Manufacturer Model Type EG BE No. / ABE Audi A1 8X e1 * 2007 / 46 * 0414

Transcription

1 K Water Heater Thermo Top Evo Parking Heater E With FuelFix Installation Documentation Validity Manufacturer Model Type EG BE No. / ABE 8X e * 007 / 46 * 044 Motorisation Fuel Transmission type Output in kw Displacement in cm³ Engine code.0 TSFI Petrol SG CHZB.4 TSFI Petrol SG 9 4 CZCA.4 TSFI Petrol AG 9 4 CZCA.4 TDi ultra Diesel SG 66 4 CUSB.6 TDi Diesel SG CXMA SG = manual transmission AG = 7-gear S tronic From model year 05 Left-hand drive vehicle Verified equipment variants: Automatic air-conditioning Front fog lights Xenon headlights LED daytime running lights Start - Stop system Not verified: Total installation time: Manual air-conditioning Passenger compartment monitoring Alarm system Keyless start button approx. 9 hours Ident. No.: 405C_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 for Petrol Vehicles 8 Electrical System for Diesel Vehicles 9 Automatic Air-Conditioning Fan Controller 0 MultiControl CAR Option Remote Option (Telestart) ThermoCall Option Preparing Installation Location 4 Preparing Heater 7 Heater 9 Exhaust Part 0 Fuel FuelFix for Petrol Vehicles 6 FuelFix for Diesel Vehicles Combustion Air 5 Petrol Coolant Circuit 6 Coolant Circuit.4 TDI 4 Coolant Circuit.6 TDI 50 Exhaust Part 57 Final Work 60 FuelFix Template for Petrol Vehicles 6 FuelFix Template for Diesel Vehicles 6 Automatic A/C Operating Instructions for Petrol Vehicles 6 Automatic A/C Operating Instructions for Diesel Vehicles 64 Necessary Components Basic delivery scope of Thermo Top Evo based on price list Installation kit with FuelFix for 05 Petrol and diesel: 405C To be ordered additionally in case of automatic air-conditioning, automatic air-conditioning kit: 4_ 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 instructions: Arrange for the vehicle to be delivered with the tank only about ¼ full. The installation location of the push button in case of Telestart or Thermo Call should be confirmed with the end customer. Depending on the space required and the vehicle manufacturer's instructions, we recommend the use of a vehicle battery with a higher electrical capacity. Installation Overview Legend:. Heater. Engine compartment fuse holder. Passenger compartment relay and fuse holder 4. PWM Gateway 5. Circulating pump 6. MultiControl CAR 7. Metering pump 8. FuelFix Information on Total Installation Time The total installation time includes the time needed for mounting and demounting 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.: 405C_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. Always switch off the heater before refuelling. The heater may only be used with the prescribed fuel diesel (DIN EN 590) or petrol (DIN EN 8). The heater may not be cleaned with a high-pressure cleaner.. Please note ALWAYS 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. Important 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. Connectors on electronic components must audibly click into place during installation. Sharp edges should be fitted with rub protection. Spray unfinished body areas, e.g. drilled holes, with anti-corrosion wax (Tectyl 00K). 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 a programmable control module (e.g. a PWM Gateway), the corresponding settings must be checked or adjusted. 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. Important 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. Excerpt from ECE regulation (heating system) paragraph 5 for the installation of the heater Beginning of excerpt. ANNEX VII REQUIREMENTS FOR COMBUSTION HEATERS AND THEIR INSTALLATION. GENERAL REQUIREMENTS.7.. A clearly visible tell-tale in the operator's field of view shall inform when the combustion heater is switched on or off.. VEHICLE INSTALLATION REQUIREMENTS.. Scope... Subject to paragraph... combustion heaters shall be installed according to the requirements of this Annex.... Vehicles of category O having liquid fuel heaters are deemed to comply with the requirements of this Annex... 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.... A 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.. Any 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. The heater is licensed in accordance with paragraph 9, section, No. b of the StV- ZO (German Road Traffic Licensing Authority). Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE

