Webasto Transit Vancouver Wagon User manual

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
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2
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.
DOC P/N 5012631B KIT P/N 5012603 Printed in USA Webasto N.A., Inc.

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Vancouver Ford Transit
– 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.
– ALWAYS carefully follow Webasto installation and repair instructions and heed all
WARNINGS.
– Webasto rejects any liability for problems and damage caused by the system being
installed by untrained personnel.

Table of Contents
Kit Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.0 General Service and Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1 Refrigerants and Other Chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 System Flushing, Purging, and Pressure Testing for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.3 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.4 Applicability of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.5 Meaning of Warnings, Cautions and Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.6 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.7 Legal Provisions for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.8 Prohibition on Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Vehicle preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
General References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Kit Component Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
A/C Hose Crimping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Hose Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Electrical and Hose Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Refrigerant System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Basic Board Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Extreme Board Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Initial Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Wiring Diagram - Basic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Wiring Diagram - Extreme Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
LIMITED WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

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Vancouver Ford Transit
Kit Contents
Item
Number Part Number Description Quantity
15012567 BRACKET LONDON TRANSIT WAGON 1
262U00025459 UNDER CHASSIS CONDENSER 1
3 5010279 BOLT HEX M6-1 6G X 16 8.8 ZP DIN 933 8
45012085 VAC KIT VANCOUVER 12V W-THERMO-
STAT 1
562017067 FILTER DRYER R134A 1
662036025 SUPPORT - FILTER 1
75001321 BOLT M6-1.0 x 20 11
85011771 LABEL REFRIGERANT CHARGE R134A
2.7LBS 1
921499 P-Clip 1
10 152560 FEDERRING DIN128-A6-PHRF 1

Ford Transit Vancouver
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11 5011741 BRACKET ANGLE CONDENSER REAR 1
12 5011706 BRACKET ANGLE CONDENSER FRONT 1
13 5011761 BAG COMPRESSOR CLUTCH CONNECTOR 1
14 5012221 BRACKET ADAPTER VANCOUVER 1
15 629070001 ANTI COND TAPE M9ROL 1 METER
16 5011428 CAP SCREW SOCKET HD M6-1 12mm SS 1
17 902006 SCREW PAN HD 10-16ST x 1 SELF
DRILLING 12
18 5001085 CABLE TIE HEAVY DUTY BLACK 20
19 5011594 THREADED PLATE M8X1.25 3
20 5000534 SCREW PAN T20 M4.2-1.4 STx19 TYPE-AB
SS 4
21 5001322 NUT HEX FLANGE SERRATED M6-1 6H 8.8
ZP 15

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Vancouver Ford Transit
22 5011984 BRACKET UNDERBODY RH 1
23 5011606 BRACKET UNDERBODY LH 1
24 620406 CABLE TIE 11 INCH BLACK 40
25 5011030 FITTING REFRIG 45 -10THD TO -10H 1
26 5011002 FITTING REFRIGERANT 90 -6CONN -6HOSE 1
27 PPC201065 TXV MOUNTING PLATE OUTER 1
28 5011164 REFRIGERANT HOSE BURGAFLEX H-06-
3090-R 6 METERS
29 62U003AA020 AIR DUCT 4 GRIGLIE D67 NERO 1
30 5011008 FITTING REFRIGERANT 90 -06THD -06HOSE 3
31 5011244 SPLICER IN LINE -10HOSE WITH PORT 1
32 629069011 RACCORDO SCARICO COND.D.12 A T 1

Ford Transit Vancouver
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33 6233268 BAG PRESSURE SWITCH 035OFF-21ON 1
34 5011166 REFRIGERANT HOSE BURGAFLEX H-10-
3090-R
12
METERS
35 5011231 SPLICER IN LINE -08HOSE WITH PORT 1
36 5011165 REFRIGERANT HOSE BURGAFLEX H-08-
3090-R 8 METERS
37 5011010 FITTING REFRIGERANT 90 -08THD -08HOSE 1
38 5012631B MANUAL INSTALL VANCOUVER TRANSIT
EXR 1
39 5011029 FITTING REFRIGERANT 45 -08THD -08HOSE 1
40 147729 M4 SCREW 6
41 5012013 M4 NUT 6
42 905163 BOLT HEX M8-1.25 6G x 25 8.8 ZP DIN933 7
43 902713 WASHER FLAT 0.3125 x 0.75 x 0.062 ZP 7

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Vancouver Ford Transit
44 5012513 BASIC BOARD 1
45 5012514 EXTREME BOARD 1
46 5012655 BOARD BRACKET KIT 2
47 5011593 SCREW 4.2 X 16MM SELF DRILLING BLACK 4
48 5011082 WARRANTY STATEMENT AC 1
49 5011232 SPLICER IN LINE -10HOSE WITH PORT 1
50 5012015 WASHER FLAT M6x18x1.6 ZP DIN933 8
51 5011487 SCREW SELF DIRLLING 0.25 X 1 INCH 1
52 5011005 FITTING REFRIGERANT 90 -12THD -10HOSE 1
53 62043118 PRESSURE SWITCH 3 LEVEL SICEB CONN
INTGR 1
54 62U003AA093 LONDON COVER MODULE AIR 1 1

Ford Transit Vancouver
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55 5011493 RIVET NUT HEAVY DUTY m8 2
56 500413 HEAT SLEEVE - ORANGE 1 METER
57 5011592 RUBBER GROMMIT - 2 INCH 1
58 5012577 AC CONTROL HARNESS - SWITCH 1
59 5012448 BATTERY POSITIVE CABLE 6AWG 1
60 5012009 JUMPER - GROUND 1
61 5012572 JUMPER - BOARD TO BOARD 1
62 5012571 JUMPER - POSITIVE 1
63 5012570 GND - EXTREME BOARD 1
64 5012429 LP/HP SWITCH HARNESS 1
65 5012584 CONDENSER HARNESS 2

Ford Transit Vancouver
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66 5012643 COMPRESSOR HARNESS 1
67 5012586 LP SWITCH HARNESS 2
68 5012630 CONTROL HEAD ASSY AC TRANSIT 1
69 5012420 BLOWER HARNESS 1
70 689184 M5 NUT 1
71 5012652 FUSE - 70 AMP MIDI 1