ALWAYS follow all Webasto installation and repair instructions and observe all warnings.

Transcription

1 Water Heater Unit Feel the drive Thermo Top E Additional Heater Thermo Top C Additional Heater e e Installation Instructions Alfa Romeo 47 Gasoline and Diesel from Model Year 00 Left-hand drive vehicle not for JTD 6V not with GTA WARNING! Hazard warning: Incorrect installation or repair of Webasto heating systems may cause a fire or result in the emission of carbon monoxide, which can be fatal. Serious or fatal injuries can be caused as a result. Specialist company training, technical documentation, specialized tools and equipment are required to install and repair Webasto heating and cooling systems. NEVER attempt to install or repair Webasto heating or cooling systems if you have not successfully completed the company training and thereby acquired the required technical skills, or if you do not have access to the required technical documentation, tools and equipment needed to carry out correct installation and repairs. ALWAYS follow all Webasto installation and repair instructions and observe all warnings. Webasto does not accept any liability for defects and damage that are attributable to installation by untrained staff. Ident. No.:60A_EN Fee Euro 0.00 Webasto AG

2 Alfa Romeo 47 Table of Contents Validity Heater Unit/Installation Kit Foreword General Instructions Special Tools Explanatory Notes on Document 4 Preliminary Work 5 Heater unit installation location 5 Preparing electrical system 6 Electrical system 7 Fan controller 8 Fan controller with switch-off function for passenger compartment monitoring 9 Preparing installation location 0 Preparing heater unit heater unit Exhaust gas 4 cooling coil 5 horns 5 Coolant for gasoline engine 6 Coolant for diesel engine 9 Fuel Combustion air 5 Final Work 6 Operating Instructions for End Customer 7 Template for Fuel Standpipe 8 Template for Fuel sender 8 Validity Manufacturer Model Type EG-BE No./ABE Fiat Alfa (Alfa Romeo) e * 98/4 * 0070 *... Engine type Engine model Output in kw Displacement in cm³ AR70 Gasoline AR04 Gasoline AR0 Gasoline A000 Diesel Vehicle and engine types, equipment variants and national specifications not listed in these installation instructions have not been tested. However, installation according to these installation instructions may be possible. The installation location of the digital timer should be confirmed with the end customer before installation. 60A_EN

3 Alfa Romeo 47 Heater Unit/Installation Kit Quantity Description Order No.: Retail Accessories for Thermo Top E Gasoline See price list or Retail Accessories for Thermo Top E Diesel See price list or Retail Accessories for Thermo Top C Gasoline See price list or Retail Accessories for Thermo Top C Diesel See price list and Installation kit for Alfa Romeo 47 Gasoline and Diesel 097A Foreword These installation instructions apply to Alfa Romeo 47 Gasoline and Diesel vehicles - for validity, see page - from model year 00 and later, assuming technical modifications to the vehicle do not affect installation, any liability claims excluded. Depending on the vehicle version and equipment, modifications may be necessary during installation with respect to these installation instructions. However, the stipulations in the "installation instructions" and "operating and maintenance instructions" for the Thermo Top C/E must always be observed. The corresponding rules of technology and any information from the vehicle manufacturer should be observed during the installation work. General Instructions Installation should be carried out according to the general, standard rules of technology. Unless specified otherwise, fasten hoses, lines and wiring harnesses to original vehicle lines and wiring harnesses using cable ties. Sharp edges should be fitted with edge protectors (split-open plastic hose). Spray unfinished body areas, e.g. drilled holes, with anti-corrosion wax (Tectyl 00K, Order No. 9). Special Tools - Torque wrench for.0-0 Nm - Hose clamping pliers 60A_EN

