Transit London

Extreme Climate
Chassis-Mounted Condenser

Ford Transit
2015 - 2019
3.5 and 3.7 Liter Engines
148” wheelbase - All Roof Heights
3 2 1 For kit 5013292A

Special instructions for these models

Part locations may differ slightly dependent on
the vehicle-specific configuration.

Legend
1 London HVAC Unit Assembly
2 Coolant Valve
3 Coolant Pump

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

DOC P/N 5013295A KIT P/N 5013292A Printed in USA Webasto N.A., Inc.
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.

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Ford Transit London

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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Kit Contents

Item
Part Number Description Quantity
Number

HVAC KIT LONDON 12V W-THERMO-

1 5011500A 1
STAT

2 5011595A BRACKET - TRANSIT LONDON 1

3 62U00025459C CONDENSER - UNDERCHASSIS 1

4 5011825A BRACKET RDR UBC TRANSIT 1

5 5011824A BRACKET - SUPPORT RL UBC TRANSIT 1

BRACKET - SUPPORT CONDENSER -

6 5011822B 1
FRONT

7 5011823A BRACKET - SUPPORT UBC TRANSIT 3

8 5011821A BRACKET - ANGLE SUPPORT - REAR 1

9 5013295A MANUAL - INSTALLATION 1

10 5011082C WARRANTY STATEMENT 1

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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

RELAY BOARD HVAC EXTREME W/

16 5012514A 1
LABEL

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

HOSE HEATER 0.75 ID GATES BLUE STRIPE

25 5013225A 1
4M

26 503221A HOSE HEATER 5/8 INCH ID 21M 1

WIRE HARNESS - T-STAT or LOW PRESSURE

27 5012587A 2
SWITCH - 8600mm

WIRE HARNESS - HEATER CONTROL

28 5012948A 1
EXTENSION SEALED

WIRE HARNESS - COMPRESSOR -

29 5012643A 1
12,000mm

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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WIRE HARNESS - BLOWER - 5500-

33 5012876A 1
8100mm

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

FITTING REFRIGERANT 90 -12TUBE-O -

44 5011005B 1
10HOSE

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

FITTING REFRIGERANT 180 -06THD -

50 5011212B 1
06HOSE

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

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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

NUT HEX FLANGE SERRATED M6-1 6H

61 5001322A 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

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Ford Transit London

76 5013547A COUPLER REDUCER 3/4 X 5/8 PLASTIC 1

77 5012120A BLEEDER VALVE OD 16mm 1

INTRODUCTION

1.0 General Service and Safety Precautions

WARNING
Never service, repair, or troubleshoot this system unless you are a professional air conditioning/refrigeration service per-
son. Improper servicing can lead to serious injury or death from fire, electric shock, or explosion.

Refrigeration and air conditioning devices are extremely complicated by nature. Servicing, repairing, and
troubleshooting these products should be done only by those with the necessary knowledge, training, and equipment.

1.1 Refrigerants and Other Chemicals

Contact with refrigerant, mixtures of refrigerant and oil, or other chemicals can cause a variety of injuries including burns
and frostbite. For example, if refrigerant contacts skin or eyes it can cause severe frostbite. Also, in the event of a
compressor motor failure, some refrigerant and oil mixtures can be acidic and cause chemical burns.
To avoid injury, wear appropriate protective eye wear, gloves, and clothing when servicing an air conditioning or
refrigeration system. Refer to your refrigerant supplier for more information.
If refrigerant or mixtures of refrigerant and oil come in contact with skin or eyes, flush the exposed area with water and
get medical attention immediately.

1.2 System Flushing, Purging, and Pressure Testing for Leaks

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®
unit or similar equipment designed for R134a refrigerant systems.
Follow these precautions when flushing/purging a system or pressure testing a system for leaks:
• Use flushing products according to the manufacturer’s instructions.
• To purge a system, use only dry nitrogen.
• When pressure testing for leaks, use only
• regulated dry nitrogen or dry nitrogen plus trace amounts of the serial label refrigerant, in this case, R134a.
• When purging or pressure testing any refrigeration or air conditioning system for leaks, never use air, oxygen or
acetylene.
• Oxygen can explode on contact with oil.
• Acetylene can decompose and explode when exposed to pressures greater than approximately 15 PSIG.
• Combining an oxidizing gas, such as oxygen or air, with an HCFC or HFC refrigerant under pressure can result in
a fire or explosion.
• Use a pressure regulating valve and pressure gauges.

