Manufacturer Model Type EG-BE No./ ABE Fiat Doblo 263 e3 * 2007 / 46 * 0007 *... Fiat Doblo Cargo 263 e3 * 2007 / 46 * 0002 *...

Transcription

1 Water Heater Thermo Top Evo Parking Heater E Installation Documentation Fiat Doblo / Doblo Cargo Validity Manufacturer Model Type EG-BE No./ ABE Fiat Doblo 63 e3 * 007 / 46 * 0007 *... Fiat Doblo Cargo 63 e3 * 007 / 46 * 000 *... Motorisation Fuel Transmission type Output in kw Displacement in cm³ Engine code.3 JTD Diesel SG A JTD Diesel SG A JTD Diesel SG A.000 SG = manual transmission From Model Year 00 Left-hand drive vehicle Verified equipment variants: Manual / automatic air-conditioning system Front fog light Not verified: Total installation time: Passenger compartment monitoring approx. 8 hours Ident. No.: 35994C_EN Status: 3..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 3 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 for Manual Air-Conditioning 9 Fan Controller for Automatic Air-Conditioning Digital Timer 3 Remote Option (Telestart) 3 Preparing Bracket 4 Preparing Heater 4 Heater 5 Coolant Circuit.6 /.0 JTD 6 Coolant Circuit.3 JTD Combustion Air 8 Exhaust Gas 9 Fuel 34 Final Work 37 Template for Bracket 38 Template for Fuel Standpipe 39 Operating Instructions for Manual Air-Conditioning 40 Operating Instructions for Automatic Air-Conditioning 4 Necessary Components Basic delivery scope of Thermo Top Evo in accordance with price list Installation kit for Fiat Doblo / Doblo Cargo 00 Diesel: 35993C To be ordered additionally in case of automatic air-conditioning Automatic A/C kit 36747A 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. Engine compartment fuse holder 3. Passenger compartment fuse holder 4. Circulating pump 5. Digital timer 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.: 35994C_EN Status: 3..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..3 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. 39). 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 IN- STALLATION. 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...3. In the case of M and M3 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..3. Fuel supply.3.. The fuel filler must not be situated in the passenger compartment and must be provided with an effective cap to prevent fuel spillage..3.. 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.: 35994C_EN Status: 3..0 Webasto Thermo & Comfort SE 3

4 Information on Validity This installation documentation applies to Fiat Doblo / Doblo Cargo Diesel vehicles - for validity, see page - from model year 00 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 self-clamping 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 5x3 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 and 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.: 35994C_EN Status: 3..0 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 and remove the battery. Remove the air filter together with the intake hose. Remove the coolant reservoir cap. Remove the bumper. Remove the left-hand headlight. Remove the underride protection. Remove the fuel tank in accordance with manufacturer's instructions (only in case of Doblo Cargo). Remove the rear bench seat. Open the tank-fitting service lid. Remove the fuel-tank sending unit in accordance with the manufacturer's instructions. Remove the lower instrument panel trim, driver and front passenger'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 in the engine compartment. Heater Installation Location Heater Installation location Ident. No.: 35994C_EN Status: 3..0 Webasto Thermo & Comfort SE 5

6 Preparing Electrical System rt/sw rt 4² gn/ws 0,75² Manual air-conditioning F3 86 F a rt 4² Insert red (rt) wire in K/87a and black (sw) wire in K/30. Insert 5A fuse F4 into fuse carrier. Preparing K relay and fuse F4 br K sw 4² Drill out hole of fuse holder to 6.5mm dia. Preparing passenger compartment fuse holder gn/ws rt sw Automatic air-conditioning Install wire section 3 and 4 in protective sleeving provided. Allocating wires 6 br 7 rt 0,75² A E 7 5 IPCU E A 3 4 Connect the wires to the IPCU socket. IPCU view on contact side. The pre-programmed settings are to be checked during the function check on the vehicle and adjusted if necessary. Duty cycle: 35% Frequency: 00Hz Voltage: 4.V Function: High-side Premounting IPCU 5 6 Ident. No.: 35994C_EN Status: 3..0 Webasto Thermo & Comfort SE 6

