Water Heater. Installation Documentation Renault Scenic / Grand Scenic / Megane. Thermo Top Evo Parking Heater. Validity

Transcription

1 Water Heater Thermo Top Evo Parking Heater E Installation Documentation Renault Scenic / Grand Scenic / Megane Validity Manufacturer Model Type EG-BE No./ ABE Renault Scenic JZ e * 00 / 6 * 079 *... Renault Grand Scenic JZ e * 00 / 6 * 079 *... Renault Megane KZ/Z/BZ/DZ e * 00 / 6 * 07 *... Motorisation Fuel Transmission type Output in kw Displacement in cm³ Engine code.5 D Diesel 5-speed SG K9K.5 D Diesel 6-speed SG 8 46 K9K.5 D Diesel 6-gear EDC 8 46 K9K.6 D Diesel 6-speed SG R9M.0 D Diesel 6-speed SG M9R.0 D Diesel 6-speed AG M9R SG = Manual transmission EDC = Dual clutch transmission AG = Automatic transmission from Model Year 0 Left-hand drive vehicle Verified equipment variants: Manual / automatic air-conditioning system Front fog light Bi-Xenon with headlight washer system Daytime Running Lights / LED Daytime Running Lights Start / Stop Bumper, GT optics Not verified: Total installation time: Passenger compartment monitoring approx. 9 hours Ident. No.: 866B_EN Status:.0.0 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 8 Fan Controller 9 Digital Timer Remote Option Telestart Preparing Installation Location Preparing Heater 8 Coolant Circuit of Manual and EDC Transmissions 0 Coolant Circuit of Automatic Transmission Heater 9 Fuel Combustion Air 4 Exhaust Gas 5 Final Work 4 Operating Instructions for Manual Air-Conditioning 4 Operating Instructions for Automatic Air-Conditioning 44 Necessary Components Basic delivery scope Thermo Top Evo in accordance with price list Installation kit for Renault Scenic / Grand Scenic / Megane 0 Diesel: 865B to be ordered additionally in case of.0 automatic transmission: Exhaust silencer: 0075B 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 Overview Legend:. Heater. Fuse holder of engine compartment. Fuse holder of passenger compartment 4. Circulating pump 5. Digital timer (Scenic installation location) 6. Metering pump Information on Total Installation Time The total installation time includes the time needed for mounting and demounting of 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.: 866B_EN Status:.0.0 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 7). 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. Sharp edges should be fitted with rub protection (split-open fuel hose)! Spray unfinished body areas, e.g. drilled holes, with anti-corrosion wax (Tectyl 00K, Order No. 9). 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 an IPCU, the corresponding settings must be checked or adjusted before the installation. 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 For vehicles with an EU permit, no entry in accordance with 9 Sub-Section 4 of Annex VIII b to the Road Traffic Act is required.. Excerpt from the directive 00/56/EC Appendix VII 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. Ident. No.: 866B_EN Status:.0.0 Webasto Thermo & Comfort SE

4 Information on Validity This installation documentation applies to the Renault Scenic / Grand Scenic / Megane Diesel vehicles starting with model year 0 - for validity, see page - 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 Webasto Thermo Test Diagnosis with current software Dimensions All dimensions are in mm. Tightening torque values Tightening torque values of 5x heater bolts = 8Nm. Tightening torque values of 5x5 retaining plate of water connection piece bolts = 7Nm. Tighten other bolt connections in accordance with manufacturer's instructions or in accordance with state-of-the-art-technology. Explanatory Notes on Document You will find an identification mark on the outside top right corner of the page in question to provide you with a quick overview of the individual working steps. Mechanical system Special features are highlighted using the following symbols: Specific risk of injury or fatal accidents Electrical system Specific risk of damage to components Coolant circuit Specific risk of fire or explosion Combustion air Fuel Exhaust gas Reference to general installation instructions of the 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 Software Ident. No.: 866B_EN Status:.0.0 Webasto Thermo & Comfort SE 4

