installation documentation skoda fabia /...
TRANSCRIPT
Water Heater
Installation documentation
Ident. No.: 1316385C_EN Fee Euro 10.00 © Webasto AG
Skoda Fabia / Roomster
Petrol
from Model Year 2010
Left-hand drive vehicle
Manual transmission / direct shifting transmission (DSG)
Feel the drive
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 heat-er 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 tech-nical 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 installa-tion by untrained staff.
Thermo Top Evo Parking Heatere1
00 0258
Skoda Fabia / Roomster
Table of Contents
Validity
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 in-stallation.
Manufacturer Model Type EG-BE No./ABESkoda Fabia 5J e11 * 2001/116 * 0291 * ...Skoda Roomster 5J e11 * 2001/116 * 0291 * ...
Engine type Engine model Output in kW Displacement in cm³CHFA Petrol 44 1198CGPA Petrol 51 1198CBZA Petrol / TSI 63 1197CBZB Petrol / TSI 77 1197
Validity 2Heater / Installation Kit 3Foreword 3General Instructions 3Special Tools 3Explanatory Notes on Document 4Preliminary Work 5Heater installation location 5Preparing electrical system 6Electrical system 8Fan controller for manual air conditioning 9Automatic air-conditioning fan controller 11Remote option Telestart 13
Preparing installation location 14Preparing heater 15Installing heater 17Coolant circuit 19Fuel 21Combustion air 24Exhaust gas 25Final Work 26Template for Fuel Standpipe 27Operating Instructions for End Customer 28
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Skoda Fabia / Roomster
Heater / Installation Kit
Also required with automatic air-conditioning
ForewordThis installation documentation applies to Skoda Fabia / Roomster Petrol vehicles - for validity, see page 2 - from model year 2010 and later, assuming technical modifications to the vehicle do not affect installation, any liability claims excluded. Depending on the vehicle version and equipment, modifica-tions may be necessary during installation with respect to this installation documentation.
However, the stipulations in this "installation documentation" and the "operating instructions" and "in-stallation 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 InstructionsInstallation should be carried out according to the general, standard rules of technology. Unless spec-ified 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 100K, Order No. 111329).Check or adjust the corresponding settings before installing an IPCU!
Special Tools- Torque wrench for 2.0 - 10 Nm- Hose clamping pliers- Metric thread-setter kit
Quantity Description Order No.:1 Basic delivery scope Thermo Top Evo See price list1 Installation kit for Skoda Fabia / Roomster 2010 petrol 1316384A1 Heater control See price list
Quantity Description Order No.:1 Automatic A/C kit 1315239B
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Skoda Fabia / Roomster
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.
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Special features are highlighted using the following symbols:
The arrow in the vehicle icon indicates the position on the vehicle and the viewing angle.
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 Webas-to components or to the manufacturer's vehicle-specific documents.
Reference to a special technical feature.
Mechanical system
Electrical system
Coolant circuit
Fuel
Exhaust gas
Combustion air
Software
All dimensions are in mm!Tightening torque of 5x13 heater bolts = 8Nm!Tightening torque of 5x15 bolt of water connection piece retaining plate = 7Nm!
Skoda Fabia / Roomster
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
Remove page 28 "Operating Instructions for End Customer" and add to the vehicle operating instruc-tions.
Installa-tion loca-tion
Heater installation location
1 Heater
1
1
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Skoda Fabia / Roomster
Bending angle bracket
Preparing fuse holder of passen-ger com-partment
Preparing fuse holder of passen-ger com-partment
Premount-ing IPCU
Preparing electrical system
1 Angle bracket
1 Fuse holder of passenger compartment2 M5x12 bolt, washer, nut3 Angle bracket
F4 25A and K1 relay inserted. Insert red (rt) wire in the K1/87a relay socket and black (sw) wire in the K1/30 relay socket.
Automatic air-conditioning
Connecting wires to IPCU socket.IPCU view on contact side.The IPCU is pre-programmed with the follow-ing adjustment values. These adjustment val-ues are to be checked during function control of the vehicle and adapted if necessary.
Duty cycle: 100%Frequency: 1000 HzVoltage: 3.6VFunction: High-side
90°
30
1
3
1
2
2
86
85 30
87a87
K1
gn/ws0,75²
F4
br0,5²
rt4²
rt/sw0,5²
F3
1
2sw4²
rt4²
85
A
E
86
IPCU
5
6
4
rt0,5²
sw0,5²
gn/ws0,5² 3
br0,5²
A
1586 85
E
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Skoda Fabia / Roomster
Preparing IPCU
Mount IPCU after installation on Socket 2.Pull red (rt) wire and black (sw) wire into protective sleeving.