7 Drill out 6.5 mm dia. hole from fuse holder. Preparing K relay and fuse F4 3 rt/sw rt 4² gn/ws 0,75² Produce connections as shown in wiring diagram. F3 86 F a K 5 IPCU E A 3 4 Preparing IPCU K relay br sw 4² rt 4² 3 4 All vehicles Complete connector of metering pump after routing. Pin assignment is not relevant. 5 5 Connector housing Lock 3 Blue/brown (bl/br) wires 4 Coding 5 Timer lock Disassembling connector 4 Ident. No.: 35994C_EN Status: 3..0 Webasto Thermo & Comfort SE 7

8 Electrical System Positive and earth wire Positive wire on positive terminal of battery Earth wire on negative terminal of battery Wiring harness pass through Protective rubber plug 5 6 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 of engine compartment 4.5 mm dia. hole at position in coolant reservoir. 5.5x9.5 self-tapping screw; fuse holder retaining plate F and F fuses 7 Passenger compartment fuse holder K relay pulled off for better display. M6x bolt, existing threaded hole Passenger compartment fuse holder 8 Ident. No.: 35994C_EN Status: 3..0 Webasto Thermo & Comfort SE 8

9 Fan Controller for Manual Air-Conditioning F F Webasto HG X 5 X Fb GR Fiat Fa 30 5 Wiring diagram rt/sw rt 4² ge gn/ws 0,75² or 4² br rt/sw rt 4² gn/ws 0,75² GS 0 X0 F3 F4 or 4² br a K sw 4² rt 4² + M - GM WG br 3 Webasto components Vehicle components Colours and symbols HG TT-Evo heater GM Fan motor rt red X 6-pin heater connector GS Fan switch ws white X -pin heater connector GR Fan relay sw black X0 4-pin connector WG Resistor group br brown Heater control Fa Fuse gn green K Fan relay Fb Fuse ge yellow F 0A fuse or orange F 30A fuse F3 A fuse X Cutting point F4 5A fuse Wiring colours may vary. Connect wiring harness of heater to wiring harness of passenger compartment fuse holder according to wiring diagram. Install wiring harness of fan control on the right vehicle side. Legend Connecting wiring harness of heater 9 Ident. No.: 35994C_EN Status: 3..0 Webasto Thermo & Comfort SE 9

10 Connection to -pin connector from the fan motor. Produce connections as shown in wiring diagram. 4 Orange (or) wire of -pin GM connector Orange (or) wire of GR 3 Wire red (rt) K/87a 4 Wire black (sw) K/30 Connecting fan motor 3 0 Ident. No.: 35994C_EN Status: 3..0 Webasto Thermo & Comfort SE 0

11 Fan Controller for Automatic Air-Conditioning F F Webasto HG X 5 X 86 Fiat a T08 M Wiring diagram ge F08 St A 5 9 or 4² hbl/gn br X0 rt/sw rt 4² gn/ws 0,75² or 4² hbl/gn ws/bl rt/sw rt 4² F3 gn/ws 0,75² F4 IPCU 5 86 E 3 sw 4² St B M07 St C St A a 5 85 A 4 br br K 7 6 rt 4² + N085 M - sw 4² 3 Webasto components Vehicle components Colours and symbols HG TT-Evo heater N085 Fan motor rt red X 6-pin heater connector M070 A/C control panel sw black X -pin heater connector M07 Fan controller ge yellow X0 4-pin connector T08 Fan relay gn green Heater control F08 40A fuse or orange K Fan relay St A -pin connector M07 ws white F 0A fuse St B -pin connector M07 br brown F 30A fuse St C -pin connector M07 hbl light blue F3 A fuse F4 5A fuse IPCU Pulse width modulator IPCU adjustment values: Duty cycle: 35% Frequency: 00Hz Voltage: 4.V X Cutting point Function: High-side Wiring colours may vary. Legend Ident. No.: 35994C_EN Status: 3..0 Webasto Thermo & Comfort SE

