Table of Contents
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Transit
London
Extreme Climate
Under-body Condenser
Legend
1 London HVAC Unit Assembly
2 Coolant Valve
3 Coolant Pump
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 5011865
KIT P/N 5011815
1
2
3
Printed in USA
Webasto N.A., Inc.
Ford Transit
2015 - Present 3.5 Liter
148" wheelbase - All Roof Heights
For kit 5011815
Special instructions for these models
Part locations may differ slightly dependent on
the vehicle-specific configuration.
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Related Manuals for Webasto Transit London
Summary of Contents for Webasto Transit London
- Page 1 2 Coolant Valve 3 Coolant Pump 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 5011865 KIT P/N 5011815 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.
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Page 3: Table Of Contents
Ford Transit London Table of Contents Kit Contents ..............5 INTRODUCTION . -
Page 4: Kit Contents
London Ford Transit Kit Contents Kit Contents for kit # 5011815 Number Description Quantity 5011500A HVAC KIT LONDON 12V W-THERMOSTAT PPC201065A TXV MOUNTING PLATE OUTER 629069011A RACCORDO SCARICO COND.D.12 A T 5011428A CAP SCREW SOCKET HD M6-1 12mm SS 152560 FEDERRING DIN128-A6-PHRF 9027035A BAG BRACKET U4847econ FOR TP50E... - Page 5 Ford Transit London 5001322A NUT HEX FLANGE SERRATED M6-1 6H 8.8 ZP 5011592A GROMMET LOCK 2IN ID1 5-8IN BLACK 5011593A SCREW 4.2 X 16MM SELF DRILLING BLACK 21499A TUBE CLAMP D_b_d 62U00025459C UNDERCHASSIS CONDENSER HTC 14 kW 62043400B LOW PRESSURE SWITCH 62043118 PRESSURE SWITCH - 3 LEVEL 62U003AA020B...
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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: General References
Ford Transit General References • 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. • Fit edge protectors (split fuel hose, grommet, split-loom, etc.) to sharp edges. •... -
Page 10: Kit Components
London Ford Transit Kit Components 3. Mount the coolant valve near the left-rear wheel. 4. In front of the left-rear wheel, between the inner and outer body panels, drill two 1 3/4 inch (45 millimeters) holes, five inches (127 millimeters) apart. Remove the material between the holes and protect the cut edge against corrosion and wire chafing. - Page 11 Ford Transit London 6. Using the 0.25 in. X 3/4 in. self-tapping screw and coolant pump mount, secure the coolant pump to the chassis outrigger next to the fuel tank. 7. Install the receiver/dryer in the receiver/dryer mounting clamp. Loosely install the trinary switch in the receiver/dryer.
- Page 12 London Ford Transit 9. Expand the six existing holes on the condenser to 4mm. 10.Install the condenser reinforcement brackets on the condenser. NOTE: There are three right-angle con- denser mounting brackets. The ‘long side’ of the bracket attaches to the condenser assembly.
- Page 13 Ford Transit London NOTE: The condenser is installed on the left side of the vehicle next to the fuel tank. Refer to images in this manual for more detail. 12. Hold the condenser in place and mark the four mounting hole locations. NOTE: In some cases you will only have to drill three holes.
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Page 14: A/C Hose Crimping
London 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 15 Ford Transit London D. Lubricate the fitting with PAG oil and insert the fitting until the shoulder of the fit- ting is touching the clip holder. E. Using Oetiker pliers, crimp the clips closed.
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Page 16: Hose Installation
London Ford Transit Hose Installation NOTE: Before cutting any hoses ensure there is enough hose for proper routing and securing of the hose. 15. Using a #6 90º and a #6 180º fitting, connect a hose between the evaporator high- pressure port and the outlet of the receiver/ dryer. - Page 17 Ford Transit London 18. Using a #8 service fitting, connect the A/C hose to the A/C compressor using #8 45º fitting. Using a #10 45º fitting and a #10 service fitting, route the A/C line from the compressor to the service fitting location. 19.
- Page 18 London Ford Transit 21. Route the coolant return hose between the bleeder valve and the inlet side of the coolant valve. The bleeder valve should be facing up. NOTE: Coolant hoses removed for clarity. 22. Route the rest of the return hose from the outlet of the coolant valve through the hole drilled in the floor.
- Page 19 Ford Transit London NOTE: The following step applies only to vehicles with factory up-fitter ports. NOTE: When using the factory up-fitter ports, two 3/4” to 5/8” reducers are used. 24. Connect the return and supply hoses to the appropriate up-fitter ports. NOTE: A 3/4 in.
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Page 20: Electrical Installation
London Ford Transit NOTE: Do not secure the drain hose to the other hoses at the roof level. The drain hose must be lower than the London HVAC unit. 27. Connect the drain hoses to the London HVAC unit. Tie both sides together with a “T”... - Page 21 Ford Transit London 30.Connect the blower motor connector (1) and the thermostat connector (2). 31. Connect the low-pressure switch. 32. Route the wiring harness down the left-rear corner of the vehicle. Using the provided p-clips and tie-straps, secure as necessary.
- Page 22 London Ford Transit NOTE: Any extra harness length can be secured behind the relay strip mounting panel. 33. Mount the relay strip and fuse block to a bracket fabricated for that purpose. Route the wiring harness over the wheel well. 34.
- Page 23 Ford Transit London 36. Route the coolant pump harness through the hole. NOTE: Headliner shown installed for refer- ence purposes. 37. Drill a 1.25 inch (32 mm) hole in the rear of the left foam panel, approximately centered between the two indents. Route the control panel wiring harness through the hole and to the top center of the windshield.
- Page 24 London Ford Transit NOTE: Due to vehicle variances, some images may not be representative. 39.Replace the bottom 60 amp fuse with a 70 amp fuse. Reinstall the power distribution center at this time. 40.Connect the pink wire to a 12V ignition circuit in the open connector in the battery compartment.
- Page 25 Ford Transit London 42. Cut the dome light bezel and panel to accept the control panel. Install the control panel in the dome light bezel. 43. Connect and install the control panel and install the package tray.
- Page 26 London Ford Transit 44. Connect the condenser fans and the pressure switch on the receiver/dryer. 45. Connect the coolant pump. 46. Using the supplied connector and the proper crimping tool, connect the A/C compressor electrical connector.
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Page 27: Initial Start
Ford Transit Initial Start A/C System: 47. Recharge the vehicle per the chart below. Item Type Quantity Lubricant PAG oil (per compressor specification) 4 ounces Refrigerant R134a 2.7 lbs. Coolant System: 48. Start the engine and monitor the coolant level, add as necessary. Follow the vehicle manufacturer’s recommendation for coolant type. -
Page 28: Wiring Diagram
Ford Transit Wiring Diagram... - Page 29 Ford Transit...
- Page 30 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 32 Webasto Product N.A., Inc. Technical Assistance Hotline USA: (800) 555-4518 Canada: (800) 667-8900 www.webasto.us Org.3/2016 Rev. 12/2021 P/N 5011865 www.techwebasto.com...