Opel Astra / Astra Caravan / Astra GTC / Astra Twin Top

Transcription

1 Water Heater Feel the drive Thermo Top C Parking Heater e Installation documentation Opel stra / stra Caravan / stra GTC / stra Twin Top Petrol and Diesel from Model Year 004 Left-hand drive vehicle WRNING! 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. LWYS 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.: 005H_EN Fee Euro 0.00 Webasto G

2 Table of Contents Table of Contents Validity Foreword 4 General Instructions 4 Heater / Installation Kit 4 Special Tools 4 Explanatory Notes on Document 5 Preliminary Work 6 Heater installation location 6 Preparing wiring harness 7 Vehicles with automatic air-conditioning (ECC and SC) 7 Vehicles with passenger compartment monitoring 7 Electrical system 8 Fan control 9 Vehicles with passenger compartment monitoring 7 Manual air conditioning without passenger compartment monitoring 0 Manual air conditioning with passenger compartment monitoring utomatic /C without passenger compartment monitoring (ECC and SC) utomatic /C with passenger compartment monitoring (ECC and SC) Remote option (Telestart) 4 Combustion air 5 Preparing installation location 6 Preparing heater 8 Installing heater 8 Fuel 0 Metering pump 0 Fuel extraction Coolant circuit.4 litre;.0 litre petrol 4 Coolant circuit of.6 litre Z6EP;.8 litre petrol and. litre;.7 litre diesel 5 Coolant circuit.6 litre Z6ER 6 Coolant circuit.6 litre Z6LET 7 Coolant circuit.9 litre diesel 8 Cutting hoses to length 9.6 litre petrol Z6EP 9.6 litre petrol Z6ER 9.6 litre petrol Z6LET 0.8 litre petrol 0.0 litre petrol. litre and.7 litre diesel.9 litre diesel Preparing hoses ll vehicles ll vehicles except.0 litre petrol.0 litre petrol Hose installation.6 litre petrol Z6EP 9.6 litre petrol Z6ER 9.6 litre petrol Z6LET 0.8 litre petrol 0.0 litre petrol. litre diesel 40.7 litre diesel 4.9 litre diesel Exhaust gas 45 Petrol 46 Diesel 46 ll vehicles Final Work 48 Template for fuel-tank sending unit 49 Template for Fuel Standpipe 50 Operating Instructions for End Customer 5

3 Validity Manufacturer Model Type EG-E-No. / E Opel stra H -H e*00 / 6*06 Opel stra H -H e*00 / 6*09 Opel stra H Twin Top -H/C e4*00 / 6*0094 Engine type Engine model Output in kw Displacement in cm³ Z4EL Petrol Z4EP Petrol Z6EP Petrol Z6ER Petrol Z6LET Petrol 598 Z8ER Petrol Z8E Petrol Z0LEH Petrol (OPC) Z0LEL Petrol Z0LER Petrol ZDTH Diesel Z7DTL Diesel Z7DTH Diesel Z7DTJ Diesel DTJ Diesel Z7DTR Diesel DTR Diesel Z9DTL Diesel Z9DT Diesel Z9DTH Diesel 0 90 Vehicle models, engine types, equipment variants as well as national specifications, which are not listed in this installation documenation, have not been tested. However, installation according to this installation documentation may be possible. The installation location of a digital timer and summer/winter switch should be confirmed with the end customer before installation.

4 Heater / Installation Kit Quantity Designation Order No.: Opel-specific delivery scope Thermo Top C Petrol 84D Opel Catalogue No.: 7400 Opel-specific delivery scope Thermo Top C Diesel 844D Opel Catalogue No.: 740 lso required: Quantity Designation Order No.: Installation kit for Opel stra 004 Petrol and Diesel 0047F Opel Catalogue No.: 745 Heater control See Opel price list dditionally required for.9 litre diesel Quantity Designation Opel Order No.: racket of vacuum valve 7444 Foreword This installation documentation applies to Open stra H vehicles - for validity, see page - from model year 004 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, where this is the case the stipulations in this "installation documentation" and "operating instructions" and the "installation instructions" for the Thermo Top C should 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 must be provided with rub protection (cut-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 - Riveting pliers 4

5 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. i 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. 5