12 K relay pulled off for better display! M6x bolt, existing threaded hole Passenger compartment fuse holder Installation of fuse holder Connect wiring harness of heater 4 to wiring harness of fuse holder according to wiring diagram. Route wiring harnesses of fan control to the right vehicle side. 4 3 Brown (br) wire of IPCU/85 3 Green/white (gn/ws) wire of IPCU/86 Connecting wiring harness of heater Connection of fan motor on connector B from fan controller. Produce connection as shown in wiring diagram. 5 Orange (or) wire of connector B/ IPCU/85 3 Black (sw) wire of K/30 4 Red (rt) wire of K/87a 5 Orange (or) wire of fuse F08 Fan motor connection Connection of IPCU to -pin connector A 4 of the fan controller. Produce connection as shown in wiring diagram. Red (rd) wire of IPCU/E Black (sw) wire of IPCU/A 3 Light blue/green (hbl/gn) wire of connector M07 A/ 5 Light blue (hbl/gr) wire of M070/5 Connection of IPCU 5 4 Ident. No.: 35994C_EN Status: 3..0 Webasto Thermo & Comfort SE

13 Digital Timer Digital timer digital timer 5 Remote Option (Telestart) Fasten receiver with adhesive tape. receiver 6 Antenna antenna 7 Temperature sensor T00 HTM Fasten temperature sensor with adhesive tape. temperature sensor 8 Ident. No.: 35994C_EN Status: 3..0 Webasto Thermo & Comfort SE 3

14 Preparing Bracket Separate bracket at the marking and bend according to template. Discard section Preparing bracket 8 9 Bracket M6x35 bolt, 0 shim, pin lock Preparing bracket 0 Inclined perforated bracket, angled down 68 6 Preparing perforated bracket 5 Preparing Heater Water connection pieces, sealing ring [x each] 5x5 self-tapping bolt, retaining plate of water connection pieces water connection pieces Ident. No.: 35994C_EN Status: 3..0 Webasto Thermo & Comfort SE 4

15 4 5x3 self-tapping bolt [x] 90 moulded hose, 0 mm dia. clamp [x] 3 Fuel line 4 Bracket bracket 3 Heater Replace original vehicle bolt at position with M6x40 bolt, spring lock washer and large diameter washer. Large diameter washer, flanged nut, existing hole heater 3 Insert 0 mm shim between body and bracket. 0 mm shim, flanged nut heater 4 Flanged nut, existing bolt Perforated bracket 3 5x3 self-tapping bolt heater 3 5 Ident. No.: 35994C_EN Status: 3..0 Webasto Thermo & Comfort SE 5

16 Coolant Circuit.6 /.0 JTD WARNING! Any coolant running off should be collected in an appropriate container. Install hoses so that they are kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that other hose cannot 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 D C A B All spring clips = 5 mm dia. All hose clamps = 0-7 mm dia.! = Original vehicle hose = Black (sw) rubber isolator. Connecting pipe = 8x8mm dia. Connecting pipe = 5x8 mm dia. Ident. No.: 35994C_EN Status: 3..0 Webasto Thermo & Comfort SE 6

17 A X C B Discard section X. Hose D = 8x0 moulded hose A = 870 B = 0 C = 050 Cutting hoses to length X X D A Push braided protection hoses onto hose A and C and cut to length. Cut heat shrink plastic tubing to length. 5 mm long heat shrink plastic tubing [4x] Preparing hoses C Shape 48 mm dia. rubber-coated p-clamp. Insert 0 mm shim between vehicle carrier and rubber-coated pipe clamp. M6x5 bolt, 0 mm shim, flanged nut, existing hole rubbercoated pipe clamp 6 Remove original vehicle hose of engine outlet / heat exchanger inlet completely! Cutting point 7 Ident. No.: 35994C_EN Status: 3..0 Webasto Thermo & Comfort SE 7