5 Preliminary Work All "Scenic" and "Grand Scenic" will be referred to as "Scenic" from this point forward. Vehicle Open the fuel tank cap. Ventilate the fuel tank. Close the fuel tank cap again. Depressurise the cooling system. Remove the battery with carrier completely. Remove the air filter together with the intake hose. Drain the coolant. Remove the air resonator. Remove the wheel well trim on the left. Remove the front bumper trim. Remove the underride protection. Remove the instrument panel trim on the driver's side. Remove the accelerator pedal. Remove the side trim centre console on the driver's side. Heater Remove years that do not apply from the type and duplicate label. Attach the duplicate label (type label) in the appropriate place inside the engine compartment. Heater Installation Location Image shows.5 manual transmission and.0 with manual and automatic transmission. Heater Installation location Image shows.5 with EDC transmission and.6 with manual transmission. Heater Installation location Ident. No.: 866B_EN Status:.0.0 Webasto Thermo & Comfort SE 5

6 6 000 gn/ws 0,75² Preparing Electrical System Wire sections retain their numbering in the entire document. 400 X sw 0,5² br 0,5² Discard section X. Supplied fan wiring harness contains red (rt) 4² wire and black (sw) 4² wire. Cutting wires to length rt 0,75² All wire sections will be needed to connect the auxiliary heater / /000 rt 4² All wires are 500mm long for all vehicles except.0 AG. All wires are 000mm long for.0 AG vehicle. Cutting wires to length 0 500/ /000 sw 4² Lock IPCU socket with fuse holder of passenger compartment 4. M5x6 bolt, washer [x], nut Angle bracket Preparing fuse holder 4 A E Ident. No.: 866B_EN Status:.0.0 Webasto Thermo & Comfort SE 6

7 Fuse holder of passenger compartment rt/sw 0,5² rt 4² F 86 gn/ws 0,75² F a K 4 IPCU A E 5 Produce connections as shown in wiring diagram. Pull wires and 5 as well as wire 4 into one protective sleeving each. Insert IPCU, K relay and 5A fuse F4. The pre-programmed settings (see legend of wiring diagram) must be checked on the vehicle during the function test and adjusted, if necessary. Preparing fuse holder br 0,5² IPCU view on contact side. Fuse holder of engine compartment 80 Figure 4a = Megane Figure 4b = Scenic 4 Fuses F- Perforated bracket (angle down by 90 for Megane.) M5x6 bolt, washer [x], nut 4 Fuse holder retaining plate Preparing fuse holder 4a 4 4b 4 All vehicles Complete connector or metering pump again after routing. Pin assignment is not relevant! 5 5 Connector housing Lock Blue / brown (bl / br) wires 4 Coding 5 Timer lock Dismantling connector 5 Ident. No.: 866B_EN Status:.0.0 Webasto Thermo & Comfort SE 7

8 Electrical System Positive and earth wire Positive wire on positive support point Earth wire on negative battery terminal Wiring harness pass through Protective rubber plug Wiring harnesses of fan controller, heater control 6 7 Do not install the metering pump wiring harness until later together with fuel pipe along the original vehicle fuel lines on the underbody Wiring harness routing diagram Fuse holder in engine compartment of the Megane M6x0 bolt, large diameter washer, flanged nut Perforated bracket Fuses F and F 8 9 Fuse holder in the engine compartment of the Scenic Original vehicle stud bolt, flanged nut Perforated bracket Fuses F and F Ident. No.: 866B_EN Status:.0.0 Webasto Thermo & Comfort SE 8

