Webasto Thermo Top Evo Start Installation Documentation Kia Carens

Page 1
Water Heater
Thermo Top Evo Parking Heater
E1
00 0258
Installation Documentation Kia Carens

Validity

Manufacturer Model Type EG-BE No./ABE
Kia Carens e4 * 2001 / 46 * 0633 * ...
Motorisation Fuel
1.6 GDi Petrol 6-speed SG 99 1591 G4FD SG = Manual transmission
From Model Y ear 2014 Left-hand drive vehicle
Verified equipment variants:
Not verified: Xenon
Total installation time: approx. 8.5 hours
Manual / automatic air-conditioning system Front fog light LED daytime running lights Headlight washer system
Output in kW
Displacement in cm³
Engine code
Ident. No.: 1321247A_EN Status: 13.09.2013 © Webasto Thermo & Comfort SE
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Kia Carens
Validity 1 Necessary Components 2 Installation Overview 2 Information on Total Installation Time 2 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 11 Digital Timer 14 Remote Option (Telestart) 14 Remote Option (Thermo Call TC3) 15
Preparing Installation Location 16 Preparing Heater 17 Installing Heater 19 Fuel 20 Combustion Air 24 Exhaust Gas 26 Coolant Circuit 28 Final Work 34 Template for Fuel Standp ipe 35 Operating Instructions for Manual Air-Conditioning 36 Operating Instructions for Automatic Air-Conditioning 37
• Basic delivery scope of Thermo Top Evo in accordance with price list
• Installation kit for Kia Carens 2014 Petrol: 1321246A
• additionally required in case of automatic air-conditioning: Automatic air-conditioning kit for Kia Carens: 1321248A
• 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
7
6
1
5
2
3
4

Table of Contents

Necessary Components

Installation Overview

Legend:
1. Heater
2. Engine compartment fuse
holder
3. Passenger compartment relay and fuse holder
4. IPCU (only with automatic air­conditioning)
5. Circulating pump
6. Digital timer
7. Metering pump

