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

Transcription

1 Water Heater Unit Feel the drive Thermo Top C Additional Heater e Installation Instructions Chevrolet Captiva Diesel from Model Year 007 Left-hand drive vehicle Automatic 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.:808A_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 Preliminary Work 5 Heater unit installation location 5 Electrical Connections 6 Fan controller for manual air conditioning 7 Automatic air-conditioning fan controller 8 Remote option (Telestart) Coolant connection diagram Preparing heater unit Preparing installation location 5 heater unit 6 Coolant connection 7 Fuel Connection 9 Combustion air Exhaust system Final Work Operating Instructions for End Customer 5 Validity Manufacturer Model Type EG-BE No./ABE GM Daewoo Chevrolet Captiva KLAC e * 00 / 6 * 0 Engine type Engine model Output in kw Displacement in cm³ Z0S Diesel 0 99 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. 808A_EN

3 Heater Unit/Installation Kit Quantity Description Order No.: Retail accessories with desired heater control See price list Installation kit for Chevrolet Captiva Diesel (basic kit) 90707A Additional kit for Chevrolet Captiva Diesel with Automatic Transmission 90705A Also required with automatic air-conditioning: Quantity Description Order No.: Kit for Chevrolet Captiva with Automatic Air-Conditioning 90705B Foreword These installation instructions apply to Chevrolet Captiva Diesel vehicles with an automatic transmission - for validity, see page - from model year 007 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, the stipulations in the "installation instructions" and "operating and maintenance instructions" for the Thermo Top C/P/E must always be observed. The corresponding rules of technology and any information from the vehicle manufacturer should be observed during the installation work. General Instructions Installation should be carried out according to the general, standard rules of technology. Unless specified otherwise, fasten hoses, lines and wiring harnesses to original vehicle lines and wiring harnesses using cable ties. 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 808A_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 connection Fuel connection Exhaust system 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. 808A_EN

5 Preliminary Work WARNING! - 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. - Completely remove the battery - Remove the fuse and relay box - Remove the engine cover - Remove the engine control unit - Disconnect the power-steering fluid reservoir - Disconnect the expansion tank - Remove the charge-air tube between the air filter and the turbocharger - Disconnect the air hose from the charge-air tube to the engine at the engine - Remove the filler neck of the window washer system - Remove the vent line at the top to the coolant expansion tank - Open the fuel tank cap, ventilate the tank. - Close the tank cap again. - Remove the underride protection - Open the left tank mounting service lid - Remove the glove compartment Remove page 5 "Operating Instructions for End Customer" and insert with vehicle operating instructions. Heater unit installation location Picture shows vehicle without automatic transmission! Heater unit Installation location 808A_EN 5

6 Electrical Connections Wiring harness pass through Protective rubber plug Digital timer Digital timer rt sw Do not install the metering pump cable harness until later together with fuel pipe along the original vehicle fuel lines on the underbody Wiring harness installation diagram bl 6 Fuse holder, K relay 5 Summer/winter switch option 5 Move original vehicle clip Angle acket Drill out hole to 9 mm dia., mount M6 rivet nut, M6x0 bolt, spring lockwasher Fuse holder 5 K relay 6 Align M5x6 bolt, large diameter washer, M5 flanged nut to right in oblong hole Summer/winter switch, drilled hole mm dia. 808A_EN 6

7 Fan controller for manual air conditioning Webasto Chevrolet Captiva 0 5 HG X F EF Wiring diagram for manual air conditioning gn/ ws rt/ws a K 85 0 rt sw M GM GS bl/sw Webasto components Components of Chevrolet Captiva Colors and symbols HG Heater unit TT-C/E GM Fan motor rt red X 6-pin connector GS Fan switch ws white F Fuse EF 0 A fan fuse sw black K Fan relay own gn green bl blue Legend X Cutting point Wiring colors may vary. Connection to -pin connector from fan motor. Make connections as shown in the wiring diagram with the connectors provided. 5 Brown () wire to connector Brown () wire from fuse block Red (rt) wire to K/87a 5 Black (sw) wire from K/0 Connecting fan motor 6 808A_EN 7