18 Separate original vehicle hose at the markings [x] Heat exchanger inlet coupling (is reused) 3 Discard hose sections 4 Discard clamp Preparing hose C Coupling on heat exchanger inlet Apply black (sw) rubber isolator D Premounting hose C and D 9 Push coupling onto the heat exchanger inlet. Fasten black (sw) rubber isolator with cable tie on brake line! D Connecting heat exchanger inlet C 30 C Install hose C through rubber-coated pipe clamp. Routing in engine compartment 3 Ident. No.: 35994C_EN Status: 3..0 Webasto Thermo & Comfort SE 8

19 Connecting heater outlet C 3 Combustion air silencer 5 mm dia. pipe clamp 3 M5x6 bolt, flanged nut 4 Angle bracket 5 9 mm dia. rubber-coated p-clamp Premounting silencer Angle bracket Original vehicle nut silencer 34 Install M6x40 spacer nut on original vehicle bolt. spacer nut 35 Ident. No.: 35994C_EN Status: 3..0 Webasto Thermo & Comfort SE 9

20 48 mm dia. rubber-coated p-clamp M6x5 bolt 3 Circulating pump circulating pump 3 36 Mount wiring harness on circulating pump and on heater. 37 A In the original vehicle hose cut a notch of 3mm width and 5mm length. Mounting wiring harness Premounting hose A A 38 Original vehicle hose Connecting engine outlet 39 Ident. No.: 35994C_EN Status: 3..0 Webasto Thermo & Comfort SE 0

21 C A Install hose A through rubber-coated p-clamp. Routing in engine compartment 40 A A 4 Install hose A through rubber-coated p-clamp. Routing in engine compartment Connecting circulating pump 4 Align hoses. Ensure sufficient distance from neighbouring components. Connecting heater inlet B 43 Ident. No.: 35994C_EN Status: 3..0 Webasto Thermo & Comfort SE

22 Coolant Circuit.3 JTD WARNING! Any coolant running off should be collected in an appropriate container. Install hoses so that they are kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that other hose cannot 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 Ø 7 A D B C All spring clips = 5 mm dia. = AGR. Connecting pipe = 8x8mm dia. Connecting pipe = 8x0 mm dia. Ident. No.: 35994C_EN Status: 3..0 Webasto Thermo & Comfort SE

23 Discard section X. Hose A = 80, 8x8mm dia. moulded hose C B D X B = 75 C = 0 D = 80 Cutting hoses to length X A B Push braided protection hoses onto hose B and D and cut to length. Cut heat shrink plastic tubing to length. 5 mm long heat shrink plastic tubing [4x] Preparing hoses D Detach retaining clip from original vehicle wiring harness. Route original vehicle wiring harness as shown. Relocating wiring harness 44 Remove and discard spring clip. Pull hose of engine outlet / heat exchanger inlet off connection piece of engine outlet. Cutting point 45 Ident. No.: 35994C_EN Status: 3..0 Webasto Thermo & Comfort SE 3

24 Install 90 connecting pipe A Connecting engine outlet 46 Install connecting pipe Hose on heat exchanger inlet Connecting heat exchanger inlet 47 B A Routing in engine compartment 48 Hose on heat exchanger inlet Cable tie Routing in engine compartment D 49 Ident. No.: 35994C_EN Status: 3..0 Webasto Thermo & Comfort SE 4

25 D Cable tie B 50 Routing in engine compartment Connecting heater outlet D 5 Combustion air silencer 5 mm dia. pipe clamp 3 M5x6 bolt, flanged nut 4 Angle bracket 5 9 mm dia. rubber-coated p-clamp Premounting silencer Angle bracket Original vehicle nut silencer 53 Ident. No.: 35994C_EN Status: 3..0 Webasto Thermo & Comfort SE 5