9 Fan Controller F F Webasto HG X 5 X Renault F40 F0 0 5 Wiring diagram rt/br 4² br 0,5² rt/sw 0,5² rt 4² ge 0,5² rt 4² rt/br 4² X0 St 6 5 rt/sw 0,5² br 0,5² rt 4² F br 0,5² 86 gn/ws 0,75² 85 0 F4 87 sw 4² 87a K 86 gn/ws 0,75² 6 IPCU 85 br 0,5² A E rt 0,75² 5 rt 4² gn/ws 0,75² or*/ge** 0,5² sw 0,5² rt 0,75² or*/ge** 0,5² GE St 9 M KB rt/ws 0,5² 6 St Webasto components Vehicle components Colours and symbols HG TT-Evo heater GE Fan unit rt red X 6-pin heater connector KB A/C control panel sw black X -pin heater connector F0 5A fuse ge yellow X0 4-pin connector F40 40A fuse gn green Heater control St 6-pin connector GE or orange K Fan relay St 40-pin connector KB ws white F 0A fuse St 4-pin connector KB br brown F 0A fuse F A fuse F4 5A fuse IPCU Pulse width modulator IPCU adjustment values: Duty cycle: 65% * Automatic air-conditioning Frequency: 400Hz ** Manual air-conditioning Voltage: 9V X Cutting point Function: Low-side Wiring colours may vary. Legend Ident. No.: 866B_EN Status:.0.0 Webasto Thermo & Comfort SE 9

10 Original vehicle stud bolt, flanged nut Angle bracket fuse holder of passenger compartment 0 Connect the wiring harness of the fuse holder for the passenger compartment with the wiring harness of the heater according to the wiring diagram and so that the wires of the same colour are connected. Connecting wiring harnesses 6 Connection to fuse and relay box. Cut wires to length. Produce connections as shown in wiring diagram. 4 4 Warning: Output fuse F40 (Terminal 5) switches off after a time lag. Socket for fuse F40 Red/brown (rt/br) wire of fuse F40 4 Red/brown (rt/br) wire of fan unit 4 6 Red (rt) wire from K/87a Black (sw) wire from K/0 Red (rt) wire of IPCU/5 Green/white (gn/ws) wire of IPCU/86 Connection of fuse box 5 Connection on 6-pin connector from the fan unit. Orange (or) wire for automatic air-conditioning or yellow (ge) wire for manual air-conditioning system. Produce connections as shown in wiring diagram. Orange (or) / yellow (ge) wire of fan unit connector Pin 5 Orange (or) / yellow (ge) wire of A/C control panel 5 Black (sw) wire of IPCU/A Red (rt) wire of IPCU/E Connecting fan unit Ident. No.: 866B_EN Status:.0.0 Webasto Thermo & Comfort SE 0

11 7 7 Figure 4a = Megane Figure 4b = Scenic Produce connections as shown in wiring diagram. Self-tapping screw 5.5x; existing hole or dia. 4 mm hole, if not available Original vehicle bolt 7 Brown (br) wire of IPCU/85, cable lug Connecting IPCU to earth 4a 4b Digital Timer Scenic Digital timer digital timer 5 Megane Digital timer digital timer 6 Remote Option Telestart Fasten receiver with adhesive tape. receiver 7 Ident. No.: 866B_EN Status:.0.0 Webasto Thermo & Comfort SE

12 Antenna antenna 8 Temperature sensor T00 HTM Fasten temperature sensor with adhesive tape. temperature sensor 9 Ident. No.: 866B_EN Status:.0.0 Webasto Thermo & Comfort SE

13 Preparing Installation Location Cut original vehicle bracket at the marking. Discard section Cutting off bracket 0 9.mm dia. hole, rivet nut 55 rivet nut 45 Remove electric auxiliary heater with bracket (loosen water connections, remove wiring, original vehicle bolts will be re-used). Remove control unit of electrical auxiliary heater with bracket. Remove control unit - not in case of.0 AG. Preparing installation location Remove control unit of electrical auxiliary heater. Remove rubber plug (will be reused), discard bracket. perforated bracket Ident. No.: 866B_EN Status:.0.0 Webasto Thermo & Comfort SE

