Citroen Jumpy / Fiat Scudo / Peugeot Expert

Transcription

1 Water Heater Feel the drive Thermo Top E Parking Heater Thermo Top C Parking Heater e e Installation documentation Citroen Jumpy / Fiat Scudo / Peugeot Expert Diesel from Model Year 007 Left-hand drive vehicle 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, specialised tools and equipment are required to install and repair Webasto heating and cooling systems. Only original Webasto parts must be used. For this, also see the catalog of air and water heater accessories from Webasto. 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. The initial startup is to be executed with the Webasto Thermo Test Diagnosis. Webasto does not accept any liability for defects and damage that are attributable to installation by untrained staff. Ident. No.: 64D_EN Fee Euro 0.00 Webasto AG

2 Table of Contents Validity Heater/Installation Kit Foreword General Instructions Special Tools Explanatory notes on document 4 Preliminary Work Heater installation location Preparing electrical system 6 Electrical system 7 Fan control for manual air conditioning 8 Automatic air-conditioning fan control 0 Digital timer Preparing installation location Preparing heater Installing heater 6 Fuel 7 Coolant circuit 8 Final Work Operating Instructions for End Customer 4 Validity Manufacturer Model Type EG-BE No./ABE Citroen Jumpy G9 e * 00/6 * 048 *... Fiat Scudo 70 e * 00/6 * 0 *... Peugeot Expert G9 e * 00/6 * 049 *... Engine type Engine model Output in kw Displacement in cm³ RHK Diesel Vehicle and engine types, equipment variants and national specifications not listed in this installation documentation have not been tested. However, installation according to this installation documentation may be possible. The installation location of the digital timer should be confirmed with the end customer before installation. 64D_EN

3 Heater/Installation Kit Quantity Designation Order No.: Retail accessories with desired heater control See price list Also required: Installation Kit for Citroen Jumpy / Fiat Scudo / Peugeot Expert Diesel with manual air conditioning 6A or: Installation Kit for Citroen Jumpy / Fiat Scudo / Peugeot Expert Diesel Automatic Air-Conditioning 8C Heater recommended for the respective vehicle class: Vehicle Compact car Mid-size car, estate car Heater Thermo Top E Thermo Top C The selection of the heater is based on the passenger compartment size of the vehicle and the level of comfort required by the customer. Foreword This installation documentation applies to the Citroen Jumpy / Fiat Scudo / Peugeot Expert Diesel vehicles - for validity, see page - from model year 007 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. However, the stipulations in this "installation documentation", the "operating instructions" and "installation 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 rub protection (split-open fuel 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 64D_EN

4 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 Coolant circuit 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 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. All dimensions are in mm! Tightening torque of hose clamps = Nm! Tightening torque of Ejot screws, Ejot studs = 0 Nm! 64D_EN 4

5 Preliminary Work WARNING! - Open the fuel tank cap and vent the fuel tank. - Close the fuel tank cap again. - Disconnect the battery "earth" or "ground" connection. - Depressurise 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 air filter together with the intake hose - Remove the fresh-air supply line above the engine. - Open the fuse box in the engine compartment. - Remove the cover above the glove compartment. - Remove the footwell trim on the driver's side - Remove the A/C control panel (only with automatic air-conditioning). Heater installation location Heater Remove page 4 "Operating Instructions for End Customer" and add to the vehicle operating instructions. Installation location 64D_EN

6 Preparing electrical system a K. Manual air conditioning Produce connections as shown in wiring diagram. Red (rt) wire 0.7² Black (sw) 4² wire Blue (bl) wire.² 4 Brown (br) wire 4² Brown (br) wire 0.7² Preparing additional K. relay Automatic air-conditioning a 8 0 K Remove red (rt) wire from K/87a and discard. Produce connections as shown in wiring diagram. Pull green/white (gn/ws) wire 0.7² into protective sleeving provided. Preparing K Produce connections as shown in wiring diagram. A 86 8 E IPCU 86 8 E A Red (rt) wire 0.7² Black (sw) wire 0.7² 4 Brown (br) wire 0.7² Preparing IPCU 4 Cut wires, pull wires 7 and 8 through protective sleeving t a K 87z 87 87a Produce connections as shown in wiring diagram. Red (rt) wire 0.² 00 6 Blue (bl) wire 0.² 00 7 Black (sw) wire 0.² Brown (br) wire 0.² Red (rt) wire 0.² 80 Preparing K D_EN 6

7 Electrical system Earth connection Original vehicle earth support point Wiring harness pass through Protective rubber plug Route wiring harness of heater and metering pump along original vehicle fuel lines on underbody Wiring harness routing diagram 4 Positive connection Fuse holder, K relay Original vehicle positive support point Original vehicle stud bolt, flanged nut Angle bracket Mx6 bolt, washer, retaining plate or fuse holder, K relay, flanged nut on angle bracket 64D_EN 7

