Water Heater Thermo Top Evo Parking Heater E 00 058 Installation Documentation Alfa Romeo Giulietta Validity Manufacturer Model Type EG-BE No./ ABE Alfa Romeo Giulietta 940 e * 007 / 46 * 007 *... Motorisation Fuel Transmission type Output in kw Displacement in cm³ Engine code.4 TB 6V Petrol SG 88 68 98A4000.0 JTDM 6V Diesel SG 5 956 940A4000 SG = manual transmission From model year 00 Left-hand drive vehicle Verified equipment variants: Not verified: Exclusion: Total installation time: Manual / automatic air-conditioning system Front fog light Front fog lightbi-xenon / headlight washer system Passenger compartment monitoring TCT 6-speed dual clutch transmission approx. 7 hours Ident. No.: 666E_EN Status: 5..0 Webasto Thermo & Comfort SE
Table of Contents Validity Necessary Components Installation Overview Notes on Total Installation Time Information on Operating and Installation Instructions Notes on Validity 4 Technical Instructions 4 Explanatory Notes on Document 4 Preliminary Work 5 Heater Installation Location 5 Preparing Electrical System 6 Electrical System 8 Fan Controller of All Vehicles 9 Optional Heater Control Preparing Bracket Preparing Installation Location Preparing Heater 5 Installing Heater 5 Combustion Air 6 Fuel 7 Coolant Circuit for Petrol Vehicles Coolant Circuit for Diesel Vehicles 6 Exhaust Gas Final Work 6 Fuel standpipe template 7 Operating Instructions for Manual Air-Conditioning 8 Operating Instructions for Automatic Air-Conditioning 9 Necessary Components Basic delivery scope of Thermo Top Evo based on price list Installation kit for Alfa Romeo Giulietta 00 petrol: 665A Installation kit for Alfa Romeo Giulietta 00 diesel: 664A 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. Relay and fuse holder of passenger compartment 4. IPCU 5. Circulating pump 6. Digital timer 7. Metering pump 5 4 6 7 Notes 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.: 666E_EN Status: 5..0 Webasto Thermo & Comfort SE
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. Connectors on electronic components have to audibly click into place during installation. Sharp edges should be fitted with rub protection. Spray unfinished body areas, e.g. drilled holes, with anti-corrosion wax (Tectyl 00K, 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 00 058 EMC Directive ECE R0 E 0 567 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 theinstallation 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.: 666E_EN Status: 5..0 Webasto Thermo & Comfort SE
Notes on Validity This installation documentation applies to Alfa Romeo Giulietta Petrol and 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 Instructions Special tools Hose clamp pliers for self-clamping hose clamps Hose clamp pliers for Clic hose clamps of type W Automatic wire stripper 0. - 6mm² 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 and 5x heater stud 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-theart-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.: 666E_EN Status: 5..0 Webasto Thermo & Comfort SE 4
Preliminary Work Vehicle Open the fuel tank cap. Ventilate the fuel tank. Close the fuel tank cap again. Depressurise the cooling system. Remove the engine design cover. Completely remove the battery. Remove the battery carrier. Remove the intake air pipe at the engine according to the manufacturer's instructions (.4 TB only). Remove the lower engine cover. Remove the lower cover of the bumper. Remove the cover of fuel lines on the right-hand side of the underbody. Drain the engine coolant according to the manufacturer's instructions. Remove the rear bench seat surface (screw fitting x at the front underneath the felt cover). Open the tank-fitting service lid. Remove the fuel-tank sending unit in accordance with the manufacturer's instructions. Remove the lower trim in the footwell on the front passenger's side. Remove the lateral trim of the centre console in the footwell. Remove the glove compartment. Remove the trim of the shift lever (for digital timer only). 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 Figure shows.4 TB 6V Heater Installation location Ident. No.: 666E_EN Status: 5..0 Webasto Thermo & Comfort SE 5