14 All vehicles except.0 AG Perforated bracket Electric auxiliary heater Original vehicle bolts perforated bracket 4 Separate white (ws) and blue (bl) [x each] wires of auxiliary heater control unit connector at position. Separating blue (bl) and white (ws) wires Extend white (ws) wires and of auxiliary heater control unit connector with red (rt) wires. 8 and 9 as well as with shrink connectors. Extend blue (bl) wires 4 and 5 of auxiliary heater control unit connector with red (rt) wires. 0 and as well as with shrink connectors. Extending wiring of auxiliary heater Push one 0mm dia. corrugated tube [x 500mm long] each onto red (rt) and black (sw) wires. Re-install white (ws) and blue (bl) wires [x each] to the auxiliary heater. Earth wire of auxiliary heater Connecting auxiliary heater 7 Ident. No.: 866B_EN Status:.0.0 Webasto Thermo & Comfort SE 4

15 Cut perforated bracket to length and angle down x by 90. Discard section. 5 5 Preparing perforated bracket Perforated bracket Control unit of auxiliary heater Loosely mount original vehicle bolt, flanged nut Premounting control unit of auxiliary heater 8 7 mm dia. hole 5 Hole for control unit 5 9 Original vehicle stud bolt, flanged nut Control unit of electric auxiliary heater Original vehicle bolt, flanged nut 4 Tighten bolt control unit 4 0 Ident. No.: 866B_EN Status:.0.0 Webasto Thermo & Comfort SE 5

16 Mount connectors on control units. Route corrugated tubes [x] with feed lines of auxiliary heater to the underbody along the cross member. Original vehicle stud bolt, flanged nut Control unit control unit.0 AG Separate white (ws) and blue (bl) [x each] wires of auxiliary heater control unit connector at position. Separating blue (bl) and white (ws) wires Extend white (ws) wires and of auxiliary heater control unit connector with red (rt) wires. 8 and 9 as well as with shrink connectors. Extend blue (bl) wires 4 and 5 of auxiliary heater control unit connector with red (rt) wires. 0 and as well as with shrink connectors. Extending wiring of auxiliary heater 4 0 Centrally separate 0mm dia. corrugated tube [x 050mm long] and push each part onto red (rt) and black (sw) wires. Re-install white (ws) and blue (bl) wires [x each] to the auxiliary heater. Connecting auxiliary heater 4 Ident. No.: 866B_EN Status:.0.0 Webasto Thermo & Comfort SE 6

17 Position control unit on the frame side member as shown. Copy hole pattern [x] Copying hole pattern 5 Remove control unit. 9. mm dia. hole, rivet nut [x each] rivet nuts 6 Attach connector to control unitof electrical auxiliary heater. Fasten corrugated tubes 4 [x] with supply lines of auxiliary heater using cable tie. M6x0 bolt, spring lockwasher [x each] control unit Route corrugated tubes [x] with supply lines of auxiliary heater. lines 8 Ident. No.: 866B_EN Status:.0.0 Webasto Thermo & Comfort SE 7

18 Preparing Heater Water connection piece, sealing ring [x each] 5x5mm self-tapping bolt, retaining plate of water connection piece water connection pieces 9.5 and.0 Only install bracket A in case of.5 with SG and.0 with SG and AG. Insert rubber plug into bracket. Part A of bracket 5x self-tapping bolt [x] Premounting heater 40 All vehicles 5x self-tapping bolt [x] Part B of bracket bracket B 4 Shorten combustion air pipe to 80mm only in case of.0 AG. 90 moulded hose, 0 mm dia. clamp Wiring harness of circulating pump attached Premounting heater 4 Ident. No.: 866B_EN Status:.0.0 Webasto Thermo & Comfort SE 8

19 Original vehicle bolt, existing threaded hole Part B of bracket Loosely mounting heater 4 Align heater as shown. Part B of bracket Copy hole pattern, 7mm dia. hole [x] Holes for heater 44 Copy hole pattern at position. Remove heater and drill 7mm dia. hole into cross member at position. Hole for heater 45 Ident. No.: 866B_EN Status:.0.0 Webasto Thermo & Comfort SE 9

