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

Transcription

1 Water Heater Feel the drive Thermo Top Evo Parking Heater e Installation documentation Audi A6 / A6- Avant / Audi A7 Sportback.0 and.0 TDI quattro from model year 0 Left-hand drive vehicle Automatic transmission Climatronic 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.: 7500C_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 5 Heater installation location 5 Preparing electrical system 6 Electrical system 8 Fan controller 9 Digital timer Remote option (Telestart) Preparing installation location Preparing heater heater 6 Coolant circuit.0 TDII 7 Coolant circuit.0 TDII Fuel 5 Exhaust gas 9 Final Work 0 Adaptation of Climatronic J55 control unit 0 Operating Instructions for End Customer Validity Manufacturer Model Type EG-BE No./ABE Audi A6 4G e * 007 / 46 * 046 *... Audi A6 Avant 4G e * 007 / 46 * 046 *... Audi A7 Sportback 4G e * 007 / 46 * 046 *... Engine type Engine model Output in kw Displacement in cm³ CGLC Diesel / quattro CDUC Diesel / quattro 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. 7500C_EN

3 Heater/Installation Kit Quantity Description Order No.: Basic delivery scope Thermo Top Evo See price list Audi A6 / A7 installation kit 0.0 and.0 TDI quattro 7499A Heater control See price list.0 TDI additionally requires Quantity Description Order No.: Add-on kit for Audi A6 / A6- Avant / A7 0.0 TDI 8098A Foreword This installation documentation applies to Audi A6 / A6- Avant / Audi A7 Sportback /.0 and.0 TDI quattro 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. However, the stipulations in this "installation documentation", the "operating and installation instructions" for the Thermo Top Evo 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. Insulate loose wires 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). When installing an IPCU, the appropriate settings must be checked and set prior to the installation. Special Tools - Torque wrench for.0-0 Nm - Hose clamping pliers - 5mm dia. punching tool - Metric thread-setter kit 7500C_EN

4 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 Electrical system Coolant circuit Fuel Exhaust gas Combustion air Software 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 5x heater bolts = 8Nm! Tightening torque of 5x5 bolt of water connection piece retaining plate = 7Nm! 7500C_EN 4

5 Preliminary Work WARNING! - Open the fuel tank cap, ventilate the tank. - Close the fuel tank cap again. - 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. - Disconnect the battery (luggage compartment). - Remove the engine design cover. - Remove the air filter together with the intake hose. - Remove the right-hand front wheel. - Remove the right-hand front wheel well trim. - Remove the right-hand underride protection. - Remove the front underride protection, located in the centre. - Remove the rear bench seat. - Remove the fuel-tank sending unit in accordance with the manufacturer's instructions. - Remove the lower instrument panel trim on the front passenger's side. - Remove the glove compartment. - Remove the A-pillar trim on the front passenger's side. - Remove the A/C control panel in accordance with the manufacturer's instructions. Heater installation location Heater Remove page "Operating Instructions for End Customer" and add to the vehicle operating instructions. Installation location 7500C_EN 5

6 Preparing electrical system Wire sections retain their numbering throughout the whole document bl br Cut metering pump connector with blue and brown (bl/br) 00mm wires to length (connector will later be remounted with the butt connector). Blue and brown wires (br/bl), 000mm each, will be needed to connect the time-delay relay! Cutting wiring harness of metering pump to length 000 gn/ws 0,5² Preparing additional lines 6 50 rt 0,75² Produce connections as shown in wiring diagram t a 5 ZR 87z 87 7 Preparing time-delay relay 87a Turn perforated bracket about 90 in it's longitudinal axis Preparing perforated bracket 7500C_EN 6

7 Perforated bracket M6x0 bolt, flanged nut, existing hole perforated bracket Cut thread of M6 in existing hole of positive support point (check depth, about 8mm)! Preparing positive support point 7500C_EN 7

