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

Transcription

1 Water Heater Unit Feel the drive Thermo Top E Additional Heater Thermo Top Additional Heater Thermo Top P Additional Heater e e e Installation Instructions Skoda Octavia.4 MPI /.6 FSI /.8 TFSI from Model Year 004 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.:904070_EN Fee Euro 0.00 Webasto AG

2 Table of ontents 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 Installing K relay and fuse holder 7 limatic fan controller 8 limatronic fan controller 0 Remote option (Telestart) Preparing combustion air 4 Premounting exhaust system 5 Preparing installation location 6 Installing heater unit 6 Fuel 8 oolant on.4 MPI oolant on.6 FSI 5 oolant on.8 TFSI 9 Exhaust gas 4 Final Work 5 Operating Instructions for End ustomer 6 Validity Manufacturer Model Type EG-BE No./ABE Skoda Octavia Z e * 00/6 * 00 *... Engine type Engine model Output in kw Displacement in cm³ BA Gasoline BLF Gasoline BZB Gasoline 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 _EN

3 Heater Unit/Installation Kit Quantity Description Order No.: Retail accessories with desired heater control See price list Installation Kit for Skoda Octavia.4 MPI/.6 FSI A In addition to the installation kit for the.4 MPI/.6 FSI, the following will also be required for the.8 TFSI: Quantity Description Order No.: Installation Kit for Skoda Octavia.8 TFSI 66A Also required with limatronic: Quantity Description Order No.: limatronic kit 90645A Heater unit recommended for the respective vehicle class: Vehicle ompact car Mid-size car, station wagon Full-size car, van, offroader Heater Unit Thermo Top E Thermo Top 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 Skoda Octavia.4 MPI /.6 FSI /.8 TFSI vehicles - for validity, see page - from model year 004 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 /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 _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 oolant Fuel Exhaust gas ombustion 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! _EN 4

5 Preliminary Work WARNING! - Open fuel tank cap, ventilate tank. - lose the tank cap again. - Depressurize the cooling system. - opy 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. - Disconnect and remove the battery. - Remove the battery carrier. - Remove the engine cover. - Remove the left front wheel. - Remove the front section of the left front wheel well trim. - Remove the left-hand front fog light or, on vehicles without front fog lights, the left-hand cover. - Remove the underride protection. - Remove the right-hand underbody trim. - Remove the rear bench seat - Open the right-hand fuel sender service lid. - Remove the footwell trim on the driver's side. - Remove the lower instrument panel trim on the driver's side - Remove the footwell trim on the front passenger side (only on vehicles with limatronic) Heater unit installation location Heater unit Remove page 6 "Operating Instructions for End ustomer" and add to the vehicle operating instructions. Installation location _EN 5

6 Electrical system Fuse holder, relay K Route wiring harnesses of fan controller, digital timer and metering pump in cable duct to firewall. Information on installing K relay and fuse holder on following page. Digital timer and summer/winter switch option Summer/winter switch, drilled hole mm dia. Digital timer 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 Wiring harness pass through in engine compartment Protective rubber plug Wiring harness of fan controller and digital timer 4 Wiring harness pass through of passenger compartment Wiring harness of fan controller Protective rubber plug Wiring harness of digital timer _EN 6

7 Installing K relay and fuse holder over of fuse/relay carrier in engine compartment ut away bar in shaded area ountersink 5 mm dia. hole [x] from behind Preparing fuse and relay carrier 6 M5x countersunk head screw [x] Installing fuse and relay carrier 7 With limatronic, replace F 5 A fuse with A fuse! Insert 5 mm dia. large diameter washer between cover and retaining plate of fuse holder. 4 Large diameter washer, retaining plate of fuse holder, M5 flanged nut M5 flanged nut Relay K 4 Fuse holder Installing fuse and relay carrier 8 Route brown (br) ground wire to original vehicle ground support point below headlight and connect. Fuse/relay carrier Original vehicle positive support point Red (rt) positive wire onnecting positive and ground wire _EN 7