1 Velcro strip3 0.5mm² black (sw) wire of IPCU/A4 0.5mm² brown (br) wire of IPCU/855 0.5mm² red (rt) wire of IPCU/E6 0.5mm² green/white (gn/ws) wire of
IPCU/86
2
3
6
3
5
4
1
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Skoda Fabia / Roomster
Wiring har-ness rout-ing diagram
Electrical system
Connection to positive battery terminal
1 Positive distributor on battery2 Positive wire to secured connection
Digital timer
1 Digital timer
Fuse holder of engine compartment
1 4.5mm dia. hole; 5.5x13mm self-tapping screw, retaining plate of fuse holder
2 F1-2 fuses mounted3 Earth wire on negative battery terminal
Wiring harness pass through of passenger compartment
1 Protective rubber plug pass through coolant reservoir
2 Wiring harness of engine compartment fuse holder
4
1
2 5
1
Do not install the metering pump wiring harness until later togeth-er with fuel pipe along the origi-nal vehicle fuel lines on the underbody
62
1
3
7
2
1
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Skoda Fabia / Roomster
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Fan controller for manual air conditioning
Wiring dia-gram
Webasto components Vehicle components Colours and symbols
Legend
HG Heater TT-Evo V2 Fan motor rt redX1 6-pin heater connector SB39 Fuse, 30A ws whiteX2 2-pin heater connector N24 Resistor group sw blackX10 4-pin connector
Heater controlE9 Switch unit br brownT... Connector gn green
K1 Fan relayF1 Fuse, 20AF2 Fuse, 30AF3 Fuse, 1A X Cutting pointF4 Fuse, 25 A Wiring colours may vary.
31
30
15
Skoda
SB39
sw/rt2,5²
sw/rt2,5²
T10d/1
E9
5 T5h
T5h4321
rt/ws4²
N24
T4aa2314+
-
V2M
rt
br
Webasto
HG
X2 1 2 X152F2 F1
br0,5²
gn/ws0,75²
ge0,5²
rt/sw0,5²
rt4²
br0,5²
X10
86
85 30
87a87
K1
gn/ws0,75²
F4
br0,5²
rt4²
rt/sw0,5²
F3
sw4²
1
2
rt4²
9
Skoda Fabia / Roomster
1316385C_EN
1 Fuse holder of passenger compartment2 Original vehicle bolt3 Angle bracket
Installing fuse holder of passen-ger com-partment
Connect same colour wires of wiring harness in the fuse holder of passenger compartment 1 and wiring harness in the fuse holder of engine compartment 2 according to wiring diagram.
Connect-ing the wir-ing harnesses
Produce connections as shown in wiring dia-gram.
1 Black (sw) wire from K1/302 Black/red (sw/rt) wire of fan unit3 Black/red (sw/rt) wire of fuse SB394 Central electrical box5 Red (rt) wire from K1/87a
Connect-ing central electrical box
8
1
2
3
9
1
2
10
1
5
3
2
4
10
Skoda Fabia / Roomster
Wiring dia-gram
Legend
Automatic air-conditioning fan controller
Webasto components Vehicle components Colours and symbolsHG Heater TT-Evo J126 Fan unit rt redX1 6-pin heater connector J255 A/C control panel ws whiteX2 2-pin heater connector SB39 Fuse, 30A sw blackX10 4-pin connector
Heater controlT... Connector br brown
bl blueK1 Fan relay gn greenF1 Fuse, 20A ge yellowF2 Fuse, 30AF3 Fuse, 1AF4 Fuse, 25 AIPCU Pulse width modulatorIPCU adjustment values:Duty cycle: 100%Frequency: 1000 HzVoltage: 3.6 V X Cutting pointFunction: High-side Wiring colours may vary.
31
3015
Skoda
sw
sw
SB39
T6aa26
J126M
0,35²
0,35²
2,5²sw/rt
2,5²sw/rt
Webasto
HG
X2 1 2 X152F2 F1
gn/ws0,75²
ge0,5²
rt/sw0,5²
rt4²
br0,5²
X10
86
85 30
87a87
K1
gn/ws0,75²
F4
br0,5²
rt4²
rt/sw0,5²
F3 1
2sw4²
rt4²
4
6
5
rt0,5²
sw0,5²
3gn/ws
0,5²
br0,5²
T16d14
J255
br0,5²
86
85
A
EIPCU
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Skoda Fabia / Roomster
Installing fuse holder of passen-ger com-partment
Connect-ing the wir-ing harnesses
Installing IPCU
Connect-ing central electrical box
1 Fuse holder of passenger compartment2 Original vehicle bolt3 Angle bracket
Connect same colour wires in wiring harness of passenger compartment fuse holder 1 and wiring harness of heater 3, as well as addi-tional brown (br) wire 2 and additional green/white (gn/ws) wire 4 according to wiring diagram.