4 Information on Validity This installation documentation applies to Petrol and diesel vehicles - for validity, see page - from model year 05 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 auto-tightening hose clamps Hose clamp pliers for Clic hose clamps of type W Automatic wire stripper mm² Crimping pliers for cable lug / tab connector 0.5-6mm² Torque wrench for.0-0 Nm Hose clamping pliers Metric thread-setter kit Deep-hole marker Webasto Thermo Test diagnosis with current software Dimensions All dimensions are in mm. Tightening torque values Tightening torque values of 5x heater bolts and 5x heater stud bolts = 8Nm. Tightening torque value of 5x5 water connection piece retaining plate bolt = 7Nm. Tighten other bolt connections in accordance with manufacturer's instructions or in accordance with state-of-the-arttechnology. 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. Special features are highlighted using the following symbols: Mechanical System Specific risk of damage to components. Electrical System Specific risk due to electrical voltage. Coolant Circuit Specific risk of injury or fatal accidents. Combustion Air Specific risk of fire or explosion. Fuel Reference to the manufacturer's vehiclespecific documents or to the general installation instructions of Webasto components. F Reference to a special technical feature. Exhaust Gas Software The arrow in the vehicle icon indicates the position on the vehicle and the viewing angle. Tightening torque according to the manufacturer's vehicle-specific documents. Nm! Ident. No.: 405C_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 the battery. Remove the windscreen wipers. Remove the coolant reservoir cap. Remove the drain pipe of the air filter box. Remove the air filter (not in case of.4tdi). Remove the air filter intake hose (not in case of.4tdi). Remove the engine control unit. Remove the coolant reservoir partition wall. Remove the windscreen wiper motor. Remove the left front wheel. Remove the left wheel-well inner panel. Remove the horn(s) (there can be one or two) together with the bracket. Remove the underride protection. Remove the right vehicle underbody trim. Remove the left and right lateral instrument panel trim. Remove the lower instrument panel trim on the left. Remove the glove box completely. Fold up the seating area of the rear bench seat or remove it (depends on the equipment). Open the tank-fitting service lid. Heater Remove years that do not apply from the type and duplicate label. Attach the duplicate label (type label) visibly in the appropriate place in the engine compartment. Heater Installation Location Heater Installation Location Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 5

6 Preparing Electrical System rt 0,75² sw 0,75² rt 4² sw 4² rt 0,5² sw 0,5² 4 Wire sections retain their numbering in the entire document. Produce all following electrical connections as shown in the wiring diagram. 4 Red (rt) wire of fan wiring harness Black (sw) wire of fan wiring harness Red (rt) wire of PWM control system wiring harness Black (sw) wire of PWM control system wiring harness Assigning wires Check the PWM Gateway settings when starting up the heater and adjust if necessary. Settings: GND IN KL 5 OUT SH Duty cycle: 00% (DC) Frequency: not relevant Voltage:.6V Function: High side View of PWM GW br 0,5² rt 4² rt/sw 0,5² gn/ws 0,5² rt 0,5² sw 0,5².8 GND 6. 4 IN 6. KL5 6. PWM.8 SH 6. F4 4.8 F F 4.8 F a 6. RSH F5 4.8 F sw 4² rt 4² Interlocking PWM GW and passenger compartment relay and fuse holder sockets, inserting connector into bushing and connecting wires.8 OUT Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 6

7 Diesel only Copy hole pattern, 7mm dia. hole Hole for fuse holder All vehicles Passenger compartment relay and fuse holder PWM GW socket Angle bracket 4 M5x6 bolt, large diameter washer [x], nut Premounting passenger compartment relay and fuse holder 4 6 5A fuse F4 PWM GW Relay K passenger compartment relay and fuse holder 7 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 7

8 Electrical System for Petrol Vehicles Engine compartment fuse holder Passenger compartment wiring harness pass through Positive wire Positive wire on positive distributor Nm! Passenger compartment rubber plug pass through Wiring harnesses of heater, heater control Rubber plug pass through, coolant reservoir 8 9 Wiring harness routing diagram Route the metering pump wiring harness later, together with the fuel line, along the original vehicle fuel lines on the underbody. Nm! 4 0 Engine compartment fuse holder Fuses F- Angle bracket M6x0 bolt, large diameter washer, existing hole, flanged nut 4 M5x6 bolt, large diameter washer [x], retaining plate of fuse holder, nut Earth wire Earth wire on original vehicle earth support point Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 8

