Manufacturer Model Type EG BE No. / ABE VW Passat 3C e1 * 2001/116 * 0307 *... VW Passat 3C e1 * 2007 / 46 * 0547 *

Transcription

1 Water Heater Thermo Top Evo Parking Heater E Installation Documentation VW Passat / CC Validity Passat Manufacturer Model Type EG BE No. / BE VW Passat C e * 00/6 * 007 *... VW Passat C e * 007 / 46 * 0547 * Motorisation Fuel Transmission type Output in kw Displacement in cm³ Engine code,4 Petrol TSI SG CX,0 Petrol TSI SG CCZB,0 Petrol TSI DSG CCZB,0 Diesel SG CFFB,0 Diesel DSG CFFB,0 Diesel DSG CFGB CC Manufacturer Model Type EG BE No. / BE VW CC CC e * 00 / 6 * 0468 * Motorisation Fuel Transmission type Output in kw Displacement in cm³ Engine code,0 Petrol TSI SG CCZB,0 Petrol TSI DSG CCZB,0 Diesel SG CFFB,0 Diesel DSG CFFB,0 Diesel DSG CFGB SG = manual transmission DSG = direct gear transmission From Model Year 0 Left-hand drive vehicle Verified equipment variants: Not verified: Total installation time: Climatronic Front fog light Passenger compartment monitoring Xenon with headlight washer system Suspension control and levelling system Climatic approx. 7 hours Ident. No.: 76D_EN Status: Webasto Thermo & Comfort SE

2 Table of Contents Validity Necessary Components Installation Overview Information on Total Installation Time Information on Operating and Installation Instructions Information on Validity 4 Technical Information 4 Explanatory Notes on Document 4 Preliminary Work 5 Heater Installation Location 5 Preparing Electrical System 6 Electrical System 7 Fan Controller 8 Digital Timer 0 Remote Option (Telestart) 0 Preparing Installation Location Preparing Heater Installing Heater 6 Coolant Circuit.4 TSI 8 Coolant Circuit.0 TSI 9 Coolant Circuit Diesel 4 Fuel 9 Final Work 4 Template for Fuel Standpipe Petrol 6 Template for Fuel Standpipe Diesel 7 Operating Instructions for End Customer 8 Necessary Components Basic delivery scope of Thermo Top Evo in accordance with price list Installation kit for VW Passat / CC 0 Petrol and diesel: 75B Climatronic kit: 77 Heater control in accordance with price list and upon consultation with end customer In case of Telestart, indicator lamp in accordance with price list and in consultation with end customer Installation Overview Legend:. Heater. Engine compartment fuse holder. Passenger compartment fuse holder 4. Circulating pump 5. Digital timer 6. Metering pump Information on Total Installation Time The total installation time includes the time needed for mounting and demounting of the vehicle-specific components, the heater specific installation time and all other times required for the system integration and initial start-up of the heater. The total installation time may vary for vehicle equipment other than provided. Ident. No.: 76D_EN Status: Webasto Thermo & Comfort SE

