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

Transcription

1 Water Heater Unit Feel the drive Thermo Top E Additional Heater e Installation Instructions Chevrolet Aveo Gasoline Notchback from Model Year 006 Hatchback from Model Year 008 Left-hand drive vehicle Manual transmission 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, specialized tools and equipment are required to install and repair Webasto heating and cooling systems. 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. Webasto does not accept any liability for defects and damage that are attributable to installation by untrained staff. Ident. No.:44A_EN Fee Euro 0.00 Webasto AG

2 Table of Contents Validity Heater Unit/Installation Kit Foreword General Instructions Special Tools Explanatory Notes on Document 4 Preliminary Work 5 Heater unit installation location 5 Preparing electrical system 6 Electrical system 7 Fan controller for manual air conditioning 8 Automatic air-conditioning fan controller 9 Remote option (Telestart) Preparing installation location Premounting heater unit heater unit 4 Coolant on. liter and.4 liter 69 kw gasoline engine 6 Coolant on.4 liter 74 kw gasoline engine 0 Combustion air Fuel 4 Exhaust gas 7 Final Work 8 Template for Angle Bracket 9 Template for Fuel Standpipe 0 Operating Instructions for End Customer Validity Manufacturer Model Type EG-BE No./ABE Chevrolet Aveo KLAS e4 * 00/6 * 006 Engine type Engine model Output in kw Displacement in cm³ BD Gasoline/LPG 6 06 F4D Gasoline/LPG F4D4 Gasoline Vehicle and engine types, equipment variants and national specifications not listed in these installation instructions have not been tested. However, installation according to these installation instructions may be possible. The installation location of a digital timer and summer/winter switch should be confirmed with the end customer before installation. 44A_EN

3 Heater Unit/Installation Kit Quantity Description Order No.: Retail accessories with desired heater control See price list Installation kit for Chevrolet Aveo Gasoline 44A Heater unit recommended for the respective vehicle class: Vehicle Compact car Heater Unit Thermo Top E Foreword These installation instructions apply to Chevrolet Aveo vehicles with a Gasoline engine - for validity, see page - in the notchback version from model year 006 and in the hatchback version from model year 008 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 these installation instructions. However, where this is the case the stipulations in the "installation instructions" and "operating and maintenance instructions" for the Thermo Top E 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 should be fitted with edge protectors (split-open plastic 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 - Metric thread-setter kit 44A_EN

4 Explanatory Notes on Document To provide you with a quick overview of the individual working steps, you will find an identification mark on the outside top right corner of the page in question. Mechanical system Electrical system Coolant Fuel Exhaust gas Combustion air Special features are highlighted using the following symbols: Specific risk of injury or fatal accidents. Specific risk of damage to components. Specific risk of fire or explosion. Reference to general installation instructions of Webasto components or to the manufacturer's vehicle-specific documents. Reference to a special technical feature. The arrow in the vehicle icon indicates the position on the vehicle and the viewing angle. All dimensions are in mm! Tightening torque of hose clamps = Nm! Tightening torque of Ejot screws, Ejot studs = 0 Nm! 44A_EN 4

5 Preliminary Work WARNING! - Open fuel tank cap, ventilate tank. - Close the tank cap again. - Disconnect the battery "earth" or "ground" connection. - Depressurize the cooling system. - Copy the factory number from the original type label to the duplicate type label. - Remove years that do not apply from the duplicate label. - Attach the duplicate label (type label) in the appropriate place. - Remove the left front wheel. - Remove front left wheel well trim. - Open the right-hand fuel sender service lid. - Remove the fuel-tank sending unit in accordance with the manufacturers specifications. - Remove the left-hand instrument panel trim. - Remove the A/C control panel. Heater unit installation location Heater unit Remove page "Operating Instructions for End Customer" and add to the vehicle operating instructions. Installation location 44A_EN 5

