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

Transcription

1 Air Heater Unit Feel the drive Air Top 000 ST B Additional Heater Air Top 000 ST D Additional Heater e *00/56*00 Installation Instructions VW T5 Gasoline and Diesel from Model Year 00 For left-hand drive vehicles only 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.: 9057C_EN Fee Euro 0 Webasto AG

2 Table of Contents Validity Heater Units Foreword General Instructions Special tools Explanatory Notes on the Document General Installation Diagram 5 Preliminary Work 6 Heater Unit Installation Location 6 Preparing Installation Location 7 Preparing Heater Unit 8 Heater Unit 9 Combustion Air 0 Fuel Connection Metering Pump Fuel Removal on Vehicles without Additional or Auxiliary Heater Fuel Removal on Vehicles with Additional or Auxiliary Heater Exhaust System 5 Optional Exhaust Muffler 5 Optional Hot Air System 6 Optional Recirculating Air 9 Electrical Connections 0 Optional Combination Timer 0 External Temperature Sensor 0 Remote Option (Telestart) Fault Code Deactivation 6 Final Work 7 Operating Instructions for End Customer 8 Template for Fuel Sender 9 Template for Fuel Standpipe 0 Validity Manufacturer Model Type EG-BE No./ABE Volkswagen Transporter T5 L8 Foreword These installation instructions apply to VW T5 vehicles with a Gasoline and Diesel engine (van with partition wall) from model year 00 and later, assuming technical modifications to the vehicle do not affect installation, any liability claims excluded. Vehicles and equipment variants, which are not listed in these installation instructions, have not been tested. However, installation according to these installation instructions may be possible. Depending on the version and the equipment variants of the vehicle, changes may be necessary relative to these "installation instructions" during installation and must be adjusted accordingly. However, where this is the case the stipulations in the "installation instructions" and "operating and maintenance instructions" for the Air Top 000 ST should be observed. The installation location of heater controls and the routing of the air ducting parts must be coordinated with the final customer prior to installation! WARNING! Original load-bearing components of the vehicle and/or component used for crash safety may not be modified for the hot air and recirculating air ducting! 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).

3 Heater Units/Installation Kit Quantity Description Order No.: Standard Delivery Scope Air Top 000 ST Gasoline 9008C Standard Delivery Scope Air Top 000 ST Diesel 9008C Comfort Delivery Scope Air Top 000 ST Gasoline 90085C Comfort Delivery Scope Air Top 000 ST Diesel 9008C Installation kit for VW T5 Gasoline and Diesel 9056A The installation kit contains the acket with fastening parts. The required air ducting parts must be ordered as an option from the Webasto Accessories Catalog in accordance with the customer order! To be ordered as an option for vehicles without factory-installed additional heater: Quantity Description Order No.: Fuel standpipe 008B To be ordered as an option for vehicles with factory-installed additional heater: Quantity Description Order No.: 6x5x6 mm fuel standpipe 067A To be ordered as an option when using fresh-air mode: Quantity Description Order No.: External temperature sensor B To be ordered as an option when using Telestart: Quantity Description Order No.: Bag for retrofitting T80 90B The materials used for this application example - in accordance with validity on page - are contained in the following list. In case of deviations in accordance with the customer order, the materials actually required can be ordered from the currently valid Webasto Accessories Catalog. Quantity Description Order No.: Flexible tube PAK, inside dia.= 60 mm (cut to length) 9897 Flexible tube PAK, inside dia.= 55 mm (cut to length) 76 5 Clamp, mm dia. 965 Air outlet, Da = 60 mm; Da = 9 mm; L = 65 mm 8789A Air outlet, Da = 55 mm; Da = 87 mm; Distributor with butterfly valve, outside dia.. = 55 mm; L = 95 mm 07 Reducing piece, Da = 60 mm; Da = 55 mm; L = 5 mm 985A Special tools - Torque wrench for.0-0 Nm - Metric thread-setter kit - Blind rivet tool

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 Hot air system Fuel connection Exhaust system 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. i 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.