Information on Total Installation Time

The total installation time inclu des the time needed for mo unting and demounting of th e 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.
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Kia Carens Information on Operating and Installation Instructions
1 Important Information (not complete)
1.1 Installation and Repair
The improper installation or repair of Webasto heating and cooling sys­tems can cause fire or the leakage of deadly carbon monoxide, lead ing to serious injury or death.
T o 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 per sons trained and certified in a Webasto training co urse. NEVER try to inst all or repair W e­basto heating or cooling systems if you have not completed a W eba st o 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 inst allation and repa ir work properly .
Only use genuine Webasto part s. See t he W eba st o air and wa ter hea t-
ers accessories catalogue for this purpose.
1.2 Operation
To ensure safe operation, we recommend having the heater checked every two years by an authorised Webasto de aler, 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 pet-
rol (DIN EN 227). The heater may not be cleaned with a high-pressure cleaner.
1.3 Please note
ALW A YS follow all Webasto installat ion and operating instructions and observe all warnings.
T o become familiar with and underst and all functions and properties of the heate r, 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 W ebast o for all inst allat ion and repair work.
Important
Webasto shall assume no liability for defect s, 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 must audibly snap into place during assembly.
Sharp edges should be fitted with rub protection. Spray unfinished body areas, e.g. drilled holes, with anti-corrosion wax (Tectyl 100K, Order No. 111329).
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.
2 Statutory regulations governing installation
Guidelines Thermo Top Evo
Heating Directive ECE R122 E1 00 0258 EMC Directive ECE R10 E1 03 5627
Note
The regulations of these guidelines are binding in the scope of the Directive 70/156/EEC and/or 2007/46/EC (for new vehicle models from 29/04/2009) 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 th e type approval for the heater and therefore invalidation o f the general homologation of the vehicle.
For vehicles with an EU permit, no entry in accordance with § 19 Sub-Section 4 of Annex VIII b to the Road Traffic Act is required.
Note
2.1 Excerpt from the directive 2001/56/EC Appendix VII for the installation of the heater
Beginning of excerpt.
ANNEX VII
REQUIREMENTS FOR COMBUSTION HEATERS
AND THEIR INSTALLATION
1. GENERAL REQUIREMENTS
1.7.1. A clearly visible tell-tale in the operator's field of vie w sh all infor m when the combustion heater is switched on or off.
2. VEHICLE INSTALLATION REQUIREMENTS
2.1. Scope
2.1.1. Subject to paragraph 2.1.2. combustion heaters shall be installed ac­cording to the requirements of this Annex.
2.1.2. Vehicles of category O having liquid fuel heate rs are deemed to compl y with the requirements of this Annex.
2.2. Positioning of heater
2.2.1. 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.
2.2.2. 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 part s and suit able vent ila­tion, by the use of fire resistant materials or by the use of heat shields.
2.2.3. In the case of M2 and M3 vehicles, the heate r must not be positioned in the passenger compartment. However, an installation in an effectively sealed envelope which also complies with the conditions in paragraph
2.2.2 may be used.
2.2.4. The label referred to in paragr aph 1.4 or a duplicate, must be posi tioned so that it can be easily read when the heater is installed in the vehicle.
2.2.5. Every reasonable precaution should be taken in positioning the heater to minimise the risk of injury and damage to personal property.
2.3. Fuel supply
2.3.1. The fuel filler must not be situated in the passenger compartment and must be provided with an effective cap to prevent fuel spillage.
2.3.2. In the case of liquid fuel heaters, where a supp ly sep ar ate to t hat of the vehicle is provided, the type of fuel and its filler point must be clearly la­belled.
2.3.3. A notice, indicating that the heater must be shut down before ref uelling, must be affixed to the fuelling point. In addition a suitable instruction must be included in the manufacturer's operating manual.
2.4. Exhaust system
2.4.1. The exhaust outlet must be locat ed so as t o pr event emissions f rom en­tering the vehicle through ventilators, heated air inlets or opening win­dows.
2.5. Combustion air inlet
2.5.1. The air for the combustion chamber of the heater must not be drawn from the passenger compartment of the vehicle.
2.5.2. The air inlet must be so positioned or guarded that blocking by rubbish or luggage is unlikely.
2.6. Heating air inlet
2.6.1. 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.
2.6.2. The inlet duct must be protected by mesh or other suitable means.
2.7. Heating air outlet
2.7.1. Any ducting used to route the ho t ai r th roug h th e vehicle must be so po­sitioned or protected that no injury or damage could be caused if it were to be touched.
2.7.2. The air outlet must be so positioned or guarded that blockin g by rubbish or luggage is unlikely.
End of excerpt. In multilingual versions the German language is binding.
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Special Tools
• Hose clamp pliers for self-clamping hose clamps
• Hose clamp pliers for Clic hose clamps of type W
• Automatic wire stripper 0.2 - 6mm²
• Crimping pliers for cable lug / tab connector 0.5 - 6mm²
• Torque wrench for 2.0 - 10 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 5x13 heater bolts and 5x11 heater stud bolts = 8Nm.
• Tightening torque values of 5x15 retaining plate of water connection piece bolt = 7Nm.
• Tighten other bolt connections in accordance with manufacturer's instr uctions or in accordance with state-of-the­art-technology.

Information on Validity

This installation documentation applies to Kia Carens Petrol vehicles - for validity, see page 1 - from model year 2014 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

Explanatory Notes on Document

top right corner of the page in question to provide you with a quick overview of the individual working steps.
Mechanical system
Electrical system
Coolant circuit
Combustion air
Fuel
Exhaust gas
Special features are highlighted using the following symbols:You will find an identification mark on the outside
Specific risk of injury or fatal accidents
Specific risk of damage to components
Specific risk of fire and explosion
Reference to general installation instructions of the Webasto component s 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
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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 cover.
• Disconnect and completely remove the ba tte ry .
• Remove the battery carrier.
• Completely remove the air filter box.
• Remove the control unit.
• Remove the right headlight.
• Remove the bumper cover.
• Remove the underride protection of the engine.
• Detach the underride protection of the fuel lines on the left.
• Remove the left and middle seat of the second seat row.
• Open the tank-fitting service lid in the middle.
• Remove the fuel-tank sending unit in accordance with the manufacturer's instructions.
• Remove the lateral instrument panel trim on the front passenger's side.
• Remove the glove compartment.
• Remove the glove compartment trim.
• Remove the lower A-pillar trim on the front passenger's side (only for Thermo Call).
Heater
• Remove years that do not apply from the type and duplicate label.
• Attach the duplicate label (type label) in the app ro pri at e pla ce in the en g ine com par tm en t.