Commercial cylinders of nitrogen contain pressures in excess of 2000 PSIG at 70°F. At pressures much lower than 2000
PSIG, compressors can explode and cause serious injury or death. To avoid over pressurizing the system, always use a
pressure regulating valve on the nitrogen cylinder discharge. The pressure regulator must be able to reduce the pressure
down to 1 or 2 PSIG and maintain this pressure. The regulating valve must be equipped with two pressure gauges:
• one gauge to measure cylinder pressure, and
• one gauge to measure discharge or down-stream pressure.

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London Ford Transit

In addition to a pressure regulating valve and gauges, always install a pressure relief valve. This can also be a frangible disc
type pressure relief device. This device should have a discharge port of at least 1/2” MPT size. The valve or frangible disc
device must be set to release at 175 PSIG.
• Do not pressurize the system beyond 150 PSIG field leak test pressure. When field testing a system for leaks, 150
PSIG is adequate test pressure.
• Disconnect nitrogen cylinder and evacuate the system before connecting the refrigerant container. Disconnect the
nitrogen cylinder and release the pressure in the system before connecting a refrigerant container to the system. The
higher pressure gas in the system can explode the refrigerant container.

1.3 Scope
These non-binding installation instructions are intended to support trained or certified dealers, and personnel in the installa-
tion of the Webasto London-series HVAC unit. Provided these instructions are followed properly and all options listed in the
parts breakdown are installed, this system will provide supplemental heating and cooling.

1.4 Applicability of Manual

These non-binding installation 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 vehicle you are working
on. Technical modifications that differ from the instructions set forth exclude all liability claims. Acknowledged engineering
conventions must be observed for the installation work. Carefully read all documentation prior to installation.

CAUTION
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 vehicle,
or vehicle components.
Non-compliance with the installation instructions and information contained therein will void the warranty. The same
applies for repairs performed by untrained personnel and repairs not using original equipment spare parts.

1.5 Meaning of Warnings, Cautions and Notes

WARNING:
This heading is used to highlight that non-compliance with instructions or procedures may cause injuries or lethal accidents
to personnel.

CAUTION:
This heading is used to highlight that non-compliance with instructions or procedures may cause damage to equipment.

NOTE:

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Ford Transit London

This heading is used to highlight and draw specific attention to information.

1.6 Safety
All relevant state and provincial regulations, if any, governing the installation of this device must be observed! The gen-
eral safety regulations for the prevention of accidents and the relevant operating safety instructions must be observed at
all times.

1.7 Legal Provisions for Installation

EPA regulations stipulate that all vehicles requiring the removal of refrigerants be serviced by a certified technician under
section 608 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.

1.8 Prohibition on Venting

Section 609 of the Clean Air Act prohibits individuals from intentionally venting ozone-depleting substances used as
refrigerants (generally CFCs and HCFCs), and their substitutes (such as HFCs) into the atmosphere while maintaining, ser-
vicing, repairing, or disposing of air-conditioning or refrigeration equipment.

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London Ford Transit

Parts needed for the installation of the London HVAC Unit and related components:

Item Part Number Description Quantity

Number
65 5011594A THREADED PLATE M8X1.25 4
2 5011595A BRACKET - TRANSIT LONDON 1
56 905163Z BOLT HEX M8-1.25 8
1 5011500A HVAC KIT LONDON 12V W-THERMOSTAT 1
39 6241258A COOLANT VALVE 1
63 21499A TUBE CLAMP 1
59 5001321A BOLT HFH M6-1.0 6g x 20 7
57 902713Z WASHER FLAT 0.3125 x 0.75 5
61 5001322A NUT HEX FLANGE SERRATED M6-1 6H 8.8 3
20 5013072A BAG - CABLE TIES AND TRIM 1
15 5012655A BRACKET KIT - RELAY BOARD 1
16 5012514A RELAY BOARD HVAC EXTREME W/LABEL 1
58 5011487A SCREW SELF DIRLLING 0.25 X 1 INCH 4
67 50000039A SCREW SELF DRILLING 0.25-14ST X 1.5 1
13 9027035A BAG - BRACKET U4847 1
14 1317523A CIRCULATION PUMP - U4847 1
3 62U00025459C CONDENSER - UNDERCHASSIS 1
6 5011822B BRACKET - SUPPORT CONDENSER - FRONT 1
8 5011821A BRACKET - ANGLE SUPPORT - REAR 1
71 5013476A SCREW CROSS RECESS M4x14 6
72 5012013A NUT NYLOCK M4-0.7 6
68 5001301A RIVET NUT FLUSH M6-1.0 2
11 62017067A FILTER / DRYER R134-A 1
12 62036025D BRACKET - FILTER / DRYER 1
55 62043118A PRESSURE SWITCH - 3 LEVEL 1
4 5011825A BRACKET RDR UBC TRANSIT 1
7 5011823A BRACKET - SUPPORT UBC TRANSIT 3
5 5011824A BRACKET - SUPPORT RL UBC TRANSIT 1