3 Information on Operating and Installation Instructions Important Information (not complete). Installation and Repair The improper installation or repair of Webasto heating and cooling systems can cause fire or the leakage of deadly carbon monoxide, leading to serious injury or death. To install and repair Webasto heating and cooling systems you need to have completed a special company training course and have the appropriate technical documentation, special tools and special equipment. Installation and repair may ONLY be carried out by persons trained and certified in a Webasto training course. NEVER try to install or repair Webasto heating or cooling systems if you have not completed a Webasto training course, you do not have the necessary technical skills and you do not have the technical documentation, tools and equipment available to ensure that you can complete the installation and repair work properly. Only use genuine Webasto parts. See the Webasto air and water heaters accessories catalogue for this purpose.. Operation To ensure safe operation, we recommend having the heater checked every two years by an authorised Webasto dealer, especially when used over a long period and/or under extreme environmental conditions. Do not operate the heater in closed rooms due to the danger of poisoning and suffocation. lways switch off the heater before refuelling. The heater may only be used with the prescribed fuel Diesel (DIN EN 590) or petrol (DIN EN 7). The heater may not be cleaned with a high-pressure cleaner.. Please note LWYS follow all Webasto installation and operating instructions and observe all warnings. To become familiar with and understand all functions and properties of the heater, the operating instructions must be read carefully and observed at all times. For proper, safe installation and repair work, the installation instructions with all warnings and safety information must be carefully read and observed at all times. Please always contact a workshop authorised by Webasto for all installation and repair work. IMPORTNT Webasto shall assume no liability for defects, damage and injuries resulting from a failure to observe the installation, repair and operating instructions of the information contained in them. This liability exclusion particularly applies to improper installations and repairs, installations and repairs by untrained persons or in the case of a failure to use genuine spare parts. The liability due to culpable disregard to life, limb or health and due to damage or injuries caused by a wilful or reckless breach of duty remain unaffected, as does the obligatory product liability. 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. Insulate loose wire ends and tie back. Sharp edges should be fitted with rub protection (split-open fuel hose)! Spray unfinished body areas, e.g. drilled holes, with anti-corrosion wax (Tectyl 00K, Order No. 9). Observe the instructions and guidelines of the respective vehicle manufacturer for demounting and mounting vehicle specific components! The initial startup is to be executed with the Webasto Thermo Test Diagnosis. When installing an IPCU, the corresponding settings must be checked or adjusted before the installation. Statutory regulations governing installation Guidelines Thermo Top Evo Heating Directive ECE R E EMC Directive ECE R0 E NOTE The regulations of these guidelines are binding in the scope of the Directive 70/56/EEC and/or 007/46/EC (for new vehicle models from 9/04/009) and should also be observed in countries in which there are no special regulations. IMPORTNT Failure to follow the installation instructions will result in the invalidation of the type approval for the heater and therefore invalidation of the general homologation of the vehicle. NOTE For vehicles with an EU permit, no entry in accordance with 9 Sub-Section 4 of nnex VIII b to the Road Traffic ct is required.. Excerpt from the directive 00/56/EC ppendix VII for the installation of the heater Beginning of excerpt. NNEX VII REQUIREMENTS FOR COMBUSTION HETERS ND THEIR IN- STLLTION. GENERL REQUIREMENTS.7.. clearly visible tell-tale in the operator's field of view shall inform when the combustion heater is switched on or off.. VEHICLE INSTLLTION REQUIREMENTS.. Scope... Subject to paragraph... combustion heaters shall be installed according to the requirements of this nnex.... Vehicles of category O having liquid fuel heaters are deemed to comply with the requirements of this nnex... Positioning of heater... Body sections and any other components in the vicinity of the heater must be protected from excessive heat and the possibility of fuel or oil contamination.... The combustion heater shall not constitute a risk of fire, even in the case of overheating. This requirement shall be deemed to be fulfilled if the installation ensures an adequate distance to all parts and suitable ventilation, by the use of fire resistant materials or by the use of heat shields.... In the case of M and M vehicles, the heater must not be positioned in the passenger compartment. However, an installation in an effectively sealed envelope which also complies with the conditions in paragraph.. may be used...4. The label referred to in paragraph.4 or a duplicate, must be positioned so that it can be easily read when the heater is installed in the vehicle...5. Every reasonable precaution should be taken in positioning the heater to minimise the risk of injury and damage to personal property... Fuel supply... The fuel filler must not be situated in the passenger compartment and must be provided with an effective cap to prevent fuel spillage.... In the case of liquid fuel heaters, where a supply separate to that of the vehicle is provided, the type of fuel and its filler point must be clearly labelled.... notice, indicating that the heater must be shut down before refuelling, must be affixed to the fuelling point. In addition a suitable instruction must be included in the manufacturer's operating manual..4. Exhaust system.4.. The exhaust outlet must be located so as to prevent emissions from entering the vehicle through ventilators, heated air inlets or opening windows..5. Combustion air inlet.5.. The air for the combustion chamber of the heater must not be drawn from the passenger compartment of the vehicle..5.. The air inlet must be so positioned or guarded that blocking by rubbish or luggage is unlikely..6. Heating air inlet.6.. The heating air supply may be fresh or recirculated air and must be drawn from a clean area not likely to be contaminated by exhaust fumes emitted either by the propulsion engine, the combustion heater or any other vehicle source..6.. The inlet duct must be protected by mesh or other suitable means..7. Heating air outlet.7.. ny ducting used to route the hot air through the vehicle must be so positioned or protected that no injury or damage could be caused if it were to be touched..7.. The air outlet must be so positioned or guarded that blocking by rubbish or luggage is unlikely. End of excerpt. In multilingual versions the German language is binding. Ident. No.: 76D_EN Status: Webasto Thermo & Comfort SE