5 General Installation Diagram Digital timer: comfort accessory Not with TRS! Installation diagram for AT 000 ST Fuel filter: option Terminal 5 Jumper 0.75 mm² 0.75 mm² sw Terminal 0 Terminal 58.0 mm² 0.75 mm² rt gr Terminal.0 mm² 0.5 mm² sw 0.5 mm² bl 0.5 mm² rt 0.5 mm² ws Connection diagram for comfort digital timer 5

6 Preliminary Work WARNING! - Disconnect the battery "earth" or "ground" connection. - 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. - Open fuel tank cap, ventilate tank. - Close the tank cap again. - Remove the underbody protection on the right and left (if present). - Remove the fuel tank (only on vehicles without installed auxiliary or additional heater). - Remove the fuel-tank sending unit in accordance with the manufacturer's instructions (only on vehicles without installed auxiliary or additional heater). - Remove the trim on the front passenger side entrance (only with recirculating air mode). - Remove the lower instrument panel trim on the driver's side. Heater unit installation location Heater unit Installation location 6

7 Preparing installation location Rivet nut (x) in existing holes rivet nuts Bracket M6x0 bolt, large diameter washer on rivet nuts 7 Loosely mount acket Copy hole pattern [x] to door sill Remove acket, drill 9. mm dia. hole; install rivet nuts Copying hole pattern 7

8 Preparing heater unit With fresh-air mode, an underride protection as shown in Figure must be installed if not present! Heater unit Mount base seal Protective grill Preparing heater unit 5 Cut approx. 60 mm off 60 mm dia. flexible tube. Heater unit Wiring harness 60 mm dia. flexible pipe, 60 mm long mm dia. hose clamp Premounting heater unit 6 Route through wire of metering pump downward. Fasten hot-air flexible tube on acket with cable tie. Bracket Large diameter washer, spring lockwasher, M6 nut [x each] Mount edge protection, 70 mm long [x] 5 Cable tie acket 5 7 Exhaust pipe, hose clamp P-clamp, 0 mm spacer sleeve, M6x0 bolt, flanged nut Combustion-air intake pipe, 7 mm dia. hose clamp Protective cap 5 Mecanyl fuel line, hose section, 0 mm dia. hose clamp [x] lines 5 8 8

9 heater unit Preassembled heater unit M6x0 bolt, spring lockwasher, flanged nut [x each] heater unit 9 Preassembled heater unit M6x0 bolt, spring lockwasher, flanged nut [x each] heater unit 0 9

10 Combustion air Shape combustion-air intake pipe as shown in picture. i Combustion-air intake pipe Cable tie intake pipe 0

11 Fuel Connection 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. Complete connector with single wire seal [x], tab connector and connector housing on wire of metering pump from heater unit and connect to wiring harness of metering pump. Plug connection on wiring harness of metering pump Connecting wiring harness of metering pump Cut heat protection hose as shown in Figure and. Pull wiring harness of power supply and wiring harness of metering pump and Mecanyl fuel line into one heat protection hose each. Wiring harness of power supply in heat protection hose Mecanyl fuel line and wiring harness of metering pump in heat protection hose Cable tie lines Route wiring harness of power supply and wiring harness of metering pump and Mecanyl fuel line over heat guard plate on left-hand side of vehicle. Route wiring harness of power supply further to battery. Wiring harness of power supply in heat protection hose Mecanyl fuel line and wiring harness of metering pump in heat protection hose Wiring harness of power supply Cable tie lines

12 Metering pump 6 Cut Mecanyl fuel line to length at installation location of metering pump. Metering pump 5 Rubber-coated pipe clamp Silentblock, flanged nut Hose section, 0 mm dia. hose clamps [x] 6 Hose section, 0 mm dia. hose clamp Remaining end of Mecanyl fuel line Hose section, 0 mm dia. hose clamps [x] Preassembling metering pump 5 5 Ensure proper installation position of metering pump, see "Installation Instructions. Installation location on left on strut before vehicle fuel tank! i Preassembled metering pump Flanged nut on silent block in existing hole Original vehicle strut Remaining end of Mecanyl fuel line Installation location of metering pump 6 Fuel line from heater unit on pressure side of metering pump [side with connector]. Preassembled metering pump Wiring harness for metering pump, singlewire sealing [x], tab connector, connector housing Fuel line from heater unit, 0 mm dia. hose clamp on premounted hose section Connecting metering pump 7

13 Fuel Removal on Vehicles without Additional or Auxiliary Heater Remove fuel tank according to manufacturer's specifications. Remove fuel-tank sending unit according to manufacturer's specifications. Cut out template and lay on. Fuel-tank sending unit Template Copy hole pattern, 6 mm dia. hole Removing fuel 8 Shape fuel standpipe according to template, cut to length and install, see "installation instructions". Fuel-tank sending unit Fuel standpipe i fuel standpipe 9 Install fuel-tank sending unit according to manufacturer's specifications. 5 Fuel tank Fuel-tank sending unit 5 Fuel standpipe Remaining end of Mecanyl fuel line Hose section, 0 mm dia. Caillau clamp [x] Connecting fuel line 0 Clip fuel line from fuel standpipe into existing fastening points. Remount fuel tank. Fuel tank Remaining end of Mecanyl fuel line Fastening points [x] fuel line