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Ford Transit
General References
• The locations of the components outlined in the manual are for reference only. If alternate locations re used the
wiring harness cannot be extended.
• 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.
• Replace hose clamps as necessary. Hose clamps should be inspected before re-use. Look for damage to the
screw and to the band due to fatigue, corrosion, or improper installation.
• Some components pictured in this manual are prototype parts. Production parts may appear different.

Vehicle and kit preparation

Refer to the manufacturer’s instructions as
necessary:
• Remove the driver’s seat.
• Remove the battery.
• Remove the overhead package tray.
• Remove the battery tray.
• Remove the upper trim from the b- through e-pillars on the left side.
• Install the auxiliary A/C compressor.

1. Install the A/C compressor and mounting kit.

London HVAC Unit Installation

2. Insert the four threaded mounting plates

(65) in the locations as shown.

3. Install the mounting bracket (2, 56) and

London HVAC unit (1).

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London Ford Transit

4. Mount the coolant valve (39) near the left-

rear wheel using a p-clip (63) and an M6 bolt
and nut (59, 57, 61).

NOTE: Alternate method: drill two 2-inch

holes in the location shown and install
edge trim to protect against chaffing.
5. 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
(20) against corrosion and wire chafing.

NOTE: The location of the extreme board is

not critical. Consider the best location for
installation and future service.
6. Install the extreme board and bracket (15, 16,
58) on the left side of the vehicle, along the
top of the wall.

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Ford Transit London

NOTE: Alternate method: drill two 2-inch

holes in the location shown and install edge
trim to protect against chaffing.
7. Drill two 1 3/4 inch (45 millimeters) holes in
front of the left-rear wheel, similar to
previously done. Install edge protection
around the cut hole and protect against
chaffing.

8. Using the 1/4 in. X 1 1/2 in. self-tapping

screw (67) and coolant pump mount, secure
the coolant pump to the chassis outrigger
next to the fuel tank (13, 14).

9. Expand the 6 existing holes on the condenser

(3) to 4mm. Install the condenser
reinforcement brackets (6, 8) on the
condenser using 6 M4 bolts and nuts (71,
72).

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London Ford Transit

10. Install the filter/dryer in the filter/dryer

mounting clamp (11, 12). Loosely install the
trinary switch (55) in the filter/dryer.

XXX

11.Install the filter/dryer assembly and the filter/

dryer bracket (4, 59). Use the existing
threaded holes in the chassis to mount the
bracket (56) Tighten the trinary switch.

NOTE: There are three right-angle con-

denser mounting brackets. The ‘long side’
of the bracket attaches to the condenser
assembly.
12. Loosely mount the three right angle
condenser mounting brackets (7, 59, 61) and
the straight bracket (5, 59, 61) to the
condenser.

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Ford Transit London

NOTE: The condenser is installed on the left

side of the vehicle next to the fuel tank.
13. Hold the condenser in place and mark the
four mounting hole locations.

XXX

NOTE: In some cases you will only have to

drill three holes. One may already have the
appropriate threaded insert installed.
14. Drill four 3/8 inch holes and install the
threaded inserts (68) using an appropriate
tool.

NOTE: The A/C hose is shown installed for

clarity.
NOTE: The angled side of the bracket is
nearest the A/C fitting to prevent interfer-
ence between the bracket and the fitting.
15. Install the condenser assembly (59).

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London Ford Transit

Electrical Installation
Refer to this graphic for electrical connections as needed.