6 Preliminary Work Warning! - Disconnect the battery earth connection. - Remove the battery (only on.9 litre diesel vehicle). - 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. - ttach the duplicate label (type label) in the appropriate place. - Remove the air filter together with the intake hose. - Open the fuel tank cap and vent the fuel tank. - Close the fuel tank cap again. - Remove the front grill. - Remove the bumper. - Remove the front section of the wheel well trim on the right. - Remove the horns. - Remove the vacuum valve (only on.9 litre diesel vehicle). - Remove the underride protection (depending on vehicle equipment). - Remove the rear bench seat. - Remove the service cover of the fuel-tank sending unit. - Remove the lower instrument panel trim on the driver's side. - Remove the glove compartment (only on vehicles with manual air conditioning). - Remove the /C control panel (only on vehicles with automatic air-conditioning). - Remove the -pillar trim in the footwell on the front passenger side. - Remove the left-hand door sill cover completely (only on vehicles with alarm system). - Open the cable duct under the door sill cover (only on vehicles with alarm system). Heater installation location () Heater Installation location 6

7 Preparing wiring harness Vehicles with automatic air-conditioning (ECC and SC) 00 sw 0,75² Wire section will be required later for connection on /C control panel. Cutting wires to length Vehicles with passenger compartment monitoring Wire sections,, 4 and 5 will be required later for switching off passenger compartment monitoring sw 0,75² Cutting wires to length 0 rt a F rt/ws gn/ws 4 br 85 0 K sw sw 85 0 K. sw Premounting K. relay with passenger compartment monitoring HG a sw sw 7

8 Electrical system Wiring harness pass through Detach bracket of wiring harness () from stud bolt (). () Protective rubber plug Digital timer, summer/winter switch option () Digital timer, drilling template () Summer/winter switch, mm dia. hole i sw Do not install the metering pump wiring harness until later together with fuel line along the original vehicle fuel lines on the underbody Electrical diagram Fuse holder, K relay () Original vehicle stud bolt (/), bracket of wiring harness (/), plastic nut () ngle bracket () Retaining plate of fuse holder, M4x0 bolt, washers, M4 nut (4) Fuse holder (5) Earth support point, 5.5x self-tapping screw (6) k relay, 5.5x self-tapping screw 4 dditional K. relay with passenger compartment monitoring () Original vehicle stud bolt (/), bracket of wiring harness (/), K. relay (), plastic nut () K. relay 5 8

9 Fan control Vehicles with passenger compartment monitoring Push included protective sleeving onto additional line (wire section 5) up to cable grommet in passenger compartment. Route additional line along left-hand -pillar in cable duct to rear () lack (sw) 0.75 mm² wire section 5 from K./87 Routing additional line 6 Passenger compartment monitoring is switched off on rear zone module behind lefthand luggage compartment trim. () Wire section 5 () Connector 5 disconnected () Socket of connector 5 Disconnecting connector 7 Dismantle connector 5. Cut off front cable tie. Press both unlocking lugs toward rear with small screwdriver and pull off connector housing. () Connector 5 Unlocking connector 8 Connection on blue (bl) connector 5 from rear zone module. Produce connections according to wiring diagram on Page 0 or, depending on vehicle equipment. () Connector 5, Pin () Wire section 5 Connecting line 9 Passenger compartment monitoring must be reprogrammed to additional heating mode with TECH tester according to manufacturer's instructions. 9

10 5 Manual air conditioning without passenger compartment monitoring Connection on 5-pin connector of resistor group R_60. Produce connections as shown in wiring diagram with blade connectors provided. 4 () 5-pin connector of resistor group () Violet (vi) wire from fan controls (5) Red (rt) wire from K/87a () Violet (vi) wire to resistor of speed (4) lack (sw) wire from K/0 Fan control 0 Webasto Opel 0 i 5 HG 4 gn/ws rt/ws a 85 0 K F 5 rt sw 5 C4 rt _60 4 or vi bl C4 gn 4 5 rt 0 FE4 0 K5_ _5 86 Wiring diagram of manual air conditioning without passenger compartment monitoring + br R_60 sw P P - sw M M5_60 Webasto components Opel components Colours and symbols HG TT-C heater FE4 Fan fuse rt red 6-pin heater connector K5_5 Fan relay ws white F Fan fuse _60 Fan controls sw black K Fan relay R_60 Resistor group br brown M5_60 Fan motor gn green vi violet or orange bl blue Cutting point Wiring colours may vary. Legend 0