26 Install M6x40 spacer nut on original vehicle bolt. spacer nut mm dia. rubber-coated p-clamp M6x5 bolt 3 Circulating pump circulating pump 3 55 Mount wiring harness on circulating pump and on heater. Mounting wiring harness 56 Routing in engine compartment B 57 Ident. No.: 35994C_EN Status: 3..0 Webasto Thermo & Comfort SE 6

27 B Route hose B through rubber-coated p-clamp. Connecting circulating pump 58 Align hoses. Ensure sufficient distance from neighbouring components. Connecting heater inlet C 59 Ident. No.: 35994C_EN Status: 3..0 Webasto Thermo & Comfort SE 7

28 Combustion Air Discard section X. Combustion air pipe a = 300 Cutting combustion air pipe to length a X Route fuel line and wiring harness of metering pump to the engine compartment and onto the underbody along original vehicle lines. Combustion air pipe 3 Mount wiring harness of heater. combustion air pipe 3 60 Secure wiring harnesses and combustion air pipe with cable tie. Silencer Combustion air pipe combustion air pipe 6 Ident. No.: 35994C_EN Status: 3..0 Webasto Thermo & Comfort SE 8

29 Exhaust Gas a b Discard section X. Exhaust pipe Exhaust end section Preparing exhaust.6 /.0 JTD.3 JTD pipe a = b = X Angle down perforated bracket. 58 Preparing perforated bracket 90 Perforated bracket Flanged nut, original vehicle bolt perforated bracket 6 Remove retaining clip at position (to be reused later) and drill 6.5 mm dia. hole in cutout centre. Hole in cross member 63 Ident. No.: 35994C_EN Status: 3..0 Webasto Thermo & Comfort SE 9

30 Angle bracket Silencer 3 M6x bolt, spring lockwasher silencer 3 64 Reinsert retaining clip after installation. M6x0 cap screw, flanged nut 3 Angle bracket silencer 3 65 Hose clamp Exhaust pipe 3 Exhaust-gas insulation exhaust pipe /.0 JTD Insert 0mm shim between perforated bracket and pipe clamp. M6x5 bolt, 0 mm shim, pipe clamp, flanged nut Exhaust pipe Routing exhaust pipe 67 Ident. No.: 35994C_EN Status: 3..0 Webasto Thermo & Comfort SE 30

31 Hose clamp Exhaust pipe exhaust pipe mm dia. hole; rivet nut rivet nut Ensure sufficient distance from neighbouring components. Hose clamp Exhaust end section 3 M6x60 bolt, spring lockwasher, large diameter washer, pipe clamp, 40mm shim exhaust end section 3 70 Underride protection 60mm dia. hole Cutting out underride protection 7 Ident. No.: 35994C_EN Status: 3..0 Webasto Thermo & Comfort SE 3

32 Align the exhaust end section at the centre of the hole. Underride protection mounted Aligning exhaust end section 7.3 JTD Insert 0mm shim between perforated bracket 4 and pipe clamp. Exhaust pipe 3 M6x5 bolt, 0mm shim, flanged nut Routing exhaust pipe Align spacer bracket on charge-air hose. Pushing on spacer bracket 74 Hose clamp Exhaust pipe exhaust pipe 75 Ident. No.: 35994C_EN Status: 3..0 Webasto Thermo & Comfort SE 3

33 9. mm dia. hole; rivet nut rivet nut 5 76 Ensure sufficient distance from neighbouring components. Hose clamp Exhaust end section 3 M6x60 bolt, spring lockwasher, large diameter washer, pipe clamp, 40mm shim exhaust end section 3 77 Underride protection 60mm dia. hole 70 Cutting out underride protection Align the exhaust end section at the centre of the hole. Underride protection mounted Aligning exhaust end section 79 Ident. No.: 35994C_EN Status: 3..0 Webasto Thermo & Comfort SE 33