4 Alfa Romeo 47 Explanatory Notes on Document To provide you with a quick overview of the individual working steps, you will find an identification mark on the outside top right corner of the page in question. Mechanical system Electrical system Water Fuel Exhaust gas Combustion air Special features are highlighted using the following symbols: Specific risk of injury or fatal accidents. Specific risk of damage to components. Specific risk of fire or explosion. Reference to general installation instructions of Webasto components or to the manufacturer's vehiclespecific documents. Reference to a special technical feature. The arrow in the vehicle icon indicates the position on the vehicle and the viewing angle. All dimensions are in mm! Tightening torque of hose clamps = Nm! Tightening torque of Ejot screws, Ejot studs = 0 Nm! 60A_EN 4

5 Alfa Romeo 47 Preliminary Work WARNING! - Open fuel tank cap, ventilate tank. - Close the tank cap again. - Disconnect the battery "earth" or "ground" connection. - Depressurize the cooling system. - Copy the factory number from the original type label to the duplicate type label. - Remove years that do not apply from the duplicate label. - Attach the duplicate label (type label) in the appropriate place. - Remove the engine cover on the left. - Remove the coolant reservoir cap on the right. - Remove the complete intake hose. - Disconnect the expansion tank and lay it aside. - Expose the distributor B in the engine compartment. - Remove the right-hand wheel well trim. - Remove bumper - Remove the horns. - Remove the horn cable up from the wiring harness sleeve up to the frame side member. - Insulate the horn cable and route it under the right-hand headlight. - Remove the underride protection. - Remove the trim of the fuel lines on the underbody. - Remove the lighting unit for the passenger compartment (only with passenger compartment monitoring). - Remove the rear bench seat (only for gasoline vehicles). - Open the tank-fitting service lid (only for gasoline vehicles). - Remove the fuel-tank sending unit according to the manufacturer's instructions (only for gasoline vehicles). Remove page 7 "Operating Instructions for End Customer" and add to the vehicle operating instructions. Heater unit installation location Heater unit Installation location 60A_EN 5

6 Alfa Romeo 47 Preparing electrical system Cut away insulation along marking in area of hole. Cutting out insulation 90 Bending perforated bracket 70 Only with passenger compartment monitoring a Produce connections as shown in wiring diagram. Also connect additional green/white (gn/ws) wire to K/86 and pull into included protective sleeving. Preparing K 85 0 K Produce connections as shown in wiring diagram. rt a 85 0 K. Preparing K. br 4 rt 60A_EN 6

7 Alfa Romeo 47 Electrical system Wiring harness pass through Protective rubber plug Wiring harness of digital timer, additional green/white (gn/ws) wire with passenger compartment monitoring Digital timer Digital timer 4 5 Wiring harness installation diagram Do not install the metering pump cable harness until later together with fuel pipe along the original vehicle fuel lines on the underbody Wiring harness routing Wiring harness of heater unit, fuel line Fuse holder, relay K Angled-down perforated bracket M6x0 bolt, M6 flanged nut on existing hole k relay, M5x bolt, washer, spring lockwasher, M5 nut 4 Retaining plate of fuse holder, M5x bolt, washer, spring lockwasher, M5 nut 60A_EN 7

8 Alfa Romeo 47 Fan controller HG X 4 Webasto F F B 7 A Alfa Romeo B F9 F F5 0 A 0 5 Wiring diagram gn/ ws rt/ws rt hbl/ rt a K hbl/ rt M0 M A N85 B sw br M70 M7 Webasto components Vehicle components Colors and symbols HG Heater unit TT-C/E N85 Fan motor rt red X 6-pin heater unit connector M0 Body computer ws white F Replace 5 A with 7.5 A M7 Fan controller sw black fuse. M70 Air-conditioning control panel br brown K Fan relay B Distributor in engine compartment gn green F Fuse, 7.5 A hbl light blue F9 5 A fuse B Distributor in engine compartment F Fuse 40A X Cutting point F5 Fuse 40A Wiring colors may vary. Connection on connector A 5, Pin from distributor B in engine compartment. Produce connections as shown in wiring diagram. Legend 5 Light blue/red (hbl/rt) wire of connector A/ Black (sw) wire from K/0 Red (rt) wire from K/87a 4 Light blue/red (hbl/rt) wire of connector A/7 for distributor B Connecting fan-motor A_EN 8