Heater Installation Location

1 Heater
Installation location
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86
85 30
87a87
K1
gn/ws
0,75²
F4
br
0,5²
rt
rt/sw
0,5²
F3
1
2
sw
rt
2 1
2
1
2
1
2
3
rt
0,75²
1000
4
sw
1000
0,75²
100
gn/ws
0,75²
5
100
br
0,75²
6
86 85
A
E
IPCU
3
4
6
A
15
86
85
E
gn/ws
0,75²
5
br
0,75²
sw
0,75²
rt
0,75²

Preparing Electrical System

Wire sections retain their numbering in the entire document.
Manual air-conditioning
Produce connections as shown in wiring dia­gram.
Connect wires in accordance with wiring dia­gram. 25A fuse F4 and K1 relay will only be inserted after installation of relay and fuse holder of passenger compartment.
1 Passenger compartment relay and fuse
holder
2 M5x16 bolt, angle bracket, large diame-
ter washer, self-locking nut Red (rt) wire from K1/87a Black (sw) wire from K1/30
Premount­ing passen­ger compart­ment relay and fuse holder
Premount­ing passen­ger compart­ment relay and fuse holder
Automatic air-conditioning
Preparing lines
Connect wires to socket IPCU. IPCU view on contact side. The IPCU attached in the kit is pre-pro­grammed with the following settings:
Duty cycle: 100% (DC) Voltage: 3.6V Function: High-side
Ident. No.: 1321247A_EN Status: 13.09 .2013 © Webasto Thermo & Comfort SE
The settings must be checked during the start-up of the heater and adjusted if neces­sary.
Premount­ing IPCU
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3
2
2 6
4
1
1 35
123
456
86
85 30
87a87
K1
gn/ws
0,75²
F4
br
0,5²
rt
rt/sw
0,5²
F3
1
2
sw
rt
A
E
IPCU
85
86
6
4
3
5
gn/ws
0,75²
rt
0,75²
sw
0,75²
br
0,75²
3
4
90°
28
1
4
1 43
5 5
2
Connect wires in accordance with wiring dia­gram. Interlock socket IPCU partment relay and fuse holder
2 and passenger com-
1.
Red (rt) wire from K1/87a Black (sw) wire from K1/30 Red (rt) wire of IPCU/E Black (sw) wire of IPCU/A Green/white (gn/ws) wire from IPCU/86 and K1/86 Brown (br) wire of IPCU/85 and K1/85
Produce connections as shown in wiring dia­gram. Insert K1 relay and 25A fuse F4. IPCU will only be inserted after installation of relay and fuse holder . Pull wires and into pro­tective sleeving.
Connecting wires
Preparing K1 relay, IPCU and F4
All vehicles
Angle bracket for engine compartment
1
fuse holder
Complete connector of metering pump again after routing. Pin assignment is not relevant.
1 Connector housing 2 Lock 3 Blue/brown (bl / br) wires
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4 Coding 5 Timer lock
Preparing angle bracket
Disman­tling con­nector
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1
2
6
1 32
4
Do not install the metering pump wiring harness until later togeth­er with the fuel line along the original vehicle fuel lines on the underbody
718
1

Electrical System

Wiring harness pass through
1
Protective rubber plug
2 Wiring harnesses of heater and heater con-
trol
Fuse holder for engine compartment
1
M5x16 bolt, large diameter washer [2x], re­taining plate for fuse holder, nut
2 Angle bracket 3 Original vehicle stud bolt, flanged nut 4 Fuses F1-2
Positive wire
Wiring har­ness rout­ing diagram
Earth wire
Positive wire on positive battery distributor
1
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Earth wire on original vehicle earth support point
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Webasto
31
30 15
Kia
HG
X2
1 2
X1
52
F2 F1
gn/ws
0,75²
ge
0,5²
rt/sw
0,5²
rt
br
0,5²
X10
86
85 30
87a87
K1
gn/ws
0,75²
F4
br
0,5²
rt
rt/sw
0,5²
F3
br
0,5²
M27
M
F6
GRs
1 2
1
M22
63
24
M06
124 3
M22A
F16
M22B
17 2
F34
1
2
rt
sw
gn
gn
M22A

