ALWAYS follow all Webasto installation and repair instructions and observe all warnings.

Transcription

1 Water Heater Feel the drive Thermo Top Evo Parking Heater e Installation documentation Skoda Fabia / Roomster Petrol from Model Year 00 Left-hand drive vehicle Manual transmission / direct shifting transmission (DSG) 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.: 685C_EN Fee Euro 0.00 Webasto AG

2 Table of Contents Validity Heater / Installation Kit Foreword General Instructions Special Tools Explanatory Notes on Document Preliminary Work 5 Heater installation location 5 Preparing electrical system 6 Electrical system 8 Fan controller for manual air conditioning 9 Automatic air-conditioning fan controller Remote option Telestart Preparing installation location Preparing heater 5 heater 7 Coolant circuit 9 Fuel Combustion air Exhaust gas 5 Final Work 6 Template for Fuel Standpipe 7 Operating Instructions for End Customer 8 Validity Manufacturer Model Type EG-BE No./ABE Skoda Fabia 5J e * 00/6 * 09 *... Skoda Roomster 5J e * 00/6 * 09 *... Engine type Engine model Output in kw Displacement in cm³ CHFA Petrol 98 CGPA Petrol 5 98 CBZA Petrol / TSI 6 97 CBZB Petrol / TSI Vehicle and engine types, equipment variants and national specifications not listed in these installation instructions have not been tested. However, installation according to this installation documentation may be possible. The installation location of the digital timer must be coordinated with the end-customer before the installation. 685C_EN

3 Heater / Installation Kit Quantity Description Order No.: Basic delivery scope Thermo Top Evo See price list Installation kit for Skoda Fabia / Roomster 00 petrol 68A Heater control See price list Also required with automatic air-conditioning Quantity Description Order No.: Automatic A/C kit 59B Foreword This installation documentation applies to Skoda Fabia / Roomster Petrol 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. However, the stipulations in this "installation documentation" and the "operating instructions" and "installation instructions" for the Thermo Top Evo 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 plastic hose). Spray unfinished body areas, e.g. drilled holes, with anti-corrosion wax (Tectyl 00K, Order No. 9). Check or adjust the corresponding settings before installing an IPCU! Special Tools - Torque wrench for.0-0 Nm - Hose clamping pliers - Metric thread-setter kit 685C_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 Coolant circuit Fuel Exhaust gas Combustion air Software 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 5x heater bolts = 8Nm! Tightening torque of 5x5 bolt of water connection piece retaining plate = 7Nm! 685C_EN

5 Preliminary Work WARNING! - Open the fuel tank cap, ventilate the tank. - Close the fuel tank cap again. - 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 windscreen wiper - Remove coolant reservoir cap - Remove coolant reservoir partition wall - Remove the windscreen wiper motor reservoir. - Remove the air filter together with the intake hose - Remove the battery - Remove the underride protection - Remove the right vehicle underbody trim - Fold up surface of the rear bench seat - Open the tank-fitting service lid. - Remove right light switch - Detach the central electrical box under the steering wheel - Remove the A/C control panel (only with automatic air-conditioning). - Remove side instrument panel trim at the left Heater installation location Heater Remove page 8 "Operating Instructions for End Customer" and add to the vehicle operating instructions. Installation location 685C_EN 5

6 0 Preparing electrical system Angle bracket 90 Bending angle bracket Fuse holder of passenger compartment M5x bolt, washer, nut Angle bracket Preparing fuse holder of passenger compartment rt/sw rt ² gn/ws 0,75² F 5A and K relay inserted. Insert red (rt) wire in the K/87a relay socket and black (sw) wire in the K/0 relay socket. F br 86 F a K rt ² sw ² Preparing fuse holder of passenger compartment gn/ws A br E 86 IPCU 85 E A 5 6 rt sw Automatic air-conditioning Connecting wires to IPCU socket. IPCU view on contact side. The IPCU is pre-programmed with the following adjustment values. These adjustment values are to be checked during function control of the vehicle and adapted if necessary. Duty cycle: 00% Frequency: 000 Hz Voltage:.6V Function: High-side Premounting IPCU 685C_EN 6

7 Mount IPCU after installation on Socket. Pull red (rt) wire and black (sw) wire into protective sleeving. 6 Velcro strip 0.5mm² black (sw) wire of IPCU/A 0.5mm² brown (br) wire of IPCU/ mm² red (rt) wire of IPCU/E 6 0.5mm² green/white (gn/ws) wire of IPCU/86 Preparing IPCU 5 685C_EN 7

8 Electrical system Connection to positive battery terminal Positive distributor on battery Positive wire to secured connection Digital timer Digital timer 5 Do not install the metering pump wiring harness until later together with fuel pipe along the original vehicle fuel lines on the underbody Wiring harness routing diagram Fuse holder of engine compartment.5mm dia. hole; 5.5xmm self-tapping screw, retaining plate of fuse holder F- fuses mounted Earth wire on negative battery terminal 6 Wiring harness pass through of passenger compartment Protective rubber plug pass through coolant reservoir Wiring harness of engine compartment fuse holder 7 685C_EN 8

