1.6 Liter Gasoline and 2.0 Liter Gasoline Eco Fuel; 2.0 Liter SDI from Model Year 2005 Left-hand drive vehicle

Transcription

1 Water Heater Unit Feel the drive Thermo Top E Additional Heater Thermo Top C Additional Heater Thermo Top P Additional Heater e e e Installation Instructions VW Caddy.6 Liter Gasoline and.0 Liter Gasoline Eco Fuel;.0 Liter SDI from Model Year 005 Left-hand drive vehicle WARNING! Hazard warning: Incorrect installation or repair of Webasto heating systems may cause a fire or result in the emission of carbon monoxide, which can be fatal. Serious or fatal injuries can be caused as a result. Specialist company training, technical documentation, specialized tools and equipment are required to install and repair Webasto heating and cooling systems. NEVER attempt to install or repair Webasto heating or cooling systems if you have not successfully completed the company training and thereby acquired the required technical skills, or if you do not have access to the required technical documentation, tools and equipment needed to carry out correct installation and repairs. ALWAYS follow all Webasto installation and repair instructions and observe all warnings. Webasto does not accept any liability for defects and damage that are attributable to installation by untrained staff. Ident. No.:907D_EN Fee Euro 0.00 Webasto AG

2 Table of Contents Validity Heater Unit/Installation Kit Foreword General Instructions Special Tools Explanatory Notes on Document 4 Preliminary Work 5 Heater unit installation location 5 Electrical system 6 Fuse holder and relay K 7 Climatic fan controller 8 Climatronic fan controller 0 Remote option (Telestart) Preparing heater unit Preparing installation location heater unit 4 Fuel 6 Coolant for gasoline engine Coolant for diesel engine 5 Combustion air 9 Exhaust gas 0 Final Work Operating Instructions for End Customer Validity Manufacturer Model Type EG-BE No./ABE VW Caddy KN L 0 VW Caddy K50 e*00/6*05*... Engine type Engine model Output in kw Displacement in cm³ BSE Gasoline BSX Gasoline [Eco Fuel] BDJ Diesel Vehicle and engine types, equipment variants and national specifications not listed in these installation instructions have not been tested. However, installation according to these installation instructions may be possible. The installation location of a digital timer and summer/winter switch should be confirmed with the end customer before installation. 907D_EN

3 Heater Unit/Installation Kit Quantity Description Order No.: Retail accessories with desired heater control See price list Installation kit for VW Caddy.6 Liter Gasoline and.0 Liter 907B Gasoline Eco Fuel;.0 Liter SDI Also required with Climatronic Quantity Description Order No.: IPCU Kit for Climatronic 90645A Heater unit recommended for the respective vehicle class: Vehicle Compact car Mid-size car, station wagon Full-size car, van, offroader Heater unit Thermo Top E Thermo Top C Thermo Top P The selection of the heater unit is based on the passenger compartment size of the vehicle and the level of comfort required by the customer! Foreword These installation instructions apply to VW Caddy.6 Liter Gasoline and.0 Liter Gasoline Eco Fuel;.0 Liter SDI vehicles - for validity, see page - from model year 005 and later, assuming technical modifications to the vehicle do not affect installation, any liability claims excluded. Depending on the vehicle version and equipment, modifications may be necessary during installation with respect to these installation instructions. However, the stipulations in the "installation instructions" and "operating and maintenance instructions" for the Thermo Top C/P/E must always be observed. The corresponding rules of technology and any information from the vehicle manufacturer should be observed during the installation work. General Instructions Installation should be carried out according to the general, standard rules of technology. Unless specified otherwise, fasten hoses, lines and wiring harnesses to original vehicle lines and wiring harnesses using cable ties. Sharp edges should be fitted with edge protectors (split-open plastic hose). Spray unfinished body areas, e.g. drilled holes, with anti-corrosion wax (Tectyl 00K, Order No. 9). Special Tools - Torque wrench for.0-0 Nm - Hose clamping pliers - Metric thread-setter kit 907D_EN

4 Explanatory Notes on Document To provide you with a quick overview of the individual working steps, you will find an identification mark on the outside top right corner of the page in question. Mechanical system Electrical system Water Fuel Exhaust gas Combustion air Special features are highlighted using the following symbols: Specific risk of injury or fatal accidents. Specific risk of damage to components. Specific risk of fire or explosion. Reference to general installation instructions of Webasto components or to the manufacturer's vehicle-specific documents. Reference to a special technical feature. The arrow in the vehicle icon indicates the position on the vehicle and the viewing angle. All dimensions are in mm! Tightening torque of hose clamps = Nm! Tightening torque of Ejot screws, Ejot studs = 0 Nm! 907D_EN 4