1 Battery 12V power 8 Thermostat

2 Ignition ON 12V power 9 Compressor
3 Battery ground 10 Heat switch (NEO 3 only - goes to blower pin C) #
4 Blower motor connection at evaporator assembly 11 AC switch (NEO 2/3 - goes to AC blower pin C)
5 Blower motor connection at controller 12 AC swtich - extreme system only *
6 Coolant pump 13 Condenser fan connection at condenser *
7 Coolant valve 14 Condenser fan connection at extreme board *
# not used in this kit. Insulate and protect the wire * Used only in Extreme systems

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Ford Transit London

Extreme Board Layout

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London Ford Transit
Parts required for electrical installation:
Item Part Number Description Quantity
Number
18 5012813A CONTROLLER - NEO 2 HVAC 1
35 5010321A WIRE HARNESS - COOLANT PUMP 1
28 5012948A WIRE HARNESS - HEATER CONTROL EXTENSION SEALED 1
33 5012876A WIRE HARNESS - BLOWER - 5500-8100mm 1
34 5012880A WIRE HARNESS - NEO ADAPTER 1
29 5012643A WIRE HARNESS - COMPRESSOR - 12,000mm 1
32 5012883A WIRE HARNESS - EXTREME BOARD 1
27 5012587A WIRE HARNESS - T-STAT or LOW PRESSURE SWITCH 1
20 5013072A BAG - CABLE TIES AND TRIM As needed
69 5013178 BAG - ELECTRICAL SMALL PARTS 1
36 5012447A BATTERY CABLE - POWER 1
37 5012570A BATTERY CABLE - GROUND 1
30 5012429A WIRE HARNESS - LP-HP SWITCH 5,900mm 1
31 5012584A WIRE HARNESS - CONDENSER FAN 2

NOTE: A dome-light bezel location was used

for this installation, the control panel can be
mounted in alternate locations.
16.Cut the dome light bezel and panel to accept
the control panel. Install the NEO control panel
(18) in the dome light bezel.

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Ford Transit London

17.Drill a 1.25 inch (32 mm) hole in the rear of the

left foam panel, approximately centered between
the two indents.

18.Route the following harnesses from the area

above the rear-view mirror through the hole and
down the b-pillar:
• coolant pump (35)
• coolant valve (28)
• blower harness (33)
• a/c compressor harness (29)
• extreme wiring harness (32)

19.Insert the blue wire labeled AC BLOWER ON from

the NEO adapter harness (34) into cavity C of the
blower harness X1 connector.

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London Ford Transit

20.Connect the blower harness and NEO

adapter harness to the NEO controller. Install
the dome light bezel on the package tray.

NOTE: Refer to the diagram earlier in this

manual for more information
21.Connect the following connectors to the
NEO controller adapter harness:
• coolant pump
• coolant valve
• compressor
Secure unused connectors to the wire harness
as necessary using electrical tape.

AAAAAA

Connect the extreme relay board harness to

the thermostat and NEO adapter harnesses
(27).

AAAAAA

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Ford Transit London

22. Install the control panel and install the dome

light bezel.
Secure wiring harnesses as necessary (20).

AAA

23. Route the power portion of the blower

harness and the NEO adapter harness under
the flooring toward the battery compartment.

NOTE: Be sure that the circuit used for con-

stant power is capable of supporting the
amperage draw of the HVAC unit.
NOTE: Due to vehicle variances some con-
nectors will be different than what is pic-
tured.
24.Connect the pink wires to a 12V ignition
circuit in the open connector in the battery
compartment (69).

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London Ford Transit

25. Connect the ground wires to a good ground

point. Route and secure the wiring to prevent
chaffing. Do not connect the power wire at
this time.

26. Connect the extreme board harness to the

extreme board.

XXX

27. Connect the ground cable (37) to a clean,

secure ground location. Route the power
cable (36) from the extreme board to the
driver’s seat base power connections.

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Ford Transit London

28. Drill a 1 3/4 in. (45 mm) hole in the body

cavity behind the driver’s seat. Paint the cut
edge to protect against corrosion and install
edge trim to protect the wires (20).

29. Route the following harnesses through the

hole in the floor:
• coolant pump
• a/c compressor
• condenser fans (31)
• LP/HP switch (30)

XXX

30.Connect the coolant valve electrical

connector.

XXX

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London Ford Transit

NOTE: Be sure to connect the thermostat

connector to the brass terminals on the
thermostat.
31.Connect the blower motor connector and
the thermostat connector. Connect the
blower harness ground connector to one of
the London mounting bolts.

32. Connect the condenser fans and the

pressure switch on the filter/dryer.

33. Connect the coolant pump.

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Ford Transit London

34. Route the A/C compressor harness to the

engine compartment. Using the supplied
connector and the proper crimping tool,
connect the A/C compressor electrical
connector.

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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. Place two properly-sized clips in the clip holder.