11 Manual air conditioning with passenger compartment monitoring Produce connection in accordance with Figure 0 and Page 9. Produce connections as shown in following wiring diagram with blade connectors provided. Fan control Webasto Opel 0 i 5 HG 4 gn/ws rt/ws F 5 rt 5 C4 rt _60 4 or vi bl C4 gn 0 FE4 0 K5_ sw br 87a K sw 4 sw sw K. 87a 4 5 P R_60 P sw 5 5 rt _5 + - sw sw M M5_60 Wiring diagram for manual air conditioning with passenger compartment monitoring RZM Webasto components Opel components Colours and symbols HG TT-C heater FE4 Fan fuse rt red 6-pin heater connector K5_5 Fan relay ws white F Fan fuse _60 Fan controls sw black K Fan relay R_60 Resistor group br brown K. dditional relay M5_60 Fan motor gn green RZM Rear zone module vi violet or orange bl blue Cutting point Wiring colours may vary. Legend

12 utomatic /C without passenger compartment monitoring (ECC and SC) Connection on grey (gr) -pin connector ZF -, Pin from /C control panel. Produce connections as shown in following wiring diagram with blade connectors provided. Replace F 5 fuse with fuse. () lack (sw) wire from K/0 () Wire section () -pin grey (gr) connector ZF - Fan control Webasto Opel 0 i 5 HG 4 gn/ ws rt/ws 87a K F rt sw! sw ZF- Wiring diagram for automatic air-conditioning without passenger compartment monitoring (ECC and SC) K br Webasto components Opel components Colours and symbols HG TT-C heater K /C control panel rt red 6-pin heater connector ZF - Grey (gr) connector K ws white F Replace 5 with sw black fuse. br brown K Fan relay gn green Legend Insulate wire end and tie back Cutting point Wiring colours may vary.

13 utomatic /C with passenger compartment monitoring (ECC and SC) Produce connection in accordance with Figure and Page. Produce connections as shown in following wiring diagram with blade connectors provided. Fan control Webasto Opel 0 i 5 HG 4 gn/ws rt/ws F! rt sw a K 85 0 br sw 4 sw sw sw ZF- K Wiring diagram of automatic airconditioning with passenger compartment monitoring (ECC and SC) K. 87a sw 5 5 RZM Webasto components Opel components Colours and symbols HG TT-C heater K /C control panel rt red 6-pin heater connector ZF - Grey (gr) connector K ws white F Replace 5 with RZM Rear zone module with sw black fuse. connector 5 br brown K Fan relay gn green K. dditional relay Insulate wire end and tie back Cutting point Wiring colours may vary. Legend

14 Remote option (Telestart) i Receiver 5.5 mm dia.hole, M5x bolt, flanged nut [x] racket Mounting receiver On vehicles without solar reflect windscreen. ntenna Mounting antenna On vehicles with solar reflect windscreen (approval stamp on windscreen at lower left "C" Use provided fields 70 x0 mm. Mounting antenna 4 Warning! When routing antenna cable in area of airbags, observe instructions of vehicle manufacturer. Only with T00HTM Temperature sensor T00HTM Mounting temperature sensor 5 4

15 Combustion air a Combustion air pipe a = 00mm Discard section Cutting combustion air pipe to length Ensure proper installation position of combustion-air intake silencer, see "Installation Instructions. Remove retaining clip and fasten wiring harness above wheel well with cable tie i Premounting intake silencer 6 Combustion-air intake hose shortened Intake silencer Included clip with cable tie in existing hole Premounting intake silencer 7 5

16 Preparing installation location Cut included 00 mm long edge protection in centre. Wiring harness of heater 00 mm long edge protection Mounting edge protection 8 Cross member of bumper 00 mm long edge protection Mounting edge protection 9 With horns, mount brackets as shown (depending on vehicle equipment). () Original vehicle bolt Premounting horns 0 Ensure freedom of movement of neighbouring components. () Original vehicle stud bolt, flanged nut () Horn bracket Mounting horns 6

17 With horn, mount bracket as shown. (depending on vehicle equipment). Ensure freedom of movement of neighbouring components. () Original vehicle stud bolt, flanged nut () Horn bracket Mounting horns.9 litre diesel Screw out silent block Discard original vehicle bracket of vacuum valve Removing original vehicle bracket racket of vacuum valve: Opel Catalogue No.: 7444 Screw in silent block [x] Mounting included bracket 4 racket of vacuum valve 4 Original vehicle stud bolt, flanged nut of horn bracket Vacuum valve Original vehicle flanged nuts Mounting vacuum valve 4 5 7

