Citroen Jumper X2/50 / Fiat Ducato 250 / Peugeot Boxer X2/50

Transcription

1 Air Heater Feel the drive Air Top 000 ST Air Heater e Installation documentation Citroen Jumper X/50 / Fiat Ducato 50 / Peugeot Boxer X/50 Diesel from model year 009 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, specialised tools and equipment are required to install and repair Webasto heating and cooling systems. Only original Webasto parts must be used. For this, also see the catalog of air and water heater accessories from Webasto. 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. The initial startup is to be executed with the Webasto Thermo Test Diagnosis. Webasto does not accept any liability for defects and damage that are attributable to installation by untrained staff. Ident. No.: 5905C_EN Fee Euro 0.00 Webasto AG

2 Citroen Jumper X/50 / Fiat Ducato 50 / Peugeot Boxer X/50 Table of Contents Validity Heater/Installation Kit Foreword General Instructions Special Tools Explanatory notes on document 4 Preliminary Work 5 Heater installation location 5 Electrical system 6 Remote option of combination timer 7 Preparing installation location 8 Preparing heater 9 heater 0 Hot air Combustion air 6 Fuel 7 Exhaust gas 0 Final Work Template for fuel standpipe Validity Manufacturer Model Type EG-BE No./ABE Citroen Jumper X/50 L77 Fiat Ducato 50 e * 00 / 6 * 0 *... Fiat Ducato 50 L778 Fiat Ducato 50 L L779 Peugeot Boxer X/50 L77 Peugeot Boxer X/50 L77 Vehicle and engine types, equipment variants and national specifications not listed in this installation documentation have not been tested. However, installation according to this installation documentation may be possible. The installation location of the heater controls and the tool kit are to be coordinated with the end-customer before the installation. WARNING! Original vehicle supporting components and/or components that serve the purpose of crash safety may not be processed for the hot air and recirculating air ducting. 5905C_EN

3 Citroen Jumper X/50 / Fiat Ducato 50 / Peugeot Boxer X/50 Heater/Installation Kit Quantity Designation Order No.: retail accessories Air Top 000 ST See price list Installation Kit Air Top 000 Standard 90050A Installation kit Citroen Jumper X/50 / Fiat Ducato 50 / Peugeot 5904A Boxer X/ Diesel Heater control See price list Foreword This installation documentation applies to Citroen Jumper X/50 / Fiat Ducato 50 / Peugeot Boxer X/50 Diesel vehicles ( van with partition wall) - for validity, see page - from model year 009 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, and are to be adjusted accordingly. However, the stipulations in this "installation documentation"; the "operating instructions " and the "installation instructions" for the Air Top 000 ST 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 rub protection (split-open fuel 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 - Webasto flattening tool, Ident No.: 89A - Metric thread-setter kit - 60mm dia hole saw 5905C_EN

4 Citroen Jumper X/50 / Fiat Ducato 50 / Peugeot Boxer X/50 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 Heating air 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 for fuel, hot air and combustion air clamps =.0 Nm! Tightening torque for exhaust gas hose clamps = 6.0 Nm! Tightening torque for fuel tank pipe = 5.0 Nm! 5905C_EN 4

5 Citroen Jumper X/50 / Fiat Ducato 50 / Peugeot Boxer X/50 Preliminary Work WARNING! - Open the fuel tank cap and vent the fuel tank. - Close the fuel tank cap again. - Remove the battery cover. - Disconnect the battery "earth" or "ground" connection. - Depressurise 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. - Remove the A-pillar trim on the left and right. - Remove the driver's seat. - Remove the tool kit fully with the bracket. - Remove the double seat bench. - Remove the floor trim. - Remove the heat protection plate of the exhaust system. - Open the tank-fitting service lid. - Remove the fuel-tank sending unit in accordance with the manufacturer's instructions. Heater installation location Heater Installation location 5905C_EN 5

6 Citroen Jumper X/50 / Fiat Ducato 50 / Peugeot Boxer X/50 Electrical system Fuse holder, earth wire Fuse holder 4 mm dia. hole; 5.5x9x5 self-tapping screw; retaining plate of fuse holder Earth wire 4 Negative terminal of battery Wiring harness routing Wiring harness of heater 4 Wiring harness routing diagram Heater control 4 5 Positive wire Drill mm dia. hole; thermostat Positive wire Positive distributor of battery 5905C_EN 6

