Transit Vancouver 5011493 RIVET NUT HEAVY DUTY m8 500413 HEAT SLEEVE - ORANGE 1 METER 5011592 RUBBER GROMMIT - 2 INCH 5012577 AC CONTROL HARNESS - SWITCH 5012448 BATTERY POSITIVE CABLE 6AWG 5012009 JUMPER - GROUND 5012572 JUMPER - BOARD TO BOARD 5012571 JUMPER - POSITIVE 5012570...
  • Page 10 Ford Transit Vancouver 5012643 COMPRESSOR HARNESS 5012586 LP SWITCH HARNESS 5012630 CONTROL HEAD ASSY AC TRANSIT 5012420 BLOWER HARNESS 689184 M5 NUT 5012652 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

    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 14: Vehicle 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 5011493 RIVET NUT HEAVY DUTY m8 905163 BOLT HEX M8-1.25 6G x 25 8.8 ZP DIN933 5012567 BRACKET LONDON TRANSIT WAGON 5011594 THREADED PLATE M8X1.25 5011493 RIVET NUT HEAVY DUTY m8 5011984 BRACKET UNDERBODY RH 5011606...
  • Page 17 Ford Transit Vancouver 4. Place the 3 threaded plates (19) in the locations as shown. 5. Using 3 M8 bolts (42), install the upper evaporator bracket (1). 6. Hold the rear headliner section in place. Mark and slot the headliner to clear the upper bracket mounting tabs.
  • Page 18 Vancouver Ford Transit 7. Cut a hole in the headliner, approximately 2 in X 12 in (51mm X 305 mm) behind the Vancouver unit, but concealed by the evaporator trim piece. Cut a piece of hardboard (lauan or similar) that will be above the headliner to mount the air-handler trim to.
  • Page 19 Ford Transit Vancouver 10. Install the condenser assembly to the condenser bracket using 4 M6 bolts (7). 11. Mount the filter/dryer (5,6) to the condenser mount bracket using two M6 bolts and nuts (7,21). 53) to the filter/ 12. Mount the pressure switch ( dryer.

  • 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 5011592 RUBBER GROMMIT - 2 INCH 5011164 REFRIGERANT HOSE BURGAFLEX H-06-3090-R As needed 5011165 REFRIGERANT HOSE BURGAFLEX H-08-3090-R As needed 5011166 REFRIGERANT HOSE BURGAFLEX H-10-3090-R As needed 500413 HEAT SLEEVE - ORANGE 5011008...
  • Page 23 Ford Transit Vancouver NOTE: The location of this hole is not critical, but it must avoid the factory-equipped rear HVAC module. 13. Drill a 2 in (51 mm) hole approximately 2.5 in (64 mm) from the side wall, and approximately 3.5 in (89 mm) from the chassis outrigger.
  • Page 24 Vancouver Ford Transit 16. Using a #8 90º fitting (37), route A/C hose (36) from the condenser to the auxiliary A/C compressor. Do not connect the hose to the compressor at this time. NOTE: Cover the ends of the hose with tape to prevent debris from entering the hose.
  • Page 25 Ford Transit Vancouver NOTE: Install the service fittings with fittings parallel to the ground, or slightly upward to prevent the service caps retaining water. 19.Route and secure the A/C hoses along the chassis (18, 24, 9, 51). In a location that provides service access, cut the A/C hoses and install the two service ports (35,49).

  • Page 26: Electrical And Hose Installation

    Ford Transit Vancouver Parts Required for Electrical and Hose Installation Item Part Number Description Quantity Number 5012655 BOARD BRACKET KIT 5012513 BASIC BOARD 5012514 EXTREME BOARD 5011487 SCREW SELF DIRLLING 0.25 X 1 INCH As needed 5012577 AC CONTROL HARNESS - SWITCH 5012448 BATTERY POSITIVE CABLE 6AWG 5012570...
  • Page 27 Ford Transit This page intentionally left blank...

  • Page 28: Refrigerant System Diagram

    Vancouver Ford Transit Refrigerant System Diagram...

  • Page 29: Basic Board Layout

    Ford Transit Basic Board Layout Note: Some connections may not be used in this installation.

  • Page 30: Extreme Board Layout

    Ford Transit Extreme Board Layout...
  • Page 31 Ford Transit Vancouver 21. 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. 22. Replace one of the 60 amp fuses with the supplied 70 amp fuse (71).
  • Page 32 Vancouver Ford Transit NOTE: The wiring must be routed above and behind the air bags. NOTE:Route the battery power and ground har- nesses (59, 63) along the roof-line of the vehicle to the circuit boards. Connect to the basic circuit board using the longer +BAT and -GND posts.
  • Page 33 Ford Transit Vancouver 26. Connect the following harnesses to the boards: • LP switch (67) • Thermostat (67) • Blower fans (69) Glue the reinforcement board to the top of the head- liner. Install the headliner segments, routing the A/C hoses and the wiring through the pass-through cut into the headliner and reinforcement board.
  • Page 34 Vancouver Ford Transit 29. Make the following connections at the Vancouver unit: 1. thermostat 2. blower motors 3. pressure switch 30. Using the drain T (32) and the drain hose (4), connect the two drain ports together. Route the drain hose through the headliner, down the body in the right-rear corner and through an existing hole in the body.
  • Page 35 Ford Transit Vancouver 32. Connect the filter/dryer connector. 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.
  • Page 36 Vancouver Ford Transit 35. Remove the storage compartment insert. Plug in and install the control panel (68) in the overhead storage bin. 36. Secure the wiring harness to protect against heat and chaffing (18, 24, 17).

  • Page 37: 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 38: Wiring Diagram - Basic

    Ford Transit Wiring Diagram - Basic...

  • Page 39: Wiring Diagram - Extreme Components

    Ford Transit Wiring Diagram - Extreme Components...
  • Page 40 Ford Transit...

  • Page 41: Limited Warranty

    Replacement parts are covered for six (6) months or the remainder of the original warranty period, whichever is longer. The intent of the Webasto warranty is to protect the original end-user of the Air Conditioning System from defects and provide free repair and replacement of defective parts in the manner provided herein. During the warranty period, the exclusive remedy will be for Webasto, at their discretion, to repair or replace those parts which are demonstrated to be defective in material or workmanship.
  • Page 44 Webasto Product N.A., Inc. Technical Assistance Hotline USA: (800) 555-4518 Canada: (800) 667-8900 www.webasto.us Org.08/2017 Rev. 08/2018 www.techwebasto.com...

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