Fan Controller for Manual Air-Conditioning

Wiring dia­gram
Webasto components Vehicle components Colours and symbols
HG Heater TT-Evo F6 40A fuse rt red X1 6-pin heater connector F34 7.5A fuse sw black X2 2-pin heater connector F16 10A fuse ge yellow F1 20A fuse GRs Fan relay gn green F2 30A fuse M06 Fan resistor bl blue X10 4-pin connector
Heater control
F3 1A fuse M22B Connector M22 pk pink F4 25A fuse M22 A/C control module
M27 Fan motor ws white M22A Connector M22 br brown
Legend
K1 Fan relay
X Cutting point
Wiring colours may vary.
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1
3
2
4
5
10
1
2
11
2
1
12
1 2
2 1
3
1
2
Remove original vehicle bolt 3. Insert pre­mounted angle bracket panel carrier
5 and instrument panel 4 and
2 between instrument
align (see next figure). Mount original vehicle bolt
3 again.
1 Passenger compartment relay and fuse
holder
K1 relay
1 2 25A fuse F4
Mounting passenger compart­ment relay and fuse holder
Mounting K1 and F4
Wiring harness on heater
1 2 Wiring harness of passenger compart-
ment relay and fuse holder
Connecting same col­our wires of wiring har­nesses
Connection to 2-pin connector 1 from fan mo­tor M27. Produce connections as shown in wiring diagram.
2 Green (gn) wire from fan relay 3 Green (gn) wire of connector M27
Red (rt) wire from K1/87a
Connecting fan motor
Black (sw) wire from K1/30
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Webasto
31
30 15
Kia
HG
X2
1 2
X1
52
F2 F1
gn/ws
0,75²
ge
0,5²
rt/sw
0,5²
rt
X10
86
85 30
87a87
K1
gn/ws
0,75²
F4
rt
rt/sw
0,5²
F3
br
0,5²
br
0,5²
86 85
A E
IPCU
br
0,5²
6
br
0,75²
M21
6
GRr
rt
0,75²
sw
0,75²
4
3
rt
1
gn/ws
0,75²
2
sw
16814
F16F4
F15F6
M21-B
5
bl
0,5²
bl
0,5²
gn
gn
GRs
1
M27
M
2
M33
1 3
4
1
M21-B

Fan Controller for Automatic Air-Conditioning

Wiring dia­gram
Webasto components Vehicle components Colours and symbols
HG Heater TT-Evo F6 40A fuse rt red X1 6-pin heater connector F15 7.5A fuse sw black X2 2-pin heater connector F4 7.5A fuse ge yellow F1 20A fuse F16 10A fuse gn green F2 30A fuse GRs Fan relay bl blue X10 4-pin connector
F3 1A fuse M21-B Connector KB F4 25A fuse M21 A/C control panel K1 Fan relay M27 Fan motor IPCU Pulse width modulator
IPCU settings:
Duty cycle: 100% (DC) Voltage: 3.6V Function: High-side
Heater control
GRr Fan controller ws white M33 Connector GRr br brown
X Cutting point
Wiring colours may vary.
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Legend
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1
2
14
1
15
2
1161 2
2 1
3
1
2
1 Passenger compartment relay and fuse
holder
2 M5x16 bolt, large diameter washer [2x],
nut, existing hole
Mount IPCU
1
Mounting passenger compart­ment relay and fuse holder
Mounting IPCU
Wiring harness on heater
1 2 Wiring harness of passenger compart-
ment relay and fuse holder
Connecting same col­our wires of wiring har­nesses
Connection to 2-pin connector 1 from fan mo­tor M27. Produce connections as shown in wiring diagram.
2 Green (gn) wire from fan relay 3 Green (gn) wire of connector M27
Red (rt) wire from K1/87a
Connecting fan motor
Black (sw) wire from K1/30
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1
2
4
3
3
3
4
Connection to 4-pin connector 3 from fan controller. Produce connection s as shown in wiring diagram.
1 Blue (bl) wire from A/C control panel M21 2 Blue (bl) wire from connector GRr
Red (rt) wire of IPCU/E Black (sw) wire of IPCU/A
Fan con­troller con­nection
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1
18
1
3
19
2
1
3
20
2
1
21

Digital Timer

Figure shows variant with start-stop button.
1 Digital timer

Remote Option (Telestart)