8 Fan control for manual air conditioning Webasto F HG X 4 Citroen, Fiat, Peugeot sw 4² GS sw 4² Fx GR 0 D + 6 Wiring diagram rt 4² 87a K 4 br 4² sw 4² 4 rt 4² St A sw 4² rt 0,7² bl,² bl rt 4² br 4² a 8 0 K. 4 bl 4 WG + M - rt 4² GM Webasto components Vehicle components Colours and symbols HG Heater TT-C/E GM Fan motor rt red X 6-pin heater connector GRs Fan relay ws white F A fuse GS Fan switch sw black K Fan relay WG Resistor group br brown K. Additional relay St A 6-pin connector bl blue Fx Fuse bl blue Legend X Cutting point Wiring colours may vary. 64D_EN 8

9 Original vehicle bolt K. relay Installing K. relay 6 4 Connection to 6-pin connector 7 before the fan motor. Produce connections as shown in wiring diagram. 8 Black (sw) wire K./87 Black (sw) wire of connector, Pin 4, disconnected Red (rt) wire of connector, Pin, disconnected 4 Black (sw) wire from K/0 Red (rt) wire from K/87a 6 Red (rt) wire of K./87a 8 Brown (br) wire K./0 Connecting fan motor Wire-side view of connection on 6-pin connector. Red (rt) wire of connector, Pin Black (sw) wire of connector, Pin 4 View of 6- pin connector 8 Connection to -pin connector from resistor group. Produce connections as shown in wiring diagram. 4 Blue (bl) wire of connector, Pin, disconnected x connector 4 Blue (bl) wire to K./87a Connecting resistor group 9 64D_EN 9

10 Automatic air-conditioning fan control gn/ws 0,7² HG X 4 Webasto IPCU 86 8 br 0,7² A E 87a K t a F sw 0,7² rt 0,7² sw 0,² 0 br 0,² K sw 4² rt 0,² 87z 87a 87 rt ge/gn,0² rt sw 0,² Citroen, Fiat, Peugeot ge 4² ge/gn,0² F GR ge 4² ws,0² ws,0² 4 OBD M GM GRr ge/sw 0,² ge/sw 0,² F rt 0,² bl 0,² St A KB F4 hbl 0,² hbl 0,² 8 0 D + 6 Wiring diagram Webasto components Vehicle components Colours and symbols HG Heater TT-C/E GRr Fan controller rt red X 6-pin heater connector GR Fan relay ws white F A fuse GM Fan motor sw black K Fan relay KB A/C control panel br brown K Additional relay F Fuse IPCU Pulse width modulator F4 A fuse gn green IPCU adjustment values: St A Connector, -pin, KB ge yellow Duty cycle: 4% OBD Diagnostics connector OBD hbl light blue Frequency: 00Hz Voltage: 4.6V Wiring colours may vary. Function: High-side X Cutting point Secure IPCU socket with double-sided adhesive tape. Connect green/white (gn/ws) wire of K/86 to IPCU/86. Legend Installing IPCU 0 64D_EN 0

11 Brown (br) wire of IPCU/8 Mount M6x6 bolt, flanged nut in existing hole Connecting earth wire of IPCU 4 Connection to -pin connector from fan controller. Produce connections as shown in wiring diagram. Yellow/black (ge/sw) wire of A/C control panel Red (rt) wire of IPCU/E Black (sw) wire of IPCU/A 4 Yellow/black (ge/sw) connector of fan controller Connecting IPCU Connection to 4-pin connector from fan controller. Produce connections as shown in wiring diagram. Yellow (ge) wire of fan relay Black (sw) wire from K/0 4 Y-adapter Yellow (ge) wire of fan motor connector Connecting fan controller 4 Secure K relay with double-sided adhesive tape. Installing K relay 4 64D_EN

12 -pin connector Pin 8. Light-blue (hbl) wire Connector shown with connector housing removed. Connection on A/C control panel Red (rt) wire of K/87z Blue (bl) wire of K/87 Light-blue (hbl) wire, -pin connector, Pin 8 Light-blue (hbl) fuse F4 Connection to -pin connector 4 from A/C control panel. Produce connections as shown in wiring diagram. Connection on A/C control panel Connection to connector OBD 6. Produce connections as shown in wiring diagram. 7 Brown (br) wire of K/ Yellow/green (ge/gn) wire of earth Black (sw) wire of K/ 4 White (ws) wire of Terminal White (ws) wire of OBD connector, Pin 7 Green/yellow (gn/ge) wire of connector OBD, Pin 4 Connecting K relay 6 7 Digital timer Digital timer Installing digital timer 8 64D_EN

13 Preparing installation location Insert M6x0 bolt with large diameter washer in original vehicle hole from above. Mounting bolt 9 Preparing heater To disconnect connector of circulating pump, remove device cover. 4 Spring clip [x] Circulating pump 4 Clamp Hose on heater inlet Dismantling circulating pump Reinstall circulating pump after replacing. 9 pump cover Replacing circulating pump cover 0 Bracket 9 mm dia. rubber-coated p-clamp, plastic nut [x each] on existing stud bolt Preparing bracket 64D_EN