8 Automatic air-conditioning fan controller Webasto Chevrolet 0 5 X HG gn/ ws rt/ws 87a F rt F EF + - M GM Automatic air-conditioning circuit diagram K rt,5² ² ² sw gr/sw vi vi a R GR 85 0 K. 6 A A5 A 0,75² rt,0² ² sw KB B B sw Webasto components Components of Chevrolet Captiva Colors and symbols HG Heater unit TT-C/E GM Fan motor rt red X 6-pin heater unit connector GR Fan controller ws white F Fuse, 5 A KB Air-conditioning control sw black element K Fan relay F Fuse 0A own K. Additional relay EF Fuse 0A gn green R 0.9 ohm resistor A Connector for A/C control bl blue panel B Connector for A/C control GR gray panel vi violet Legend X Cutting point Wiring colors may vary. 808A_EN 8

9 Preparing electrical system ² Produce connections as shown in wiring diagram. Crimp cable lug onto own () wire 0.75² provided and onto own () wire section 6 ². Cutting own () wire to length rt,5² 5 ² ² Produce connections as shown in wiring diagram. Pull wires, and in protective sleeving provided a 85 0 K. Preparing additional relay K. 0,75² rt ² 7 components 5 Resistor becomes hot! Ensure sufficient spacing (at least 0 mm) to neighboring components. M5x0 cap screw, large diameter washer, nut [x] Angle acket M6x0 bolt, spring lockwasher, own () ground wires 0.75² and 6 ² on existing threaded hole 5 Mount edge protection resistor and additional relay 8 Produce connections as shown in wiring diagram. Brown () wire 5 ² from K/87a to resistor Additional relay K. M5x6 bolt, flanged nut on existing hole Connecting resistor and additional relay 9 808A_EN 9

10 Connection to -pin connector from fan motor. Produce connections as shown in wiring diagram (crimp and shrink) Violet (vi) wire from connector Violet (vi) wire to fan controller Red (rt) wire ² from K./0 5 Brown () wire ² from K./87 6 Brown () wire from fuse EF 7 Red (rt) wire.5² from K./86 8 Red (rt) wire to K/87a 9 Black (sw) wire from K/0 0Brown () wire to connector Connecting fan motor Cut away insulation of glove compartment at marking. Cutting away insulation 808A_EN 0

11 Remote option (Telestart) Existing hole, M5x6 bolt, washer, flanged nut Receiver Telestart acket receiver Antenna antenna Temperature sensor for HTM00 only Fasten temperature sensor with suitable means (double-sided adhesive tape) temperature sensor 808A_EN

12 Coolant connection diagram WARNING! Tighten all hose clamps to Nm. 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 hose clamps and spring band clamps so that no other hose can be damaged. The connection should be "inline" based on the following diagram: Coolant routing diagram C B A Ø 0x0 All spring clips without a specific designation = 7 mm dia. = Black (sw) rubber isolator. All hose clamps without a specific designation = 0-7 mm dia. All connecting pipes without a specific designation = dia. 8x0. = hose section between circulating pump and heater unit inlet. 808A_EN

13 A X C Preparing heater unit a = 60 mm c = 50 mm a c Discard section X Cutting coolant hoses to length B Remove water pump from heater unit. Hose section and spring clip will be reused. Discard retaining clip and bolt. Removing water pump Replace 9 lid. i Replacing pump lid Connect adapter wire for water pump, cut to length and connect identical colors to wiring harness of water pump 5 using connectors. Heater unit 9 water pump Water pump Preassembling water pump A_EN

14 A Tighten EJOT screws to 0 Nm! Hose Ejot stud [x] Preassembling heater unit B 6 B A Bracket part Ejot screw [x] Preassembling heater unit 7 Rubber-coated pipe clamp, 9 mm dia. M6x0 bolt, flanged nut M6 Angle acket Rubber-coated pipe clamp, 8 mm dia. 5 M6x bolt, flanged nut M6 Preassembling heater unit A_EN

