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 Volvo S60 / V60 from model year 00 Volvo V70 / S80 from model year 007 S60 / V60 / V70 / S80 Petrol S60 / V60 / V70 Diesel Left-hand drive vehicle Automatic air-conditioning 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 pas 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 staup 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 9 Digital timer S60 / V60 Digital timer V70 Remote option (Telesta) Preparing installation location Preparing heater heater 5 Coolant circuit 7 Combustion air Fuel Final Work 9 Operating Instructions for End Customer 0 Validity Manufacturer Model Type EG-BE No. / ABE Volvo S60 F e9 * 007 / 6 * 00 *... Volvo V60 F e9 * 007 / 6 * 00 *... Volvo V70 B e9 * 00/6 * 0065 *... Volvo S80 e9 * 00/6 * 0057 *... Volvo S60 / V60 Engine type Engine model Output in kw Displacement in cm³ B6T Petrol T B66T Petrol T 595 B0T Petrol.0T B0T Petrol T B60T Petrol T6 95 D50T Diesel D 0 98 D5T Diesel D Volvo V70 / S80 Engine type Engine code Engine model Output in kw Displacement in cm³ B6T 8 Petrol 596 B0T7 7 Petrol B0S Petrol 07 / B0T6 Petrol B55T6 56 Petrol 7 5 B55T0 60 Petrol 70 5 B60T 99 Petrol 0 / 95 B6S 98 Petrol 75 / 79 9 D6T 76 Diesel D50T 5 Diesel 0 98 D0T 75 Diesel D5T5 69 Diesel 0 00 D5T 7 Diesel 9 00 D5T 7 Diesel 6 00 D5T0 70 Diesel 5 00 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 digital timer should be confirmed with the end customer before installation. 685C_EN

3 Heater / Installation Kit Quantity Description Order No.: Basic delivery scope of Thermo Top Evo See price list Installation kit Volvo S60 / V60 / V70 / S80 Petrol and Diesel 685B Heater control See price list Foreword This installation documentation applies to Volvo S60 / V60 vehicles from model year 00 and later as well as Volvo V70 / S80 vehicles from model year 007 and later - for validity see page - Petrol and Diesel see page, if technical modifications in the vehicle do not influence the installation, excluding any kind of liability claims. Depending on the vehicle version and equipment, modifications may be necessary during installation with respect to this installation documentation. In any case, however, it is necessary to observe the specifications in this "installation documentation", the "operating instructions" and the "installation instructions" for the Thermo Top Evo. 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. Insulate loose wires and tie back. 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). When installing an IPCU, the corresponding settings must be checked or adjusted before the installation. 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 "eah" 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 windscreen wipers. - Remove the upper and front coolant reservoir cap. - Remove the engine control unit. - Remove the right front wheel. - Remove the wheel well trim on the right. - Drain off the coolant according to the manufacturer's instructions. - Remove the accelerator pedal. - Remove the glove compament. - Detach and lower the exhaust system according to the manufacturer's instructions. - Remove fuel tank according to the manufacturer's instructions. - Remove the fuel-tank sending unit in accordance with manufacturer's instructions. Heater installation location Heater Remove page 0 "Operating Instructions for End Customer" and add to the vehicle operating instructions. Installation location 685C_EN 5

6 Preparing electrical system Protective rubber plug Removing protective rubber plug Fuse holder of passenger compament Wire sections retain their numbering in the entire document Cutting wires to length br sw bl bl Fuse holder of passenger compament Detach red () ² wire and discard Detaching red () wire 685C_EN 6