9 Fan controller for manual air conditioning F F Webasto HG X 5 X SB 9 Skoda 0 5 Wiring diagram ge rt ² sw/rt,5² rt/sw rt ² gn/ws 0,75² sw/rt,5² T0d/ rt/ws ² br rt/sw rt ² gn/ws 0,75² 5 T5h E9 X0 F F T5h rt br br a K sw ² + M - br V Taa N Webasto components Vehicle components Colours and symbols HG Heater TT-Evo V Fan motor rt red X 6-pin heater connector SB9 Fuse, 0A ws white X -pin heater connector N Resistor group sw black X0 -pin connector E9 Switch unit br brown Heater control T... Connector gn green K Fan relay F Fuse, 0A F Fuse, 0A F Fuse, A X Cutting point F Fuse, 5 A Wiring colours may vary. Legend 685C_EN 9

10 Fuse holder of passenger compartment Original vehicle bolt Angle bracket 8 Connect same colour wires of wiring harness in the fuse holder of passenger compartment and wiring harness in the fuse holder of engine compartment according to wiring diagram. fuse holder of passenger compartment Connecting the wiring harnesses 9 Black (sw) wire from K/0 Black/red (sw/rt) wire of fan unit Black/red (sw/rt) wire of fuse SB9 Central electrical box 5 Red (rt) wire from K/87a Produce connections as shown in wiring diagram. Connecting central electrical box C_EN 0

11 Automatic air-conditioning fan controller Webasto Skoda 0 5 HG Wiring diagram F F X 5 X ge sw/rt,5² SB9 br X0 rt/sw rt ² gn/ws 0,75² sw 6 sw/rt,5² T6aa rt/sw rt ² gn/ws 0,75² gn/ws F F rt 5 sw M J6 br br a K rt ² br 86 IPCU 85 E A sw 6 J55 T6d sw ² Webasto components Vehicle components Colours and symbols HG Heater TT-Evo J6 Fan unit rt red X 6-pin heater connector J55 A/C control panel ws white X -pin heater connector SB9 Fuse, 0A sw black X0 -pin connector T... Connector br brown Heater control bl blue K Fan relay gn green F Fuse, 0A ge yellow F Fuse, 0A F Fuse, A F Fuse, 5 A IPCU Pulse width modulator IPCU adjustment values: Duty cycle: 00% Frequency: 000 Hz Voltage:.6 V X Cutting point Function: High-side Wiring colours may vary. Legend 685C_EN

12 Fuse holder of passenger compartment Original vehicle bolt Angle bracket fuse holder of passenger compartment Connect same colour wires in wiring harness of passenger compartment fuse holder and wiring harness of heater, as well as additional brown (br) wire and additional green/white (gn/ws) wire according to wiring diagram. Connecting the wiring harnesses Ensure sufficient distance from light switch. Glue IPCU socket (velcro strip) IPCU Black (sw) wire from K/0 Black/red (sw/rt) wire of fan unit Black/red (sw/rt) wire of fuse SB9 Central electrical box 5 Red (rt) wire from K/87a Produce connections as shown in wiring diagram. Connecting central electrical box 5 685C_EN

13 5 Connector T6d Red (rt) wire of IPCU/E Black (sw) wire J6 Black (sw) wire of IPCU/A 5 Black (sw) wire J55 / T6d Pin Connecting air-conditioning control panel 5 Remote option Telestart Fasten receiver with double-sided adhesive tape. receiver 6 Antenna antenna 7 Temperature sensor T00 HTM Fasten temperature sensor with double-sided adhesive tape. temperature sensor 8 685C_EN

14 Preparing installation location Install original vehicle hole, rivet nut rivet nut 9 TSI only Turn T-piece as shown. Aligning T- piece 0 All vehicles Remove original vehicle flanged nut, will be reused. Removing flanged nut Cut out insulation mat at the markings. Cutting out insulation mat 685C_EN

15 Remove original vehicle bolt ; will be reused later. Removing bolt Preparing heater 90, 8mm dia. coolant connecting piece, sealing ring 5x5mm self-tapping bolt, retaining plate of coolant connecting piece 8mm dia. coolant connecting piece, sealing ring coolant connecting piece All 80, 8x8mm dia. moulded hoses Discard section X. D A X A = 00 D = 00 Cutting hoses to length C B 5 5 mm dia. spring clip Combustion air pipe Fuel line Hose section, clamp [x] Premounting heater 6 685C_EN 5

16 Bracket 00 mm edge protection M6x bolt, spring lockwasher, M6x0 spacer nut Preparing bracket 7 5x self-tapping bolt [x] bracket 8 Mount wiring harness of circulating pump on heater and circulating pump 8 mm dia. rubber-coated p-clamp Circulating pump M6x6 bolt, flanged nut, existing hole circulating pump A 9 All connecting pipes 8x8mm dia. All spring clips 5mm dia. hoses D B C 0 685C_EN 6