14 Fuel Removal on Vehicles with Additional or Auxiliary Heater Cut off fuel line to additional or auxiliary heater as shown. Mount fuel standpipe in cutting point as shown. Fuel line to additional or auxiliary heater Fuel standpipe, 0 mm dia. hose clamp [x]. Remaining end of Mecanyl fuel line from metering pump Hose section, 0 mm dia. hose clamp [x] Removing fuel

15 Exhaust system Align exhaust pipe as shown. Drill mm dia. condensed-water drain hole at lowest point in exhaust pipe. Ensure sufficient distance to neighboring components. Exhaust pipe P-clamp, 0 mm spacer sleeve, self-tapping screw Fastening exhaust pipe Optional Exhaust Muffler Installation of exhaust muffler as shown in Figure 6 is not possible on a vehicle with underride protection equipment! Exhaust pipe Underride protection Exhaust muffler Remove p-clamp at position again. Exhaust pipe P-clamp Removing p-clamp 5 Cut off exhaust pipe as shown in Figure and mount muffler. Exhaust pipe 5 Angle acket, M6x0 bolt, flanged nut on acket Exhaust muffler, M6x0 bolt, flanged nut on angle acket Hose clamp [x] muffler 6 5

16 Optional Hot Air System WARNING! The routing of the air ducting parts shown is an application example on the van with a partition wall. Should other versions and equipment variants be used, then the appropriate adjustments must be made. Before installation, the routing of the air ducting parts must be coordinated with the end customer! Install flexible tubes so that they are kink-free. Unless specified otherwise, always fasten using ackets and cable ties. The hot air ducting on this version example is executed as shown in the following diagram: Diagram for hot air ducting 7 = Heater unit = Flexible tube, 60 mm dia. = Dia. 55x60 mm adapter 5 = Air distributor = Flexible tube, 55 mm dia. 6 = Air outlet 7 = Flexible tube, 60mm dia. 8 = Air outlet 6

17 Optional Hot Air System Fold back cover under front passenger seat. Lay on dia. 55x60 adapter as shown. Dia. 55x60 mm adapter Copy hole pattern, 60 mm dia. hole Hole under front passenger seat 7 Mount adapter in hole from above and glue in with Sicaflex. Dia. 55x60 mm adapter Gluing in adapter 8 Mount 60 mm dia. flexible tube on adapter. Route wiring harness of controls through protective rubber plug into passenger compartment. 60 mm dia. flexible pipe, 60 mm long mm dia. hose clamp [x] Wiring harness of controls Protective rubber plug Pass throughs into passenger compartment 9 55 mm dia. hole at position in partition wall. Mount air outlet and fasten with blind rivets. Partition wall Air outlet Hole in partition wall 0 7

18 Cut 55 mm dia. flexible tube to length as shown and mount on adapter. 55 mm dia. flexible tube mm dia. hose clamp Bracket with hose clamp, self-tapping screw [x] Routing under front passenger seat Cut 55 mm dia. flexible tube and 5 to length as shown. Mount air distributor as shown. Air outlet must be aligned so that hot air is not directed at controls (e.g. handake lever)! 6 55 mm dia. flexible tube from Adapter Air distributor, adjustable 55 mm dia. flexible tube to air outlet 5 55 mm dia. flexible tube Air outlet 6 End cap Mounting distributor 5 8

19 Optional Recirculating Air No underride protection is required for the option recirculating air mode! Underride protection Underride protection Lay air outlet on entrance trim on front passenger side as shown; copy inside dia. and hole pattern for fastening [x] to trim. Remove air outlet and drill 60 mm dia. hole in trim and entrance on front passenger side. Entrance trim on front passenger side Air outlet air outlet Hole for fastening air outlet [x] in trim. Mount air outlet in trim and fasten with blind rivets. Entrance on front passenger side Air outlet 60 mm dia. hole in entrance 5 Remove protective grill at position. Cut 60 mm dia. flexible tube to length as shown and mount on air outlet. Seal off pass through at position with Sicaflex. 60 mm dia. flexible tube Air outlet mm dia. hose clamp intake hose 6 Following installation, seal off pass through at position with Sicaflex. 9