Preparing Electrical System rt/sw 0,5² rt 4² gn/ws 0,75² Wire sections retain their numbering in the entire document. F 86 F4 87 87a rt 4² Connect wires to K relay socket. Insert 5A fuse F4. K relay will only be inserted after installation of the passenger compartment relay and fuse holder. Inserting F4, preparing K relay 85 0 K br 0,5² sw 4² 7 000 ge 0,75² 4 500 sw 0,5² Preparing wires 6 00 br 0,5² 00 rt 0,5² 5 00 gn/ws 0,75² IPCU view on contact side. Check IPCU settings before start-up of heater and adjust if necessary. A 5 86 85 E 5 IPCU 86 85 A E IPCU settings: Duty cycle: 65% Frequency: 400Hz Voltage: 9V Function: Low-side Checking IPCU 4 7 6 5 4 Attach IPCU socket and passenger compartment relay and fuse holder together. Detach/remove K/85 and K/86 contacts. Mount provided contacts on wires according to wiring diagram. Brown (br) wire of K/85 4 Green/white (gn/ws) wire of K/86 Red (rt) wire of IPCU/E 4 Black (sw) wire of IPCU/A 5 Green/white (gn/ws) wire of K/86 and IPCU/86 6 Brown (br) wire of K/85 and IPCU/85 7 Yellow (ge) wire of IPCU/5 Premounting passenger compartment relay and fuse holder/ipcu socket Ident. No.: 666E_EN Status: 5..0 Webasto Thermo & Comfort SE 6
rt/sw 0,5² rt 4² gn/ws 0,75² 7 ge 0,75² br 0,5² F 86 F4 87 87a K 85 0 sw 4² 5 rt 4² 86 gn/ws 0,75² 5 IPCU 85 br 0,5² 6 E A 4 rt 0,5² sw 0,5² Premounting passenger compartment relay and fuse holder/ipcu socket 4 Reassemble connector of metering pump after routing. Pin assignment is not relevant. 5 5 Connector housing Lock Blue/brown (bl / br) wires 4 Coding 5 Timer lock Dismantling connector Ident. No.: 666E_EN Status: 5..0 Webasto Thermo & Comfort SE 7
Electrical System Wiring harness pass through.4 TB Protective rubber plug Wiring harness pass through.0 JTDM Protective rubber plug 4 5 Wiring harness routing diagram Do not install the metering pump wiring harness until later together with the fuel pipe along the original vehicle fuel lines in a corrugated tube on the underbody. Positive and earth wire Positive wire on positive battery terminal 8mm dia. cable lug, earth wire on original vehicle earth support point 6 Fuse holder of engine compartment Angle bracket, drill out hole in short leg to 8.5mm dia Original vehicle stud bolt Fuse holder, M5x6 bolt, washer [x], nut 7 Ident. No.: 666E_EN Status: 5..0 Webasto Thermo & Comfort SE 8
Fan Controller of All Vehicles Webasto HG Alfa Romeo F0 0 5 Wiring diagram X 5 X F F 0 86 0 M00 T08 85 87 ge 0,5² F08 br 0,5² X0 rt/sw 0,5² rt 4² rt/sw 0,5² rt 4² gn/ws 0,75² gn/ws 0,5² gr/rt F F4 6 gr/rt 5 86 gn/ws 0,75² IPCU br 0,5² 85 5 E A 6 rt 0,5² sw 0,5² ge 0,75² 86 85 0 br 0,5² br 0,5² 87 87a K rt 4² sw 4² 7 M070 ws/rt 4 ws/rt 5 4 M07 6 M N85 Webasto components Vehicle components Colours and symbols HG Heater TT-Evo F0 Fuse rt red X 6-pin heater connector M00 Body computer sw black X -pin heater connector T08 Relay ge yellow X0 4-pin connector of F08 Fuse gn green heater control M070 A/C control panel gr grey K Fan relay M07 Fan controller ws white F 0A fuse N85 Fan unit br brown F 0A fuse F A fuse F4 5A fuse IPCU Pulse width modulator IPCU settings: Duty cycle: 65% Frequency: 400Hz Voltage: 9V X Cutting point Function: Low-side Wiring colours may vary. Legend Ident. No.: 666E_EN Status: 5..0 Webasto Thermo & Comfort SE 9