7 Connect wires according to wiring diagram. IPCU and pulse relay will be inseed after installing the fuse holder. 6 5 Socket pulse relay K Fuse holder of passenger compament Red () wire of F and K/0 Brown (br) wire of IPCU/85 and K/ Red () wire of IPCU/E Black (sw) wire of IPCU/A Red () wire of K/5 Blue (bl) wire of K/87z Blue (bl) wire of K/87a Connecting the wires 7 Inse fuse F A. /sw ² F gn/ws 0,75² F Connecting the wires IPCU 86 E A 85 5 sw br 6 bl 5 5 t a 0 K 87z 87 87a br 7 bl IPCU view on contact side. The pre-programmed adjustment values are to be checked during function check of vehicle, and adjusted if necessary. A E 5 IPCU E A Duty cycle: 56% Frequency: 00Hz Voltage:,0V Function: High-side Premounting IPCU 685C_EN 7

8 Electrical system Positive and eah wire Positive wire on positive battery terminal Eah wire on negative battery terminal Wiring harness pass through Protective rubber plug Wiring harnesses of heater, heater control 5 6 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 7 8 Fuse holder of engine compament 5.5 mm dia. hole at position in battery box. See page 0 for wiring harness routing. Fuse holder of engine compament F- fuses M5x6 bolt, large diameter washer [x], nut Retaining plate of fuse holder 685C_EN 8

9 Fan controller Webasto Volvo 0 5 F F HG X 5 X A/ B/ Wiring diagram br X0 /sw /sw ² ² F ge gn/ws 0,75² gn/ws 0,75² F C/ GRs /9 5 CEM /56 sw 6/8 M ge/ ge/ GM ge/ br 5 5 t a 0 K IPCU 86 E A z 6 87 bl sw bl bl 6/0 vi/sw vi/sw / /6 vi/ sw GRr sw/ws br 87a 7 bl M DMM CCM Webasto components Vehicle components Colours and symbols HG TT-Evo heater GRr Fan controller / red X 6-pin heater connector / -pin connector, GRr sw black X -pin heater connector GM Fan motor 6/8 ge yellow X0 -pin connector CCM A/C control unit /6 gn green Heater control DMM Defroster valve motor or orange K Fan relay 6/0 -pin connector DMM ws white K Delayed pulse relay GRs Fan relay /9 ws white F Fuse, 0A CEM Central electrical box /56 br brown F Fuse, 0A A/ Fuse F Fuse, A B/ Fuse F Fuse, A C/ Fuse IPCU Pulse width modulator IPCU settings: Duty cycle: 56% Frequency: 00Hz Voltage:,0V X Cutting point Function: High-side Wiring colours may vary. Legend 685C_EN 9

10 Wiring harnesses Cable tie Routing wiring harnesses 9 Fold back floor covering. 7mm dia. hole at position 5. When drilling, pay attention to components located behind! Inse IPCU after installation. 5 Angle bracket Fuse holder of passenger compament M5x6 bolt, large diameter washer [x], nut 5 M6x bolt, flanged nut 0 6mm dia. hole at position. When drilling, pay attention to components located behind. Inse pulse relay K after installation. Socket pulse relay K M5x6 bolt, large diameter washer [x], nut socket of pulse relay Connect heater wiring harness to fuse holder wiring harness of passenger compament according to wiring diagram, so that the wires of the same colour are connected. fuse holder of passenger compament Connecting wiring harnesses 685C_EN 0

11 Connection to -pin connector from fan controller /. Produce connections as shown in wiring diagram. Violet/black (vi/sw) wire of GRr connector / Pin Violet/black (vi/sw) wire of A/C control unit Red () wire of IPCU/E Black (sw) wire of IPCU/A Connecting fan controller Connection to -pin connector from defroster valve motor DMM 6/0. Produce connections as shown in wiring diagram. 6 Blue (bl) wire (eah) Blue (bl) wire of DMM 6/0 connector Pin Blue (bl) wire of K/87z Blue (bl) wire of K/87a Connecting valve motor 7 Connection to -pin connector from defroster valve motor DMM 6/0. Produce connections as shown in wiring diagram. Red () wire of fan relay Red () wire of DMM 6/0 connector Pin Red () wire of K/5 Connecting valve motor 5 5 Digital timer S60 / V60 Digital timer digital timer 6 685C_EN