8 limatic fan controller Webasto Skoda 0 rt/ws sw/ge 5 Wiring diagram F rt S40 gn/ws rt/ws rt/ws gn/ws K 87a sw sw/bl T0k J0 rt/ws 5 T5 X 4 HG ge Dg br + M - br rt/sw V 4 4 N4 T5 T4r Webasto components Vehicle components olors and symbols HG Heater unit TT-/E S40 40 A fan fuse rt red X 6-pin heater unit connector J0 Air-conditioning control ws white unit F 5 A fuse E6 Heater switch sw black K Fan relay N4 Resistor group br brown V Fan motor gn green T... onnector ge yellow Legend X utting point Wiring colors may vary _EN 8

9 Detach original vehicle fuse carrier [instrument panel at upper left] and unlock contact lock. Detach black/yellow (sw/ge) wire, 4 mm² on fuse output S40. onnecting central electrical box 0 Produce connections as shown in wiring diagram. Lock contact lock following installation! 4 Black/yellow (sw/ge) wire with original standard power timer Insert red (rt) wire from K/87a with crimped-on standard power timer in fuse output S40 Black (sw) wire K/0 with crimped-on tab connector 4 AMP connector onnecting central electrical box _EN 9

10 limatronic fan controller Webasto Skoda 0 rt/ws F! S rt/ge rt/ws T0k 5 Wiring diagram rt/ws 5 IPU E rt 5 sw/ws J55 6 T6f A sw/ws gn/ws gn/ws sw/ws bl/ws X 4 HG ge Dg T6t 4 J6 V T6t M br br Webasto components Vehicle components olors and symbols HG Heater unit TT-/E S Fan fuse rt red X 6-pin heater unit connector J55 Air-conditioning control ws white unit F 5 A replaced with V Fan motor sw black A fuse J6 Fan control unit br brown K Fan relay T... Plug connections ge yellow IPU Pulse width modulator gn green bl blue IPU adjustment values: Duty cycle: 0 % Insulate wire ends and Frequency: 400 Hz tie back Voltage: 8 V X utting point Function: High-side Wiring colors may vary. Legend _EN 0

11 Produce connections as shown in wiring diagram. Position of free sockets dependent on vehicle equipment. 5 4 Socket for IPU Original vehicle M6 bolt Brown (br) wire of IPU/85 4 Wiring harness with red (rt) wire of IPU/E and black/white (sw/ws) wire of IPU/A 5 Green/white (gn/ws) wire of IPU/86, AMP housing onnecting central electrical box Produce connections as shown in wiring diagram. Insulate red (rt) wire of K/87a 4 and tie back. Insert IPU in socket. AMP connector Black (sw) wire from K/0 onnecting central electrical box 4 Route wiring harness IPU along air duct to center console. Routing wiring harness of IPU 4 Route wiring harness of IPU to original vehicle wires to fan unit. Routing wiring harness of IPU _EN

12 onnection on connector T6t of fan unit. Produce connections as shown in wiring diagram. Disconnect fan unit. Red (rt) wire of IPU/E Black/white (sw/ws) wire of A/ control unit 5 Black/white (sw/ws) wire from IPU/A 4 Black/white (sw/ws) wire of connector T6t/ onnecting fan unit Fasten fan unit again. Fasten wiring harness on original vehicle wires with cable tie. Fastening wiring harness _EN

13 Remote option (Telestart) If M6 screw is not present, then use suitable M6 screw with spring lockwasher. Receiver Bracket, lower hole drilled out to 6.5 mm dia. Installing receiver 8 Antenna Installing antenna _EN

14 Preparing combustion air a ombustion air pipe a = 50 Discard section X utting combustion air pipe to length X Ejot stud Preparing heater unit 4 Insert one washer each between heater unit and bracket 5 at positions. 5 M6x0 spacer nut on Ejot stud Ejot screw, washer [x each] 7 mm dia. clamp 4 ombustion air pipe Preparing heater unit 6 Ejot screw [x] ombustion air muffler Retaining clip in hole of heater unit 4 Hose section, 0 mm dia. clamp [x] 5 Fuel line 6 Strut Preparing heater unit _EN 4

15 Premounting exhaust system Exhaust pipe a = 90 Exhaust end section b = 40 Discard section X Preparing exhaust pipe a b X 4 Slide insulation onto exhaust pipe M6x6 bolt, spring lockwasher Premounted M6x0 spacer nut Exhaust pipe with insulation 4 Red (rt) rubber isolator 5 Hose clamp [x] 6 Exhaust muffler Preassembling exhaust pipe Hose clamp Red (rt) rubber isolator Exhaust end section Preassembling exhaust end section Exhaust end section Aligning exhaust end section _EN 5