4 Information on Validity This installation documentation applies to VW Passat / CC Petrol and diesel vehicles - for validity, see page - from model year 0 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 this installation documentation. Vehicle and engine types, equipment variants and other specifications not listed in this installation documentation have not been tested. However, installation according to this installation documentation may be possible. Technical Information Special tools Hose clamp pliers for self-clamping hose clamps Hose clamp pliers for Clic hose clamps of type W utomatic wire stripper mm² Crimping pliers for cable lug / tab connector 0.5-6mm² Torque wrench for.0-0 Nm Hose clamping pliers Webasto Thermo Test Diagnosis with current software Dimensions ll dimensions are in mm Tightening torque values Tightening torque values of 5x heater bolts = 8Nm Tightening torque values of 5x5 retaining plate of water connection piece bolts = 7Nm. Tighten other bolt connections in accordance with manufacturer's instructions or in accordance with state-of-theart-technology. Explanatory Notes on Document You will find an identification mark on the outside top right corner of the page in question to provide you with a quick overview of the individual working steps. Mechanical system Special features are highlighted using the following symbols: Specific risk of injury or fatal accidents Electrical system Specific risk of damage to components Coolant circuit Specific risk of fire and explosion Combustion air Fuel Exhaust gas Reference to general installation instructions of the Webasto components or to the manufacturer's vehicle-specific documents. Reference to a special technical feature The arrow in the vehicle icon indicates the position on the vehicle and the viewing angle Software Ident. No.: 76D_EN Status: Webasto Thermo & Comfort SE 4

5 Preliminary Work Vehicle Open the fuel tank cap. Ventilate the fuel tank. Close the fuel tank cap again. Depressurise the cooling system. Disconnect and remove the battery completely together with the carrier. Remove the air filter together with the intake hose. Remove the coolant reservoir cap. Remove the underride protection. Remove the wheel-well inner panel on the left. Remove the rear bench seat. Open the right-hand tank-fitting service lid. Remove the fuel-tank sending unit in accordance with the manufacturer's instructions. Remove the footwell trim on front passenger side. Remove the fuse holder trim in the passenger compartment on the driver's side. Remove the instrument panel trim at the left. Heater Remove years that do not apply from the type and duplicate label. ttach the duplicate label (type label) in the appropriate place in the engine compartment. Heater Installation Location Heater Installation location Ident. No.: 76D_EN Status: Webasto Thermo & Comfort SE 5

6 Preparing Electrical System Wire sections retain their numbering in the entire document. Detach red (rt) wire from fuse F4 and discard. Removing wire IPCU view on contact side. The IPCU provided in the kit is pre-programmed with the following settings E IPCU E Duty cycle: 0% Frequency: 400Hz Voltage: 8V Function: High side The adjustment values must be checked during the function check of the vehicle and adjusted, if necessary. Preparing IPCU rt/sw 0,5² rt 4² gn/ws 0,75² IPCU is to be inserted only after fuse holder has been premounted. Connect wires to socket IPCU. Draw wire and into the protective sleeving. F br 0,5² IPCU E rt 0,5² sw 0,5² Red (rt) wire of IPCU/E Black (sw) wire of IPCU/ Preparing IPCU IPCU M5x6 bolt, large diameter washer [x], retaining plate of fuse holder, self-locking M5 flanged nut ngle bracket Red (rt) wire of IPCU/E Black (sw) wire of IPCU/ Premounting passenger compartment fuse holder Ident. No.: 76D_EN Status: Webasto Thermo & Comfort SE 6