12 Digital timer V70 Digital timer digital timer 7 Remote option (Telesta) Fasten receiver with adhesive tape. receiver 8 Antenna antenna 9 Temperature sensor T00 HTM Install temperature sensor with adhesive tape. temperature sensor 0 685C_EN

13 Preparing installation location Remove cover Dismantling cover Cut out pass through and reinstall. Discard section Cutting out pass through Install M6 rivet nut [x] in existing holes. rivet nut Wiring harness of circulating pump Wiring harness of metering pump Wiring harness of heater Pulling through lines 685C_EN

14 Preparing heater Water connection piece, sealing ring [x each] 5x5 self-tapping bolt, retaining plate of water connection piece water connection piece 5 D Hose C / D = 8mm dia., 90 moulded hose. 5 mm dia. spring clip [x] 8x8mm dia. connecting pipe, 5mm dia. spring clip [x each] Premounting hoses C 6 Bracket 5x self-tapping bolt [x] Premounting bracket 7 6 5mm dia. clamp Insulation protection strips pasted 80mm combustion air pipe Combustion air silencer 5 5x self-tapping bolt 6 0mm combustion air pipe combustion air silencer C_EN

15 Spacer bracket 80mm combustion air pipe mm dia. spring clip 0mm combustion air pipe Fastening combustion air pipe 9 Slide 0mm corrugated tube onto fuel line (subsequently, draw wiring harness of metering pump into corrugated tube.) 90 moulded hose, 0mm dia. clamp Fuel line, 0mm dia. clamp Cable tie Premounting fuel line 0 heater Route combustion air pipe through pass through at position. Mount passed-through wiring harness of heater and wiring harness of circulating pump on heater. Mount heater as shown; hook into original vehicle hole. heater Loosely mount bolts [x]. Existing holes, M6x6 bolt, spring lockwasher, large diameter washer [x each] Bracket of heater heater 685C_EN 5

16 Wrap wiring harnesses with rub protection Pass through Aligning pass through Mount bolt loosely. Hose clamp M6x0 bolt, spring lockwasher, large diameter washer Exhaust system exhaust system Tighten all loose screw connections. M6x0 bolt, spring lockwasher, large diameter washer exhaust system 5 685C_EN 6

17 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 E Ø 7 D C B Ø 7 Ø 7 A Ø 8x5 Ø All spring clips without a specific designation = 5 mm dia. All connecting pipes without a specific designation = 8x8mm dia. 685C_EN 7

18 Remove hose section from heat exchanger inlet. Engine outlet hose section Cutting point 6 Quick-release coupling will be reused. Carefully remove clamp, making sure not to damage quick-release coupling. Discard hose section. Processing hose section E 7 Hose E = 8mm dia., 90 moulded hose. Observe coding of quick-release coupling. Premounting hose E 8 Quick-release coupling, heat exchanger inlet Heat exchanger inlet connection E 9 685C_EN 8

19 D E Hose bracket A/C line Connecting heater outlet 0 Replace cover of circulating pump axially against 9 cover with sealing ring. Replacing circulating pump cover Fasten hose A = 8x0mm dia. moulded hose and hose B = 8mm dia. (0mm long) hose with 7mm dia. spring clip [x] to circulating pump. Bracket Retaining clip with rubber base, M6x0 pan head screw 8x5 connecting pipe, 5mm dia. spring clip Premounting circulating pump B A Install circulating pump on existing stud bolt with plastic nut [x]. B Engine outlet hose section Wiring harness of circulating pump mounted and connecting circulating pump A 685C_EN 9

20 E Align hoses. Ensure sufficient distance to neighbouring components. D Hose bracket [x] Connecting heater inlet C B 685C_EN 0