16 Preparing installation location Slide one large diameter washer each onto original vehicle stud bolt [x] and secure against falling off with putty etc. Edge protection Installing edge protection 4 Installing heater unit Large diameter washer, M8 flanged nut [x each] Installing heater unit 5 Ensure freedom of movement of exhaust system relative to adjacent components and lines. Original vehicle wiring harnesses (secured with cable ties) Horn Exhaust pipe with insulation Aligning exhaust system 6 5 Ensure freedom of movement of exhaust system relative to adjacent components and lines. Position red (rt) rubber isolator as shown. Picture shows vehicle with headlight washer system. Headlight washer system Exhaust pipe with insulation 4 Horn 5 Horn bracket Aligning exhaust system _EN 6

17 Punch through perforation in heater unit lid at position. Wiring harness of heater unit lip-type cable tie able tie onnect wiring harness of heater unit _EN 7

18 Fuel AUTION! Open the vehicle's fuel tank cap, ventilate the tank and then re-close the tank lock. atch 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. Fuel line Installing fuel line 6 9 Fasten fuel line and wiring harness of metering pump in coolant reservoir on original vehicle lines with cable ties. Pay particular attention to freedom of movement of wiper linkage. Installing lines 0 Guide fuel line and wiring harness of metering into original vehicle line duct and route to underbody. Installing lines _EN 8

19 0 Skoda Octavia Route fuel line and wiring harness of metering pump along original vehicle fuel lines to fuel tank. Line duct Installing lines Silent block, large diameter washer, M6 flanged nut Remove sealing plug Installing silent block Fuel line Wiring harness of metering pump, connector mounted Metering pump 4 Plug remounted 5 Rubber-coated p-clamp, flanged nut on silent block 6 Hose section, 0 mm dia. clamp [x] Installing metering pump ut standpipe and 90 molded hose to length. 4.5 mm dia. Removing fuel 7.5 mm dia _EN 9

20 0 mm dia. aillau clamp in center between beads on end of standpipe. 7.5 mm dia. Standpipe 90 molded hose Premounting fuel standpipe 4.5 mm dia. 6 ut mm off blind plug. Fuel-tank sending unit utting off blind plug 7 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..5 mm dia. aillau clamp Preassembled molded hose with standpipe 0 mm dia. aillau clamp 4 Fuel line onnection to fueltank sending unit 4 8 Hose section, 0 mm dia. clamp [x] Fuel line onnecting metering pump _EN 0

21 oolant on.4 MPI 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: oolant routing diagram A B All spring clips without a specific designation = 7 mm dia. = Original vehicle spring clip. All connecting pipes = 0x0 mm dia. All hose clamps = 0-7 mm dia.! _EN

22 a = 670 b = 0 c = 770 A X B Discard section X utting coolant hoses to length A Push braided protection hoses onto hose A and and cut to length. ut heat shrink plastic tubing to length. 5 mm long heat shrink plastic tubing [4x] Preparing coolant hoses Premounting coolant hoses b a 40 Pull off hose on engine outlet/heat exchanger inlet on connection piece of engine outlet. Spring clip will be reused. Install battery carrier. utting point _EN

23 Hose on heat exchanger inlet onnecting heat exchanger inlet 4 4 b Routing in engine compartment onnecting heater unit 44 Routing in engine compartment a _EN

24 a 7x6 double clip on hose A and brake line from brake master cylinder Original vehicle spring clip onnecting engine outlet 46 Ensure sufficient distance to neighboring components. M6x0 screw, spring lockwasher on existing thread 9 mm dia. rubber-coated p-clamp [x] Fastening hoses a b _EN 4

25 oolant on.6 FSI 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: oolant routing diagram A B All spring clips without a specific designation = 7 mm dia. = Original vehicle spring clip. All hose clamps = 0-7 mm dia.! onnecting pipe = 0x0 mm dia. = Black (sw) rubber isolator _EN 5