Ensure sufficient distance from light switch 1.
2 Glue IPCU socket (velcro strip)
Produce connections as shown in wiring dia-gram.
1 Black (sw) wire from K1/302 Black/red (sw/rt) wire of fan unit3 Black/red (sw/rt) wire of fuse SB394 Central electrical box5 Red (rt) wire from K1/87a
11
1
2
3
12
1
2
3
4
13
1
2
14
1
5
3
2
4
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Skoda Fabia / Roomster
Connect-ing air-con-ditioning control panel
Installing receiver
Installing antenna
Installing tempera-ture sensor
1 Connector T16d 2 Red (rt) wire of IPCU/E3 Black (sw) wire J1264 Black (sw) wire of IPCU/A5 Black (sw) wire J255 / T16d Pin14
Remote option Telestart
Fasten receiver 1 with double-sided adhesive tape.
1 Antenna
Temperature sensor T100 HTM
Fasten temperature sensor 1 with double-sid-ed adhesive tape.
1
1 15
1 2 3
4
5
1
16
1
17
1
18
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Skoda Fabia / Roomster
Installing rivet nut
Aligning T-piece
Removing flanged nut
Cutting out insulation mat
Preparing installation location
1 Install original vehicle hole, rivet nut
TSI only
Turn T-piece 1 as shown.
All vehicles
Remove original vehicle flanged nut 1, will be reused.
Cut out insulation mat 1 at the markings.
19
1
20
1
21
1
22
1
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Skoda Fabia / Roomster
Removing bolt
Installing coolant connect-ing piece
Cutting hoses to length
Premount-ing heater
Remove original vehicle bolt 1; will be reused later.
Preparing heater
1 90°, 18mm dia. coolant connecting piece, sealing ring
2 5x15mm self-tapping bolt, retaining plate of coolant connecting piece
3 18mm dia. coolant connecting piece, seal-ing ring
All 180°, 18x18mm dia. moulded hosesDiscard section X.
A = 200D = 200
1 25 mm dia. spring clip2 Combustion air pipe3 Fuel line4 Hose section, clamp [2x]
23
1
3
1
2
24
D X
C
A
B
25
26
1
2
4
3
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Skoda Fabia / Roomster
Preparing bracket
Installing bracket
Installing circulating pump
Installing hoses
1 Bracket2 100 mm edge protection3 M6x12 bolt, spring lockwasher, M6x20
spacer nut
1 5x13 self-tapping bolt [3x]
Mount wiring harness of circulating pump 4 on heater and circulating pump
1 48 mm dia. rubber-coated p-clamp2 Circulating pump3 M6x16 bolt, flanged nut, existing hole
All connecting pipes 18x18mm dia.All spring clips 25mm dia.
27
1
2
3
28
1
1
1
293
1
2
4
30
D
C
A
B
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Skoda Fabia / Roomster
Preparing exhaust pipe
Installing exhaust pipe
Installing exhaust pipe
Installing heater
1 Exhaust pipea = 540
2 Exhaust end sectionb = 100
Discard section X
1 Slide on exhaust-gas insulation2 Exhaust pipe3 Hose clamp
1 M6x12 bolt, spring lockwasher, large diam-eter washer, pipe clamp
2 Slide on exhaust-gas insulation3 Exhaust pipe
Installing heater
1 Install M6x20 bolt, spring lockwasher2 Bracket
a b
1 2
X
312 13
32
2
1
3
33
1
2
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Skoda Fabia / Roomster
Installing heater
Installing heater
1 Loosely mount original vehicle bolt 2 Bracket
Tighten all screw connections.
1 Bracket2 Original vehicle flanged nut
34
1
2
35
1
2
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Skoda Fabia / Roomster
Hose rout-ing dia-gram
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:
All spring clips = 25mm dia. 1 = Original vehicle spring clip . All connecting pipes without a specific designation and = dia. 18x18 mm.
BD
1
A
C
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Skoda Fabia / Roomster
Cutting point
Cutting point
Connect-ing heat exchanger inlet
Connect-ing engine outlet
63 and 77 kW
1 Engine outlet hose section2 Remove hose section of heat exchanger
inlet and discard3 Original vehicle spring clip will be reused.
44 and 51 kW
1 Engine outlet hose section2 Remove hose section of heat exchanger
inlet and discard3 Original vehicle spring clip will be reused.