18 ll vehicles Existing holes [x] will be used for installation of heater. Mounting bracket 6 Preparing heater Tighten Ejot screws to 0 Nm. Heater racket Ejot screw [x] Preparing heater 7 Installing heater Heater racket M6x50 bolt, 0 mm long spacer sleeve, M6 flanged nut 4 M6x50 bolt, large diameter washer, outside diameter mm, 0 mm long spacer sleeve, large diameter washer, outside diameter 7.6 mm, M6 flanged nut Mounting heater 4 Loosely mount bracket Heater Ejot screw [x] 4 Copy hole pattern, drill 9 mm hole [x] 4 Mounting heater 8 8

19 Install bracket on heater again. Tighten Ejot screws to 0 Nm. M6x0 bolt, spring lockwasher, large diameter washer, M6 rivet nut Ejot screw [x] 4 M6x0 bolt, spring lockwasher, M6 rivet nut Mounting heater 4 9 Flexible pipe 7 mm dia. clamp Heater Mounting combustion-air intake pipe 0 9

20 Fuel CUTION! 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. WRNING! The fuel line and wiring harness are routed to the metering pump as shown in the wiring harness routing diagram. () Mecanyl fuel line () Hose section, 0 mm dia. hose clamp [x] Connection to heater () Mecanyl fuel line () Metering pump wiring harness Routing lines 5 Metering pump Ensure proper installation position of metering pump, see "Installation Instructions". Installation location on left in front of vehicle fuel tank. (5) ngle bracket, drill out to 8.5 mm dia. on short leg () Original vehicle bolt (4) Rubber-coated p-clamp () Metering pump () Silent block, flanged nut [x] i Installation location of metering pump 4 0

21 Fuel line from heater on pressure side of metering pump () Hose section, 0 mm dia. hose clamp [x] () Wiring harness of metering pump, connector mounted (5) Cable tie Connection to metering pump 4 Fuel extraction Vehicles with single-line system Detach cover of fuel-tank sending unit and lay slightly to one side for drilling. Watch for splinters when drilling. () Fuel-tank sending unit () Lay on template () Copy hole pattern, drill 6 mm dia. hole Preparing fuel-tank sending unit 5 Further installation corresponds to that for two-line system, as everything is identical. Vehicles with two line system except Z7DTR / 7DTR and Z7DTJ/7DTJ Detach cover of fuel-tank sending unit and lay slightly to one side for drilling. Watch for splinters when drilling. () Fuel-tank sending unit () Lay on template () Copy hole pattern, drill 6 mm dia. hole Preparing fuel-tank sending unit 6 Shape fuel standpipe according to template, cut to length and install, see "installation instructions". i Installing fuel standpipe 7

22 Install fuel-tank sending unit according to manufacturer's instructions. 4 5 () Fuel-tank sending unit () Fuel standpipe (5) Remaining section of Mecanyl fuel line () Hose section (4) 0 mm dia. Caillau clamp [x] Connecting fuel line litre Diesel Z7DTR / 7DTR and Z7DTJ / 7DTJ Detach cover of fuel-tank sending unit and lay slightly to one side for drilling. Watch for splinters when drilling. () Lay on template () Copy hole pattern, drill 6 mm dia. hole Preparing fuel-tank sending unit 9 Shape fuel standpipe according to template, cut to length and install, see "installation instructions". i Installing fuel standpipe 40 Install fuel-tank sending unit in accordance with manufacturer's instructions. 4 5 () Fuel standpipe () Fuel line, hose section, 0 mm dia. Caillau clamp [x] Connecting fuel line 4 4

23 4 5 Fuel line from fuel standpipe on intake side of metering pump. Slide fuel hose 4 as protective hose onto fuel line. Check the position of the components; adjust if necessary. Check that they have freedom of movement. () Hose section, 0 mm dia. hose clamps [x] (5) Cable tie Connection to metering pump 4

24 Coolant circuit.4 litre;.0 litre petrol WRNING! ny coolant running off should be collected using an appropriate container. Route coolant hoses kinkfree. Unless specified otherwise, always fasten using cable ties. Position clamps so that other hose cannot be damaged. The heater must be filled with coolant when installing the hoses. The connection should be "inline" based on the following diagram: Ø Ø Hose installation diagram ll spring clips without a specific designation = 7 mm dia. ll connecting pipes = 5x0 mm dia. = lack (sw) rubber isolator [x] only with.0 litre petrol. 4