The clips should both be facing the same direction
for ease of assembly.

C. Slide the hose in the clip holder until the cut

edge of the hose is against the small opening in
the clip holder.

30
Ford Transit London

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 5012954A).

31
London Ford Transit

Hose Installation
Refer to the diagram below for a general overview of the system.
NOTE: Not all kits will utilize the heating portions of this diagram.

32
Ford Transit London

NOTE: When working with constant-tension band clamps, always use tools designed for them.
Using slip-joint, tongue-and-groove, or other types of pliers will compromise the integrity of the
clamps. Failure to do so can cause leaks, damaging the vehicle.

Parts required for hose installation:

Item Part Number Description Quantity

Number
22 5013213A HOSE - REFRIGERANT -6 As needed
51 5011002A FITTING REFRIGERANT 90 -6CONN -6HOSE 1
52 5013071A BAG - TXV PLATE 1
44 5011005B FITTING REFRIGERANT 90 -12TUBE-O -10HOSE 1
49 5011232B SPLICER IN LINE -10HOSE WITH PORT 1
24 5013168A HOSE - REFRIGERANT -10 As needed
54 6233268A BAG - PRESSURE SWITCH 1
27 5012587A HARNESS - T-STAT or LOW PRESSURE SWITCH - 8600mm 1
47 5011030B FITTING REFRIGERANT 45 -10THD TO -10H 1
42 5011029B FITTING REFRIGERANT 45 -08THD -08HOSE 1
23 5013159A HOSE - REFRIGERANT -8 As needed
46 5011231B SPLICER IN LINE -08HOSE WITH PORT 1
43 5011244B SPLICER IN LINE -10HOSE WITH PORT 1
50 5011212B FITTING REFRIGERANT 180 -06THD -06HOSE 1
41 5011028B FITTING REFRIGERANT 45 -06THD -06HOSE 1
45 5011008B FITTING REFRIGERANT 90 -06THD -06HOSE 1
48 5011010B FITTING REFRIGERANT 90 -08THD -08HOSE 1
26 503221A HOSE HEATER 5/8 INCH ID 21M 1
25 5013225A HOSE HEATER 0.75 ID GATES BLUE STRIPE As needed
73 5011861A CLAMP SPRING BAND 22mm 12
77 5012120A BLEEDER VALVE OD 16mm 1
75 5012117A TEE COOLANT 19-16mm 2
74 5011862A CLAMP SPRING BAND 27mm 4
76 5013547A COUPLER REDUCER 3/4 X 5/8 PLASTIC 1
64 629069011A TEE DRAIN HOSE 12MM OD 1

33
London Ford Transit

A/C Hose Installation

NOTE: Before cutting any hoses ensure
there is enough hose for proper routing and
securing of the hose.
35. Using a #6 90º fitting, route a high-pressure
A/C hose from the evaporator through the
hole drilled in the floor (51, 22, 52).

36. Using a #10 90º fitting and the low-pressure

switch splice (44, 49, 24), fabricate a short
section of low-pressure hose with the low
pressure switch. Install the low-pressure
switch (54) on the splice fitting and install this
hose on the upper port on the London unit.

37. Connect the low pressure switch wiring

harness (27) to the extreme board and the
low-pressure switch. Route the low-pressure
A/C hose from the low-pressure splice
through the hole drilled in the floor.

34
Ford Transit London

38.Using a #10 45º fitting (47), route the low-

pressure A/C hose from the service fitting to
the A/C compressor.

39.Using a #8 45º fitting (42, 23) route the high-

pressure hose from the compressor to the
area of the condenser.

NOTE: Service ports should be located in a

location that allows easy servicing.
NOTE: Orient the service ports with the
caps rotated slightly upward to prevent
moisture from collecting in the caps.
40.Cut the hoses where appropriate and install
the service ports (46, 43).

35
London Ford Transit

41. Using the #6 180º fitting (50), connect the

filter/dryer output port.

...

42.Using a #6 45º and a #6 90º fitting (41, 45,

22), connect the filter/dryer input port to the
condenser outlet port.

43. Using the #8 90º fitting (48), connect the

hose from the service port to the condenser
assembly.

xxx

36
Ford Transit London

Heater Hose installation.

44.Using a short length of hose, install a bleeder

valve to the return (upper) port on the London
HVAC unit (26, 73, 77).

45. Route the coolant hose from the bleeder

valve to the coolant valve inlet (upper) port
(73). Route the coolant hose from the outlet
port through the hole in the floor and into
the engine compartment.