20 Coolant Circuit of Manual and EDC Transmissions WARNING! Any coolant running off should be collected using an appropriate container. Install hoses so that they are kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that no other hose can be damaged. When installing the hoses, the heater must be filled with coolant. The connection should be "inline" based on the following diagram: Hose routing diagram Ø 7 G Ø 0x8 F E # Ø 0x0 Ø 7 Ø 7 a b A B C D All spring clips without a specific designation = 5mm dia. = Original vehicle spring clip. # = Connecting pipe and spring clips only in case of.5 and.6 All connecting pipes without a specific designation and = 8x8 mm dia. = Electrical auxiliary heater. Ident. No.: 866B_EN Status:.0.0 Webasto Thermo & Comfort SE 0

21 Coolant Circuit of Automatic Transmission WARNING! Any coolant running off should be collected using an appropriate container. Install hoses so that they are kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that no other hose can be damaged. When installing the hoses, the heater must be filled with coolant. The connection should be "inline" based on the following diagram: Hose routing diagram Ø 7 G Ø 0x8 F E a b Ø 0x0 c A B C D Ø 7 Ø 7 All spring clips without a specific designation = 5mm dia. = Original vehicle spring clip. All connecting pipes without a specific designation and = 8x8 mm dia. = Electrical auxiliary heater. Ident. No.: 866B_EN Status:.0.0 Webasto Thermo & Comfort SE

22 B A C D E G X F Discard section X. A = 0 B = 00 C = 0 D = 60 E = 90 F = 0 G = 00 Cutting hoses to length X X E 80mm heat shrink plastic tubing Premounting hoses E and F A F 46 50mm heat shrink plastic tubing Preparing hose A 47 Circulating pump Mounting of circulating pump B A Premounting circulating pump 48 Ident. No.: 866B_EN Status:.0.0 Webasto Thermo & Comfort SE

23 Mount 50mm edge protection [4x] edge protection 49.0 SG Route hoses downwards. Hose of auxiliary heater outlet / engine inlet Remove hose bracket and discard Hose on auxiliary heater inlet / heat exchanger outlet Cutting point 50 0 Mark respective directions of flow on the hoses. Separate hoses at the markings. 5 Hose section will be re-used Hose section on engine inlet Hose section of heat exchanger outlet 4 Discard section Cutting point Separate hose of auxiliary heater outlet at the marking. Discard section b Hose section will be re-used. Preparing hose b 5 Ident. No.: 866B_EN Status:.0.0 Webasto Thermo & Comfort SE

24 .0 AG Remove hose bracket and discard Label separation line Hose on heat exchanger outlet / auxiliary heater inlet Marking separation line 0 5 Mark directions of flow on the hoses. Separate hoses at the markings. 55 Hose section of auxiliary heater outlet will be reused Hose section on engine inlet Hose section of auxiliary heater inlet will be reused a Hose section of heat exchanger outlet Cutting point a 54 Separate hose of auxiliary heater inlet at the markings Discard cut-off sections b Hose section will be re-used. Preparing hose b c Separate hose of auxiliary heater outlet at the marking. Connect hose sections b and c. Discard section Preparing hoses b 56 Ident. No.: 866B_EN Status:.0.0 Webasto Thermo & Comfort SE 4

25 .5 Mark separation lines. 50 Hose on auxiliary heater inlet / heat exchanger outlet Hose of auxiliary heater outlet / engine inlet Remove hose bracket [x] and discard Marking separation line 0 57 Mark directions of flow on the hoses. Route hoses downwards and separate at the markings. 4 Hose section of auxiliary heater inlet will be reused Hose section of heat exchanger outlet Hose section on engine inlet 4 Discard hose bracket 5 Discard section Cutting point Separate hose of auxiliary heater inlet at the marking. a Hose section will be re-used b Hose section will be re-used Preparing hose a b 59.6 Mark separation line. 0 Hose on auxiliary heater inlet / heat exchanger outlet Hose of auxiliary heater outlet / engine inlet Remove hose bracket and discard Marking separation line 0 60 Ident. No.: 866B_EN Status:.0.0 Webasto Thermo & Comfort SE 5