25 Coolant circuit of.6 litre Z6EP;.8 litre petrol and. litre;.7 litre diesel WRNING! ny coolant running off should be collected using an appropriate container. Route coolant hoses kinkfree. Unless specified otherwise, always fasten using cable ties. Position clamps so that other hose cannot be damaged. The heater must be filled with coolant when installing the hoses. The connection should be "inline" based on the following diagram: Ø Ø 0x0 C Hose installation diagram Ø ll spring clips without a specific designation = 7 mm dia. ll connecting pipes without a specific designation = 5x0 mm dia. 5

26 Coolant circuit.6 litre Z6ER WRNING! ny coolant running off should be collected using an appropriate container. Route coolant hoses kinkfree. Unless specified otherwise, always fasten using cable ties. Position clamps so that other hose cannot be damaged. The heater must be filled with coolant when installing the hoses. The connection should be "inline" based on the following diagram: Ø Hose installation diagram Ø ll spring clips without a specific designation Connecting pipe = 5x0 mm dia. = lack (sw) rubber isolator [x]. = 7 mm dia. 6

27 Coolant circuit.6 litre Z6LET WRNING! ny coolant running off should be collected using an appropriate container. Route coolant hoses kinkfree. Unless specified otherwise, always fasten using cable ties. Position clamps so that other hose cannot be damaged. The heater must be filled with coolant when installing the hoses. The connection should be "inline" based on the following diagram: Ø Hose installation diagram Ø ll spring clips without a specific designation ll connecting pipes = 5x0 mm dia. = lack (sw) rubber isolator [x]. = 7 mm dia. 7

28 Coolant circuit.9 litre diesel WRNING! ny coolant running off should be collected using an appropriate container. Route coolant hoses kinkfree. Unless specified otherwise, always fasten using cable ties. Position clamps so that other hose cannot be damaged. The heater must be filled with coolant when installing the hoses. The connection should be "inline" based on the following diagram: Ø 5 Ø 5 Hose installation diagram ll spring clips without a specific designation ll connecting pipes = 8x0 mm dia. = 7 mm dia. 8

29 Hose : Cutting hoses to length.4 litre petrol Cut away hose just behind elbow. Hose : a a = 600mm b = 500mm Discard section Cutting hoses to length b Hose :.6 litre petrol Z6EP Cut away hose just behind elbow. a = 600mm b = 600mm c = 00mm Hose : a C Discard section Cutting hoses to length b c Hose :.6 litre petrol Z6ER Cut away hose just behind elbow. a = 800mm b = 460mm Hose : a Discard section Cutting hoses to length b 9

30 Hose :.6 litre petrol Z6LET Cut away hose just behind elbow. a = 440mm b = 80mm Hose : a Discard section Cutting hoses to length b Hose :.8 litre petrol Cut away hose just behind elbow. a = 700mm b = 600mm Hose : a C Discard section Cutting hoses to length b Hose :.0 litre petrol Cut away hose just behind elbow. a = 400mm b = 00mm Hose : a Discard section Cutting hoses to length b 0

31 Hose :. litre and.7 litre diesel Cut away hose just behind elbow. a = 700mm b = 550mm Hose : a C Discard section Cutting hoses to length b Hose :.9 litre diesel Cut away hose just behind elbow. a = 000mm b = 50mm Hose : a Discard section Cutting hoses to length b Preparing hoses Divide braided protection hose in centre. () raided protection hose complete [x] () raided protection hose cut to length [x] () Cut heat shrink plastic tubing [6x] in centre Preparing hoses 4

32 Routing hoses ll vehicles 7 mm dia. spring clip [x] Connection to heater 44 () 40 mm spacer nut, rubber-coated p-clamp [x], M6x0 bolt, spring lockwasher () M6x50 bolt, spring lockwasher, large diameter washer Fastening on engine support 45 ll vehicles except.0 litre petrol () M6x50 bolt (engine side to wheel well), large diameter washer, pin lock () 0 mm shim () Rubber-coated p-clamp, 48 mm dia. Fastening on frame side carrier litre petrol () Perforated bracket () M6x0 bolt (engine side to wheel well), pin lock () M6x0 bolt (wheel well to engine side), flanged nut [x each] (4) 9 mm dia. rubber-coated p-clamp [x] Fastening on frame side carrier 4 47

33 Hose installation.4 litre petrol Route coolant hose to cutting point. 48 () Hose section of heat exchanger inlet () Engine outlet hose section Cutting point 49 () Hose of engine outlet Routing in engine compartment Connection to engine outlet 50 efore connecting, fill the water hoses with coolant. () Hose on heat exchanger inlet Connection to heat exchanger inlet 5 lign hoses and over entire length and fix in place with cable ties.