9 Alfa Romeo 47 Fan controller with switch-off function for passenger compartment monitoring Webasto Alfa Romeo 0 5 HG X 4 gn/ws gn/ ws rt/ws F rt hbl/ rt F B 7 A F9 F B 0 F5 A Wiring diagram a K 87a sw rt hbl/rt sw/ vi K6 E 7 M0 M A N85 B br br 85 0 K. rt sw/ vi M70 M7 Webasto components Vehicle components Colors and symbols HG Heater unit TT-C/E N85 Fan motor rt red X 6-pin heater unit connector M0 Body computer ws white F Replace 5 A with 7.5 A M7 Fan controller sw black fuse. M70 Air-conditioning control panel br brown K Fan relay K6 Passenger compartment sensor gn green K. Additional relay B Distributor in engine compartment hbl light blue F Fuse, 7.5 A vi violet F9 5 A fuse B Distributor in engine compartment F Fuse 40A X Cutting point F5 Fuse 40A Wiring colors may vary. 4 Passenger compartment monitoring is switched off on passenger compartment sensor K6 in lighting unit in passenger compartment. Produce connections as shown in wiring diagram. Connect green/white (gn/ws) 5 wire from K/86 to K./ Note: Passenger compartment monitoring will be deactivated while heating mode is active! 5.5x9.5 self-tapping screw K. relay Red (rt) wire of K/0 4 Red (rt) wire from K/87a 5 Black/violet (sw/vi) wire K6/ 6 Black/violet (sw/vi) wire (original vehicle ground) 7 Brown (br) wire of K./85 on ground point Legend Switching off passenger compartment monitoring 60A_EN 9

10 Alfa Romeo 47 Preparing installation location Remove original vehicle bolt for plastic bracket of servo cooling hose and discard. Detaching plastic bracket 0 Remove plastic bracket from servo cooling hose. Removing plastic bracket 5 Copy hole pattern, drill 6.5 mm hole [x each] Additional bracket Plastic bracket Copying hole pattern 4 Connect additional bracket and plastic bracket 4 with M6x5 bolt, large diameter washer, flanged nut [x each]. Lay on additional bracket flush with right-hand side and lower edge on cross member. Copy hole pattern, drill 6.5 mm hole [x each] Holes in cross member 60A_EN 0

11 Alfa Romeo 47 Premounted additional bracket M6x0 bolt, flanged nut M6x0 bolt, large diameter washer, flanged nut additional bracket mm dia. hole [x each] 65 mm 40 mm Holes in cross member mm dia. hole 65 mm Drilling hole in cross member A_EN

12 Alfa Romeo 47 Preparing heater unit X B X A a = 60 b = 050 c = 90 Discard sections X Cut heat protection hose in half and push onto hose A and B. Cutting coolant hoses to length X C X Ejot stud [x] Hose section, 0 mm dia. clamp [x] Fuel line Preparing heater unit 7 C Hose B with 90 elbow on heater unit inlet 7 mm dia. spring clip 7 mm dia. hose clamp Premounting coolant hoses B 8 60A_EN

13 Alfa Romeo 47 heater unit Flanged nut [x] on Ejot stud heater unit 9 In case of tolerance deviations, use x 5 mm shims at Position 5. Strut M6x0 bolt, 5 mm spacer sleeve (see following photo), flanged nut 4 Ejot stud, flanged nut 5 5 mm shim strut mm shim Positioning shim Wiring harness of heater unit 4 Connecting wiring harness 6 60A_EN

14 Alfa Romeo 47 Exhaust gas Exhaust pipe a = 0 Exhaust end section b = 80 Discard section X Preparing exhaust pipe a b X Hose clamp [x] Position red (rt) rubber isolator Exhaust pipe exhaust pipe Original vehicle bolt Angle bracket angle bracket 4 4 M6x0 bolt, large diameter washer, flanged nut on angle bracket Hose clamp Exhaust end section 4 Muffler muffler and end section 5 60A_EN 4