26 Mark directions of flow on the hoses. Separate hoses. Hose section of auxiliary heater inlet will be reused Hose section of auxiliary heater outlet will be reused Cutting point 50 b 6 Remove fabric protective hose in the area of the cutting point. Separate hose of auxiliary heater outlet at the markings. Discard cut-off sections b Hose section will be re-used Preparing hose 6 Separate hose of auxiliary heater inlet at the marking. Discard section a Hose section will be re-used Preparing hose a b/c 6 E All vehicles Hose b = all vehicles except.0 AG. Hose b / c =.0 AG. Insert hose group E / F beneath hose bracket and route behind the cross member. Route hose b / c through hose bracket in the engine compartment alongside hose F (see following image). Premounting hoses F 64 Ident. No.: 866B_EN Status:.0.0 Webasto Thermo & Comfort SE 6

27 b/c Routing in engine compartment F 65 b/c Hose b / c has been put back to provide a better view. Original vehicle clamp Hose section on engine inlet 50mm edge protection [x] Connecting engine outlet F G 66.0 SG Mind components located behind. 7mm dia. hole Hole for auxiliary heater b Route earth wire to the left side of the vehicle. Insert 8mm shim between cross member and perforated bracket 5. Hose on heat exchanger outlet Original vehicle spring clip [x] 4 M6x5 bolt, 8mm shim, flanged nut Installation and connection of auxiliary heater Ident. No.: 866B_EN Status:.0.0 Webasto Thermo & Comfort SE 7

28 .0 AG Remove original vehicle clip at position. Insert 0mm shim between cross member and auxiliary heater. M6x5 bolt, spring lockwasher, large diameter washer, 0mm shim, existing threaded hole of auxiliary heater auxiliary heater c b a 69 Route earth wire to the left side of the vehicle. Installation and connection of auxiliary heater 70 b a.5 and.6 5 Route earth wire to the left side of the vehicle. Insert 8mm shim between cross member and perforated bracket 5. Hose a with long arm on auxiliary heater inlet. Original vehicle spring clip [x] Hose on heat exchanger outlet 4 M6x5 bolt, large diameter washer, 8mm shim, flanged nut Installation and connection of auxiliary heater 4 7 A All vehicles B E Align hoses. Connect hoses A and b or A and c in case of.0 AG. Ensure sufficient distance from neighbouring components, correct if necessary. Mounting of circulating pump M6x5 bolt, spring lockwasher, large diameter washer Installation and connection of circulating pump F 7 Ident. No.: 866B_EN Status:.0.0 Webasto Thermo & Comfort SE 8

29 E A Heater D Position heater and fasten it using bolt. Connect hoses D and E. Align hoses A and D behind the heater. M6x0 bolt, large diameter washer, flanged nut heater C 7 C Image shows.5 with SG. Align hose C to heater. B Part B of bracket M6x0 bolt, large diameter washer, flanged nut [x each] and connecting heater 74 For all vehicles except.0 AG, at position the earth wire of the auxiliary heater is also fastened (see small image). Original vehicle bolt, existing threaded hole Original vehicle bolt, flanged nut 4 Part B of bracket heater 4 75 All vehicles 4 Attach wiring harness of heater [x] Fuel line 0 mm dia. clamp 4 Cable tie Connection of fuel line 76 Ident. No.: 866B_EN Status:.0.0 Webasto Thermo & Comfort SE 9

30 Wiring harness of circulating pump Connecting wiring harness 77 b All vehicles except.0 AG Align hoses. Ensure sufficient distance from neighbouring components, correct if necessary. Hose bracket Inserting hose bracket G 78.0 AG Align hoses. Ensure sufficient distance from neighbouring components, correct if necessary. Hose bracket Inserting hose bracket G c b 79 Ident. No.: 866B_EN Status:.0.0 Webasto Thermo & Comfort SE 0