Mount K relay and IPCU 5 first after installing angle bracket on relay and fuse holder. 5 4 Angle bracket, washer [x], M5x6 bolt, nut Original vehicle hole, M6x5 bolt, 0mm shim, flanged nut Mounting relay and fuse holder of passenger compartment 8 Connect wiring harness of passenger compartment relay and fuse holder with wiring harness of heater in accordance with wiring diagram in such a way that same colour wires are connected to each other. Connecting wiring harness 9 4 Produce connections as shown in wiring diagram. Green/red (gr/rt) wire of fan controller Green/red (gr/rt) wire of fuse F08 Red (rt) wire of K/87a Black (sw) wire of K/0 4 Yellow (ge) wire of IPCU/5 Connecting fan controller 0 Produce connections as shown in wiring diagram. 4 White/red (ws/rt) wire of fan controller White/red (ws/rt) wire of A/C control panel Red (rt) wire of IPCU/E 4 Black (sw) wire of IPCU/A Connecting fan controller Ident. No.: 666E_EN Status: 5..0 Webasto Thermo & Comfort SE 0
Optional Heater Control Receiver Original vehicle hole, M5x6 bolt, flanged nut Installing receiver Antenna Installing antenna Temperature sensor T00 HTM Fasten temperature sensor with adhesive tape. Installing temperature sensor 4 Digital timer Digital timer Installing digital timer 5 Ident. No.: 666E_EN Status: 5..0 Webasto Thermo & Comfort SE
5 5 Preparing Bracket Perforated bracket 50 Bending perforated bracket at an angle 50 Drill 5.5mm dia. hole into bracket as shown. 48 0 Preparing bracket 6 Drill 5.5mm dia. hole into bracket as shown. 0 48 Preparing bracket 7 Combustion air pipe shortened to 80mm. 5 4 5 5mm dia. clamp, M5x6 bolt, flanged nut Intake silencer 4 Perforated bracket 5 Perforated bracket, M6x6 bolt, flanged nut Premounting.4 TB bracket 6 8 Ident. No.: 666E_EN Status: 5..0 Webasto Thermo & Comfort SE
Shorten combustion air pipe 5 to 00mm and mould as shown. 5 5mm dia. clamp, M5x6 bolt, flanged nut, perforated bracket Intake silencer Bracket 4 Perforated bracket, M6x6 bolt, flanged nut Premounting bracket.0 JTDM 4 4 9 Preparing Installation Location Align bracket, note dimensioning. 5mm.4TB 0 80mm.0JTDM Aligning bracket 0 Copy hole pattern [x] for 9.mm dia. hole. Copying hole pattern a Copy hole pattern [x] for 9.mm dia. hole. Copying hole pattern Ident. No.: 666E_EN Status: 5..0 Webasto Thermo & Comfort SE
Slit 8x hose longitudinally and slide on to vacuum line, secure with cable ties (.0 JTDM only). Rivet nut [x] Installing rivet nuts Rivet nut [x] Installing rivet nuts A 4 M6x0 bolt, spring lockwasher [x] Installing bracket 5 M6x0 bolt, spring lockwasher [x] Installing bracket 6 Ident. No.: 666E_EN Status: 5..0 Webasto Thermo & Comfort SE 4
Preparing Heater Water connection piece, sealing ring [x each] 5x5 self-tapping bolt, retaining plate of water connection pieces Mounting water connection piece 7 Screw 5x self-tapping bolts [4x] in existing holes by a max. of thread turns. Premounting bolts loosely 8 Installing Heater Insert heater in bracket and align. 5x5 Self-tapping bolt [x] Installing heater 9 5x5 Self-tapping bolt [x] Installing heater 0 Ident. No.: 666E_EN Status: 5..0 Webasto Thermo & Comfort SE 5
Combustion Air Ensure sufficient distance from neighbouring components. Intake hose Heater Installing.0 JTDM combustion air pipe Ensure sufficient distance from neighbouring components. Intake hose Heater Installing.4 TB combustion air pipe Ident. No.: 666E_EN Status: 5..0 Webasto Thermo & Comfort SE 6
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 as shown in the wiring harness routing diagram. Discard section X. 80 moulded hose Preparing heater connection X 5 4 Image shows.0 JTDM Attach connector of heater wiring harness 4 [x] to the heater and secure/fasten it using cable ties. Ensure sufficient distance from neighbouring components. Fuel line, metering pump cable, 0mm dia. corrugated tube Moulded hose, 0 mm dia. clamp [x] Connecting heater 4 Route fuel line and wiring harness of metering pump in 0mm dia. corrugated tube to the right side of the vehicle and secure it with cable ties [x]. Routing on underbody 5 Ident. No.: 666E_EN Status: 5..0 Webasto Thermo & Comfort SE 7