5 Preliminary Work WARNING! - Open fuel tank cap, ventilate tank. - Close the tank cap again. - Disconnect the battery "earth" or "ground" connection. - Depressurize the cooling system. - Copy the factory number from the original type label to the duplicate type label. - Remove years that do not apply from the duplicate label. - Attach the duplicate label (type label) in the appropriate place. - Completely remove the battery. - Remove the battery carrier. - Remove the engine cover. - Remove the air filter together with the intake hose. - Remove the right front wheel. - Remove the front section of the right front wheel well trim. - Remove the underride protection (if present). - Remove the bumper. - Remove the washer reservoir. - Remove the right-hand underbody trim - Remove the footwell trim on the driver's side and front passenger side - Remove the lower instrument panel trim on the driver's side - Remove the fuel-tank sending unit according to the manufacturer's instructions (with gasoline only). Heater unit installation location Heater unit Remove page "Operating Instructions for End Customer" and add to the vehicle operating instructions. Installation location 907D_EN 5

6 Electrical system Wiring harness of heater unit Guide wiring harness of heater unit in front of radiator at position and route to right along upper edge of radiator. Then route into engine compartment again at position. Fastening is not carried out until after heater unit is installed! Fuse holder, relay K For information on installing fuse holder and K relay, see page 7. Relay K Fuse holder Do not install the metering pump cable harness until later together with fuel pipe along the original vehicle fuel lines on the underbody Wiring harness installation diagram 4 5 Wiring harness pass through Original vehicle wiring harness pass through Wiring harnesses for fan controller and heater control Digital timer, summer/winter switch option Digital timer Summer/winter switch, drilled hole mm dia. 907D_EN 6

7 Fuse holder and relay K Countersink holes from behind for M5 countersunk head screws Cover of fuse/relay carrier in engine compartment Cut away bar in shaded area 5.0 mm dia. hole [x] Holes for fuse holder and K relay 40 6 M5x countersunk head screw [x] fuse holder and K relay 7 On vehicles with Climatronic, replace 5 A fuse F 7 with A fuse provided M5 flanged nut Large diameter washer (between cover and retaining plate) Retaining plate 4 M5 flanged nut 5 Relay K 6 Fuse holder fuse holder and K relay 8 Route brown (br) ground wire to original vehicle ground support point below headlight and connect. Fuse/relay carrier Original main vehicle fuse Red (rt) positive wire Connecting positive and ground wire 9 907D_EN 7

8 Climatic fan controller Fuse socket dependent on vehicle equipment SC or SC5; wire color black (sw) or black/yellow (sw/ge). Detach original vehicle fuse carrier (instrument panel at lower left) and unlock contact lock. Uncrimp black (sw) or black/yellow (sw/ge) wire on fuse output SC or SC5. Uncrimping wire 0 Produce connection as shown in wiring diagram. Black (sw) or black/yellow (sw/ge) wire with original standard power timer AMP housing [x] Contact lock locked 4 Black (sw) wire to K/0 5 Red (rt) wire from K/87a with standard power timer engaged in fuse output SC or SC5 wiring harness D_EN 8

9 Climatic fan controller Webasto VW Caddy 0 HG 4 X F rt sw oder sw/ge 4² SC oder SC5 sw oder sw/ge 4² T0k rt/ws 5 T5 5 Wiring diagram a 4² J0 oder E K rt/sw 4 T5 sw 4² + - M V 4 N4 T4r br Webasto components Vehicle components Colors and symbols HG Heater unit TT-C/E SC Fan fuse rt red X 6-pin heater unit connector SC5 Fan fuse ws white F 5 A fuse J0 Control unit of air conditioning sw black K Fan relay E6 Heater switch br brown N4 Resistor group ge yellow V Fan motor T... Plug connections Legend 907D_EN 9

10 Climatronic fan controller 4 Produce connections as shown in wiring diagram. Position of free sockets dependent on vehicle equipment. Connect black (sw) wire from K/0 to green/white (gn/ws) wire (AMP connector). Insulate red (rt) wires K/87a 4 and tie back. IPCU socket wiring harness of Climatronic Fasten brown (br) wire IPCU/85 on original vehicle ground point. IPCU ground wire Route wiring harness from IPCU to original vehicle wires to fan unit. Routing wiring harness of IPCU 4 Connector T6t Black/white (sw/ws) wire to connector T6t/ Black/white (sw/ws) wire from IPCU/A 4 Red (rt) wire from IPCU/E 5 Black/white (sw/ws) wire from Climatronic control unit 6 Wiring harness from IPCU Connecting wires D_EN 0