7 Electrical System Positive and earth wire Positive wire to positive battery distributor Earth wire on original vehicle earth support point Wiring harness routing Route wiring harnesses in original vehicle cable duct 4 5 Wiring harness routing diagram Do not install the metering pump wiring harness until later together with fuel pipe along the original vehicle fuel line on the underbody 45 Fuse holder of engine compartment 5.5mm hole at position. When drilling, watch for components located behind. M5x6 bolt, washer [x], retaining plate of fuse holder, self-locking M5 flanged nut Fuses F- 6 Wiring harness pass through Use free protective rubber plug Wiring harnesses of heater, heater control 7 Ident. No.: 76D_EN Status: Webasto Thermo & Comfort SE 7

8 Fan Controller F br 0,5² F Webasto HG X 5 X rt/sw 0,5² rt/sw 0,5² rt 4² rt 4² ge 0,5² gn/ws 0,75² gn/ws 0,75² rt 0,5² sw 0,5² sw/ ws J bl/ ws VW T6h SC 9 T0f 0 5 Wiring diagram X0 F sw/ ws br 0,5² br 0,5² IPCU E 4 M J6 T6be Webasto components Vehicle components Colours and symbols HG TT-Evo heater J6 Fan unit rt red X 6-pin heater connector T6be 6-pin connector J6 sw black X -pin heater connector J55 /C control unit ge yellow X0 4-pin connector T6h 6-pin connector J55 gn green Heater control SC9 40 fuse bl blue K Fan relay T0f 0-pin ws white F 0 fuse connection br brown F 0 fuse F fuse IPCU Pulse width modulator IPCU adjustment values: Duty cycle: 0% Frequency: 400Hz Voltage: 8V X Cutting point Function: High side Wiring colours may vary. Legend Ident. No.: 76D_EN Status: Webasto Thermo & Comfort SE 8

9 ngle bracket Original vehicle bolt Installing fuse holder of passenger compartment 8 Connect the wiring harness of the fuse holder in passenger compartment to the wiring harness of heater according to the wiring diagram, with same colour wires connected to each other. Connecting wiring harnesses 9 Connection to 6-pin connector T6be from the fan unit. Produce connections as shown in wiring diagram. Black/white (sw/ws) wire from 6-pin connector T6be pin Black/white (sw/ws) wire from /C control unit Red (rt) wire of IPCU/E Black (sw) wire of IPCU/ Connecting fan unit 0 Ident. No.: 76D_EN Status: Webasto Thermo & Comfort SE 9

10 Digital Timer Digital timer digital timer Remote Option (Telestart) Degrease adhesive area. Fasten receiver with adhesive tape. receiver ntenna antenna Temperature sensor T00 HTM Fasten temperature sensor with adhesive tape. Installing temperature sensor 4 Ident. No.: 76D_EN Status: Webasto Thermo & Comfort SE 0

11 Preparing Installation Location Pull out connector and put it aside. Remove retaining plate, will be remounted later. Removing retaining plate 5 Wiring harness of heater Routing wiring harness 6 Discard section Hose section 0 Shortening hose section 7 Remove clip for coupling line, will be reused (petrol and diesel manual transmission only). Slide 0mm moulded hose on original vehicle stud bolt (on frame side member over the transmission). hose section 8 Ident. No.: 76D_EN Status: Webasto Thermo & Comfort SE

12 .0 TSI and.0 D Manual transmission Premount clip of coupling line on hose bracket - only with petrol and diesel manual transmission. M6x countersunk head screw Preparing hose bracket 9 Preparing Heater Water connection piece, sealing ring [x each] 5x5mm self-tapping bolt, retaining plate of water connection piece water connection pieces 0 Bracket section 5x self-tapping bolt [x] bracket section Discard section X. Exhaust pipe a = 470 Exhaust end section b = 45 Preparing exhaust pipe a b X Ident. No.: 76D_EN Status: Webasto Thermo & Comfort SE