26 a = 000 b = 050 Discard section X A B utting coolant hoses to length A Push braided protection hoses onto hose A and B and cut to length. ut heat shrink plastic tubing to length. B 5 mm long heat shrink plastic tubing [4x] Preparing coolant hoses b Black (sw) rubber isolator Premounting coolant hoses a 48 Pull off hose on engine outlet/heat exchanger inlet on connection piece of heat exchanger inlet. Spring clip will be reused. Install battery carrier. utting point _EN 6

27 Original vehicle spring clip b onnecting heat exchanger inlet 50 b 5 b Routing in engine compartment onnecting heater unit 5 Routing in engine compartment b a _EN 7

28 Hose of engine outlet Align rubber isolator onnecting engine outlet a 54 Ensure sufficient distance to neighboring components. M6x0 screw, spring lockwasher on existing thread 9 mm dia. rubber-coated p-clamp [x] Fastening hoses b a 55 7x6 mm double clip [x] (on hose A and brake line from brake master cylinder) onnecting engine outlet a b _EN 8

29 oolant on.8 TFSI 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: oolant routing diagram A B All spring clips without a specific designation = 7 mm dia. All connecting pipes = 0x0 mm dia. All hose clamps without a specific designation = 0-7 mm dia _EN 9

30 a = 700 b = 70 c = 70 A X B Discard section X utting coolant hoses to length A Push braided protection hoses onto hose A and B and cut to length. ut heat shrink plastic tubing to length. B 5 mm long heat shrink plastic tubing [4x] Preparing coolant hoses Black (sw) rubber isolator Premounting coolant hoses b a 57 Drill 6 mm dia. hole in cover of cable duct at position. Watch lines located behind duct when drilling! 4 M6x bolt, flanged nut on existing hole 6 mm dia. hole, clip-type cable tie 4 lip-type cable tie [x] in hole of bracket 5 Bracket Installing bracket and cliptype cable tie _EN 0

31 Angle bracket Mount M6x0 bolt, flanged nut in existing hole 59 ut off hose on engine outlet/heat exchanger inlet at marking. Install battery carrier. Hose section of heat exchanger inlet Engine outlet hose section utting point 60 Hose on heat exchanger inlet M6x0 bolt, pin lock 9 mm dia. rubber-coated p-clamp Prepare battery carrier onnecting heat exchanger inlet 6 Route hose through rubber-coated p-clamp. Routing in engine compartment _EN

32 Fasten hose on clip-type cable tie [x]!! 6 Routing in engine compartment onnecting heater unit 64 Route hose A along hose. able tie a 65 Hose of engine outlet Routing in engine compartment onnecting engine outlet a _EN

33 a Fasten hose A on clip-type cable tie!! Ensure sufficient distance to neighboring components. 4 Spacer bracket Flanged nut on M6x0 bolt 4 9 mm dia. rubber-coated p-clamp Fastening hoses _EN

34 Exhaust gas Exhaust end section Aligning exhaust end section 68 Align exhaust end section and rubber isolator. Ensure sufficient spacing of exhaust end section to transmission and to wheel well trim. (Picture shows vehicle with direct shift transmission) Installing wheel well trim 69 Underride protection 4 mm dia. hole utting out underride protection 70 Insert red (rt) rubber isolator in 4 mm dia. hole. Align exhaust end section flush on red rubber isolator. Underride protection Mounting rubber isolator _EN 4

35 Front fog light trim piece Discard section Front fog light trim piece (depending on equipment) utting front fog light trim piece to size Final Work 7 WARNING! Reassemble the disassembled components in reverse order. heck 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). - onnect the battery. - Fill and bleed the coolant circuit according to the vehicle manufacturer s specifications. - Set the digital timer. - Make settings on A/ control panel according to the "Operating Instructions for End ustomer". - heck 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. Adaptingsensitivity of passenger compartment monitoring WARNING! This can only be carried out at an authorized workshop! Observe the applicable repair manual of the respective vehicle. - onnect the VAG tester - Open Item 46 (entral Module of omfort 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. Feel the drive Webasto AG Postfach 80-8 Stockdorf Hotline 0805 / Hotfax 095 / _EN Printed in Germany /008 Printing: Steffen

36 Operating Instructions for End ustomer 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: Air outlet to windshield Set fan to level "", or possibly "" Set temperature to "max." limatic 7 Air outlet faces upward Set temperature on both sides to "HI". limatronic _EN 6