Route fuel line and wiring harness of metering pump in 0mm dia. corrugated tube to underbody and secure with cable ties. Routing in engine compartment 6 Route fuel line and wiring harness of metering pump in 0mm dia. corrugated tube on underbody and secure using cable ties. Routing on underbody 7 Perforated bracket Drill hole to 8.5mm dia. 80 Preparing perforated bracket 90 Perforated bracket M6x5 bolt, flanged nut Cable tie 4 Mounting of metering pump 4 Preinstalling metering pump mounting 8 Ident. No.: 666E_EN Status: 5..0 Webasto Thermo & Comfort SE 8
Original vehicle bolt Mounting of metering pump Installation of metering pump mounting 9 Insert metering pump into mounting. Metering pump installation 40 Wiring harness of metering pump, connector mounted Fuel line Hose section, 0 mm dia. clamp [x] Connecting metering pump 4.0 JTDM The design of the fuel standpipe is identical for the shown fuel tank sending units. Remove fuel-tank sending unit in accordance with manufacturer's instructions. Remove sticker! Fuel extraction.4 TB 4 Ident. No.: 666E_EN Status: 5..0 Webasto Thermo & Comfort SE 9
Place large diameter washer against the reference edge (dotted marking). Copy hole pattern, 6 mm dia. hole 5 Hole in fuel-tank sending unit 4 Shape fuel standpipe according to template and cut to length. Installing fuel standpipe 44 Install fuel-tank sending unit in accordance with manufacturer's instructions. Hose section, 0 mm dia. clamp [x] Fuel line 4 Fuel standpipe Connecting fuel line 4 45 Metering pump Hose section, 0 mm dia. clamp [x] Fuel line, corrugated tube Connecting metering pump 46 Ident. No.: 666E_EN Status: 5..0 Webasto Thermo & Comfort SE 0
Coolant Circuit for Petrol Vehicles 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 hoses cannot be damaged. The heater must be filled with coolant when installing the hoses. The connection should be "inline" based on the following diagram: Hose routing diagram A Ø Ø 6x8 Ø Ø 7 Ø 8x0 B C D All spring clips without a specific designation = 5 mm dia. Ident. No.: 666E_EN Status: 5..0 Webasto Thermo & Comfort SE
Discard section X. Hose A = 80 moulded hose B C D X B = 80 C = 90 D = 60 Cutting hoses to length A C Push braided protection hoses onto hose C and D and cut to length. Cut heat shrink plastic tubing to length. 50 mm long heat shrink plastic tubing [4x] Preparing hoses D Circulating pump Mounting of circulating pump Angle bracket, M6x5 bolt, flanged nut Premounting circulating pump 47 Cut provided 50 mm edge protection in the middle. 5mm edge protection [x] Inserting edge protection 48 Ident. No.: 666E_EN Status: 5..0 Webasto Thermo & Comfort SE
Battery carrier console Original vehicle hole, M6x0 bolt, large diameter washer, flanged nut Circulating pump premounted Circulating pump installation 49 Pull hose of engine outlet off connection piece discard original vehicle hose clamp. Cutting point 50 Separate provided rub protection in the middle and paste on hose clamp of hose on heat exchanger outlet. Placing rub protection 5 Route hose D in the engine compartment. Connection piece of heater outlet D Connecting heater 5 Ident. No.: 666E_EN Status: 5..0 Webasto Thermo & Comfort SE
Cable tie [x] Hose section of heat exchanger inlet D Connection of heat exchanger inlet 5 A Connection piece on engine outlet Connecting engine outlet 54 Route hose C to the circulating pump in the engine compartment. Connection piece of heater outlet C Connecting heater 55 Connection piece of circulating pump Connecting circulating pump C 56 Ident. No.: 666E_EN Status: 5..0 Webasto Thermo & Comfort SE 4