9 Electrical System for Diesel Vehicles Engine compartment fuse holder Passenger compartment wiring harness pass through Positive wire Positive wire on positive distributor Passenger compartment rubber plug pass through Wiring harnesses of heater, heater control Rubber plug pass through, coolant reservoir Nm! Wiring harness routing diagram Route the metering pump wiring harness later, together with the fuel line, along the original vehicle fuel lines on the underbody. Nm! Engine compartment fuse holder Fuses F- Angle bracket M6x0 bolt, large diameter washer, drilled hole, flanged nut 4 M5x6 bolt, large diameter washer [x], retaining plate of fuse holder, nut Earth wire Earth wire on original vehicle earth support point Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 9

10 Automatic Air-Conditioning Fan Controller Webasto rt 6² HG Audi SC 0 5 System wiring diagram F F br 0,5² rt/sw 0,5² rt 4² gn/ws 0,75² X J br 0,5² rt/sw 0,5² rt 4² gn/ws 0,5² sw 4,0² F4 F K 87a 0 rt 4² sw 4² vi/bl 0,5² 6 sw 4,0² T6y PWM GW OUT IN sw 0,5² rt 0,5² 4 M vi/bl 0,5² J6 5 T0e br 4² J55 Webasto components Vehicle components Colours and symbols HG TT-Evo heater SC 40A fuse rt red F 0A fuse J59 Relay X- contact ws white F 0A fuse J6 Fan unit sw black X0 4-pin connector of J55 A/C control panel br brown heater control T... Connector bl blue F A fuse gn green F4 5A fuse vi violet K Fan relay PWM GW Pulse width modulator Settings of PWM GW: Duty cycle: 00% (DC) Frequency: not relevant Voltage:.6V Function: High side Wiring colours may vary. Legend Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 0

11 Passenger compartment relay and fuse holder M6x0 bolt, large diameter washer, original vehicle hole, 0mm spacer, flanged nut passenger compartment relay and fuse holder 6 Wiring harness of passenger compartment relay and fuse holder Wiring harness of heater Connecting same colour wires of wiring harnesses 7 Remove LWR control unit Removing control unit 8 6-pin connector T6y Removing fan unit connector 9 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE

12 4 Violet/blue (vi/bl) wire from J55 Violet/blue (vi/bl) wire of connector T6y, pin 6 6-pin connector T6y Red (rt) wire of PWM control system wiring harness 4 Black (sw) wire of PWM control system wiring harness Connecting fan unit / PWM control 0 Black (sw) wire of fan relay Black (sw) wire of connector T6y, pin 6-pin connector T6y Red (rt) wire of K/87a, fan wiring harness Black (sw) wire of K/0, fan wiring harness Connecting fan unit/ fan wiring harness MultiControl CAR Option MultiControl CAR Remote Option (Telestart) Fasten receiver with double-sided adhesive tape. receiver Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE

13 Aerial aerial 4 Temperature sensor T00 HTM Fasten temperature sensor with doublesided adhesive tape. temperature sensor 5 ThermoCall Option Fasten receiver with double-sided adhesive tape. receiver 6 Aerial (optional) aerial 7 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE

14 Preparing Installation Location Copy hole pattern, 9.mm dia. hole; rivet nut 65 rivet nut 75 8 Install bracket. M6x0 bolt Copy hole pattern, hole Copying hole pattern 9 M0 rivet nut, original vehicle hole 9.mm dia. hole; M6 rivet nut rivet nuts 0 Drill out hole to 8.5 mm dia. Drilling angle bracket Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 4

15 Horn Original vehicle nut Angle bracket angle bracket Copy hole pattern, 7mm dia. hole 0 5 Drilling hole M6x0 bolt, flanged nut horn 40 4 Drill out hole to 8.5 mm dia. 5 Preparing perforated bracket A 5 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 5

16 0 Drill out hole to 0.5 mm dia. 40 Preparing perforated bracket B 6 4 Perforated bracket A M8x0 bolt, spring lockwasher, existing threaded hole Perforated bracket B 4 M0x6 bolt, spring lockwasher perforated brackets loosely 7 Tighten loose screw connections. M6x0 bolt, spring lockwasher [x each] Bracket M6x bolt, flanged nut [x each] 4 Perforated bracket B 5 Perforated bracket A bracket TDI 50 Preparing perforated bracket C 0 9 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 6

17 Perforated bracket B Perforated bracket C M6x bolt, flanged nut perforated bracket C 40 Preparing Heater All vehicles Water connection piece, sealing ring [x each] 5x5 self-tapping bolt, retaining plate of water connection piece water connection piece 4 Petrol and.4 TDI Screw self-tapping stud bolt M5 / M6 x 5.5 and 5x self-tapping bolts [x] in existing holes by a maximum of thread turns. Premounting bolts loosely 4 90 moulded hose, 0mm dia. clamp Premounting moulded hose 4 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 7