6 Preparing electrical system Only with automatic air-conditioning 50 sw O,75² Wire section will be required later for connection of A/C control panel. Cutting wires to length Produce connections as shown in wiring diagram. Install wire section in the protective sleeving provided a K Preparing fuse F4 F4 44A_EN 6

7 Electrical system Positive and ground connection Ground connection Positive connection Digital timer/summer/winter switch option Digital timer Summer/winter switch, drilled hole mm dia. Wiring harness installation diagram Do not install the metering pump cable harness until later together with fuel pipe along the original vehicle fuel lines on the underbody 5 Fuse holder, relay K 4 4 Wiring harness pass through 5 Original vehicle bolt, flanged nut Angle bracket M5x6 bolt, retaining plate of fuse holder, flanged nut 4 Fuse holder 5 K relay Protective rubber plug 44A_EN 7

8 Fan controller for manual air conditioning Webasto F HG Chevrolet F 0 5A Wiring diagram X 4 or 4² a rt 4² or 4² 85 0 K sw 4² GS ge br bl 4 or or WG or + M - GM sw Webasto components Vehicle components Colors and symbols HG Heater unit TT-C/E GM Fan motor rt red X 6-pin heater unit connector WG Resistor group or orange F 5 A fuse GS Fan switch sw black K Fan relay F Fuse Legend X Cutting point Wiring colors may vary. Connection to 6-pin connector 4 from fan switch. Produce connections as shown in wiring diagram. 5 Black (sw) wire from K/0 Red (rt) wire from K/87a Orange (or) wire of fuse 5 Orange (or) wire of connector for fan switch Connecting fan switch A_EN 8

9 Automatic air-conditioning fan controller Webasto F HG X 4 Chevrolet or F9 4 C7 rt/ws 4² 0 5A Wiring diagram rt 4² sw 4²!! rt/ws 4² a K sw 0,75² ge/ws 0,5² rt/ws 0,5² B KB 0 F4 bl/rt bl/ge bl/rt GRr 4 sw GM M - + Webasto components Vehicle components Colors and symbols HG Heater unit TT-C/E GM Fan motor rt red X 6-pin heater unit connector C7 6-pin white (ws) connector ws white F 5 A fuse GRr Fan controller sw black K Fan relay KB Air-conditioning control panel br brown F4 0 A additional fuse F9 0 A fuse or orange b 6-pin connector bl blue ge yellow Insulate wire ends and tie back X Cutting point Wiring colors may vary. Legend 44A_EN 9

10 Connection to -pin connector from the blower motor. Produce connections as shown in wiring diagram. 5 Red/white (rt/ws) wire of connector Black (sw) wire from K/0 4 Red (rt) wire from K/87a 5 Red/white (rt/ws) wire of Terminal 5A Connecting fan-motor 4 7 Connection to 6-pin connector 6 from A/C control element. Produce connections as shown in wiring diagram. Insulate wires and and tie back. 4 Black (sw) wire from K/0 4 Yellow/white (ge/ws) wire, Pin 5 Red/white (rt/ws) wire, Pin 7 A/C control panel Connecting A/C control panel pin connector, on contact side B B B B4 B5 B6 B7 B8 View of 6- pin connector B9 B0 B B B B4 B5 B6 9 44A_EN 0

11 Remote option (Telestart) Fasten Telestart with adhesive tape. receiver 0 Glue antenna onto windshield in black area from inside. antenna 44A_EN

12 Preparing installation location.4 liter 69 kw gasoline engine Remove original vehicle bolt at position and discard. Turn angle bracket upward as far as possible. M6x0 bolt, spring lockwasher 0 mm shim Repositioning hydraulic line.4 liter 74 kw gasoline engine Remove original vehicle bolt at position and discard. M6x0 bolt, spring lockwasher 0 mm shim Repositioning hydraulic line All vehicles Remove original vehicle nut at position. M6x0 spacer nut Rivet nut, existing hole Preparing installation location 4 Install 0 mm shim and large diameter washer between bracket and frame side member at position. M6x0 bolt, spring lockwasher M6x50 bolt, spring lockwasher Bracket bracket 5 44A_EN