15 Alfa Romeo 47 cooling coil Mount cooling coil in prepared bracket. Spacer bracket Original vehicle spacer bracket cooling coil 6 horns M6x0 bolt, flanged nut on strut Angle bracket horns Install horn bracket with original vehicle bolt on angle bracket. horns 8 60A_EN 5

16 Alfa Romeo 47 Coolant for gasoline engine WARNING! Any coolant running off should be collected using an appropriate container. Install hoses so that they are kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that no other hose can be damaged! When installing the coolant hose, the heater unit must be filled with coolant. The connection should be "inline" based on the following diagram: Coolant routing diagram A Ø 8x0 Ø 8x0 C B Undesignated connecting pipes = dia. 0x0. All hose clamps = 0-7 mm dia.! = Spring clip = 7 mm dia. = Black (sw) rubber isolator (.0 liter only)! = Black (sw) rubber isolator (.6 liter only)! 60A_EN 6

17 Alfa Romeo 47 B Routing in engine compartment C 9 B C 0 Engine-outlet hose section Hose section of heat exchanger inlet Cutting point Engine-outlet hose section Routing in engine compartment Connecting engine outlet A 60A_EN 7

18 Alfa Romeo 47 C.0 liter gasoline Ensure sufficient distance to neighboring components. Spacer bracket [x] Position black (sw) rubber isolator Hose section of heat exchanger inlet Connection on engine outlet and heat exchanger inlet B A C.6 liter gasoline A Ensure sufficient distance to neighboring components. Route hose A under original vehicle lines. Hose section of heat exchanger inlet Position black (sw) rubber isolator Spacer bracket Connection on engine outlet and heat exchanger inlet B 4 All gasoline vehicles Spacer bracket [x] spacer bracket 5 60A_EN 8

19 Alfa Romeo 47 Coolant for diesel engine WARNING! Any coolant running off should be collected using an appropriate container. Install hoses so that they are kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that no other hose can be damaged! When installing the coolant hose, the heater unit must be filled with coolant. The connection should be "inline" based on the following diagram: Coolant routing diagram A Ø 8x0 C B Undesignated connecting pipes = dia. 0x0. All hose clamps = 0-7 mm dia.! = Spring clip = 7 mm dia. = Original vehicle hose clamp. 60A_EN 9

20 Alfa Romeo 47 B Routing in engine compartment C 6 B C 7 Pull hose on engine outlet/heat exchanger inlet off connection piece of engine outlet. Spring clip will be reused. Cutting point A 8 Original vehicle spring clip Routing in engine compartment Connecting engine outlet 9 60A_EN 0

21 Alfa Romeo 47 B A Ensure sufficient distance to neighboring components. Spacer bracket [x] Hose section of heat exchanger inlet Connection on engine outlet and heat exchanger inlet C 40 Spacer bracket [x] spacer bracket 4 60A_EN

22 Alfa Romeo 47 Fuel CAUTION! Open the vehicle's fuel tank cap, ventilate the tank and then re-close the tank lock. Catch any fuel running off with an appropriate container. Install fuel line and metering-pump wiring harness so that they are protected against stone impact. Unless specified otherwise, always fasten using cable ties. Mount the fuel line and wiring harness with rub protection on sharp edges. WARNING! The fuel line and wiring harness are routed to the metering pump in as shown in the wiring harness routing diagram. M8 nut on existing stud bolt Angle bracket angle bracket 4 Fuel removal on gasoline engines 4 Metering pump Silent block, flanged nut [x] on angle bracket Hose section, 0 mm dia. clamp [x] 4 Fuel line 5 Wiring harness of metering pump, connector mounted 6 Rubber-coated pipe clamp metering pump Remove fuel-tank sending unit in accordance with manufacturer's specifications. Cut out template and lay on Copy hole pattern, 6 mm dia. hole Removing fuel 44 60A_EN