18 .6 TDI Screw 5x self-tapping bolts [4x] into existing holes by a maximum of thread turns. Premounting bolts loosely moulded hose, 0mm dia. clamp Premounting moulded hose 45 A G A = 800 B = 60 C = 90, 8mm dia. D = 60 E = 60 F = 90 G = 840 Cutting hoses to length C B D E F 46 C All spring clips = 5mm dia. 90, 8x8mm dia. connecting pipe [x] Premounting hoses E D 47 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 8

19 Heater Petrol and.4 TDI Tighten 5x self-tapping bolt Tighten M5/M6x5 self-tapping stud bolts heater 48.6 TDI Tighten 5x self-tapping bolt [x] heater 49 All vehicles Tighten 5x self-tapping bolt [x] heater 50 Circulating pump wiring harness connector Heater wiring harness connector [x] Connecting wiring harness 5 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 9

20 Exhaust Part a = 70 a = 80 X = Preparing exhaust pipe a a X 5 Silencer M6x6 bolt, spring lockwasher Angle bracket Premounting exhaust silencer 5 0mm shim M8x0 bolt, spring lockwasher, washer Premounted silencer silencer 54 Ensure sufficient distance from neighbouring components, correct if necessary. Housing of front fog light 5 mm Aligning silencer 55 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 0

21 a Hose clamp [x] exhaust pipe a 56 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE

22 Fuel 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. Provide rub protection for fuel line and wiring harness in areas where there are sharp edges. The fuel line and wiring harness are routed to the metering pump as shown in the wiring harness routing diagram. Connector X7 Dismantling metering pump connector 57 S = 800 T = 600 S T Cutting corrugated tube to length 58 Pull wiring harness of metering pump and fuel line into corrugated tube S and route in the engine compartment. S 0 mm dia. clamp Connecting heater 59 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE

23 S Route corrugated tube S to the firewall. Routing lines S 60 Fuel line and wiring harness of metering pump attached to the original vehicle wiring harness Coolant reservoir pass through Routing lines 6 Pull wiring harness of metering pump and fuel line into corrugated tube T, route in the engine compartment and along the original vehicle fuel line to the underbody. T Coolant reservoir pass through Routing lines T 6 Fuel line and wiring harness of metering pump Routing lines 6 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE

24 Cutting perforated bracket to length 6 64 Petrol and.4 TDI Insert cable tie 4 between perforated bracket and body. Premount M6x5 bolt, pin lock M6x0 bolt, flanged nut, original vehicle hole perforated bracket 4 65 Attach metering pump mount with a support angle bracket and a flanged nut to the M6x5 bolt. Close cable tie around metering pump mount. Metering pump metering pump 66 Connector X7 Completing metering pump connector Pin assignment is not relevant. 67 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 4

25 Metering pump wiring harness, connector X7 mounted Hose section, 0mm dia. clamp [x] Fuel line of heater Connecting metering pump 68.6 TDI Premount M6x5 bolt, pin lock Perforated bracket M6x0 bolt, flanged nut, original vehicle hole perforated bracket 69 Attach metering pump mount with a support angle bracket and a flanged nut to the M6x5 bolt. Metering pump metering pump 70 Connector X7 Completing metering pump connector Pin assignment is not relevant. 7 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 5

26 Metering pump wiring harness, connector X7 mounted Hose section, 0mm dia. clamp [x] Fuel line of heater Connecting metering pump 7 FuelFix for Petrol Vehicles X = Drilling template X 7 Version Work steps F and F. F Fuel tank sending unit Position mm template at raised part and lettering Hole pattern Copying hole pattern 74 Work step F. Hole made with provided drill Hole for FuelFix 75 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 6

27 Work steps F4 and F5. Bend FuelFix according to template and cut to length. Insert into hole. Inserting FuelFix 76 Inserting FuelFix 77 Work steps F5. and F5.4. Turn FuelFix as shown to align it. Aligning FuelFix 78 Work step F6. FuelFix Fuel line Hose section, 0mm dia. clamp [x] Connecting fuel line 79 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 7