34 .6 litre petrol Z6EP Route coolant hose to cutting point. 5 () Hose section of heat exchanger inlet () Engine outlet hose section Cutting point 5 () Hose of engine outlet Routing in engine compartment Connection to engine outlet 54 C efore connecting, fill the water hoses with coolant. Long side of 80 elbow on hose (). () Hose on heat exchanger inlet Connection to heat exchanger inlet 55 lign hose, and C over entire length and fix in place with cable ties. 4

35 .6 litre petrol Z6ER () Original vehicle nut () ngle bracket Routing in engine compartment 56 () lack (sw) rubber profile [x] () Rubber-coated p-clamp, 48 mm dia. () M6x0 bolt, flanged nut Routing in engine compartment 57 Position rubber profiles as shown Routing in engine compartment 58 Remove engine/heat exchanger hose group and cut off at markings. Centre section is vulcanized and remains on hose group (without function). () Remount engine/heat exchanger hose group () Remount hose section on engine outlet (4) Discard hose section Cutting point

36 () Engine/heat exchanger hose group mounted () Centre section of hose group (without function) () Connection piece on engine outlet Connection to engine outlet 60 efore connecting, fill the water hoses with coolant. () Hose section on heat exchanger inlet mounted Connection to heat exchanger inlet 6 lign hoses and over entire length and fix in place with cable ties. lign black (sw) rubber profiles..6 litre petrol Z6LET () Original vehicle nut () ngle bracket Routing in engine compartment 6 () lack (sw) rubber profile [x] () Rubber-coated p-clamp, 48 mm dia. () M6x0 bolt, flanged nut Routing in engine compartment 6 6

37 Position rubber profiles as shown 64 Cut off hose on engine outlet/heat exchanger inlet at marking. () Hose section of heat exchanger inlet () Engine outlet hose section Cutting point 65 () Hose section on heat exchanger inlet turned approx. 90 to right Routing in engine compartment Connection to heat exchanger inlet 66 efore connecting, fill the water hoses with coolant. () Engine outlet hose section () Insert spacer bracket Connection to engine outlet 67 lign hoses and over entire length and fix in place with cable ties. lign black (sw) rubber profiles. 7

38 .8 litre petrol Route coolant hose to cutting point. 68 () Hose section of heat exchanger inlet () Engine outlet hose section Cutting point 69 () Hose of engine outlet Routing in engine compartment Connection to engine outlet 70 C efore connecting, fill the water hoses with coolant. Long side of 80 elbow on hose (). () Hose on heat exchanger inlet Connection to heat exchanger inlet 7 lign hose, and C over entire length and fix in place with cable ties. 8

39 .0 litre petrol () Original vehicle nut () ngle bracket Routing in engine compartment 7 () lack (sw) rubber profile [x] () Rubber-coated p-clamp, 48 mm dia. () M6x0 bolt, flanged nut Routing in engine compartment 7 Position black (sw) rubber isolator as shown Routing in engine compartment 74 () Engine outlet hose to heat exchanger inlet Removing hose 75 9

40 () Hose section of heat exchanger inlet () 5x0 mm dia. connecting pipe; mm dia. spring clip [x] () Engine outlet hose section (4) Discard section Cutting point 4 76 () Premounted hose section on heat exchanger inlet Connection to heat exchanger inlet 77 efore connecting, fill the water hoses with coolant. () Premounted hose section on engine outlet Connection to engine outlet 78 lign hoses and over entire length and fix in place with cable ties. lign black (sw) rubber profiles. litre diesel Route coolant hose to cutting point. () Original vehicle stud bolt, rubber-coated p-clamp, plastic nut Routing in engine compartment 79 40

41 () Hose section of heat exchanger inlet () Engine outlet hose section Cutting point 80 () Hose on heat exchanger inlet Connection to heat exchanger inlet C 8 efore connecting, fill the water hoses with coolant. () Hose of engine outlet Connection to engine outlet 8 lign hose, and C over entire length and fix in place with cable ties..7 litre diesel Route coolant hose to cutting point. () Original vehicle stud bolt, rubber-coated p-clamp, 9 mm dia. plastic nut Routing in engine compartment 8 4