13 Exhaust pipe Hose clamp exhaust pipe Hose clamp Silencer M6x6 bolt, spring lockwasher silencer Exhaust end section Hose clamp exhaust end section 4 Bracket section B 5x self-tapping bolt [x] bracket section B 5 Ident. No.: 76D_EN Status: Webasto Thermo & Comfort SE

14 5mm dia. clamp Mount M5x6 bolt, flanged nut loosely combustion air pipe 6 Combustion air pipe 5 mm dia. clamp Tighten M5x6 bolt, flanged nut 4 Intake silencer combustion air pipe TSI and.0 D D C X X Hose E is used only for.4 TSI. Discard section X. Hose B = 8mm dia. 90 moulded hose Hose E = 0 mm dia. moulded hose 80 = 050 C = 65 D = 0 Cutting hoses to length B E E.4 TSI Discard section Cutting hose E to length 4 8 Ident. No.: 76D_EN Status: Webasto Thermo & Comfort SE 4

15 .0 TSI B E D X X Discard section X. Hose = 0mm dia. 80 moulded hose Hose C = 8mm dia. 90 moulded hose B = 960 D = 65 E = 050 Cutting hoses to length C Discard section [x] Cutting hose to length /B.4 TSI /.0 D = hoses and D.0 TSI = hoses B and E Slide on braided protection hoses and cut to length. Cut heat shrink plastic tubing to length. 50 mm long heat shrink plastic tubing [4x] Preparing hoses and D D/E.4 TSI /.0 D = hose C.0 TSI = hose D ll spring clips = 5mm dia. C/D Mount wiring harness of circulating pump of circulating pump Circulating pump hose and circulating pump 0 Ident. No.: 76D_EN Status: Webasto Thermo & Comfort SE 5

16 D/E.4 TSI /.0 D = hose D.0 TSI = hose E ll spring clips = 5mm dia. ll vehicles 90 moulded hose, 0mm dia. clamp [x] Fuel line hose of heater outlet Premounting fuel line 8 Installing Heater ngle down perforated bracket Drill 8.5mm dia. hole 75 Preparing perforated bracket 90 D Figure shows diesel with manual transmission (SG). Route hose D to brake booster Original vehicle stud bolt, angled down perforated bracket, M8 flanged nut Bracket section heater Ident. No.: 76D_EN Status: Webasto Thermo & Comfort SE 6

17 Diesel with direct gear transmission (DSG) Ensure sufficient distance from neighbouring components, especially between exhaust silencer and direct gear transmission (DSG) at position (5mm), correct if necessary. heater 4 ll vehicles If stud bolt is not present at position, copy hole pattern from bracket, drill 8.5mm dia. hole in cross member and fasten bracket with M8x0 bolt and flanged nut. Original vehicle stud bolt, M8 flanged nut Bracket section B heater 5 Wiring harness of heater [x] Connecting wiring harness 6 Ident. No.: 76D_EN Status: Webasto Thermo & Comfort SE 7

18 Coolant Circuit.4 TSI WRNING! ny coolant running off should be collected in an appropriate container. Install hoses so that they are kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that other hoses cannot be damaged. The heater must be filled with coolant when installing the hoses. The connection should be "inline" based on the following diagram: Hose installation diagram Ø 0x8 E Ø 7 Ø 7 Ø 0x8 D B C ll spring clips without a specific designation = Original vehicle spring clip. Connecting pipe without specific designation = 5mm dia. = 8x8mm dia. Ident. No.: 76D_EN Status: Webasto Thermo & Comfort SE 8

19 Coolant Circuit.0 TSI WRNING! ny coolant running off should be collected in an appropriate container. Install hoses so that they are kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that other hoses cannot be damaged. The heater must be filled with coolant when installing the hoses. The connection should be "inline" based on the following diagram: Hose installation diagram Ø 7 Ø 0x8 Ø 0x8 Ø 7 Ø 7 Ø 7 B E Ø 0x0 C D ll spring clips without a specific designation Connecting pipe without specific designation = 5mm dia. = 8x8mm dia. Ident. No.: 76D_EN Status: Webasto Thermo & Comfort SE 9