15 Preparing installation location Remove acket for wiring harness Removing acket for wiring harness 9 Cutting point Bracket for wiring harness Discard section Machining acket for wiring harness 0 Mount acket for wiring harness as shown acket for wiring harness Cross member for battery carrier Drill out thread to 0 mm dia. [x] Drilling out holes 808A_EN 5

16 heater unit Preassembled heater unit Loosely mount M8x0 bolt heater unit Remove original vehicle screw and discard. Removing original vehicle screw Bracket part M6 flanged nut [x] M8x0 bolt, spring lockwasher, large diameter washer acket part 5 Ensure sufficient spacing to neighboring components, especially to A/C line ; correct if necessary. Aligning heater unit 6 808A_EN 6

17 Coolant connection Pull off hose between engine outlet and heat exchanger inlet on heat exchanger. Cutting point 7 Push back heat guard. Cutting point Hose section of heat exchanger inlet Cutting point 8 Hose on heat exchanger inlet C 9 Before connecting, fill the coolant hoses with coolant. Hose of engine outlet Connection on heat exchanger inlet Connection to engine outlet A 0 808A_EN 7

18 Spacer acket [x] spacer acket Spacer acket [x] spacer acket 808A_EN 8

19 Fuel Connection 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. Included hose section as scuff guard [x] Fuel line Hose section, 0 mm dia. hose clamp [x] Connection on heater unit Mecanyl fuel pipe and metering pump cable harness lines Ensure proper installation position of metering pump, see "Installation Instructions. Installation location in front of vehicle fuel tank! Original vehicle nut Angle acket Silent block, flanged nut [x] Metering pump 5 Rubber-coated pipe clamp Installation location of metering pump A_EN 9

20 Fuel line from heater unit on pressure side of metering pump [side with connector]. Hose section, 0 mm dia. hose clamps [x] Wiring harness of metering pump, connector mounted Fuel line metering pump 6 Separate 90 molded hose at marking Discard section 5 mm Preparing fuel standpipe 7 5 Cut closure off existing removal connection piece and push on short end of 90 molded hose. Fuel line 0 mm dia. hose clamp [x] Fuel sender 5 Cable tie Removing fuel 8 80 molded hose, 0 mm dia. hose clamp [x] Fuel line from fuel standpipe on intake side of metering pump [side without connector]. Check the position of the components; adjust if necessary. Check that they have free clearance. Connecting to metering pump 9 808A_EN 0

21 Combustion air Combustion air pipe Hose clamp combustion air pipe 0 Combustion-air intake pipe 8 mm dia. p-clamp; rubber coating removed Combustion-air intake muffler Existing hole, M6 rivet nut, M6x0 bolt, spring lock washer muffler 808A_EN

22 Exhaust system Exhaust pipe a = 0 mm Exhaust end section b = 0 mm Discard section X Preparing exhaust pipe a b X Radiator cross member Drill out existing hole to 9. mm dia., mount M6 rivet nut 7 muffler Exhaust muffler M6x5 bolt, 0 mm spacer, M6 flanged nut M6x0 bolt, spring lockwasher Perforated acket muffler Exhaust pipe Position red (rt) rubber isolator Heater unit Hose clamp exhaust pipe 808A_EN

23 Ensure sufficient distance to neighboring components. Exhaust pipe Hose clamp [x] Push on red (rt) rubber isolator Exhaust end section 5 Red (rt) rubber isolator Bumper cover exhaust pipe and end section Positioning rubber isolator 6 808A_EN

24 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 the 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. - Set the manual air conditioning or automatic air conditioning according to the "operating instructions for the 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. M8x0 bolt, spring lockwasher, flanged nut [x each] battery carrier 7 - Connect the battery - Fill and bleed the coolant circuit according to the vehicle manufacturer s specifications. - Set the digital timer. - Set the manual air conditioning or automatic air conditioning according to the "operating instructions for the 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 0/007 Printing: Steffen

25 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. 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 or in the position Summer. Before parking the vehicle, make the following settings: Set temperature to "max." Set fan to level "", or possibly "" Direct air outlet toward windshield Manual air conditioning 8 Set temperature to "max." Air outlet to windshield Automatic air-conditioning 9 808A_EN 5