Attach wiring harness of circulating pump to heater and circulating pump and secure with cable ties. 57 Connection piece of circulating pump B Attaching wiring harnesses Connection of heat exchanger inlet B 58 B A Connecting hose B and hose A 59 After installing the air intake pipe check the position of hoses B and D. Align hoses. Ensure sufficient distance from adjacent components; correct if necessary. D Cable tie Routing in engine compartment B 60 Ident. No.: 666E_EN Status: 5..0 Webasto Thermo & Comfort SE 5
Coolant Circuit for Diesel Vehicles 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 hoses cannot be damaged. The heater must be filled with coolant when installing the hoses. The connection should be "inline" based on the following diagram: Hose routing diagram A Ø 7 Ø Ø 4/7 Ø Ø 5x8 Ø 5x0 Ø 5x8 Ø Ø 6/4 B C E D All spring clips without a specific designation = 5 mm dia. = Black (sw) rubber isolator [4x]. All connecting pipes = 8x8 mm dia. Ident. No.: 666E_EN Status: 5..0 Webasto Thermo & Comfort SE 6
B C D E X Discard section X. Hose A = 80 moulded hose B = 650 C = 65 D = 50 E = 950 Cutting hoses to length A B D Push braided protection hose onto hose B, D and E and cut to length. Cut heat shrink plastic tubing to length. 50 mm long heat shrink plastic tubing [6x] Preparing hoses E E Black (sw) rubber isolator x on hoses B and E Preparing hoses B C D 6 Circulating pump Mounting of circulating pump Angle bracket, M6x5 bolt, flanged nut Premounting circulating pump 6 Ident. No.: 666E_EN Status: 5..0 Webasto Thermo & Comfort SE 7
Battery carrier console Original vehicle hole, M6x0 bolt, large diameter washer, flanged nut Circulating pump premounted Circulating pump installation 6 Remove hose section of engine outlet. Discard hose clamp Cutting point 64 Remove quick-release coupling from hose discard clamp. Preparing hose 65 50 Engine outlet hose section Connection quick-release coupling Hose section of heat exchanger inlet 4 Connection of engine outlet 4 Preparing hose 66 Ident. No.: 666E_EN Status: 5..0 Webasto Thermo & Comfort SE 8
Quick-release coupling Hose section of heat exchanger inlet Connection for hose E Preparing hose of heat exchanger inlet 67 A Connection of engine outlet connection piece Connection for hose B Preparing hose of engine outlet 68 Hose group of engine outlet Connection piece on engine outlet Connecting engine outlet 69 Hose group of heat exchanger inlet Connection of heat exchanger inlet Connection of heat exchanger inlet 70 Ident. No.: 666E_EN Status: 5..0 Webasto Thermo & Comfort SE 9
E Route hose E in the engine compartment. Connection piece of heater outlet Connecting heater 7 Route hose E to heat exchanger connection. Routing E E 7 Route hose E to heat exchanger connection. 7 Hose group of heat exchanger inlet E Routing in engine compartment Connection of heat exchanger inlet 74 Ident. No.: 666E_EN Status: 5..0 Webasto Thermo & Comfort SE 0
E Align black (sw) rubber isolator to cable bracket. Aligning rubber isolator 75 E Align black (sw) rubber isolator to clamp on engine outlet. 76 Route hose D to the circulating pump. Connection piece of heater inlet Aligning rubber isolator Connecting heater D 77 Connection piece of circulating pump Cable tie [x] D E Connecting circulating pump 78 Ident. No.: 666E_EN Status: 5..0 Webasto Thermo & Comfort SE
B Connection piece of circulating pump Connecting circulating pump C 79 Route hose B to engine outlet connection. Cable tie [x] Align rubber isolator [x] Routing B 80 B A Connecting engine outlet 8 Align hoses. Ensure sufficient distance from adjacent components; correct if necessary. Cable tie E Routing in engine compartment E 8 Ident. No.: 666E_EN Status: 5..0 Webasto Thermo & Comfort SE