20 D.4 and.0 TSI Route hose to brake booster. lign hoses and D behind hose bracket. Ensure sufficient distance from neighbouring components. Original vehicle stud bolt, M8 flanged nut Routing to frame side member B 7 Figure shows manual transmission (SG). Ensure sufficient spacing between hose bracket and transmission. Routing to frame side member 8 Mount M6x0 bolt, M6 flanged nut loosely 8mm dia. rubber-coated p-clamp 8.5mm dia. hole Preparing perforated bracket 9 Figure shows manual transmission (SG). Mount original vehicle bolt, M8 nut loosely Premounted perforated bracket perforated bracket 40 Ident. No.: 76D_EN Status: Webasto Thermo & Comfort SE 0

21 D.4 TSI / SG Route hoses and D through rubber-coated p-clamp. Ensure sufficient distance from coupling hose. xmm hose bracket (retaining clip removed) Routing in engine compartment 4 Pull out coolant hose of expansion tank from connection piece, shorten by 0mm and remount. Pull off hose on engine outlet/heat exchanger inlet from connection piece. Spring clip will be reused. Cutting point 4 E Original vehicle spring clip Connection on heat exchanger inlet 4 E xmm hose bracket (retaining clip removed) Hose of engine outlet D Connecting engine outlet and heat exchanger inlet 44 Ident. No.: 76D_EN Status: Webasto Thermo & Comfort SE

22 E 5x5mm lockable spacer bracket [x] Hose of engine outlet Hose for heat exchanger outlet Routing in engine compartment D 45 lign hoses and D. Tighten M8 nut and M6 flanged nut. Ensure sufficient distance from adjacent components, especially from original vehicle wire, adjust if necessary. Routing in engine compartment E 46.0 TSI / SG (manual transmission) and DSG (direct gear transmission) Figure shows direct gear transmission (DSG). Route hoses B and E through rubber-coated p-clamp. Ensure sufficient distance from neighbouring components. xmm hose bracket (retaining clip removed) Routing in engine compartment B 47 Push back heat protection hose. Cut off hose on engine outlet/heat exchanger inlet at marking. Hose section of heat exchanger inlet Engine outlet hose section Cutting point 48 Ident. No.: 76D_EN Status: Webasto Thermo & Comfort SE

23 Hose on heat exchanger inlet Connection on heat exchanger inlet E 49 5x5mm lockable spacer bracket Hose of engine outlet B Connecting engine outlet 50 B E Figure shows direct gear transmission (DSG). lign hose B and E. Tighten M8 nut and M6 flanged nut. Ensure sufficient distance from neighbouring components, correct if necessary. Routing in engine compartment 5 Manual transmission (SG). Latch coupling line in clip and align. Ensure sufficient distance from neighbouring components. Routing of coupling line 5 Ident. No.: 76D_EN Status: Webasto Thermo & Comfort SE

24 Coolant Circuit Diesel WRNING! ny coolant running off should be collected in an appropriate container. Install hoses so that they are kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that other hoses cannot be damaged. The heater must be filled with coolant when installing the hoses. The connection should be "inline" based on the following diagram: Hose installation diagram D B C ll spring clips = 5 mm dia. ll connecting pipes and = 8x8mm dia. Ident. No.: 76D_EN Status: Webasto Thermo & Comfort SE 4

25 Mount M6x0 bolt, M6 flanged nut loosely 8mm dia. rubber-coated p-clamp 8.5mm dia. hole Preparing perforated bracket 5 D SG Route hose to brake booster. lign hoses and D behind hose bracket. Ensure sufficient distance from neighbouring components. Original vehicle stud bolt, M8 flanged nut Routing on frame side member B 54 Ensure sufficient spacing between hose bracket and transmission. Routing on frame side member 55 Latch coupling line in clip and align. Ensure sufficient distance from neighbouring components. Routing of coupling line 56 Ident. No.: 76D_EN Status: Webasto Thermo & Comfort SE 5