28 F 7.. F 7.. F 7.4. Work step F7. F F 7.. <.0 mm 50 - max00 min - F 7.5. FuelFix 90 0 mm F Work step F8. Checking firm seating of FuelFix 8 FuelFix installed Cable tie as tension relief Fuel line of FuelFix Securing fuel line 8 Version Work steps F and F. F 4 Fuel tank sending unit Position mm dia. template, copy hole pattern Copy hole pattern 4 Contact point, rim of fuel tank sending unit 5 Contact point, edge of raised part Hole for FuelFix 5 8 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 8

29 Work step F. Hole made with provided drill Move label Hole for FuelFix 84 Work steps F4 and F5. Bend FuelFix according to template and cut to length. Insert into hole. Preparing and inserting FuelFix 85 Inserting FuelFix 86 Inserting FuelFix 87 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 9

30 Work steps F5. and F5.4. Align FuelFix as shown. Aligning FuelFix 88 Work step F6. Fuel line Hose section, 0mm dia. clamp [x] FuelFix Connecting fuel line 89 Install original vehicle connector. Align and install FuelFix as shown in next figure. FuelFix 90 F 7.. F 7.. F 7.4. Work step F7. F F 7.. <.0 mm 50 - max00 min - F 7.5. FuelFix 90 0 mm F Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 0

31 Work step F8. Checking firm seating of FuelFix 9 Cable tie as tension relief Fuel line of FuelFix Securing fuel line 9 FuelFix for Diesel Vehicles X = Drilling template X 94 Work steps F and F. Move label 4 as shown. Fuel tank sending unit Position mm template at raised parts Hole pattern F Fuel extraction 4 95 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE

32 Work step F. Hole made with provided drill Hole for FuelFix 96 Work steps F4 and F5. Bend FuelFix according to template and cut to length. Insert into hole. Inserting FuelFix 97 Inserting FuelFix 98 Inserting FuelFix 99 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE

33 Inserting FuelFix 00 Move FuelFix connection piece over closed stub. Inserting FuelFix 0 Work steps F5. and F5.4. Turn FuelFix in position as shown. 0 Work step F6. FuelFix Hose section, 0mm dia. clamp [x] Fuel line Positionning FuelFix Connecting fuel line 0 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE

34 F 7.. F 7.. F 7.4. Work step F7. F F max00 min - <.0 mm F 7.5. FuelFix 90 0 mm F Work step F8. Checking firm seating of FuelFix 05 FuelFix installed Fuel line of FuelFix Cable tie as tension relief Securing fuel line 06 All vehicles. Ensure sufficient distance from neighbouring components, correct if necessary. Cable tie Fuel line of FuelFix Hose section, 0mm dia. clamp [x] Connecting metering pump 07 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 4

35 Combustion Air Copy hole pattern, drill 7mm dia. hole Copying hole pattern Combustion air pipe combustion air pipe 09 M5x6 bolt, flanged nut Silencer 5mm dia. clamp silencer 0 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 5

36 Petrol Coolant Circuit Any coolant running off should be collected in an appropriate container. Route hoses 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 modelled on an inline circuit and based on the following diagram: Hose routing diagram A E B D C All spring clips without a specific designation = 5 mm dia. All connecting pipes and = 8x8mm dia. = Original vehicle spring clip. = Black (sw) rubber isolator. Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 6

37 B E A = 80, 8mm dia. B = 800 C = 90, 8mm dia. D = 90, 8mm dia. E = 960 Cutting hoses to length A C D B Slide on braided protection hoses and cut to length. Cut heat shrink plastic tubing to size, 50mm long [4x] Black (sw) rubber isolator [x] braided protection hoses E D Connecting hose D C Circulating pump Circulating pump mount Connecting circulating pump 4 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 7

38 Flanged nut on stud bolt of heater Wiring harness of circulating pump M6x5 bolt, flanged nut 4 Perforated bracket C 4 circulating pump 5 Remove hose from engine outlet/heat exchanger inlet. Spring clips will be reused. Removing hose 6 X Cut off hose of engine outlet/heat exchanger inlet at the marking. Heat exchanger inlet hose section Remove heat shrink plastic tubing and discard Cutting point X = 7 Heat exchanger inlet hose section Premounting hose E E 8 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 8

39 Cable tie Heat exchanger inlet hose section Connecting heat exchanger inlet 9 Heat exchanger inlet hose section E Routing in engine compartment 0 E Cable tie [x] E Black (sw) rubber isolator 90 connecting pipe of hose D E Routing in engine compartment Connecting engine outlet Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 9