11 Climatronic fan controller Kabelbaum Hg Kabelbaum Climatronic VW Caddy 0 5 Wiring diagram X HG 4 F KB 5 6 T6f SC5 rt 4² a 85 0 K! gn/ ws 0,75² IPCU E A rt 0,75² sw/ws 0,75² sw/ bl/ ws ws 0,75² 0,75² sw/ ws 0,75² rt/ ge rt/ws T0k sw 4² 4 M GE T6t br br Webasto components Vehicle components Colors and symbols HG Heater unit TT-C/E SC5 Fan fuse rt red X 6-pin heater unit connector KB Air-conditioning control ws white panel F Replace 5 A fuse F ge Fan controller sw black with A fuse. T... Plug connections br brown K Fan relay gn green IPCU Pulse width modulator bl blue IPCU adjustment values: ge yellow Duty cycle: 0 % Insulate wire ends and Frequency: 400 Hz tie back Voltage: 8 V X Cutting point Function: High-side Legend 907D_EN

12 Remote option (Telestart) Drill out upper hole of bracket to 6.5 mm dia. Receiver Mount M6x bolt, large diameter washer, flanged nut in existing hole Bracket receiver 6 Antenna antenna 7 907D_EN

13 Preparing heater unit Replace circulating pump cover with cover with straight inlet Converting circulating pump Preparing installation location Washer reservoir Drill 6.5 mm dia. hole Preparing washer reservoir 8 Install washer reservoir and copy hole pattern. Hole pattern, 9. mm dia. hole Washer reservoir Copying hole pattern 9 M6 rivet nut rivet nut 0 907D_EN

14 Position rivet nut in center between A/C lines. Edge protection mm dia. hole; M6 rivet nut rivet nut 0 heater unit Loosely mounting strut Strut M6x5 bolt, spring lockwasher, large diameter washer, 5 mm shim, 0 mm shim strut Connect connector on heater unit. Loosely mount heater unit on strut. Strut Ejot screw heater unit 5 5 Insert two washers between heater unit and bracket at position. Tighten all screw connections between bracket, strut, heater unit and body. 4 Ejot screw [x] 5 Original vehicle stud bolt, M6x0 spacer nut [x] heater unit D_EN 4

15 M6x60 bolt, spring lockwasher, washer, 0 mm spacer, existing threaded hole M6x60 bolt, spring lockwasher, large diameter washer, 0 mm spacer, large diameter washer, rivet nut Washer reservoir washer reservoir 5 Washer reservoir M6x5 bolt, spring lockwasher, large diameter washer [x each], premount spacer nuts washer reservoir 6 907D_EN 5

16 Fuel CAUTION! Open the vehicle's fuel tank cap, ventilate the tank and then re-close the tank lock. Catch any fuel running off with an appropriate container. Install fuel line and metering-pump wiring harness so that they are protected against stone impact. Unless specified otherwise, always fasten using cable ties. Mount the fuel line and wiring harness with rub protection on sharp edges. WARNING! The fuel line and wiring harness are routed to the metering pump in as shown in the wiring harness routing diagram. Route wiring harness of metering pump in coolant reservoir to right and secure on original vehicle lines with cable ties. Pay particular attention to freedom of movement of wiper linkage. Coolant reservoir cap Metering pump wiring harness wiring harness of metering pump mm dia. rubber-coated p-clamp, plastic nut on original vehicle stud bolt Hose section, 0 mm dia. clamp [x] Fuel line 4 Cloth protective hose cut to,00 mm length Connection to heater unit 8 Guide fuel line and wiring harness of metering into original vehicle line duct and route to underbody. Fuel line in protective hose lines 9 907D_EN 6

17 Route fuel line and wiring harness of metering pump along original vehicle fuel lines to rear. Line duct lines 0 Metering pump of.6 liter gasoline and diesel engine Rubber-coated p-clamp, silent block, flanged nut [x] Metering pump Perforated bracket 4 Mount M6x0 bolt, large diameter washer, M6 flanged nut in existing hole metering pump 4 Fuel line Hose section, 0 mm dia. hose clamp [x] Wiring harness of metering pump, connector mounted Connecting metering pump 907D_EN 7