26 Mount original vehicle bolt, M8 nut loosely Premounted perforated bracket perforated bracket 57 D Route hoses and D behind the coupling line and through rubber-coated p-clamp. Routing in engine compartment D 58 Ensure sufficient distance from coupling line. Routing in engine compartment D 59 DSG Route hose to brake booster. lign hoses and D behind hose bracket. Ensure sufficient distance from neighbouring components. Original vehicle stud bolt, M8 flanged nut Routing on frame side member B 60 Ident. No.: 76D_EN Status: Webasto Thermo & Comfort SE 6

27 Ensure sufficient spacing between hose bracket and transmission. Routing to frame side member D 6 Route hoses and D through rubber-coated p-clamp. 6 ll vehicles Cut off hose on engine outlet/heat exchanger inlet at marking. Cutting point 6 Hose on heat exchanger inlet Routing in engine compartment Connection on heat exchanger inlet D 64 Ident. No.: 76D_EN Status: Webasto Thermo & Comfort SE 7

28 D Spacer bracket x8 spacer bracket Hose of engine outlet Connecting engine outlet D 65 Figure shows manual transmission (SG). lign hoses and D. Tighten M8 nut and M6 flanged nut. Routing in engine compartment D 66 Figure shows manual transmission (SG). Ensure sufficient distance from coupling line. xmm hose bracket (retaining clip removed) Routing in engine compartment D 67 Figure shows direct gear transmission (DSG). lign hoses and D. Tighten M8 nut and M6 flanged nut. xmm hose bracket (retaining clip removed) Routing in engine compartment 68 Ident. No.: 76D_EN Status: Webasto Thermo & Comfort SE 8

29 Fuel CUTION! Open the vehicle's fuel tank cap, ventilate the tank and then re-close the tank lock. Catch any fuel running off in an appropriate container. Route 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. WRNING! The fuel line and wiring harness are routed to the metering pump as shown in the wiring harness routing diagram. 4 Complete connector of metering pump again after routing. Pin assignment is not relevant. 5 5 Connector housing Lock Blue / brown (bl / br) wires 4 Coding 5 Timer lock Dismantling connector 69 Route fuel line and wiring harness of metering pump in 0mm corrugated tube to firewall. Routing lines 70 Route fuel line and wiring harness of metering pump in coolant reservoir on the right side of the vehicle. Pay particular attention to freedom of movement of wiper linkage. If there is an insulation mat, routing can be undertaken behind it. Original vehicle pass throughs Routing lines 7 Ident. No.: 76D_EN Status: Webasto Thermo & Comfort SE 9

30 Routing lines 7 Fuel line and wiring harness of metering pump in corrugated tube Original vehicle line duct Routing lines 7 Cut off approx. 600mm from fuel line. 4 Hose section, 0mm dia. clamp of metering pump Metering pump 4 80 moulded hose, 0mm dia. clamp [x] 5 600mm fuel line Cut off approx. 00mm from the 0mm dia. corrugated tube and slide on to fuel line and wiring harness of metering pump. Guide fuel line and wiring harness of metering pump into original vehicle line duct and route to underbody. Premounting metering pump 5 74 Original vehicle bolt Bracket of metering pump metering pump bracket 75 Ident. No.: 76D_EN Status: Webasto Thermo & Comfort SE 0

31 Slide approx. 500mm of 0mm dia. corrugated tube onto fuel line. M6x5 bolt, flanged nut of metering pump metering pump 76 Wiring harness of metering pump, connector mounted Fuel line of heater, 0mm dia. clamp Connecting metering pump 77 Petrol Remove fuel-tank sending unit in accordance with manufacturer's instructions and discard. Engage metal drilling template play-free on fuel-tank sending unit as shown. Fuel extraction 78 Ensure firm seating of template. Guide drill bit exactly perpendicular to surface of fueltank sending unit. Carefully drill at low speed and only with light pressure. 6 mm dia. drill bit Metal drilling template Hole in fuel-tank sending unit 79 Ident. No.: 76D_EN Status: Webasto Thermo & Comfort SE