40 A Connecting engine outlet B A Cable tie B B B 4 Black (sw) rubber isolator Circulating pump E Routing in engine compartment Connecting circulating pump 5 Ensure freedom of movement of shift system in case of manual transmission. Shift gears to check this. Routing in engine compartment 6 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 40

41 U V X U = 0 V = X = Cutting hose section to length 7 U U Push hose sections U and V onto original vehicle stud bolts V hose sections U and V V 8 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 4

42 Coolant Circuit.4 TDI Any coolant running off should be collected in an appropriate container. Route hoses 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 modelled on an inline circuit and based on the following diagram: Hose routing diagram A D C B All spring clips without a specific designation = 5 mm dia. All connecting pipes and = 8x8mm dia. = Original vehicle spring clip. = Coupling piece on engine outlet. Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 4

43 A D A = 800 B = 90, 8mm dia. C = 90, 8mm dia. D = 960 Cutting hoses to length B C 9 Slide on braided protection hoses and cut to length. A Cut heat shrink plastic tubing to size, 50mm long [4x] braided protection hoses D 0 Remove hose of engine outlet / heat exchanger inlet with engine outlet coupling piece. Spring clip will be reused. Cutting point Pull off heat protection hose and cut at the marking. Cutting point Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 4

44 Cut off hose on engine outlet/heat exchanger inlet at markings. X = Cutting point X Engine outlet hose section Heat exchanger inlet hose section Preparing hoses 4 55 Preparing perforated bracket D 90 5 Cable tie through both holes, do not tighten Perforated bracket D Preparing perforated bracket D 6 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 44

45 Wiring harness bracket Removing wiring harness bracket 7 Plate nut on original vehicle stud bolt Perforated bracket D perforated bracket 8 Drill out hole to 8.5 mm dia. Drilling out hole in angle bracket 9 90 Countersinking hole in angle bracket 40 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 45

46 Pin lock M6x5 countersunk head screw Preparing angle bracket 4 angle bracket 4 Original vehicle nut angle bracket 4 C M8x0 bolt, spring lockwasher, in original vehicle thread Position angle bracket (see next figure) Connecting hose C 44 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 46

47 B Circulating pump Circulating pump mount Connecting circulating pump 45 Flanged nut on stud bolt of heater Wiring harness of circulating pump M6x5 bolt, flanged nut 4 Perforated bracket C 4 circulating pump 46 D Routing hose D and installing on C C 47 Heat exchanger inlet hose section Connecting heat exchanger inlet D 48 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 47

48 A Route hose section A and connect to circulating pump Connecting circulating pump 49 D 0x5 hose bracket 5x8 hose bracket Inserting hose bracket A 50 Engine outlet hose section Connecting engine outlet D A 5 Attach original vehicle wiring harness if necessary with cable ties. Cable ties Routing in engine compartment A 5 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 48

49 D Cable ties Routing in engine compartment on angle bracket A 5 Shape 48 mm dia. rubber-coated p- clamp Preparing hose bracket 54 D Flanged nut Rubber-coated p-clamp A Routing in engine compartment 55 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 49

50 Coolant Circuit.6 TDI Any coolant running off should be collected in an appropriate container. Route hoses 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 modelled on an inline circuit and based on the following diagram: Hose routing diagram A G F E B C D All spring clips without a specific designation = 5 mm dia. All connecting pipes = 8x8 mm dia. = Original vehicle spring clip. = Coupling piece on engine outlet. Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 50

51 A G Slide on braided protection hoses and cut to length. Cut heat shrink plastic tubing to size, 50mm long [4x] Black (sw) rubber isolator [x] braided protection hoses 56 Use lower hole of perforated bracket C 4! 4 M6x5 bolt, flanged nut Circulating pump Circulating pump mount circulating pump B 57 Circulating pump wiring harness connector Connecting circulating pump 58 Remove hose of engine outlet / heat exchanger inlet with engine outlet coupling piece. Heat protection and spring clip will be reused. Cutting point 59 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 5

52 Pull off heat protection hose and cut at the marking. Cutting point 60 Cut off hose on engine outlet/heat exchanger inlet at markings. X = Cutting point X 6 Engine outlet hose section Heat exchanger inlet hose section Preparing hoses 6 Copy hole pattern, 9mm dia. hole; rivet nut 50 rivet nut 6 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 5