8 Electrical system Positive and earth wire Shorten M6x0 bolt to 0mm! M6x0 bolt, toothed washer, cable lug, positive wire on positive support point Earth wire on original vehicle earth support point Wiring harness pass through Protective rubber plug (hidden) Wiring harness of heater and heater control 4 5 Do not install the metering pump wiring harness until later together with fuel pipe along the original vehicle fuel lines on the underbody Wiring harness routing diagram 4 Fuse holder engine compartment Observe sufficient distance to positive support point 4. If necessary, bend perforated bracket again! M5x6 bolt, washer [x], nut F- fuses (replace F with A) 6 Wiring harness routing Cut edge protection in middle! Wiring harness of heater and heater control 50 mm edge protection C_EN 8

9 Fan controller Webasto Audi 0 5 F F HG X 5 X J55 T0c SC SC Wiring diagram 4 rt 4² ge 0,5² rt/sw gn/ws 0,5² 0,75² br 0,5² gn/ws 0,75² T4cb 4 J6 M * * gr br X0 8 br rt 0,75² 6 0 t a 5 ZR 87z 87 87a 7 bl gr br St A br 0,5² 5 HSF Webasto components Vehicle components Colours and symbols HG Heater TT-Evo J6 Fan unit rt red X 6-pin heater connector T4cb 4-pin J6 connector sw black X -pin heater connector J55 Control unit of A/C control ge yellow X0 4-pin connector panel gn green Heater control T0c 0-pin connector J55 or orange F Fuse 0A SC Fuse ws white F Replace 0A with A SC Fuse br brown fuse. HSF Switch glovecompartment gr grey ZR Time-delay relay lighting ST A -pin HSF connector * Wiring harness of glove compartment lighting X Cutting point Wiring colours may vary. Legend 7500C_EN 9

10 5 ZR socket Soldering end connector Wiring harness of heater Green/white (gn/ws) wire of ZR/5 - J55 T0c/0 Green/white (gn/ws) wire of ZR/5 - X/5 heater Red/black (rt/sw) wire of X0 heater control Red (rt) wire of F fuse Brown (br) wire of ZR/ - heater earth wire Red (rt) wire of ZR/0 Connection of time-delay relay mm dia. hole at position. Route ZR wiring harness to glove compartment lighting connector! 5.5x self-tapping screw ZR socket Mounting time-delay relay socket 9 Connection to -pin connector 4 of glove compartment lighting. Produce connections as shown in wiring diagram. 8 7 Green (gr) wire of glove compartment lighting wiring harness Brown (br) wire of glove compartment lighting wiring harness Brown (br) wire of -pin connector pin 5 Green (gr) wire of -pin connector pin 7 8 Blue (bl) wire of ZR/87 Brown (br) wire of ZR/87z Glove compartment lighting connection Connection to 0-pin T0c connector Pin0 A/C control unit. Microtimer on green/white (gn/ws) wire Crimp and insert into free pin 0 socket. Produce connection as shown in wiring diagram. T0c connector dismantled Connection of A/C control unit 7500C_EN 0

11 Digital timer Digital timer digital timer Remote option (Telestart) Receiver Original vehicle bolt Bracket receiver Antenna antenna 4 Temperature sensor T00 HTM Fasten temperature sensor with adhesive tape. temperature sensor C_EN

12 Preparing installation location Existing hole, install rivet nut [4x] rivet nut 6 Fuel hose on original vehicle stud bolt 50 mm edge protection edge protection 7 Wiring harness of heater Routing wiring harness of heater 8 Preparing heater Water connection piece, sealing ring [x each] Self-tapping bolt 5x5, retaining plate, water connection piece Assembling water connection piece C_EN

13 Bracket part A Mount M5x6 bolt, self-locking nut, loosely 5mm dia. clamp Premounting clamp 0 Bracket part A Self-tapping bolt 5x [x] bracket Discard section X. Exhaust pipe a = 0 Preparing exhaust pipe a X Lightly bend exhaust end section at the end as shown (threaded insert points to the right). Silencer Preparing silencer 7500C_EN