17 Exhaust pipe a = 50 Exhaust end section b = 00 Discard section X Preparing exhaust pipe a b X Slide on exhaust-gas insulation Exhaust pipe Hose clamp exhaust pipe M6x bolt, spring lockwasher, large diameter washer, pipe clamp Slide on exhaust-gas insulation Exhaust pipe exhaust pipe heater Install M6x0 bolt, spring lockwasher Bracket heater 685C_EN 7

18 Loosely mount original vehicle bolt Bracket heater Tighten all screw connections. Bracket Original vehicle flanged nut heater 5 685C_EN 8

19 Coolant circuit 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 hoses, the heater must be filled with coolant. The connection should be "inline" based on the following diagram: Hose routing diagram B C D A All spring clips = 5mm dia. = Original vehicle spring clip. All connecting pipes without a specific designation and = dia. 8x8 mm. 685C_EN 9

20 6 and 77 kw Engine outlet hose section Remove hose section of heat exchanger inlet and discard Original vehicle spring clip will be reused. Cutting point 6 and 5 kw Engine outlet hose section Remove hose section of heat exchanger inlet and discard Original vehicle spring clip will be reused. Cutting point 7 D All vehicles The following figures show. TSI! Original vehicle spring clip Connecting heat exchanger inlet 8 Ensure sufficient distance to neighbouring components, correct if necessary. Engine outlet hose section Connecting engine outlet A 9 685C_EN 0

21 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 fuel line and metering pump to right-hand vehicle side Route wiring harness of heater to heater and insert! Routing in engine compartment 0 Route fuel line and wiring harness of metering pump to original vehicle fuel lines at the installation location of the metering pump. Routing in engine compartment Fuel line, metering pump wiring harness Original vehicle pass through of fuel lines lines 685C_EN

22 Drill out perforated bracket at Position to 8.5mm dia. and angle down. 75 Preparing perforated bracket 90 Metering pump Metering pump mount Cable tie drawn through mount of metering pump Perforated bracket 5 M6x5 bolt, flanged nut Premounting metering pump 5 Original vehicle bolt of fuel tank fastening Perforated bracket metering pump Wiring harness of metering pump, connector mounted Fuel line of heater Hose section, 0 mm dia. clamp [x] Connecting metering pump 5 685C_EN

23 Remove fuel-tank sending unit in accordance with manufacturer's instructions. Place large diameter washer d a =.6 as shown on fuel-tank sending unit. Copy hole pattern, 6 mm dia. hole Copying hole pattern 6 Shape fuel standpipe according to template, cut to length and install. fuel standpipe 7 Install fuel-tank sending unit in accordance with manufacturer's instructions. Fuel line Hose section, 0 mm dia. clamp [x] Fuel standpipe Connecting fuel line 8 Check the position of the components; adjust if necessary. Check that they have freedom of movement. fuel line, fuel standpipe Hose section, 0 mm dia. clamp [x] Connecting metering pump 9 685C_EN

24 Combustion air Install coolant reservoir partition. Original vehicle bolt at Position against M6x50 bolt. Silencer Combustion air pipe M6x50 bolt, spring lockwasher, pipe clamp, 0mm shim, original vehicle threaded hole silencer C_EN

25 Exhaust gas Drill out perforated bracket at position to 8.5mm dia. and angle down. Preparing perforated bracket 90 0 Silencer Hose clamp Exhaust end section Perforated bracket 5 M6x6 bolt, spring lockwasher Premounting silencer 5 5 Ensure sufficient distance to neighbouring components, correct if necessary. Exhaust pipe Hose clamp Perforated bracket M8 flanged nut, spring lockwasher, original vehicle stud bolt silencer 5 685C_EN 5

26 Final Work WARNING! Reassemble the disassembled components in reverse order. Check all hoses, clamps and all electrical connections for firm seating. Insulate all loose wires and tie back. Only use manufacturer-approved coolant. Spray the heater components with anti-corrosion wax (Tectyl 00K, Order No. 9). - Connect the battery - Fill and bleed the coolant circuit according to the vehicle manufacturer s specifications. - Adjust digital timer, teach Telestart - Make settings on A/C control panel according to the "Operating Instructions for End Customer". - Place instruction signboard "Switch off parking heater before refuelling in the area of the filler neck - For initial start-up and function test, refer to installation instructions Feel the drive Webasto AG Postfach 80 D-8 Stockdorf / Germany National Hotline: ( Cent aus dem deutschen Festnetz) Hotfax: Hotmail: hotline@webasto.de 685C_EN Printed in Germany 0/0 Printing: Steffen 6

27 Template for Fuel Standpipe 00mm Scale : Compare the size of the printed version with dimension lines. Permitted tolerance a maximum of %. Set the printer settings to no margin or minimise margins and 00% of the normal size. 00mm 0 685C_EN 7

28 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. On vehicles with anti-theft alarm, the passenger compartment monitoring system must be deactivated. For information on deactivation, please see the vehicle owner's manual. Before parking the vehicle, make the following settings: Set temperature to "max." Set fan to level "", max. "" Direct air outlet toward windscreen Manual air conditioning 5 Direct air outlet toward windscreen Set temperature to "HI" Automatic air-conditioning 5 685C_EN 8