Webasto Ford Transit User manual

Transit London
Extreme Climate
Chassis-Mounted Condenser
Legend
1 London HVAC Unit Assembly
2 Coolant Valve
3CoolantPump
Special Tools
– Oetiker pliers (Webasto P/N 5012954A)
– Rivnut installation tool
– Hole saw kit
– Refrigerant recovery and recharging machine
– Weather-Pack/Metri-Pack crimping tool 12085270
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2
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Ford Transit
2015 - 2019
3.5 and 3.7 Liter Engines
148” wheelbase - All Roof Heights
For kit 5013292A
Special instructions for these models
Part locations may differ slightly dependent on
the vehicle-specific configuration.
DOC P/N 5013295A KIT P/N 5013292A Printed in USA Webasto N.A., Inc.

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London 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.

Ford Transit London
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Kit CoTable of Contentsntents
Kit Contents with Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 and kit preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
London HVAC Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
General References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Wiring Harness Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Extreme Board Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
A/C Hose Crimping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Hose Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
A/C Hose Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Heater Hose installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Initial Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
A/C System: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Coolant System: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
NEO 2 Extreme Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Extreme Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

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London Ford Transit
Item
Number Part Number Description Quantity
1 5011500A HVAC KIT LONDON 12V W-THERMO-
STAT 1
25011595A BRACKET - TRANSIT LONDON 1
3 62U00025459C CONDENSER - UNDERCHASSIS 1
45011825A BRACKET RDR UBC TRANSIT 1
5 5011824A BRACKET - SUPPORT RL UBC TRANSIT 1
65011822B BRACKET - SUPPORT CONDENSER -
FRONT 1
7 5011823A BRACKET - SUPPORT UBC TRANSIT 3
85011821A BRACKET - ANGLE SUPPORT - REAR 1
9 5013295A MANUAL - INSTALLATION 1
10 5011082C WARRANTY STATEMENT 1
Kit Contents

Ford Transit London
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11 62017067A FILTER / DRYER R134-A 1
12 62036025D BRACKET - FILTER / DRYER 1
13 9027035A BAG - BRACKET U4847 1
14 1317523A CIRCULATION PUMP - U4847 1
15 5012655A BRACKET KIT - RELAY BOARD 1
16 5012514A RELAY BOARD HVAC EXTREME W/
LABEL 1
17 5010740A LABEL - SERIAL NUMBER 1
18 5012813A CONTROLLER - NEO 2 HVAC 1
19 6290321660B DIFFUSER 1
20 5013072A BAG - CABLE TIES AND TRIM 1
21 62U003AA093A COVER - EVAPORATOR 1

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London Ford Transit
22 5013213A HOSE - REFRIGERANT -6 X 11M 1
23 5013159A HOSE - REFRIGERANT -8 X 6M 1
24 5013168A HOSE - REFRIGERANT -10 X 14M 1
25 5013225A HOSE HEATER 0.75 ID GATES BLUE STRIPE
4M 1
26 503221A HOSE HEATER 5/8 INCH ID 21M 1
27 5012587A WIRE HARNESS - T-STAT or LOW PRESSURE
SWITCH - 8600mm 2
28 5012948A WIRE HARNESS - HEATER CONTROL
EXTENSION SEALED 1
29 5012643A WIRE HARNESS - COMPRESSOR -
12,000mm 1
30 5012429A WIRE HARNESS - LP-HP SWITCH 5,900mm 1
31 5012584A WIRE HARNESS - CONDENSER FAN 2
32 5012883A WIRE HARNESS - EXTREME BOARD 1

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33 5012876A WIRE HARNESS - BLOWER - 5500-
8100mm 1
34 5012880A WIRE HARNESS - NEO ADAPTER 1
35 5010321A WIRE HARNESS - COOLANT PUMP 1
36 5012447A BATTERY CABLE - POWER 1
37 5012570A BATTERY CABLE - GROUND 1
38 5011556A INSULTATION HOSE 1
39 6241258A COOLANT VALVE 1
5013294A BAG - AC COMPONENTS
40 5011771A LABEL - REFRIGERANT CHARGE 1
41 5011028B FITTING REFRIGERANT 45 -06THD -06HOSE 1
42 5011029B FITTING REFRIGERANT 45 -08THD -08HOSE 1
43 5011244B SPLICER IN LINE -10HOSE WITH PORT 1

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London Ford Transit
44 5011005B FITTING REFRIGERANT 90 -12TUBE-O -
10HOSE 1
45 5011008B FITTING REFRIGERANT 90 -06THD -06HOSE 1
46 5011231B SPLICER IN LINE -08HOSE WITH PORT 1
47 5011030B FITTING REFRIGERANT 45 -10THD TO -10H 1
48 5011010B FITTING REFRIGERANT 90 -08THD -08HOSE 1
49 5011232B SPLICER IN LINE -10HOSE WITH PORT 1
50 5011212B FITTING REFRIGERANT 180 -06THD -
06HOSE 1
51 5011002A FITTING REFRIGERANT 90 -6CONN -6HOSE 1
52 5013071A BAG - TXV PLATE 1
53 5013253A ANTI-CONDENSATION TAPE 1
54 6233268A BAG - PRESSURE SWITCH 1

Ford Transit London
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55 62043118A LOW-PRESSURE / HIGH-PRESSURE SWITCH 1
5013293A BAG - HARDWARE PARTS
56 905163Z BOLT HEX M8-1.25 6
57 902713Z WASHER FLAT 0.3125 x 0.75 6
58 5011487A SCREW SELF DIRLLING 0.25 X 1 INCH 10
59 5001321A BOLT HFH M6-1.0 6g x 20 11
60 902006Z SCREW SELF DRILLING 10-16ST x 1 5
61 5001322A NUT HEX FLANGE SERRATED M6-1 6H
8.8 8
62 5011593A SCREW SELF DRILLING - BLACK 7
63 21499A TUBE CLAMP 1
64 629069011A TEE DRAIN HOSE 12MM OD 1
65 5011594A THREADED PLATE M8X1.25 4

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London Ford Transit
66 PPC301028A P-CLIP WITH RUBBER 60DIA 9
67 50000039A SCREW SELF DRILLING 0.25-14ST X 1.5 1
68 5001301A RIVET NUT FLUSH M6-1.0 4
69 5013178 BAG - ELECTRICAL SMALL PARTS 1
70 5013291A BAG ATO FUSE 20AMP 2 PIECES 1
71 5013476A SCREW CROSS RECESS M4x14 6
72 5012013A NUT NYLOCK M4-0.7 6
5013082A BAG - COOLANT SMALL PARTS
73 5011861A CLAMP SPRING BAND 22mm 12
74 5011862A CLAMP SPRING BAND 27mm 4
75 5012117A TEE COOLANT 19-16mm 2