7 Citroen Jumper X/50 / Fiat Ducato 50 / Peugeot Boxer X/50 Remote option of combination timer User installation frame as template. Combination timer combination timer C_EN 7

8 Citroen Jumper X/50 / Fiat Ducato 50 / Peugeot Boxer X/ Preparing installation location Remove protective layer. Cut out, mount and align template. Copy contour of template and hole pattern to Position [x]. Copying hole pattern 7 Remove template mm dia. hole [x] Holes in underbody 8 Install flattening tool and flatten underbody (use flattening tool of Webasto). 7 mm dia. hole [5x] Flattening underbody 9 Dismantle flattening tool. Expand the holes at Position [x] to 6mm dia. Provide all holes with corrosion protection. Holes in underbody C_EN 8

9 Citroen Jumper X/50 / Fiat Ducato 50 / Peugeot Boxer X/50 Cut out floor trim on front passenger side at the markings. Cut out elevation at Position. Reinstall floor trim and double seat bench. 0 Cutting out floor trim Preparing heater Replace bolt at Position [4x] with M6 stud bolt Mount cover cap Premounting heater Rubber gasket Spacer plate [x] Premounting heater Install spacer plate [x] Mounting spacer plates C_EN 9

10 Citroen Jumper X/50 / Fiat Ducato 50 / Peugeot Boxer X/50 heater Insert heater. Mount wiring harness on heater, shut the cover again. Secure connector with cable tie. heater 5 Spring lock washer, nut [4x each] heater C_EN 0

11 Citroen Jumper X/50 / Fiat Ducato 50 / Peugeot Boxer X/50 Hot air Route corrugated tube kink-free! The following diagram shows the hot air distribution for heating the passenger compartment and cargo space. Diagram for routing flexible tube Option A Option B Option A and B: Option A: Option B: = Cover cap of hot air inlet! = Hot air elbow = Cover cap. 4 = 60mm dia, 0mm long corrugated tube. 5 = Air distribution flap 5 = Cover cap. 7 = Air outlet 8 = 55mm dia, 480mm long corrugated tube. 5905C_EN

12 Citroen Jumper X/50 / Fiat Ducato 50 / Peugeot Boxer X/50 Option A: Heating of driver's cabin 4.8x5 blind rivet [x] Console Perforated bracket Premounting perforated bracket 7 Install 60-80mm dia clamp loosely M6x0 bolt, flanged nut mounted loosely Tubular frame of seat 4 9 mm dia. rubber-coated p-clamp Premounting perforated bracket 4 8 Insert hot air elbow through clamp and fasten on heater. Tighten all screw connections. Cover cap Fastening hot air elbow C_EN

13 Citroen Jumper X/50 / Fiat Ducato 50 / Peugeot Boxer X/50 Option B: Heating of driver's cabin and cargo space 60 mm dia. hole Hole for cargo space 0 Install air outlet with attached self-tapping screw air outlet 55x55x55 distribution flap Spacer ring [x] 60-80mm mm dia. clamp 4 Bar for Bowden cable 5 55mm dia, 480mm long corrugated tube Premounting air distribution flap 5 4 Cover cap Bowden cable Premounting air distribution flap 5905C_EN

14 Citroen Jumper X/50 / Fiat Ducato 50 / Peugeot Boxer X/50 Angle bracket Drill hole to mm dia Drilling angle bracket 4 4 Before tightening, align console 4 of heater outlet 9 mm dia. rubber-coated p-clamp [x] M6x0 bolt, flanged nut [x each] 5 Tubular frame of seat Premounting console 5 5 Install 60-80mm dia. clamp loosely on console 60mm dia, 0mm long corrugated tube corrugated tube 6 Insert air distribution flap in corrugated tube and tighten clamp. air distribution flap C_EN 4

15 Citroen Jumper X/50 / Fiat Ducato 50 / Peugeot Boxer X/50 Mount corrugated tube on air outlet and fasten with 60-80mm clamp. Connecting air outlet of cargo space 8 Remove original vehicle bolt for fastening trim, position angle bracket between frame and front passenger seat and trim, and fasten with M5x cap screw. angle bracket 9 Bowden cable Fastening Bowden cable 0 Install temperature sensor, route wire to installation location of heater control and connect. temperature sensor 5905C_EN 5