Vehicle with automatic air-conditioning
1
Receiver
2 M5x16 bolt of relay and fuse holder 3 Bracket
Mounting digital timer
Mounting receiver
Vehicle with manual air-conditioning
Receiver
1 2 Original vehicle hole, M5x16 bolt, large
diameter washer [2x], nut
3 Bracket
All vehicles
Antenna
1
Mounting receiver
Mounting antenna
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1
22123
1
24
Temperature sensor T100 HTM
Figure shows vehicle with automatic air-con­ditioning. Same procedure for manual air-conditioning.
Fasten temperature sensor tape.
1 with adhesive

Remote Option (Thermo Call TC3)

Fasten receiver 1 with adhesive tape.
Installing tempera­ture sensor
Mounting receiver
Antenna
1
Mounting antenna
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25
1 2
3
1
26
1 1
10
10
27
1
2
1
28
1

Preparing Installation Location

Vehicles with headlight washer system
Remove wind deflector plate 2. Withdraw brackets
3 Hose of headlight washer system
1
1 [2x] from holes.
7 mm dia. hole [2x], centred between the bars
Preparing installation location
Holes in cross member
Mount headlight washer system hose 2 with brackets
Cut wind deflector plate 1 at the markings and install again.
1 [2x] in holes.
Installing hose
Cutting wind de­flector plate
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1
1
40
8
10
113
30
1
31
1
1
2
30
26
20
18
85°
21
All vehicles
1
7 mm dia. hole [2x]
M6x30 bolt, 15 mm shim, pin lock
1
Holes in cross member
Inserting bolt

Preparing Heater

1 Water connectio n pieces, sealing ring [2x
each]
2 5x15 self-tapping bolt, retain ing plate of
water connection pieces
Discard section
1 2 Perforated bracket a
Mounting water con­nection pieces
Preparing perforated bracket a
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1 2
18
20
90°
20
12°
21
52
58
80°
1
33
21
31
1 Perforated bracket a
5x13 self-tapping bolt
2
Discard section
1 2 Perforated bracket b
Mounting perforated bracket a
Preparing perforated bracket b
Perforated bracket c
1
Preparing perforated bracket c
5x13 self-tapping bolt [2x]
1 2 Perforated bracket b
Perforated bracket c
3
Mounting perforated brackets b and c
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3
1 2
5
4
4
35
1
2
36
1
1

Installing Heater

1 Perforated bracket a
Perforated bracket b
2
M6 flanged nut
3 4 M6x20 bolt, flanged nut [2x each] 5 Perforated bracket c
Slit 10 mm dia. corrugated tube lengthwise. Route heater wiring harness corrugated tube
2 to heater.
1 in 10 mm dia.
Mounting heater
Routing heater wir­ing har­ness
Wiring harness of heater [2x]
1
Installing heater wir­ing har­ness
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1 2
3
4
38
1
1
1392
1

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 a suitable container. Install fuel line and metering pump wiring harness so that they are protected again st stone impact. Un-
less 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 harne ss rout ­ing diagram.
Pull fuel line 1 and wiring harness of metering pump
3 into 10 mm dia. corrugated tube 2.
4 90° moulded hose, 10 mm dia. clamp [2x]
Connect­ing heater
Fuel line and wiring harness of metering
1
pump in corrugated tube
Routing lines
Fuel line and wiring harness of metering
1
pump in corrugated tube
Routing lines
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1
1
41
1
1
2
42
1433
5
4
7
6
2
5
4
1
1
1 Fuel line and wiring harness of metering
pump in corrugated tube
Route fuel line and wiring harness of me-
1
tering pump in corrugated tube behind underride protection of fuel lines to the left.
2 Underride protection of fuel lines
Routing lines
Routing lines
Route fuel line and wiring harness of meter­ing pump the underride protection to the installation lo­cation of the metering pump.
1 2 Metering pump 3 Hose section, 10 mm dia. clamp 4 M6x25 bolt, support angle bracket, flang-
5 Perforated bracket 6 Cable tie 7 180° moulded hose, 10 mm dia. clamp
1 along original vehicle lines behind
Routing lines
Mounting of metering pump
ed nut
Premount­ing meter­ing pump
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2
3
1
45
1
3
2
46
3 2
1
47
1
1
1
2
1
Figure shows vehicle with electrical hand­brake.
1 M6 flanged nut 2 Original vehicle stud bolt, original vehicle
nut
3 Perforated bracket on original vehicle
stud bolt
Wiring harness of metering pump, con-
1
nector mounted
2 Fuel line of heater 3 10 mm dia. clamp
Mounting metering pump
Connect­ing meter­ing pump
Remove fuel-tank sending unit 1 in accord­ance with manufacturer's instructions.
2 Position flanged nut of fuel standpipe 1
between the bars
3 Copy hole pattern, 6 mm dia. hole
Shape fuel standpipe 1 according to template and cut to length.
2 6 mm dia. washer [4x]
Fuel ex­traction
Mounting fuel stand­pipe
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1 2
4
3
49
1
2
Install fuel-tank sending unit 3 in accordance with manufacturer's instructions.
1 Fuel line of fuel standpipe 2 Fuel standpipe 4 Moulded hose, 10 mm dia. clamp [2x]
Mount fuel line of fuel standp ipe 1 with 10 mm dia. clamp on 180° moulded hose the position of the components; adjust if nec­essary. Check that they have freedom of movement.
2. Check
Connect­ing fuel line
Connect­ing meter­ing pump
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50
1 2
3
4
51
1521
53
3 2
1