All vehiclesThe following figures show 1.2 TSI!
1 Original vehicle spring clip
Ensure sufficient distance to neighbouring components, correct if necessary.
1 Engine outlet hose section
361
3
2
37
3
2
1
38
1D
391A
1316385C_EN 20
Skoda Fabia / Roomster
Routing in engine compart-ment
Routing in engine compart-ment
Installing lines
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. Un-less 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 meter-ing pump 1 to right-hand vehicle side Route wiring harness of heater 2 to heater and in-sert!
Route fuel line and wiring harness of meter-ing pump 1 to original vehicle fuel lines at the installation location of the metering pump.
1 Fuel line, metering pump wiring harness2 Original vehicle pass through of fuel lines
40
21
41
1
42
2
1
1316385C_EN 21
Skoda Fabia / Roomster
Preparing perforated bracket
Premount-ing meter-ing pump
Installing metering pump
Connect-ing meter-ing pump
Drill out perforated bracket 1 at Position 2 to 8.5mm dia. and angle down.
1 Metering pump2 Metering pump mount3 Cable tie drawn through mount of metering
pump4 Perforated bracket5 M6x25 bolt, flanged nut
1 Original vehicle bolt of fuel tank fastening2 Perforated bracket
1 Wiring harness of metering pump, connec-tor mounted
2 Fuel line of heater3 Hose section, 10 mm dia. clamp [2x]
90°
75
1 2
43
1 2
5 4
3
44
1
2
45
1
3
2
1316385C_EN 22
Skoda Fabia / Roomster
Copying hole pat-tern
Installing fuel stand-pipe
Connect-ing fuel line
Connect-ing meter-ing pump
Remove fuel-tank sending unit 1 in accord-ance with manufacturer's instructions.Place large diameter washer da = 21.6 2 as shown on fuel-tank sending unit 1.
3 Copy hole pattern, 6 mm dia. hole
Shape fuel standpipe 1 according to tem-plate, cut to length and install.
Install fuel-tank sending unit 1 in accordance with manufacturer's instructions.
2 Fuel line3 Hose section, 10 mm dia. clamp [2x]4 Fuel standpipe
Check the position of the components; adjust if necessary. Check that they have freedom of movement.
1 fuel line, fuel standpipe2 Hose section, 10 mm dia. clamp [2x]
46
1
3
2
47
1
1
483
1
4
2
49
1 2
1316385C_EN 23
Skoda Fabia / Roomster
Installing silencer
Combustion air
Install coolant reservoir partition. Original ve-hicle bolt at Position 1 against M6x50 bolt.
2 Silencer3 Combustion air pipe4 M6x50 bolt, spring lockwasher, pipe clamp,
20mm shim, original vehicle threaded hole
503 2
1
4
1316385C_EN 24
Skoda Fabia / Roomster
Preparing perforated bracket
Premount-ing silenc-er
Installing silencer
Exhaust gas
Drill out perforated bracket 2 at position 1 to 8.5mm dia. and angle down.
1 Silencer2 Hose clamp3 Exhaust end section4 Perforated bracket5 M6x16 bolt, spring lockwasher
Ensure sufficient distance to neighbouring components, correct if necessary.
1 Exhaust pipe2 Hose clamp3 Perforated bracket4 M8 flanged nut, spring lockwasher, original
vehicle stud bolt
90°
30°
1322
1 2
1 2
51
5
3
4
3
1
52
2
4
1316385C_EN 25
Skoda Fabia / Roomster
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 100K, Order No. 111329).
- 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 Cus-
tomer".- 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
1316385C_EN
Feel the driveWebasto AGPostfach 80D-82132 Stockdorf / GermanyNational Hotline: 01805 93 22 78(14 Cent aus dem deutschen Festnetz)Hotfax: 0395 5592 353Hotmail: [email protected]://www.webasto.de
Printed in Germany 10/2011 Printing: Steffen 26
Skoda Fabia / Roomster
Template for Fuel Standpipe
1316385C_EN 27
0
100mm
100mm
Scale 1:1
Compare the size of the printed version with dimension lines.Permitted tolerance a maximum of 2%.
Set the printer settings to “no margin” or “minimise mar-gins” and 100% of the normal size.
Skoda Fabia / Roomster
Manual air condition-ing
Automatic air-condi-tioning
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 timeExample:For a driving time of approx. 20 min. (in one direction), we recommend not exceeding a switch-on time of 20 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:
1 Set temperature to "max."2 Set fan to level "1", max. "2"3 Direct air outlet toward windscreen
1 Direct air outlet toward windscreen2 Set temperature to "HI"
531
2 3
541
2
1316385C_EN 28