20 Electrical Connections Fuse holder retaining plate, Mx bolt, washer, M nut Wiring harness of power supply for heater unit Ground wire on negative battery terminal Positive wire on positive battery terminal fuse holder 7 Thermostat i heater control 8 Combination timer option Combination timer i combination timer 9 External temperature sensor Installation is not carried out in recirculating air mode! External temperature sensor temperature sensor 0 0

21 Remote option (Telestart) Connect receiver for Telestart as shown in wiring diagram. i M5x6 bolt, flanged nut on existing hole Telestart Telestart acket receiver Only applies for combination of standard heater control with Telestart! Connect switch as shown in wiring diagram. Standard heater control Switch switch Antenna antenna Only with Telestart HTM 00 Fasten temperature sensor with doublesided adhesive tape temperature sensor

22 i F S sw/rt 9 F 5 X rt gn/ws A 6 7 ϑ B X6 X X X6 0 X5 System wiring diagram with heater control and vehicle fan X6 M M a K 0 5 ws/rt ws/sw S6 rt F 9 8 X bl ge ϑ bl ϑ ge sw sw ge X M rt M B sw/bl 0 5 B E A X8 X0 rt sw bl R bl X8 ws S5 8 Y ϑ B sw S H X9 rt T80 X X/X/X/X5 X6 X8 X9 X0 X S9

23 X S X/X/X/X5 X6 X8 X0 X X i F sw/rt X F S6 gn/ws rt A 6 7 ϑ B X6 X X X6 System wiring diagram with combination timer, Telestart and vehicle fan X6 0 87a X5 K X X M M ws/rt ws/sw 9 8 bl ge ϑ bl ϑ ge sw sw ge M rt M B sw/bl B E A X8 X0 bl R X8 S5 8 Y ϑ B sw gr H H H5 P 7 S7 F X rt sw rt bl ws T80

24 With positive wire from terminal (5/75) to connection 0: Continuous operation with immediate heating as long as ignition is switched on Without positive wire on connection 0: Heating time is variably programmable (0 min. to 0 min.), default setting is 0 min. K-wire diagnosis W bus Input pin (Pin 6/Connector X6, wire color on wiring harness: white/red (ws/rt)): "Ventilate (fan speed is dependent on position of heater control) CO setting (see workshop manual) NOTE: If a connection is made to Terminal 0, continuous heating operation is possible with ignition switched off! In this case, no connection may be made to Terminal 5/75! Fuse present in vehicle If an external temperature sensor (B) is used, then the resistor R is replaced with the temperature sensor (B) Connection only for ADR vehicles NOTE: Gray (gr) and violet (vi) wires required for ADR function Stop signal for battery isolator switch. The stop input (if present) of the isolator switch (S) must be connected to the control unit, Pin 5/Connector X6 Legend for Wiring Diagrams Wiring Colors Wiring Cross-Sections rt red < 7.5 m m gr gray 0.5 mm 0.75 mm sw black 0.75 mm.0 mm own.0 mm.5 mm gn green.5 mm.5 mm bl blue.5 mm.0 mm ge yellow.0 mm 6.0 mm or vi ws orange violet white Legend for Wiring Diagrams

25 Pos. Name Remarks A Heater unit Air Top 000 ST A Control unit B Flame detector Only on gasoline unit B Temperature sensor Internal B Overheating sensor Overheating protection B Temperature sensor External E Glow element F V 5 A/ V 0 A fuse Blade fuse, SAE J 8 F Fuse, A Blade fuse, SAE J 8 F 5 A fuse Blade fuse, SAE J 8 H LED, green (in Pos. S) Operation indicator H LED, red (in Pos. P) Lighting for immediate heating button, ready display, switch-on check H Heating symbol in display (in Pos. P) Operation indicator H5 Lamps (in Pos. P) Display and button lighting H6 Lamp (at least. W) Switch-on check for feed device K Relay with freewheeling diode For vehicle fan M Engine Combustion and hot air fan M Engine Vehicle fan P Combination digital timer (5) Digital timer and setpoint encoder R Resistor 60 Ω Only with internal temperature sensor S Heater control Setpoint encoder switch S Isolator switch, or -pin Emergency-Stop-switch S Switch On and for feed device S Switch Ventilation S5 Switch Rollover sensor S6 Switch CO setting S7 Momentary-contact switch Immediate heating button on remote control S8 Battery isolator switch S9 Additional switch Telestart switch-off function V Diode V Diode X Plug connection, -pin At Pos. A (ST B) X Plug connection, -pin At Pos. A (ST V) X Plug connection, -pin At Pos. A (ST U) X Plug connection, -pin At Pos. A (ST Z) X5 Plug connection, -pin At Pos. A (ST Y) X6 Plug connection, -pin At Pos. A (ST X) X7 Plug connection, -pin At Pos. A (ST) X8 Plug connection, -pin X9 Plug connection, -pin At Pos. S X0 Plug connection, -pin X Plug connection, -pin At Pos. Y X Plug connection, -pin At Pos. P Y Metering pump Y Solenoid valve For feed device Legend for Wiring Diagrams 5