53 Drill out hole to 8.5 mm dia. 0 0 Preparing perforated bracket D Perforated bracket D M8x0 bolt, spring lockwasher perforated bracket D Preparing perforated bracket E Install perforated bracket E with 80 angle bracket on frame side member. M6x0 bolt, spring lockwasher perforated bracket E 67 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 5

54 55 Preparing perforated bracket F Cable tie through both holes, do not tighten Perforated bracket Preparing perforated bracket F 69 Wiring harness bracket Removing wiring harness bracket 70 Plate nut on original vehicle stud bolt Perforated bracket F perforated bracket F 7 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 54

55 A G Cable ties F Connecting heater B E 7 G Cable tie [x] Perforated bracket E Perforated bracket D Routing A 7 G A Position black (sw) rubber isolator Attach original vehicle wiring harness using a cable tie Tighten cable tie Routing 74 Heat exchanger inlet hose section Connecting heat exchanger inlet G 75 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 55

56 G Engine outlet hose section Heat exchanger inlet hose section Connecting engine outlet A 76 4 G Attach original vehicle wiring harness using a cable tie 5x5 hose bracket between hose A and hose G Install original vehicle heat protection 4 x5 hose bracket between gearshift cable and hose A Fastening hoses A and G A 77 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 56

57 Exhaust Part Route original vehicle wiring harness as shown and secure using clip-type cable tie. Routing wiring harness 78 a Hose clamp exhaust pipe a 79 Ensure sufficient distance from neighbouring components, correct if necessary. 5 mm Aligning exhaust pipe a Petrol Underride protection Hole (as per work step of the installation instructions) Hole in underride protection 8 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 57

58 Diesel Underride protection Remove insulation Hole in underride protection 8 Hole (as per work step of the installation instructions) 60 Hole in underride protection 5 8 Petrol and diesel Position exhaust end fastener as per work step of the installation instructions and copy hole pattern [x]. Copying hole pattern 84 Hole [x] as per work step 4 of the installation instructions. Holes in underride protection 85 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 58

59 5x self-tapping screw [x] as per work step 5 of the installation instructions exhaust end fastener a 86 Install underride protection. Install exhaust pipe a as per work steps 6-8 of the installation instructions. exhaust pipe a 87 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 59

60 Final Work Reassemble the components in reverse order. Check all hoses, clamps and all electrical connections for firm seating. Insulate and tie back loose lines. Only use manufacturer-approved coolant. Spray the heater components with anti-corrosion wax (Tectyl 00K). Connect the battery. Fill and bleed the coolant circuit according to the vehicle manufacturer s specifications. Program MultiControl CAR, teach Telestart transmitter. Make settings on the A/C control panel according to the Operating Instructions. Place the Switch off parking heater before refuelling caution label near the filler neck. For initial startup and function check, please see installation instructions. a Ensure sufficient distance from neighbouring components, correct if necessary. Aligning exhaust pipe a 88 Install rubber isolator, route air filter box drain pipe as shown and attach using cable tie. drain pipe of air filter box 89 Webasto Thermo & Comfort SE Postfach Gilching Germany Internet: Technical Extranet: Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 60

61 FuelFix Template for Petrol Vehicles Top view 00mm Scale : Compare size of printout with dimension lines. Allowed tolerance a maximum of %. Set the printer settings to no margin or minimise margins and 00% of the normal size. 00mm 0 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 6

62 FuelFix Template for Diesel Vehicles Top view 00mm Scale : Compare size of printout with dimension lines. Allowed tolerance a maximum of %. Set the printer settings to no margin or minimise margins and 00% of the normal size. 00mm 0 Ident. No.: 405C_EN Status: Webasto Thermo & Comfort SE 6

63 Automatic A/C Operating Instructions for Petrol Vehicles 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 deactivated in addition to the 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: The fan speed does not have to be set! Set temperature to max. Air outlet to windscreen A/C control panel 90 0A heater fuse F 0A main fuse F of passenger compartment Engine compartment fuses 9 A fuse F of heater control 5A fan fuse F4 Passenger compartment fuses 9

64 Automatic A/C Operating Instructions for Diesel Vehicles 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 deactivated in addition to the 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: The fan speed does not have to be set! Set temperature to max. Air outlet to windscreen A/C control panel 9 0A heater fuse F 0A main fuse F of passenger compartment Engine compartment fuses 94 A fuse F of heater control 5A fan fuse F4 Passenger compartment fuses 95