14 Hose clamp [x] Exhaust pipe M6x6 bolt, spring lockwasher 4 Locking tab of bracket part A (twist protection) 5 Silencer Premounting exhaust pipe and silencer TDI Discard section X. B A C D E F G H X A = 800 B = 00 C = 50 D = 80 E = 90 F = 60 G = 0 H = 700 Cutting hoses to length.0 TDI Discard section X. A B C D E F G H X A = 590 B = 80 C = 50 D = 80 E = 90 F = 60 G = 0 H = 740 Cutting hoses to length All vehicles G A Push braided protection hoses onto hoses A and H and cut to length (.0 TDI only). Heat shrink plastic tubing on position,.0 TDI only. 50 mm long heat shrink plastic tubing [4x] 50 mm long heat shrink plastic tubing Preparing hoses H 7500C_EN 4

15 Push circulating pump mount onto bracket part A at position 4! Attach wiring harness of circulating pump [x] Circulating pump Mounting circulating pump F 4 4 All connecting pipes = 90 8x8mm dia. [x], all spring clips = 5mm dia. [8x]! E C Premounting hoses G D 5 All connecting pipes = 90 8x8mm dia., all spring clips = 5mm dia. [x]! Premounting hoses 6 Tighten bolt of 5mm dia. clamp. Combustion air pipe 5 mm dia. clamp Combustion air silencer Premounting combustion air silencer C_EN 5

16 0 mm dia. clamp 90 moulded hose Premounting fuel hose on heater 8 heater M8x0 bolt, spring lockwasher [x each] heater 9 Bracket part B Self-tapping bolt 5x [x] M8x0 bolt, spring lockwasher [x] heater 0 Wiring harness of heater [x] Mounting wiring harness of heater 7500C_EN 6

17 Coolant circuit.0 TDII 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 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 H G A B E F D C All spring clips without a specific designation = 5 mm dia. = Original vehicle spring clip. = Original vehicle circulating pump. All connecting pipes and = 8x8 mm dia. 7500C_EN 7

18 B C Routing in engine compartment G Protective rubber plug Removing protective rubber plug Cut off hose of original vehicle circulating pump / engine outlet at marking. Turn original vehicle hose section on circulating pump inlet about 80 forward. Original vehicle circulating pump Engine outlet hose section Cutting point 4 Punch in 5 mm dia. hole [x] Protective rubber plug 4 80 Preparing protective rubber plug C_EN 8

19 Remove and discard original vehicle bolts at position. Air filter box 5.5x self-tapping screw [x each] 48 mm dia. rubber-coated p-clamp [x] p-clamps A 6 Cut heat protection hose in middle. Push one end each onto hoses A and H and route using rubber-coated p-clamps. Push protective rubber plug onto both hoses. Premounting hose A and H H 7 Mount air filter box. Route hoses A and H (below hose A, hidden) through the original vehicle pass through into the coolant reservoir! A 8 A B Routing in engine compartment Connecting hoses G H C_EN 9

20 Hose on circulating pump inlet H Connection of heat exchanger inlet A 40 Hose of engine outlet Spacer bracket Connecting engine outlet 4 A Ensure sufficient distance to neighbouring components, adjust, if necessary. Aligning hoses H C_EN 0

21 Coolant circuit.0 TDII 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 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 H G A B E F D C All spring clips without a specific designation = 5 mm dia. = Original vehicle spring clip. = Original vehicle circulating pump. All connecting pipes and = 8x8 mm dia. 7500C_EN

22 8 mm dia. rubber-coated p-clamp M6x0 bolt, existing threaded hole p-clamp H 4 Route hose H through rubber-coated p-clamp. Connecting heater outlet G 44 Insert hose bracket Original vehicle hose H Routing in engine compartment 45 Remove hose from engine outlet/original vehicle circulating pump. Spring clip on circulating pump will be reused. Cutting point C_EN