18 0 Preparing fuel standpipe Standpipe Molded hose 7.5 mm dia. 4.5 mm dia. Cutting standpipe and molded hose to length mm dia. 4.5 mm dia. 0 mm dia. Caillau clamp in center between beads on end of standpipe. Standpipe Molded hose Premounting standpipe and molded hose 4 Fuel removal on diesel engines Lower fuel tank in accordance with manufacturer's specifications. Cut mm off blind plug. Fuel sender Tip cut off blind plug Cutting off blind plug 5 4 Should the standpipe be slightly curved on delivery, then it must be aligned so that the end points toward the rear right. Otherwise there is a danger of the fuel gauge being impaired. Remaining section of fuel line 0 mm dia. Caillau clamp Preassembled molded hose with standpipe 4.5 mm dia. Caillau clamp Connecting fueltank sending unit 6 907D_EN 8

19 Check the position of the components; adjust if necessary. Check that they have free clearance. Fuel line from fuel-tank sending unit Hose section, 0 mm dia. hose clamp [x] Connecting metering pump 7 Metering pump of Eco Fuel Angle down perforated bracket by Rubber-coated p-clamp, silent block, flanged nut [x] Metering pump Premounting metering pump 8 Original vehicle stud bolt from fuel tank metering pump 9 Fuel line Hose section, 0 mm dia. hose clamp [x] Wiring harness of metering pump, connector mounted Connecting metering pump D_EN 9

20 Fuel standpipe of.6 liter gasoline and.0 liter Eco Fuel Remove the fuel tank according to the manufacturer's instructions. Cut mm off blind plug. Fuel sender Tip cut off blind plug Cutting off blind plug 4 Position guide clip for standpipe. Reinstall fuel tank in accordance with manufacturer's instructions mm dia. Caillau clamp Preassembled molded hose with standpipe 4 0 mm dia. Caillau clamp 5 Remaining section of fuel line Connecting fueltank sending unit.6 liter gasoline Fuel line from fuel-tank sending unit Hose section, 0 mm dia. hose clamp [x] Check the position of the components; adjust if necessary. Check that they have free clearance. Connecting metering pump 4.0 liter Eco Fuel Fuel line from fuel-tank sending unit Hose section, 0 mm dia. hose clamp [x] Check the position of the components; adjust if necessary. Check that they have free clearance. Connecting metering pump D_EN 0

21 Coolant for gasoline engine WARNING! Any coolant running off should be collected using an appropriate container. Install hoses so that they are kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that no other hose can be damaged! When installing the coolant hose, the heater unit must be filled with coolant. The connection should be "inline" based on the following diagram: Coolant routing diagram B A All spring clips without a specific designation = 7 mm dia. All connecting pipes = 0x0 dia. 907D_EN

22 a = 940 b = 000 A X B Discard section X Cutting coolant hoses to length X X y Push braided protection hoses onto hose A and B and cut to length. Cut heat shrink plastic tubing to length. y y A y y = 5 50 mm long heat shrink plastic tubing [4x] Preparing coolant hoses B Loosely mount bolt! 9 mm dia. rubber-coated p-clamp [x] M6x0 bolt, spring lockwasher 40 mm spacer nut, original vehicle stud bolt Premounting hose guide 45 Loosely mount bolt. 4 M6x0 bolt, flanged nut Original vehicle M8 nut Strut 4 9 mm dia. rubber-coated p-clamp [x] Premounting hose guide D_EN

23 Spring clip will be reused. Pull off original vehicle hose section to heat exchanger inlet and discard Original vehicle hose section from engine outlet Cutting point B 47 Original vehicle spring clip Connecting heat exchanger inlet 48 Route hose B through front p-clamp. 9 mm dia. rubber-coated p-clamp Hose routing B B 49 Route hose B through upper p-clamp. 9 mm dia. rubber-coated p-clamp Hose routing D_EN

24 B Hose A with 90 elbow on heater unit inlet! 7x7 double clip, lockable A Connecting heater unit 5 Route hose A through lower p-clamp. After routing, tighten M6x0 bolt and flanged nut at position. 7x7 double clip, lockable 9 mm dia. rubber-coated p-clamp (premounted) Hose routing A A 5 Route hose A through rear p-clamp. After routing, tighten M6x0 bolt and flanged nut at position (concealed). 9 mm dia. rubber-coated p-clamp A 5 Check routing of hoses A and B along entire length and correct if necessary. Cable tie Original vehicle hose from engine outlet Hose routing Connecting engine outlet D_EN 4

25 Coolant for diesel engine WARNING! Any coolant running off should be collected using an appropriate container. Install hoses so that they are kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that no other hose can be damaged! When installing the coolant hose, the heater unit must be filled with coolant. The connection should be "inline" based on the following diagram: Coolant routing diagram B A All spring clips without a specific designation = 7 mm dia. All connecting pipes = 0x0 dia. 907D_EN 5

