Webasto ProMaster Ibiza, Manual

Page 1: ...aw kit Refrigerant recovery and recharging machine 1 2 3 Ram ProMaster 2015 2016 3 6 Liter 136 wheelbase Single sliding door only For kit number 5012949 Special instructions for these models Part loca...

Page 2: ...WARNINGS Webasto rejects any liability for problems and damage caused by the system being installed by untrained personnel Kit Contents 4 INTRODUCTION 10 1 0 General Service and Safety Precautions 10...

Page 3: ...P SCREW SOCKET HD M6 1 12mm SS 1 4 9027035A BAG BRACKET U4847econ FOR TP50E 1 5 5001322A NUT HEX FLANGE SERRATED M6 1 6H 8 8 ZP 11 6 5013547A COUPLER REDUCER 0 75 X 0 625 1 7 5011026A FITTING 45 REFRI...

Page 4: ...27MM 6 15 901100Z HOSE HEATER 0 75 ID GATES BLUE STRIPE 3 5 meters 16 901073Z HOSE HEATER 5 8 INCH ID RUBBER 10 5 meters 17 5011487A SCREW SELF DIRLLING 0 25 X 1 INCH 5 18 5011164A REFRIGERANT HOSE B...

Page 5: ...25 5011614A AC T BLOCK KIT PROMASTER 1 26 5012950 INSTALLATION MANUAL PROMASTER IBIZA 1 27 5011506A HOSE DRAIN ID 0 4375 INCH 3 meters 28 629069011A RACCORDO SCARICO COND D 12 A T 1 29 901406Z FUSE M...

Page 6: ...SS 4500 1 36 5012880A ADAPTER HARNESS NEO 2 1 37 5012952A T STAT JUMPER FOR NO VALVE 1 38 5012817A BRACKET CONTROL HEAD NEO 2 BASIC 1 39 5012813B CONTROLLER NEO 2 HVAC 1 40 6241258A WATER VALVE WEATHE...

Page 7: ...7 Ibiza Ram ProMaster 44 5001085A CABLE TIE HEAVY DUTY 5 45 620406A CABLE TIE 11 IN BLACK 10...

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Page 9: ...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 unit or similar equ...

Page 10: ...ation instructions apply to the make model listed on the front cover of this installation manual Due to optional equipment there may be build variations between this installation manual and the vehicl...

Page 11: ...iced by a certified technician under section 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...

Page 12: ...ences Bare body parts around drilled holes for example must be treated with an anti corrosive coating Secure hoses cables and wiring harnesses with cable ties and fit protective hoses around them at c...

Page 13: ...g four existing holes install the Ibiza HVAC unit mounting brackets 22 23 using four M6 bolts and nuts 20 5 2 Install the Ibiza HVAC unit 10 3 Using the supplied 35 mm P clip install the coolant valve...

Page 14: ...cket NOTE Components pictured may be slightly different than found in some kits 5 Install a short section of inch hose and a inch to 5 8 inch adapter on the output of the coolant pump 15 6 14 Install...

Page 15: ...T VALVE HARNESS EXTENSION SEALED 1 35 5010321A COOLANT PUMP HARNESS 4500 1 36 5012880A ADAPTER HARNESS NEO 2 1 37 5012952A T STAT JUMPER FOR NO VALVE 1 38 5012817A BRACKET CONTROL HEAD NEO 2 BASIC 1 2...

Page 16: ...ground will attach to the body Attach the ground eyelet from the blower harness to clean unpainted sheet metal near the Ibiza unit NOTE Remove the body plug and route the drain tube through the facto...

Page 17: ...r harness along the body to the area of the driver s side b pillar 5 Route one end of the coolant valve and coolant pump harnesses through the hole drilled in the body Connect the coolant valve electr...

Page 18: ...s 36 into cavity C of the blower harness X1 connector 8 Connect the coolant pump and coolant valve harnesses to the NEO adapter harness Install the thermostat jumper into the NEO adapter harness 37 9...

Page 19: ...9 Install the controller and secure the wiring harness where appropriate NOTE The following step only applies if you are using the factory battery connec tions for power and ground 12 Route the power...

Page 20: ...20 Ram ProMaster Ibiza 13 Connect the two pink wires to the add a circuit 30 14 Make the following electrical connections 1 Battery 2 Battery ground...

Page 21: ...needed 19 5012117A TEE COOLANT 16 20 PLASTIC BLACK 2 44 5001085A CABLE TIE HEAVY DUTY As needed 45 620406A CABLE TIE 11 IN BLACK As needed 25 5011614A AC T BLOCK KIT PROMASTER 1 1 PPC201065A TXV MOUNT...

Page 22: ...h 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 Place two properly sized clips in the clip holder The clips should both be facing the...

Page 23: ...iza Ram ProMaster D Lubricate the fitting with PAG oil and insert the fitting until the shoulder of the fitting is touching the clip holder E Using Oetiker pliers crimp the clips closed Webasto P N 50...

Page 24: ...Ram ProMaster Ibiza 24 If you are unfamiliar with crimping A C fittings refer to the steps on the next two pages Refer to the diagram below for a general overview of the heat and a c system...

Page 25: ...return hose Do NOT cut this hose to create two equal length hoses The hose will be cut to attach to the coolant hose and the engine heater hose NOTE The upper fitting on the Ibiza is the return port 1...

Page 26: ...tee fittings 19 spring clamps 13 and 5 8 hose 16 assemble the double tee assembly as shown NOTE The heater core return hose will have factory installed bleeder valve NOTE This is a parallel connectio...

Page 27: ...ubricate o rings and fittings with PAG oil during assembly NOTE The hoses and wiring are not shown for clarity of orientation 22 Using the 6 and 10 A C fittings 7 8 trim the A C hoses to length and co...

Page 28: ...ock and A C manifold NOTE Lubricate the supplied O rings with PAG oil before installation 25 Using the supplied bolt install the A C manifold and the H Block 25 to the TXV Using the supplied fittings...

Page 29: ...he pump to activate 32 Turn the blower on and request maximum heat The coolant pump will turn on and coolant will begin to flow through the heat exchanger 33 Using the vehicle s coolant overflow cap r...

Page 30: ...30 Ibiza Ram ProMaster Wiring Diagram...

Page 31: ...Ram ProMaster Ibiza 31...

Page 32: ...Webasto Thermo Comfort N A Inc Technical Assistance Hotline USA 800 555 4518 Canada 800 667 8900 www webasto us www techwebasto com Org 6 2018 Rev 10 2020...