16 Citroen Jumper X/50 / Fiat Ducato 50 / Peugeot Boxer X/50 Combustion air a Discard section X. Combustion air pipe a = 0 Cutting combustion air pipe to length X Protective rubber plug Removing protective rubber plug Punch 6mm dia hole at centre of protective rubber plug. Insert combustion air pipe Preparing combustion air pipe 4 While inserting the protective rubber plug, please ensure that the combustion air inlet opening is not blocked Guide wiring harness of metering pump through the slit in the combustion air connection piece. 7 mm dia. clamp 4 Combustion air pipe combustion air pipe C_EN 6

17 Citroen Jumper X/50 / Fiat Ducato 50 / Peugeot Boxer X/50 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. Remove fuel-tank sending unit in accordance with manufacturer's instructions. Large diameter washer Copy hole pattern, 6 mm dia. hole Fuel extraction 5 Shape fuel standpipe according to template, cut to length and install. 6 Install fuel-tank sending unit according to manufacturer's instructions. Fuel standpipe 9 mm dia. Caillau clamp 90 moulded hose,.5 mm dia. x 4.5 mm 4 0 mm dia. Caillau clamp 5 Fuel line fuel standpipe Connecting fuel line C_EN 7

18 Citroen Jumper X/50 / Fiat Ducato 50 / Peugeot Boxer X/50 Slide fabric protection hose as rub protection onto fuel line. Slide fuel hose [x] as rub protection onto fuel line and fasten with cable tie to existing holes. Routing wire Fuel line of fuel standpipe Hose section, 0 mm dia. clamp [x] Metering pump 4 Rubber-coated pipe clamp 5 Wiring harness of metering pump, connector mounted 6 Silent block, flanged nut [x], existing hole Mounting metering pump 6 9 Slide fabric protection hose as rub protection onto fuel line of heater. Hose section, 0 mm dia. clamp [x] Connecting metering pump mm dia. hole; rivet nut 50 rivet nut C_EN 8

19 Citroen Jumper X/50 / Fiat Ducato 50 / Peugeot Boxer X/50 Cut wiring harness of metering pump 5 to length, install connector and connect with wiring harness of heater. 5 mm dia. rubber-coated p-clamp Fuel line 4 M6x0 bolt lines Fuel line Hose section, 0 mm dia. clamp [x] Metering pump wiring harness Connecting heater C_EN 9

20 Citroen Jumper X/50 / Fiat Ducato 50 / Peugeot Boxer X/50 Exhaust gas Drill out existing hole to 9. mm dia. and mount rivet nut rivet nut mm dia. hole; rivet nut 0 5 rivet nut 45 Hose clamp Exhaust pipe Slide on black (sw) rubber isolator [x] exhaust pipe 46 Exhaust pipe Angle bracket M6x0 bolt, spring lockwasher 4 M6x0 bolt, p-clamp, flanged nut 4 exhaust pipe C_EN 0

21 Citroen Jumper X/50 / Fiat Ducato 50 / Peugeot Boxer X/50 4 M6x0 bolt, spring lockwasher, large diameter washer Angle bracket M6x0 bolt, p-clamp, flanged nut 4 Align exhaust pipe exhaust pipe 4 48 Ensure sufficient distance from adjacent components; correct if necessary. Heat protection plate Position red (rt) rubber isolator [x] heat protection plate C_EN

22 Citroen Jumper X/50 / Fiat Ducato 50 / Peugeot Boxer X/50 Final Work WARNING! Mount removed parts in reverse order. Check all clamps and all electrical connections for firm seating. Secure all loose cables using cable ties. Spray heater components with anti-corrosion wax (Tectyl 00K, Order No. 9). - Connect the battery. - Adjust heater control - Check the proper function of the parking heater, see the operating instructions/installation instructions. - Place signboard "Switch off parking heater before refuelling" in the area of the filler neck - Place instruction label "Risk of fire and injury" on the right B pillar The installation location depends on the equipment, and must be coordinated with the end-customer! Variant Copy hole pattern for bracket of toolkit and fasten with original vehicle bolts and nuts. Tighten additionally with tension belt. toolkit 50 Variant Fasten toolkit with tension belt on storage. toolkit 5 Feel the drive Webasto AG Postfach 80 D-8 Stockdorf / Germany National Hotline: (4 Cent aus dem deutschen Festnetz) Hotfax: Hotmail: hotline@webasto.de C_EN Printed in Germany 06/0 Printing: Steffen

23 Citroen Jumper X/50 / Fiat Ducato 50 / Peugeot Boxer X/50 Template for fuel standpipe Watch length! Shown cut in straight section! 95mm 00 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 C_EN