31 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. Route fuel line and wiring harness of metering pump in the engine compartment in 0mm dia., 00mm long corrugated tube. lines 80 Pull fuel line and wiring harness of metering pump into corrugated tube and route it to the underbody along original vehicle lines and behind the insulation mat. lines 8 Route fuel line and wiring harness of metering pump in 00mm corrugated tube to installation location of metering pump. lines 8 Ident. No.: 866B_EN Status:.0.0 Webasto Thermo & Comfort SE

32 Perforated bracket 66 Angling down perforated bracket 90 5 Angled down perforated bracket Cable tie M6x5 bolt, support angle, flanged nut 4 Mounting of metering pump Preinstalling mount for metering pump 4 8 Perforated bracket M6x0 bolt, large diameter washer, flanged nut, existing hole of axis suspension bracket metering pump mount moulded hose Discard section Cutting moulded hose to length 85 Ident. No.: 866B_EN Status:.0.0 Webasto Thermo & Comfort SE

33 80 moulded hose Metering pump Hose section 4 0 mm dia. clamp [x] Preinstalling metering pump Cut 00mm corrugated tube to length and slide onto fuel line towards fuel standpipe 6. Check the position of the components; adjust if necessary. Check that they have freedom of movement. Fuel line from heater 0 mm dia. clamp [x] 4 Wiring harness of metering pump, connector mounted 5 Metering pump Connecting metering pump and.5 Check the position of the components; adjust if necessary. Check that they have freedom of movement. 8x5x8 fuel standpipe, 0mm dia. screw clamp [x] Fuel line, hose section, 0mm dia. clamp [x] Cutting point of fuel supply line Fuel extraction 88.6 Check the position of the components; adjust if necessary. Check that they have freedom of movement. Fuel line, hose section, 0mm dia. clamp [x] 8x5x8 fuel standpipe, 0mm dia. screw clamp [x] Cutting point of fuel return line Fuel extraction 89 Ident. No.: 866B_EN Status:.0.0 Webasto Thermo & Comfort SE

34 Combustion Air All vehicles except.0 AG Silencer Combustion air pipe Cable tie [x] on retaining plate 4 Cable tie on silencer silencer mm edge protection Cable tie Fastening combustion air pipe 9.0 AG Silencer Cable tie, original vehicle hole Combustion air pipe silencer 9 Ident. No.: 866B_EN Status:.0.0 Webasto Thermo & Comfort SE 4

35 Exhaust Gas Discard section X. Manual transmission a b Exhaust pipe a = 70mm Exhaust end section b = 0mm EDC transmission Exhaust pipe a = 00mm Exhaust end section b = 70mm Automatic transmission Preparing exhaust pipe X Exhaust pipe a = 05mm Exhaust end section b = 50mm Manual and EDC transmissions 90 9.mm dia. hole, rivet nut 0 rivet nut Manual transmission Perforated bracket 90 Angling down perforated bracket 90 Silencer Perforated bracket M6x6 bolt, spring lockwasher Premounting silencer 94 Ident. No.: 866B_EN Status:.0.0 Webasto Thermo & Comfort SE 5

36 Perforated bracket M6x0 bolt, spring lockwasher silencer 95 Exhaust pipe Spacer bracket Hose clamp [x] exhaust pipe 96 Align exhaust system. Ensure sufficient distance min. 0mm) from neighbouring components, correct if necessary. Exhaust end section Hose clamp exhaust end section 97 Cut out insulation along the markings. 60mm dia. hole Underride protection Cutting out underride protection 98 Ident. No.: 866B_EN Status:.0.0 Webasto Thermo & Comfort SE 6

37 5 0 EDC Transmission Perforated bracket 4 75 Preparing perforated bracket 0 Silencer M6x6 bolt, spring lockwasher Perforated bracket Premounting silencer 99 M6x0 bolt, spring lockwasher, large diameter washer Perforated bracket silencer 00 Spacer bracket Hose clamp [x] Exhaust pipe exhaust pipe 0 Ident. No.: 866B_EN Status:.0.0 Webasto Thermo & Comfort SE 7