13 Bend up angle bracket [x] in accordance with template mm shim [x] M6x0 bolt, flanged nut [x each] 4 Copy hole pattern, drill 9. mm dia. hole and mount rivet nut [x each] Copying hole pattern 4 6 M6x60 bolt, spring lockwasher, flanged nut [x each] angle bracket 7 Premounting heater unit. liter gasoline engine 5 A C X B a = 0 b = 70 c = 40 Discard section X Cutting coolant hoses to length X.4 liter 69 kw gasoline engine A C X 5 5 B a = 80 b = 70 c = liter 74 kw gasoline engine a = 00 b = 70 c = 40 Cutting coolant hoses to length X X Discard section X 44A_EN

14 Combustion air pipe Hose clamp Heater unit Preassembling heater unit C 8 Spring clip Preassembling heater unit 9 heater unit Ejot screw heater unit 0. liter and.4 liter 69 kw gasoline engine Install perforated bracket between bracket and heater unit at position. Ejot screw [x] Ejot screw heater unit 44A_EN 4

15 .4 liter 74 kw gasoline engine Install perforated bracket between bracket and heater unit at position. Ejot screw Ejot screw [x] heater unit 44A_EN 5

16 Coolant on. liter and.4 liter 69 kw gasoline engine WARNING! Any coolant running off should be collected using an appropriate container. Install coolant hoses kinkfree. Unless specified otherwise, always fasten using cable ties. Position clamps so that no other hose can be damaged! When installing the coolant hose, the heater unit must be filled with coolant. The connection should be "inline" based on the following diagram: Coolant routing diagram A C B All spring clips without a specific designation = 7 mm dia. All connecting pipes without a specific designation = dia. 8x0. All hose clamps without a specific designation = 0-7 mm dia. = Black (sw) rubber isolator only on. liter gasoline engine! = Black (sw) rubber isolator only on.4 liter gasoline engine! Connecting pipe = 0x0 dia.! 44A_EN 6

17 b. liter gasoline engine Black (sw) rubber isolator a Premounting hose Cutting point Hose section of heat exchanger inlet Engine outlet hose section Cutting point C 4 Ensure sufficient distance to neighboring components. Cable tie Hose on heat exchanger inlet Connecting heat exchanger inlet C 5 Ensure sufficient distance to adjacent components, especially to gearshift control! C Routing in engine compartment 6 44A_EN 7

18 a Hose of engine outlet Connecting engine outlet a 7 Install hose B on heater unit inlet (circulating pump). Position black (sw) rubber isolator Routing and connection of heater unit a b b 8.4 liter 69 kw gasoline engine Premounting hose 9 Cutting point Hose section of heat exchanger inlet Engine outlet hose section Cutting point 0 44A_EN 8

19 Ensure sufficient distance to neighboring components. Slide on black (sw) rubber isolator before installation. Hose on heat exchanger inlet Connecting heat exchanger inlet C Black (sw) rubber isolator Positioning rubber isolator a Connecting engine outlet Install hose B on heater unit inlet (circulating pump). a b Cable tie [x] Spacer bracket Routing and connection of heater unit C 4 44A_EN 9

20 Coolant on.4 liter 74 kw gasoline engine WARNING! Any coolant running off should be collected using an appropriate container. Install coolant hoses kinkfree. Unless specified otherwise, always fasten using cable ties. Position clamps so that no other hose can be damaged! When installing the coolant hose, the heater unit must be filled with coolant. The connection should be "inline" based on the following diagram: Coolant routing diagram A C B All spring clips without a specific designation = 7 mm dia. All connecting pipes = 0x0 mm dia. All hose clamps = 0-7 mm dia.! = Original vehicle spring clip! = Rubber isolator. 44A_EN 0

21 a b Premounting hose 5 Original vehicle spring clip will be reused! Disconnect hose from engine outlet Cutting point a 6 Ensure sufficient distance to neighboring components. Connecting engine outlet 7 Hose on heat exchanger inlet Connecting heat exchanger inlet C 8 44A_EN