Exhaust Gas Discard section X. Exhaust pipe a = 50 Exhaust end section b = 00 Preparing exhaust pipe a b X Perforated bracket 0 00 5 Bending perforated bracket at an angle 90 Silencer M6x6 bolt, spring lockwasher Perforated bracket Premounting silencer 8 9.mm dia. hole ; Rivet nut 40 Installing rivet nut 5 84 Ident. No.: 666E_EN Status: 5..0 Webasto Thermo & Comfort SE
Insert 5mm shim between perforated bracket and cross member. Silencer premounted with perforated bracket M6x5 bolt, spring lockwasher, 5mm shim Installing silencer 85 Hose clamp [x] Exhaust pipe Installing exhaust pipe 86 Ensure sufficient distance from neighbouring components. Exhaust end section Hose clamp Installing exhaust end section 87 Cut out sound insulation and discard. Lower engine cover Processing lower engine cover 88 Ident. No.: 666E_EN Status: 5..0 Webasto Thermo & Comfort SE 4
Lower engine cover 60mm dia. hole 5 75 Hole in lower engine cover 89 Ident. No.: 666E_EN Status: 5..0 Webasto Thermo & Comfort SE 5
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 wires. 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. Adjust digital timer, teach Telestart transmitter Make settings on A/C control panel according to the "Operating Instructions for End Customer". Affix "Switch off parking heater before refueling" caution label in area of filler neck. See installation instructions for notes on initial operation and functional test Cut out marked layer in cover. Processing lower cover of bumper 90 Align exhaust end section to the centre. Lower engine cover Aligning exhaust end section 9 Webasto Thermo & Comfort SE Postfach 40 899 Gilching Germany Internet: www.webasto.com Technical Extranet: http://dealers.webasto.com Ident. No.: 666E_EN Status: 5..0 Webasto Thermo & Comfort SE 6
Fuel standpipe template 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 minimise margins and 00% of the normal size. 00 mm 0 Ident. No.: 666E_EN Status: 5..0 Webasto Thermo & Comfort SE 7
Operating Instructions for Manual Air-Conditioning Please remove page and add to the vehicle operating instructions. Note: We recommend matching the heating time to the driving time. Heating time = driving time Example: For a driving time of approx. 0 min. (in one direction), we recommend not exceeding a switch-on time of 0 min. Passenger compartment monitoring, if installed, must be deactivated in addition to the vehicle settings for the heating operation. For instructions on deactivation, please refer to the operating instructions of the vehicle. Before parking the vehicle, make the following settings: Note: No need to pre-select the fan speed. Set temperature to "HI" Air outlet to windscreen A/C control panel 9 0A heater fuse F 0A main fuse F of passenger compartment Engine compartment fuses 9 A fuse F of heater control 5A fan fuse F4 Passenger compartment fuses 94
Operating Instructions for Automatic Air-Conditioning Please remove page and add to the vehicle operating instructions. Note: We recommend matching the heating time to the driving time. Heating time = driving time Example: For a driving time of approx. 0 min. (in one direction), we recommend not exceeding a switch-on time of 0 min. Passenger compartment monitoring, if installed, must be deactivated in addition to the vehicle settings for the heating operation. For instructions on deactivation, please refer to the operating instructions of the vehicle. Before parking the vehicle, make the following settings: Note: No need to pre-select the fan speed. Set temperature to "HI" Air outlet to windscreen A/C control panel 95 0A heater fuse F 0A main fuse F of passenger compartment Engine compartment fuses 96 A fuse F of heater control 5A fan fuse F4 Passenger compartment fuses 97