Combustion Air

1 51 mm dia. clamp 2 Silencer 3 Angle bracket 4 M5x16 bolt, flanged nut
Remove horn
1
Premount­ing silencer
Preparing installation location
Drill out existing hole to 9.1 mm dia.; rivet
1
nut
Reinstall horn.
1 Combustion air pipe 2 Angle bracket 3 M6x20 bolt
Installing rivet nut
Installing silencer
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1
1 Combustion air pipe
Installing combus­tion air pipe
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a b
1 2
X
1
55
50
12
7
20
90°
50°
1
2
56
1
23

Exhaust Gas

Discard section X.
1 Exhaust pipe
a = 360
2 Exhaust end section
b = 110
7 mm dia. hole
1
Preparing exhaust pipe
Hole for ex­haust end section
Original angle bracket
1 2 Adapted angle bracket
Preparing angle bracket
Silencer
1 2 Angle bracket 3 M6x16 bolt, spring lockwasher
Premount­ing silencer
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2 1
1 2
2
58
4
1 2
5
3
59
2
1
60
1 Angle bracket 2 M6x20 bolt, large diameter washer,
flanged nut, existing hole
Installing silencer
Slide exhaust-gas insulation 1 (330 mm long) on exhaust pipe.
2 Hose clamp [2x]
Mounting exhaust pipe
Hose clamp
1 2 Exhaust end section 3 M6x20 bolt, pipe clamp, flanged nut 4 M6x20 bolt, flanged nut 5 Angle bracket
Bumper trim
1 2 Discard section
Mounting exhaust end section
Adapting bumper trim
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Ø 27
Ø 20x18
C
D
E
F
G
H
1
A
B
2
2