23 Protective hose removed. Cut off hose at markings. Engine outlet hose section Discard hose section Original vehicle circulating pump hose section Cutting point 4 47 Original vehicle circulating pump Hose on heat exchanger inlet Original vehicle hose 4 Original vehicle spring clip Connection of heat exchanger inlet A H 48 Route hose A through rubber-coated p-clamp. B Connecting heater inlet A C 49 Insert hose bracket Routing in engine compartment H C_EN

24 Hose of engine outlet A Connecting engine outlet 5 Ensure sufficient distance to neighbouring components, adjust, if necessary. A H Aligning hoses C_EN 4

25 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 as shown in the wiring harness routing diagram. Pull fuel line and wiring harness of metering pump into corrugated tube! 0 mm dia. clamp Connecting heater 5 Route fuel line and wiring harness of metering pump in corrugated tube in the righthand wheel well to the line duct! lines 54 Route fuel line and wiring harness of metering pump in corrugated tube through original vehicle cable duct to the underbody! lines C_EN 5

26 Route fuel line and wiring harness of metering pump in corrugated tube on original vehicle fuel lines to the installation location of the metering pump. lines Perforated bracket 76 Angling down perforated bracket Discard section Perforated bracket 0 Preparing perforated bracket 90 5 Metering pump mount Metering pump Perforated bracket (angled at 90 ) 4 Perforated bracket (angled at 65 ) 5 M6x5 bolt, flanged nut Premounting metering pump C_EN 6

27 80 moulded hose 0 mm dia. clamp [x] 90 moulded hose Premounting metering pump 58 M6x0 bolt, large diameter washer, flanged nut, existing hole Perforated bracket metering pump 59 4 Connect wiring harness of metering pump and blue/brown wires (bl/br) (each 00mm long) from metering pump connector with butt connector so that the wires of the same colour are connected. Connector attached Fuel line 4 0 mm dia. clamp Connecting metering pump 60 Remove fuel-tank sending unit according to manufacturer's instructions. Drill out connection piece to.5 mm dia. Fuel extraction C_EN 7

28 Cut off standpipe at end at an angle. 5 Cutting fuel standpipe to length 6 0 mm dia. hose clamp Hose section 0 mm dia. Caillau clamp 4 Standpipe 4 6 Install fuel-tank sending unit in accordance with manufacturer's instructions. 6 Fuel line 0 mm dia. Caillau clamp 4.5x4.5 mm dia. moulded hose 5 8 mm dia. Caillau clamp 6 Coupling piece fuel standpipe Connecting fuel line Check the position of the components; adjust if necessary. Check that they have freedom of movement. 0 mm dia. clamp Fuel line in corrugated tube Connecting metering pump C_EN 8

29 Exhaust gas Remove covering cap at position! Underride protection Removing covering cap 66 Centrally position exhaust end section in hole! Underride protection mounted Aligning exhaust end section 67 Ensure sufficient distance to neighbouring components (especially to the exhaust silencer at position ), take corrective measures if necessary. Aligning silencer C_EN 9

30 Final Work WARNING! Reassemble the disassembled components 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 A/C control panel according to the "Operating Instructions for End Customer". - Place the "Switch off parking heater before refueling" signboard in the area of the filler neck - For initial start-up and function check, see installation instructions Adaptation of Climatronic J55 control unit with VAS-VCDS Function: - Control unit selection - 08 AC-heater electronics - Adaptation > activate retrofit parking heater without CAN Save Align relay socket with glove compartment trim and glove compartment cap lever! Time-delay relay mounted Aligning time-delay relay socket 69 Feel the drive Webasto AG Postfach 80 D-8 Stockdorf / Germany National Hotline: (4 Cent aus dem deutschen Festnetz) Hotfax: Hotmail: technikcenter@webasto.com C_EN Printed in Germany 06/0 Printing: Steffen 0

31 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. Passenger compartment monitoring, if installed, must be de-activated in addition to the vehicle settings for the heating cycle. Please refer to the Operating Manual of the vehicle for instructions concerning the de-activation. Before parking the vehicle, make the following settings: Set temperature on both sides to "HI". Air outlet to windscreen Climatronic C_EN