22 Hose bracket Black (sw) rubber isolator b C b a 9 Routing in engine compartment Connecting heater unit 40 44A_EN

23 Combustion air Fasten combustion air pipe on angle bracket with cable tie. combustion air pipe 4 Muffler Washer reservoir Cable tie [x] muffler 4 44A_EN

24 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 in as shown in the wiring harness routing diagram. Fuel line Hose section, 0 mm dia. clamp [x] Connecting heater unit 4 Route fuel line and wiring harness of metering pump behind insulation mat to righthand side of vehicle. lines 44 Route fuel and wiring harness of metering pump to underbody. lines 45 44A_EN 4

25 Route wiring harness of metering pump and fuel line in corrugated tube on underbody along original vehicle fuel lines to installation location of metering pump. lines 46 M6x0 bolt, angle bracket, flanged nut on existing hole of tank fastener Silent block, flanged nut [x] Rubber-coated pipe clamp 4 Metering pump metering pump 4 47 Check the position of the components; adjust if necessary. Check that they have free clearance. Corrugated tube Fuel line, hose section, 0 mm dia. clamp [x] Wiring harness of metering pump, connector mounted Connecting metering pump 48 Remove and dismantle fuel-tank sending unit according to manufacturer's instructions. Flanged nut Copy hole pattern, 6 mm dia. hole Removing fuel 49 44A_EN 5

26 Shape fuel standpipe according to template, cut to length and install. 50 Install fuel-tank sending unit according to manufacturer's specifications. Fuel line Hose section, 0 mm dia. clamp [x] fuel standpipe Connecting fuel line 5 Slide corrugated tube onto fuel line. Check the position of the components; adjust if necessary. Check that they have free clearance. Hose section, 0 mm dia. clamp [x] Connecting metering pump 5 44A_EN 6

27 Exhaust gas Exhaust pipe a = 80 Exhaust end section b = 80 Discard section X Preparing exhaust pipe a b X M6x0 bolt, flanged nut Muffler muffler 5 Hose clamp [x] Exhaust pipe exhaust pipe 54 Hose clamp Exhaust end section exhaust pipe and end section 55 44A_EN 7

28 Final Work WARNING! Reassemble the disassembled components in reverse order. Check all hoses, clamps and all electrical connections for firm seating. Secure all loose cables using cable ties. Only use manufacturer-approved coolant. Spray heater unit 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. - Make settings on A/C control panel according to the "Operating Instructions for End Customer". - Check the proper operation of the additional heater, see the operating instructions/installation instructions. - Attach the "Switch off additional heater before refueling" sticker to the left-hand B-pillar. Feel the drive Webasto AG Postfach 80-8 Stockdorf Hotline 0805 / Hotfax 095 / A_EN Printed in Germany 0/009 Printing: Steffen

29 Template for Angle Bracket 00 mm 80 Scale : Compare the size of the printed version with dimension lines. Permitted tolerance a maximum of %. Set the printer settings to no margin or minimize margins and 00% of the normal size. 00 mm 0 44A_EN 9

30 Template for Fuel Standpipe 00 mm Scale : Compare the size of the printed version with dimension lines. Permitted tolerance a maximum of %. Set the printer settings to no margin or minimize margins and 00% of the normal size. 00 mm 0 44A_EN 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. On vehicles with passenger compartment monitoring, this must be deactivated during heating! If the summer/winter switch option has been installed, this must be switched in accordance with the time of year. The heater unit will then only switch on the vehicle fan to ventilate the vehicle interior in the position Winter heat and in the position Summer. Before parking the vehicle, make the following settings: Set temperature to "max." Air outlet to windshield Set fan to level "", or possibly "" Manual air conditioning 56 Direct air outlet toward windshield Set temperature to "max." Set fan to level "", or possibly "" Automatic air-conditioning 57 44A_EN