Coolant Circuit

WARNING!
Any coolant running off should be collected in a suitable container. Install hoses so that they are kink­free. 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 in­stallation diagram
All spring clips without a specific designation = 25 mm dia.
1= Original vehicle spring clip . 2 = Black (sw) rubber isolator
All connecting pipes without a specific designation and = 18x18 mm dia.
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C
X
A
B
D E F
G
H
X
X
G
H
B
1
21 1
1
61
2 3
1
62
5
4
2
1
3
Discard section X. Hose
A = 180°, 18 mm dia. moulded hose.
B =1190 C =70 D =70 E =170 F =190 G =180 H =1260
Push braided protection hoses onto hoses B and
H and cut to length. Cut heat shrink plas-
tic tubing to length.
1 Heat shrink plastic tubing, 50 mm length
[4x]
2 Heat shrink plastic tubing, 100 mm
Cutting hoses to length
Preparing hoses
Detach original vehicle spring clip 3 and push back. Pull original vehicle hose tion piece of engine outlet
2 off connec-
1.
Cutting point
Circulating pump
1 2 Mounting of circulating pump 3 Wiring harness of circulating pump 4 M6x25 bolt 5 Original vehicle stud bolt, M6x40 spacer
nut
Mounting circulating pump
29
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63164
D
E
C
1
65
G
2
F
1
66
1
H
2
3
1 Wiring harness of circulating pump
Circulating pump
1
Connec­tion to heater
Connec­tion of heater inlet
Slide black (sw) rubber isolator onto hose
1
G
Hose bracket between hose E and F
2
Connec­tion of heat­er outlet
Align black (sw) rubber isolator 3 with gear­shift cable bracket.
1 Original vehicle spring clip 2 Hose on heat exchanger inlet
Connec­tion of heat exchanger inlet
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H
H
1
68
40
10
1
69
170H
Route hose H behind original vehicle wiring harness bracket
6.5 mm dia. hole in cross member at pos. 1.
1 M6x25 bolt with screw lock
1.
Routing in engine compart­ment
Preparing installation location
Remove original vehicle bolt 1 and discard.
Route hose H along the radiator fan to the right side of the vehicle.
Routing in engine compart­ment
Routing in engine compart­ment
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71
H
G
1
72
B
A
2
1
73
B
H
1
B
H
1 2
74
3
2
B
H
1
Align hoses. Ensure sufficient distance from neighbouring components, correct if neces­sary.
1 Position black (sw) rubber isolator
Route hose B behind original vehicle wiring harness bracket
1 Engine outlet connection piece
2.
Connec­tion of heat­er outlet
Connect­ing engine outlet
Route hose B to installation location of circu­lating pump.
1 M6x35 bolt, 38 mm dia. rubber-coated p-
clamp, 20 mm shim, original vehicle thread
2 Premounted bolt, 10 mm shim, 38 mm
dia. rubber-coated p-clamp, M6 flanged nut
Tighten lightly cable tie 3 around hose H an d
B.
1 Original vehicle hose 2 37x25 hose bracket between hose B
and
1
Routing in engine compart­ment
Fastening hoses
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B
C
1
Align hoses. Ensure sufficient distance from neighbouring components, correct if neces­sary.
1 Hose bracket between hose B and A/C
line
Connec­tion of cir­culating pump
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1 2
455
77
77
1
2

Final Work

WARNING!
Reassemble the components in reverse order. Check all hoses, clamp s and all e lectrical conne ction s for firm seating. Insulate all loose lines and tie back. Only use manufacturer-approved coolant. Spray the heater components with anti-corrosion wax (Tectyl 100K, Order No. 111329).
• Connect the battery
• Fill and bleed the coolant circuit according to the vehicle manufacturer’s specifications.
• Set the digital timer, teach telestart transmitter
• Make settings on A/C control panel according to the "Operating Instructions for End Cus­tomer".
• Place signboard "Switch off parking heater before refuelling" in the area of the filler neck
• See installation instructions for initial start-up and function test
1 Underride protection 2 60 mm dia. hole
Cutting out underride protection
Centrally align exhaust end section 2 in hole and so that it is flush with underride protection
1.
Aligning exhaust end section
Webasto Thermo & Comfort SE Postfach 1410 82199 Gilching Germany Internet: www.webasto.com Technical Extranet: http://dealers.webasto.com
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Template for Fuel Standpipe

100mm
Scale 1:1 Compare the size of the printed version with dimension
lines. Permitted tolerance a maximum of 2%.
Set the printer settings to “no margin” or “minimise mar­gins” and 100% of the normal size.
100mm
0
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2 3 1
79
2
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80
2
1

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. 20 min. (in one direction), we recommend not exceeding a switch -on time of 20 min.
Passenger compartment monitoring, if installed, must be deactivated in addition to the vehicle settings for the heating operation. Instructions for de-activation may be obtained from the operating instructions of the vehicle.
Before parking the vehicle, make the following settings:
1 Set temperature to "max." 2 Set fan to level "1", or max. "2" 3 Air outlet to windscreen
A/C control panel
30A main fuse F2 of passenger compart-
1
ment
2 20A heater fuse F1
1A fuse F3 of heater control
1 2 25A fan fuse F4
Fuses of engine compart­ment
Fuses of passenger compart­ment
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2
1
82
2
18321

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. 20 min. (in one direction), we recommend not exceeding a switch -on time of 20 min.
Passenger compartment monitoring, if installed, must be deactivated in addition to the vehicle settings for the heating operation. Instructions for de-activation may be obtained from the operating instructions of the vehicle.
Before parking the vehicle, make the following settings:
1 Set temperature on both sides to "HI“ 2 Air outlet faces "upward"
A/C control panel
30A main fuse F2 of passenger compart-
1
ment
2 20A heater fuse F1
Fuses of engine compart­ment
1A fuse F3 of heater control
1 2 25A fan fuse F4
Fuses of passenger compart­ment
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