NOTE: This step applies only if factory-sup-

plied up-fitter ports are not being utilized.
NOTE:NOTE: This is a parallel connection.
Do not restrict or obstruct the coolant flow.
NOTE: In some cases the two “T” fittings
may not be mounted immediately next to
one another.
46. Install the two “T” fittings (75, 73, 26) in the
heater core return hose as shown in the
diagram. Connect the coolant return hose to the
“bottom” T fitting.

37
London Ford Transit

NOTE: The following step applies only to

vehicles with factory up-fitter ports.
XXX

NOTE: When using the factory up-fitter

ports, two 3/4” to 5/8” reducers are used.
47. Connect the return and supply hoses to the
appropriate up-fitter ports (73).

NOTE: A 3/4 in. to 5/8 in. adapter may nec-

essary on the input and output sides of the
coolant pump.
48. Connect the supply hose from the upper “T”
fitting or up-fitter port to the input on the
coolant pump (25, 74).

xxx

49. Using the reducer (76, 74) connect the

supply hose (26, 73) from the reducer on the
output of the coolant pump to the London
HVAC unit.

38
Ford Transit London

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.
50. Connect the drain hose to the London HVAC
unit. Tie both sides together with a “T” fitting
(64).

51. Route the drain hose from the London HVAC

unit assembly down the left-rear corner of the
vehicle and through the factory-supplied hole
in the floor.

52.Cut the drain hose about 1 in. (25 mm) from

the bottom of the floor at a 45° angle, away
from the direction of travel.

39
 Ford Transit
Initial Start
Parts needed for initial start:

Item Part Number Description Quantity

Number
17 5010740A LABEL - SERIAL NUMBER 1
19 6290321660B DIFFUSER 1
62 5011593A SCREW SELF DRILLING - BLACK 6
21 62U003AA093A COVER - EVAPORATOR 1
38 5011556A INSULTATION HOSE 1
40 5011771A LABEL - REFRIGERANT CHARGE 1
53 5013253A ANTI-CONDENSATION TAPE 1
70 5013291A BAG ATO FUSE 20AMP 2 PIECES 1
60 902006Z SCREW SELF DRILLING 10-16ST x 1 As needed
57 902713Z WASHER FLAT 0.3125 x 0.75 As needed
66 PPC301028A P-CLIP WITH RUBBER 60DIA As needed
xxx

53. Place the serial number label (17) on the London unit in a location that is visible during service work.
54. Place the refrigerant charge label under the hood (40).
55. Attach the diffuser to the London unit (19, 62). XXX

XXX
56. Install fuses and ensure that ground connections are secure and tight (70).

A/C System:
57. Recharge the vehicle per the chart below and place the refrigerant label under the hood (59).

Item Type Quantity

Lubricant PAG oil (per compressor specification) 5 ounces
Refrigerant R134a 2.7 lbs.
xxx

58. Use the pipe insulation (38) and anti-condensation tape (62) to insulate the A/C hoses at the London unit and anti
condensation tape (53) to wrap all exposed metal fittings inside the vehicle.

Coolant System:
59. Start the engine and monitor the coolant level, add as necessary. Follow the vehicle manufacturer’s recommendation
for coolant type.
NOTE: The A/C button must be OFF for the pump to activate.
60. Turn the blower on and request maximum heat.
• The coolant pump will turn on and coolant will begin to flow through the heat exchanger.
61. Using the vehicle’s coolant overflow cap and the system’s bleeder valve, release trapped air from the system.
62. After all the air has been removed from the system, fill the reservoir to the proper level.
63. While monitoring the system for leaks, allow the vehicle to idle until the engine reaches normal operating
temperature.
64. Allow the vehicle to cool to a safe level.
65. Pressure test the coolant system per the manufacturer’s instructions and inspect for leaks.
66. Reinstall all interior panels and components that were removed unless otherwise instructed in this manual.
67. Install the London cover assembly if desired (21, 62).
68. Secure all hoses and wiring harnesses (60, 57, 66)

40
 Ford Transit

Wiring Diagram NEO 2 Extreme Kit

41
 Ford Transit

Extreme Board

42
NEO 1 and NEO 2 Controller Templates Ford Transit

43
 Webasto Product N.A., Inc.
Technical Assistance Hotline
USA: (800) 555-4518
Canada: (800) 667-8900

www.webasto.us
Org.: 10/2019 Rev.: 01/2021
www.techwebasto.com