42 () Hose section of heat exchanger inlet () Engine outlet hose section Cutting point 84 C () Hose on heat exchanger inlet Connection to heat exchanger inlet 85 efore connecting, fill the water hoses with coolant. () Hose of engine outlet Connection to engine outlet 86 lign hose, and C over entire length and fix in place with cable ties..9 litre diesel Route coolant hose to cutting point. () Original vehicle stud bolt, rubber-coated p-clamp, plastic nut Routing in engine compartment 87 4

43 88 () Engine outlet hose to heat exchanger inlet Removing hose 89 Protective hose removed before cutting. () Engine outlet hose section () Hose section of heat exchanger inlet Cutting point 90 () Hose of engine outlet () Spacer bracket Routing in engine compartment Connection to engine outlet 9 4

44 efore connecting, fill the water hoses with coolant. lign hose section from heat exchanger inlet () to right when installing. () Hose on heat exchanger inlet Connection to heat exchanger inlet 9 View from below. () Hose on heat exchanger inlet Connection to heat exchanger inlet 9 lign hoses and over entire length and fix in place with cable ties. 44

45 Exhaust gas () Exhaust pipe a = 00mm () Exhaust end section b = 00mm Discard section Preparing exhaust pipe a b racket M6x0 bolt, flanged nut Silencer Installing silencer Exhaust elbow Exhaust pipe Red (rt) rubber isolator Hose clamp [x] Mounting exhaust pipe Exhaust silencer Exhaust end section Hose clamp Position red (rt) rubber isolator [x] Mounting exhaust pipe and end section 96 45

46 00mm Petrol 60mm Design of underride protection/wheel well trim is dependent on vehicle equipment 70mm 75mm 5mm 90mm 0mm 97 Cut out underride protection/wheel well trim on marking. Underride protection/wheel well trim () 4 mm dia. hole Underride protection / wheel well trim 90mm 50mm 98 Diesel Design of underride protection/wheel well trim is dependent on vehicle equipment 90 mm Cut out underride protection/wheel well trim on marking. () 4 mm dia. hole Underride protection/wheel well trim 50 mm 99 ll vehicles Check the position of the components; adjust if necessary. Check that they have freedom of movement. () Underride protection / wheel well trim () Red (rt) rubber isolator positioned with groove in trim () Exhaust end section Underride protection/wheel well trim 00 46

47 () Wheel well trim () Premounted bolt from fastening of coolant hoses () Flanged nut and large diameter washer mm dia. Wheel well trim 0 47

48 Final Work WRNING! Mount removed parts in reverse order. Check all hoses, clamps and all electrical connections for firm seating. Insulate and tie back all loose wires. 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. - Set the 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 in the area of the filler neck - For initial start-up and function check, see installation instructions i Feel the drive Webasto G Postfach 80 D-8 Stockdorf / Germany National Hotline: (4 Cent aus dem deutschen Festnetz) Hotfax: Hotmail: technikcenter@webasto.com 005H_EN Printed in Germany 05/0 Printing: Steffen 48

49 Template for fuel-tank sending unit The template is dependent on the respective vehicle equipment. ll vehicles except Z7DTR / 7DTR and Z7DTJ / 7DTJ: 6 mm dia. 6 mm dia. Z7DTR / 7DTR and Z7DTJ / 7DTJ: 00mm Scale : Compare size of the printed version with dimension lines. llowed tolerance %. Correct pressure settings appropriately in case of major deviations or request original printout. 0 00mm 49

50 Template for Fuel Standpipe 00mm Scale : Compare size of the printed version with dimension lines. llowed tolerance %. Correct pressure settings appropriately in case of major deviations or request original printout. 0 00mm 50

51 Operating Instructions for End Customer Please remove page and add to the vehicle operating instructions. Passenger compartment monitoring, when installed, is deactivated when operating the parking heater. efore parking the vehicle, make the following settings: () Set air distribution to "Defrost" () Set temperature to "max." Vehicles with "Heating and ventilation system" 0 () Set air distribution to "Defrost" () Set temperature to "max." Vehicles with "utomatic air conditioning" (SC) 0 04 Observe the sequence of the settings (see following figure). () ir distribution upward () Set temperature to "max." () Set fan to level "" Vehicles with "automatic air-conditioning (ECC) Vehicles with "automatic air-conditioning" (ECC) 05 5