26 A X B a = 900 b = 950 Discard section X Cutting coolant hoses to length X X y Push braided protection hoses onto hose A and B and cut to length. Cut heat shrink plastic tubing to length. y A y y = 5 50 mm long heat shrink plastic tubing [4x] Preparing coolant hoses y B Loosely mount bolt. 9 mm dia. rubber-coated p-clamp [x] Large diameter washer, 40 mm spacer nut, original vehicle stud bolt M6x0 bolt, spring lockwasher Premounting hose guide 55 Loosely mount bolt. 4 M6x0 bolt, flanged nut Original vehicle M8 nut Strut 4 9 mm dia. rubber-coated p-clamp [x] Premounting hose guide D_EN 6

27 Spring clip will be reused. Original vehicle hose section from engine outlet Pull off original vehicle hose section to heat exchanger inlet and discard Cutting point 57 B Original vehicle spring clip Hose B with 90 elbow on heat exchanger inlet! Connecting heat exchanger inlet 58 B Route hose B through upper p-clamp. 9 mm dia. rubber-coated p-clamp B Hose routing 59 B Route hose B through upper p-clamp. 9 mm dia. rubber-coated p-clamp Hose routing D_EN 7

28 B Hose A with 90 elbow on heater unit inlet! 7x7 double clip, lockable A Connecting heater unit 6 Route hose A through lower p-clamp. After routing, tighten M6x0 bolt and flanged nut at position. 7x7 double clip, lockable 9 mm dia. rubber-coated p-clamp Hose routing A 6 Route hose A through lower p-clamp. After routing, tighten M6x0 bolt and flanged nut at position. 9 mm dia. rubber-coated p-clamp A A 6 Check routing of hoses along entire length and correct if necessary. Original vehicle hose from engine outlet Hose routing Connecting engine outlet D_EN 8

29 Combustion air Intake muffler Intake pipe, 7 mm dia. clamp Cable tie muffler and intake pipe D_EN 9

30 Exhaust gas Exhaust pipe a = 50 Exhaust end section b = 5 Discard section X Preparing exhaust pipe a B X Align muffler following installation. Ensure sufficient distance to neighboring components. 4 Exhaust muffler M6x0 bolt, large diameter washer, M6 flanged nut Angle bracket 4 Ejot screw muffler 66 Prior to installation, slide red (rt) rubber isolator with groove [x] onto exhaust pipe and align on heater unit after installing. Hose clamp [x] Red (rt) rubber isolator with groove [x] Exhaust pipe exhaust pipe 67 Hose clamp Exhaust end section exhaust end section D_EN 0

31 Final Work WARNING! Reassemble the disassembled components in reverse order. Check all hoses, clamps and all electrical connections for firm seating. Secure all loose cables using cable ties. Only use manufacturer-approved coolant. Spray the heater unit components with anti-corrosion wax (Tectyl 00K, Order No. 9). - Connect the battery - Fill and bleed the coolant circuit according to the vehicle manufacturer s specifications. - Set the digital timer. - Make settings on A/C control panel according to the "Operating Instructions for End Customer". - Check the proper operation of the additional heater, see the operating instructions/installation instructions. - Attach the "Switch off additional heater before refueling" sticker to the left-hand B-pillar. Adjust the sensitivity of the passenger compartment monitoring WARNING! Observe the valid repair manual of the respective vehicle. - Connect the VAG tester - Open Item 46 (Central Module of Comfort System) - Go to Item 0 (Adjustment) - Follow the request for the code entry and enter the code 5 - Reduce the sensitivity of the passenger compartment monitoring to 50 % - Save this setting - The adjustment of the sensitivity of the passenger compartment monitoring is completed. Adaptation of Passenger Compartment Monitoring Feel the drive Webasto AG Postfach 80-8 Stockdorf Hotline 0805 / Hotfax 095 / D_EN Printed in Germany 06/009 Printing: Steffen

32 Operating Instructions for End Customer Please remove page and add to the vehicle operating instructions. Note: We recommend matching the heating time to the driving time. Heating time = driving time Example: For a driving time of approx. 0 min. (in one direction), we recommend not exceeding a switch-on time of 0 min. If the summer/winter switch option has been installed, this must be switched in accordance with the time of year. The heater unit will then only switch on the vehicle fan to ventilate the vehicle interior in the position Winter heat and in the position Summer. Before parking the vehicle, make the following settings: Set temperature to "max." Set fan to level "", or possibly "" Direct air outlet toward windshield Climatic 69 Set temperature to "HI" [x] Air outlet to windshield Automatic air-conditioning D_EN