14 Cut 80 mm off edge protection. M6x0 bolt, flanged nut 80 mm edge protection Perforated bracket Preparing bracket Insert two washers between heater and bracket at Position. Ejot screw, washer [x] Ejot screw [x] Premounting heater Combustion air pipe a = 0 Discard section X a Cutting combustion air pipe to length X Silencer Combustion air pipe 7 mm dia. clamp 4 Retaining clip in existing hole Premounting silencer D_EN 4

15 Metering pump Silent block on existing threaded hole Moulded hose, 0 mm dia. clamp [x] 4 Rubber-coated p-clamp, flanged nut on silent block Moulded hose, 0 mm dia.clamp Premounting metering pump 4 8x0 connecting pipe 7 mm dia. spring clip 7 mm dia. clamp Premounting hose B B Shorten hose C by 0 mm 0 Cutting hose C to length C C 6 7 mm dia. spring clip 7 mm dia. clamp 8x0 connecting pipe Premounting hose C 7 64D_EN

16 Exhaust pipe a = 0 Exhaust end section b = 90 Discard section X Preparing exhaust pipe a b X Hose clamp [x] Exhaust pipe Exhaust silencer 4 Flanged nut on existing stud bolt Exhaust-pipe end section Premounting exhaust system 4 8 Installing heater M6x0 bolt, spring lockwasher, large diameter washer [x each] Installing heater 9 Flanged nut on M6x0 bolt Installing heater 0 64D_EN 6

17 Fuel Cut off fuel return line at Position. Mount fuel standpipe in cutting point. 6xx6 fuel standpipe, 8 mm dia. clamp [x] 0 mm dia. clamp Removing fuel 64D_EN 7

18 Coolant circuit WARNING! Any coolant running off should be collected in an appropriate container. Route coolant hoses kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that other hoses cannot be damaged. When installing the coolant hose, the heater must be filled with coolant. The connection should be "inline" based on the following diagram: Coolant routing diagram B C D A All spring clips = 7 mm dia. All connecting pipes = 8x0 mm dia. All hose clamps = 0-7mm dia. = Black (sw) rubber isolator. 64D_EN 8

19 Discard section X A D A= 00 D= 070 Cutting coolant hoses to length X X 80 Angle down perforated bracket by approx mm spacer sleeve M6x40 bolt, spring lockwasher, pin lock Preparing perforated bracket Remove original vehicle bolt at position. M6x40 bolt on threaded hole Perforated bracket 0 mm edge protection Installing perforated bracket Detach retaining clip [x] from original vehicle wiring harness. Remove retaining plate. Removing retaining plate 4 64D_EN 9

20 Remove hose from engine outlet/heat exchanger inlet. Cutting point Remove protective hose. Cut off hose on engine outlet/heat exchanger inlet at markings. Hose section of heat exchanger inlet Engine outlet hose section Separating hose 6 Slide heat protection hose onto hose D. Black (sw) rubber isolator Hose section of heat exchanger inlet D Preparing hose D 7 Slide heat protection hose onto hose A. Engine outlet hose section A Preparing hose A 8 64D_EN 0

21 Route through hose A to underbody and connect to connection piece on engine outlet. Engine outlet hose section A Connecting engine outlet 9 Route through hose D to underbody and connect to connection piece on heat exchanger inlet. Hose section of heat exchanger inlet Connecting heat exchanger inlet D 40 Fasten hose A and D on premounted perforated bracket with rubber-coated 4 mm dia. p-clamp [x], M6x0 bolt and flanged nut. Routing on underbody A D 4 C Route hose D through rubber-coated p-clamp. Connecting heater outlet D 4 64D_EN

22 B Connecting heater inlet A 4 Perforated bracket Cable tie Fastening hose A 44 Aligning hoses. Ensure sufficient distance from neighbouring components Spacer bracket [x] Installing spacer bracket 4 64D_EN

23 Final Work WARNING! Mount removed parts 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 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. - Adjust digital timer, teach telestart transmitter - Make settings on A/C control panel according to the "Operating Instructions for End Customer". - Place signboard "Switch off parking heater before refuelling" in the area of the filler neck - See installation instructions for initial start-up and function test Feel the drive Webasto AG Postfach 80 D-8 Stockdorf / Germany National Hotline: (4 Cent aus dem deutschen Festnetz) Hotfax: 09 9 Hotmail: technikcenter@webasto.com 64D_EN Printed in Germany /0 Printing: Steffen

24 Operating Instructions for End Customer Please remove page and add 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. If the summer/winter switch option has been installed, this must be switched in accordance with the time of year. The heater will then heat in the position Winter and in the position Summer it will only switch on the vehicle fan to ventilate the vehicle interior. Before parking the vehicle, make the following settings: Air outlet to windscreen Set temperature to "max." Manual air conditioning 46 Set temperature on right and left to "HI" Air outlet faces upward Automatic air-conditioning 47 64D_EN 4