32 6 mm dia. hole Overhanging, circumferential edge of approx. mm Drilled-out blind connection piece View of underside of fuel-tank sending unit 80 Carefully remove overhanging edge with deburring tool. Deburring tool Removing edge 8 Shape fuel standpipe according to template, cut to length and install. Installing fuel standpipe 8 Mount fuel-tank sending unit in accordance with manufacturer's instructions. Ensure sufficient spacing between hose section and edge of locking ring. 4 Hose section, 0 mm dia. clamp [x] Fuel standpipe 4 Fuel line in 0mm dia. corrugated tube fuel-tank sending unit 8 Ident. No.: 76D_EN Status: Webasto Thermo & Comfort SE

33 Diesel = = Remove fuel-tank sending unit in accordance with manufacturer's instructions. Position large diameter washer outer dia. d a =.6mm midway between the connection pieces. Copy hole pattern, 6.0mm dia. hole Fuel extraction 84 Shape fuel standpipe according to template, cut to length and install. Installing fuel standpipe 85 4 Install fuel-tank sending unit in accordance with manufacturer's instructions. Fuel standpipe Hose section, 0 mm dia. clamp [x] 4 Fuel line in 0mm dia. corrugated tube Connecting fuel line 86 Ident. No.: 76D_EN Status: Webasto Thermo & Comfort SE

34 Final Work retaining plate / connector Figure shows diesel. Insert retaining plate in hole of perforated bracket and fasten with cable tie. Remount connector. retaining plate 87 Cutting out Cut out wheel-well inner panel at the marking. Cutting out wheel-well inner panel 88 Ensure sufficient distance between wheelwell inner panel and exhaust pipe at position (min. 0mm). wheel-well inner panel Underride protection 60mm dia. hole 80 Cutting out underride protection 90 Ident. No.: 76D_EN Status: Webasto Thermo & Comfort SE 4

35 lign exhaust end section in centre of hole and flush with underride protection. ligning exhaust end section 9 WRNING! Mount removed parts in reverse order. Check all hoses, clamps and all electrical connections for firm seating. Insulate and tie back all loose lines. Only use manufacturer-approved coolant. Spray the heater 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 digital timer, teach telestart transmitter. Make settings on /C control panel according to the "Operating Instructions for End Customer". Place the "Switch off parking heater before refuelling" signboard near the filler neck. See installation instructions for initial start-up and function test. Webasto Thermo & Comfort SE Postfach Gilching Germany Internet: Technical Extranet: Ident. No.: 76D_EN Status: Webasto Thermo & Comfort SE 5

36 Template for Fuel Standpipe Petrol 00mm Scale : Compare the size of the printed version with dimension lines. Permitted tolerance a maximum of %. Set the printer settings to no margin or minimise margins and 00% of the normal size. 00mm 0 Ident. No.: 76D_EN Status: Webasto Thermo & Comfort SE 6

37 Template for Fuel Standpipe Diesel 00mm Scale : Compare the size of the printed version with dimension lines. Permitted tolerance a maximum of %. Set the printer settings to no margin or minimise margins and 00% of the normal size. 00mm 0 Ident. No.: 76D_EN Status: Webasto Thermo & Comfort SE 7

38 Operating Instructions for End Customer Please remove this page in case of Climatronic and add it to the vehicle operating instructions. 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. Passenger compartment monitoring unit, if installed, must be deactivated in addition to vehicle settings for the heating operation. For instructions on deactivation, please refer to the operating instructions of the vehicle. Before parking the vehicle, make the following settings: Set temperature to "HI ir outlet to windscreen /C control panel, variant 9 Set temperature to "HI" ir outlet to windscreen /C control panel, variant 9 0 heater fuse F 0 main fuse F of passenger compartment Fuses of engine compartment 94

39 fuse F of heater control Fuses of passenger compartment 95