21 Combustion air Install protective cap on combustion air pipe and align. Routing combustion air pipe 685C_EN

22 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. Route 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 of metering pump after routing. Pin assignment is not relevant. 5 Connector housing Lock Blue / brown (bl / br) wires Coding 5 Time lock Dismantling connector 5 5 Draw wiring harness of metering pump through 0mm corrugated tube. Degrease adhesive surface for socket. Fuel line, wiring harness of metering pump in corrugated tube Self-adhesive socket, cable tie lines 6 5mm dia. rubber-coated p-clamp 00mm edge protection Fuel line, wiring harness of metering pump in corrugated tube M6x0 bolt, flanged nut, existing hole lines 7 685C_EN

23 Route fuel line and wiring harness of metering pump in trim of fuel lines. lines 8 Angle bracket M6x0 bolt, flanged nut, existing hole angle bracket 9 M6x5 bolt, flanged nut Metering pump Metering pump suppo metering pump 50 Fuel line of Heater Wiring harness of metering pump, connector mounted Hose section, 0 mm dia. clamp [x] Connecting metering pump 5 685C_EN

24 V70 Diesel Remove fuel tank according to manufacturer's instructions. Remove fuel-tank sending unit in accordance with manufacturer's instructions. Cut off 5mm at end of connection piece and countersink slightly. Fuel extraction 5 Drill 5.mm dia. hole 5 Cut standpipe obliquely to length Discard section Fuel extraction Shoening fuel standpipe 5 5 Cut standpipe to length as shown in the middle of the bulge. Cutting point Discard section Shoening fuel standpipe C_EN

25 Paste standpipe with suitable contact adhesive in connection piece. fuel standpipe 56 Inse standpipe into existing recess. fuel standpipe 57 Install fuel-tank sending unit in tank in accordance with manufacturer's instructions. Install coupling piece on connection piece. 5 0mm dia. clamp Fuel line 5 Fuel standpipe Connecting fuel line 58 Install tank after assembly according to manufacturer's instructions. Cable tie Routing fuel line C_EN 5

26 All vehicles except V70 Diesel Figures for fuel extraction show diesel vehicle. Remove fuel tank according to manufacturer's instructions. Remove fuel-tank sending unit in accordance with manufacturer's instructions. Cut off 5mm at end of connection piece and countersink slightly. Fuel extraction 60 Drill 5.mm dia. hole 6 Cut standpipe obliquely to length Discard section Fuel extraction Shoening fuel standpipe 5 6 Cut standpipe to length as shown in the middle of the bulge. Cutting point Discard section Shoening fuel standpipe 6 685C_EN 6

27 Paste standpipe with suitable contact adhesive in connection piece. fuel standpipe 6 Fasten standpipe with retaining clamp to fuel-tank sending unit. fuel standpipe 5 65 Install fuel-tank sending unit in tank in accordance with manufacturer's instructions. Mount quick-release coupling 5 on connection piece. Fuel standpipe 0mm dia. clamp Fuel line Connecting fuel line 66 Install tank after assembly according to manufacturer's instructions. Cable tie Routing fuel line C_EN 7

28 All vehicles Check the position of the components; adjust if necessary. Check that they have freedom of movement. 80 moulded hose, 0 mm dia. clamp [x] Fuel line of fuel standpipe Connecting metering pump C_EN 8

29 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 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 instructions. - Adjust digital timer, teach remote Telesta 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. - For initial sta-up and function check, see installation instructions Cut away wheel well trim along the marking on exhaust outlet (if this has not already been done in the factory). Cutting out wheel well trim C_EN Feel the drive Webasto AG Postfach 80 D-8 Stockdorf / Germany National Hotline: ( Cent aus dem deutschen Festnetz) Hotfax: Hotmail: [email protected] Printed in Germany 0/0 Printing: Steffen 9

30 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 vehicle has passenger compament monitoring, this must be deactivated in addition to the vehicle settings for the heating operation. Deactivation instructions can be found in the operating instructions of the vehicle. Before parking the vehicle, make the following settings: Display Air outlet faces upward Set temperature on both sides to "HI" Automatic air-conditioning C_EN 0