34 Fuel CAUTION! 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. 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 as shown in the wiring harness routing diagram. Install fuel line and wiring harness of the metering pump in corrugated tube at the installation location of the metering pump. lines 80 Angle down perforated bracket 80 Preparing perforated bracket 90 Original vehicle nut Perforated bracket perforated bracket 8 Ident. No.: 35994C_EN Status: 3..0 Webasto Thermo & Comfort SE 34

35 Fix mounting of metering pump with cable tie 3 on the perforated bracket. M6x5 bolt, support angle, flanged nut 4 Metering pump Mounting metering pump Check the position of the components; adjust if necessary. Check that they have freedom of movement. Wiring harness of metering pump, connector mounted Hose section, 0 mm dia. clamp [x] 3 Fuel line of heater Connecting metering pump 3 83 The fuel tank has to be removed in accordance with manufacturer's instructions for vehicles without service lid. Remove fuel-tank sending unit in accordance with the manufacturer's instructions. Remove sticker. Fuel extraction 84 Mount large diameter washer on reference edge (broken line). Copy hole pattern, 6 mm dia. hole 8 Hole in fuel-tank sending unit 85 Ident. No.: 35994C_EN Status: 3..0 Webasto Thermo & Comfort SE 35

36 Shape fuel standpipe according to template, cut to length and install. fuel standpipe 86 Image shows vehicle with service lid. Install fuel-tank sending unit 4 according to manufacturer's instructions. 3 4 Fuel line Hose section, 0 mm dia. clamp [x] 3 Fuel standpipe Connecting fuel line 87 Check the position of the components; adjust if necessary. Check that they have freedom of movement. Fuel line of fuel standpipe Hose section, 0 mm dia. clamp [x] Connecting metering pump 88 Ident. No.: 35994C_EN Status: 3..0 Webasto Thermo & Comfort SE 36

37 Final Work WARNING! Mount removed parts in reverse order. Check all hoses, clamps and all electrical connections for firm seating. Insulate all loose wires and tie back. Only use manufacturer-approved coolant. Spray the heater components with anti-corrosion wax (Tectyl 00K, Order No. 39). Connect the battery. Fill and bleed the coolant circuit according to the vehicle manufacturer s specifications. Adjust digital timer, teach Telestart transmitter. Make settings on A/C control panel according to the "Operating Instructions for the End Customer". Place the "Switch the parking heater off before refueling" signboard in the area of the filler neck. For initial startup and function check, please see installation instructions. Align exhaust pipe towards front fog light. Ensure sufficient distance from neighbouring components, correct if necessary. Aligning exhaust pipe 89 Webasto Thermo & Comfort SE Postfach Gilching Germany Internet: Technical Extranet: Ident. No.: 35994C_EN Status: 3..0 Webasto Thermo & Comfort SE 37

38 Template for Bracket 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 minimise margins and 00% of the normal size. 00mm 0 Ident. No.: 35994C_EN Status: 3..0 Webasto Thermo & Comfort SE 38

39 Template for Fuel Standpipe 00mm Scale : Compare the size of the printed version with dimension lines. Permitted tolerance a maximum of %. Set the printer settings to no margin or minimise margins and 00% of the normal size. 00mm 0 Ident. No.: 35994C_EN Status: 3..0 Webasto Thermo & Comfort SE 39

40 Operating Instructions for Manual Air-Conditioning Please remove this 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. 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: 3 Air outlet to windscreen Set temperature to "max." 3 Set fan to level "", or max. "" A/C control panel 90 30A main fuse F of passenger compartment 0A heater fuse F Fuses of engine compartment 9 A fuse F3 of heater control 5A fan fuse F4 Fuses of passenger compartment 9

41 Operating Instructions for Automatic Air-Conditioning Please remove this 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. 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: Air outlet to windscreen Set temperature to "max." A/C control panel 93 30A main fuse F of passenger compartment 0A heater fuse F Fuses of engine compartment 94 A fuse F3 of heater control 5A fan fuse F4 Fuses of passenger compartment 95