23 Alfa Romeo 47 Shape fuel standpipe according to template, cut to length and install. fuel standpipe 45 Shorten 90 molded hose by 0 mm at.5 mm dia. (shortened side on fuel standpipe). 9 mm dia. Caillau clamp Fuel standpipe Connecting 90 molded hose 46 Install fuel-tank sending unit 4 in accordance with manufacturer's specifications. Fuel line 0 mm dia. Caillau clamp 90 molded hose Connecting fuel line 4 47 Check the position of the components; adjust if necessary. Check that they have free clearance. Hose section, 0 mm dia. clamp [x] Fuel line Connecting metering pump 48 60A_EN

24 Alfa Romeo 47 4 Fuel removal on diesel engines 5 Metering pump Silent block, flanged nut [x] on angle bracket Hose section, 0 mm dia. clamp [x] 4 Fuel line 5 Wiring harness of metering pump, connector mounted 6 Rubber-coated pipe clamp metering pump 6 49 Cut fuel return line at Position and insert support sleeves in line ends. Shorten molded hose 4 by 0 mm at.5 mm dia. Hose section (inside dia. = 8 mm) [x], mm dia. clamp [4x] 8x5x8 mm fuel standpipe 4 90 molded hose (shortened side on fuel standpipe), 0 mm dia. clamp [x] 5 Fuel line Removing fuel Insert fuel line 4 in line holder. Check the position of the components; adjust if necessary. Check that they have free clearance. 4 Hose section, 0 mm dia. clamp [x] Cable tie Connecting metering pump 5 60A_EN 4

25 Alfa Romeo 47 Combustion air Intake pipe 7 mm dia. clamp intake pipe 5 Intake pipe Cable tie Intake muffler muffler 5 60A_EN 5

26 Alfa Romeo 47 Final Work WARNING! Reassemble the disassembled components in reverse order. Check all hoses, clamps and all electrical connections for firm seating. Secure all loose cables using cable ties. Only use manufacturer-approved coolant. Spray the heater unit components with anti-corrosion wax (Tectyl 00K, Order No. 9). - Connect the battery - Fill and bleed the coolant circuit according to the vehicle manufacturer s specifications. - Set the digital timer. - Make settings on A/C control panel according to the "Operating Instructions for End Customer". - Check the proper operation of the additional heater, see the operating instructions/installation instructions. - Attach the "Switch off additional heater before refueling" sticker to the left-hand B-pillar. WARNING: During heating, three "sporadic errors" are stored in the A/C control unit: - Coolant temperature - Outside temperature sensor - Engine speed These are irrelevant and can be deleted when performing vehicle service (inspection)! Underride protection Exhaust end section Aligning exhaust end section 54 Feel the drive Webasto AG Postfach 80-8 Stockdorf Hotline 0805 / Hotfax 095 / A_EN Printed in Germany 0/008 Printing: Steffen

27 Alfa Romeo 47 Operating Instructions for End Customer Please remove page and add to the vehicle operating instructions. WARNING! Passenger compartment monitoring will be deactivated while heating mode is active! Note: We recommend matching the heating time to the driving time. Heating time = driving time Example: For a driving time of approx. 0 min. (in one direction), we recommend not exceeding a switch-on time of 0 min. Before parking the vehicle, make the following settings: Air outlet to windshield Set fan to level "" Set temperature to "max." Manual air conditioning 55 Air outlet to windshield Set temperature on both sides to "HI". Set fan to level "" Automatic air-conditioning 56 60A_EN 7

28 Alfa Romeo 47 Template for Fuel Standpipe Template for Fuel sender Ø 6mm 00 mm Scale : Compare the size of the printed version with dimension lines. Permitted tolerance a maximum of %. Set the printer settings to no margin or minimize margins and 00% of the normal size. 00 mm 0 60A_EN 8