38 Align exhaust system. Ensure sufficient distance min. 0mm) from neighbouring components, correct if necessary. Hose clamp Exhaust end section exhaust end section 0 Cut out insulation along the markings. 60mm dia. hole Underride protection 75 Cutting out underride protection 0 0 Manual and EDC Transmissions Image shows manual transmission Mount underride protection. Align exhaust end section with centre of hole. Aligning exhaust end section 04 Automatic transmission 9.mm dia. hole, rivet nut rivet nut 05 Ident. No.: 866B_EN Status:.0.0 Webasto Thermo & Comfort SE 8

39 6 Discard section Perforated bracket 6 Preparing perforated bracket 90 The earth wire of auxiliary heater is also fastened at position. M6x0 bolt, toothed washer Angle bracket angle bracket 06 Insert 0mm shim between angle bracket 6 and exhaust silencer 4. Align exhaust pipe, insert spacer bracket if necessary. Hose clamp [x] Exhaust pipe 5 M6x5 bolt, large diameter washer, 0mm shim, flanged nut exhaust pipe and silencer Align exhaust system. Ensure sufficient distance min. 0mm) from neighbouring components, correct if necessary. Hose clamp Exhaust end section exhaust end section 08 Ident. No.: 866B_EN Status:.0.0 Webasto Thermo & Comfort SE 9

40 Cut out insulation along the markings. 60mm dia. hole Underride protection 0 00 Cutting out underride protection Mount underride protection. Align exhaust end section with centre of hole. Aligning exhaust end section 0 Ident. No.: 866B_EN Status:.0.0 Webasto Thermo & Comfort SE 40

41 Final Work WARNING! Mount removed parts in reverse order. Check all hoses, clamps and all electrical connections for firm seating. Insulate and tie back all loose lines. Only use manufacturer-approved coolant. Spray heater components with anti-corrosion wax (Tectyl 00K, Order No. 9). Connect the battery. Fill and bleed the coolant circuit according to the vehicle manufacturer s specifications. Set digital timer, teach Telestart transmitter. Make settings on A/C control panel according to the "Operating Instructions for End Customer". Place the "Switch off parking heater before refuelling" signboard in the area of the filler neck. See installation instructions for initial start-up and function test. All vehicles except.0 AG Install resonator and wheel-well inner panel. Ensure sufficient distance between combustion air silencer and resonator, correct if necessary. components Align spacer bracket with wheel well trim. Aligning spacer bracket Webasto Thermo & Comfort SE Postfach Gilching Germany Internet: Technical Extranet: Ident. No.: 866B_EN Status:.0.0 Webasto Thermo & Comfort SE 4

42 Operating Instructions for Manual Air-Conditioning Please remove page in case of manual air-conditioning and add it 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. While unlocking the vehicle (when the parking heater is on) the fan control is deactivated by the parking heater. The original functionalities are available on activating the A/C control panel or switching the ignition on. After locking the vehicle, it takes the parking heater several minutes to activate the fan control. Before parking the vehicle, make the following settings: Set temperature to "max." Air outlet to windscreen A/C control panel A fuse F of heater control 5A fan fuse F4 Fuses of passenger compartment 4

43 Megane 0A main fuse F of passenger compartment 0A heater fuse F Fuses of engine compartment 5 Scenic 0A main fuse F of passenger compartment 0A heater fuse F Fuses of engine compartment 6

44 Operating Instructions for Automatic Air-Conditioning Please remove page in case of automatic air-conditioning and add it 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. While unlocking the vehicle (when the parking heater is on) the fan control is deactivated by the parking heater. The original functionalities are available on activating the A/C control panel or switching the ignition on. After locking the vehicle, it takes the parking heater several minutes to activate the fan control. Before parking the vehicle, make the following settings: Set temperature on both sides to "HI Air outlet to windscreen A/C control panel 7 A fuse F of heater control 5A fan fuse F4 Fuses of passenger compartment 8

45 Megane 0A main fuse F of passenger compartment 0A heater fuse F Fuses of engine compartment 9 Scenic 0A main fuse F of passenger compartment 0A heater fuse F Fuses of engine compartment 0