26 Shut-down on fault Faults in individual heater unit components and malfunctions during the entire operation are recognized in the control unit. The heater unit is shut down (fault lock-out) if: - No or faulty start-up - Temperature sensor defective - Open or short circuit in overheating sensor - Overheating sensor mounted incorrectly - Break or short circuit in glow element - Fan motor overloaded, blocked, short circuit or open circuit - Fault in metering pump circuit or overheating protection (only during start-up phase) - Undervoltage < 0.5 V or overvoltage >6 V and longer than 0 sec. (on heater unit with V) - Undervoltage < V or overvoltage > V and longer than 0 sec. (on heater unit with V) - Control unit defective - Overheating - Flame detector (only on gasoline heater units) In case of overheating, the fuel feed is interrupted. A run-on is carried out as with manual shut-down. Following the run-on, the heater unit is in the fault lock-out mode. The overheating is indicated by the operation indicator flashing 0 times. Eliminate fault cause. For fault release, iefly switch the heater unit off and then on again (at least sec.). If serious malfunctions, such as overheating, or no start-up occurs increasingly frequently, then the heater unit is permanently locked (F or F) and can only be returned to operation following repairs by specially trained Webasto experts. Fault code output: Note: When equipped with a heater control, fault code output is carried out after a malfunction occurs by the switch-on check/fault code display flashing. After 5 rapid flashing pulses, the fault code output is carried out with a sequence of long flashing pulses in accordance with the numbers in the table below. When equipped with a combination timer, a fault output appears in the display of the digital timer after a fault occurs. When using the heater control, the fault number is indicated by the operating indicator lamp flashing: Display Fault Code F00 Control unit fault/incorrect data record/customer bus faulty F0 No start-up (after starting attempts)/no flame formation F0 Flame failure (repeated >) F0 Undervoltage or overvoltage F0 Premature flame detection F05 Flame detector (gasoline heater unit) open or short circuit F06 Open or short circuit in temperature sensor F07 Open or short circuit in metering pump F08 Open circuit, short circuit, overloading or blocking in fan motor F09 Break or short circuit in glow element F0 Overheating: As a result, continuous heater unit lock-out F Open or short circuit in overheating sensor F Heater unit lock-out F Continuous heater unit lock-out F Overheating sensor in incorrect position F5 Open circuit in setpoint encoder Legend for Fault Code Output 6

27 Final Work WARNING! Reassemble the disassembled components in reverse order. Check all hoses, hose, spring and Caillau clamps, as well as all electrical connections for firm seating. Secure all loose cables using cable ties. Spray the heater unit components with anti-corrosion wax (Tectyl 00K, Order No. 9). - Connect the battery - Set the digital timer. - Check the proper operation of the air heater, see the operating instructions/installation instructions. - Attach the "Switch off additional heater before refueling" sticker to the left-hand B-pillar. i Feel the drive Webasto AG Postfach 80-8 Stockdorf, Germany - Hotline +9- (0) Hotfax +9-(0) Printed in Germany 0/07Printed by: Steffen

28 Operating Instructions for End Customer Please remove page and add to the vehicle operating instructions. Only for vehicles with standard heater control and Telestart! On vehicles with additional heater or auxiliary heater from factory, the fuel level may not be below / of a tank for proper operation of the Air Top 000 ST air heater! Before parking the vehicle, make the following settings:. Switch S9 set to "Open". Temperature on standard heater control set to "warm" (start-up after switch-on on hand-held transmitter) Version A: Switching on heater with Telestart 5. Switch S9 set to "Close". Temperature on standard heater control set to "warm (immediate start-up) Version B: Switching on heater with heater control 6 8

29 Template for Fuel sender 00 mm Scale : Compare the size of the printed version with dimension lines. Permitted tolerance a maximum of %. Correct major differences in the printer settings or request an original printout mm 9

30 Template for Fuel Standpipe 00 mm Scale : Compare the size of the printed version with dimension lines. Permitted tolerance a maximum of %. Correct major differences in the printer settings or request an original printout mm 0