Webasto thermo top evo Installation Documentation

Status: 19.02.2015 © Webasto Thermo & Comfort SE Validity Manufacturer Model Type EG-BE No./ ABE Skoda Rapid NH e11 * 2007 / 46 * 0250 * ... Motorisation Fuel Transmission type Output in kW Displacement in cm³ Engine code 1.6 TDI CR Diesel SG 77 1598 CAYC 1.6 TDI CR Green tec Diesel SG 77 1598 CAYC SG = manual transmission from Model Year 2013 Left-hand drive vehicle Verified equipment variants: Manual / automatic air-conditioning system Front fog light Headlight washer system Not verified: Passenger compartment monitoring Total installation time: approx. 10 hours Thermo Top Evo Parking Heater E1 00 0258

the heater specific installation time and all other times required for the system integration and initial start-up of the heater. The total installation time may vary for vehicle equipment other than provided. Ident. No.: 1319165B_EN Status: 19.02.2015 © Webasto Thermo & Comfort SE 2 Table of Contents Necessary Components Installation Overview Information on Total Installation Time Legend: 1. Heater 2. Engine compartment fuse holder 3. Passenger compartment relay and fuse holder 4. IPCU (only in case of automatic air- conditioning) 5. Circulating pump 6. Digital timer 7. Metering pump Validity 1 Necessary Components 2 Installation Overview 2 Information on Total Installation Time 2 Information on Operating and Installation Instructions 3 Information on Validity 4 Technical Information 4 Explanatory Notes on Document 4 Preliminary Work 5 Heater Installation Location 5 Preparing Electrical System 6 Electrical System 9 Manual Air-Conditioning Fan Controller 10 Automatic Air-Conditioning Fan Controller 12 Digital Timer 14 Remote Option (Telestart) 14 Preparing Bracket 15 Preparing Installation Location 15 Preparing Heater 16 Installing Heater 19 Fuel 20 Combustion Air 24 Coolant Circuit 25 Underbody Trim 29 Guard Plate 30 Final Work 31 Template for Fuel Standpipe 32 Operating Instructions for Manual Air-Conditioning 33 Operating Instructions for Automatic Air-Conditioning 34 • Basic delivery scope Thermo Top Evo in accordance with price list • Installation kit for Skoda Rapid 2013 Diesel: 1319164B • Additionally required in case of automatic air-conditioning: Automatic air-conditioning kit: 1315239C • Heater control in accordance with price list and upon consultation with end customer • In case of Telestart, indicator lamp in accordance with price list and in consultation with end customer Installation instructions • Arrange for the vehicle to be delivered with the tank only about 1/4 full. • The installation location of the push button in the case of Telestart or Thermo Call should be confirmed with the end customer. • Depending on the space required and the vehicle manufacturer's instructions, we recommend the use of a vehicle battery with a higher electrical capacity. 7 1 5 6 3 2 4

Status: 19.02.2015 © Webasto Thermo & Comfort SE 3 1 Important Information (not complete) 1.1 Installation and Repair The improper installation or repair of Webasto heating and cooling sys- tems can cause fire or the leakage of deadly carbon monoxide, leading to serious injury or death. To install and repair Webasto heating and cooling systems you need to have completed a special company training course and have the appro- priate technical documentation, special tools and special equipment. Installation and repair may ONLY be carried out by persons trained and certified in a Webasto training course. NEVER try to install or repair We- basto heating or cooling systems if you have not completed a Webasto training course, you do not have the necessary technical skills and you do not have the technical documentation, tools and equipment available to ensure that you can complete the installation and repair work properly. Only use genuine Webasto parts. See the Webasto air and water heat- ers accessories catalogue for this purpose. 1.2 Operation To ensure safe operation, we recommend having the heater checked every two years by an authorised Webasto dealer, especially when used over a long period and/or under extreme environmental conditions. Do not operate the heater in closed rooms due to the danger of poisoning and suf- focation. Always switch off the heater before refuelling. The heater may only be used with the prescribed fuel Diesel (DIN EN 590) or pet- rol (DIN EN 228). The heater may not be cleaned with a high-pressure cleaner. 1.3 Please note ALWAYS follow all Webasto installation and operating instructions and observe all warnings. To become familiar with and understand all functions and properties of the heater, the operating instructions must be read carefully and observed at all times. For proper, safe installation and repair work, the installation instructions with all warnings and safety information must be carefully read and observed at all times. Please always contact a workshop authorised by Webasto for all installation and repair work. Important Webasto shall assume no liability for defects, damage and injuries resulting from a failure to observe the installation, repair and operating instructions of the information contained in them. This liability exclusion particularly applies to improper installations and re- pairs, installations and repairs by untrained persons or in the case of a fail- ure to use genuine spare parts. The liability due to culpable disregard to life, limb or health and due to dam- age or injuries caused by a wilful or reckless breach of duty remain unaf- fected, as does the obligatory product liability. 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 wire ends and tie back. Connectors on electronic compo- nents must audibly snap into place during assembly. Sharp edges should be fitted with rub protection. Spray unfinished body ar- eas, e.g. drilled holes, with anti-corrosion wax (Tectyl 100K, Order No. 111329). Observe the instructions and guidelines of the respective vehicle manufac- turer for demounting and mounting vehicle specific components! The initial startup is to be executed with the Webasto Thermo Test Diagno- sis. When installing a programmable control module (e.g. a PWM Gateway), the corresponding settings must be checked or adjusted. 2 Statutory regulations governing installation Note The regulations of these guidelines are binding in the scope of the Directive 70/156/EEC and/or 2007/46/EC (for new vehicle models from 29/04/2009) and should also be observed in countries in which there are no special regulations. Important Failure to follow the installation instructions will result in the invalidation of the type approval for the heater and therefore invalidation of the general homologation of the vehicle. Note The heater is licensed in accordance with paragraph 19, section 3, No. 2b of the StVZO (German Road Traffic Licensing Authority). 2.1 Excerpt from ECE regulation 122 (heating system) para- graph 5 for the installation of the heater Beginning of excerpt. ANNEX VII REQUIREMENTS FOR COMBUSTION HEATERS AND THEIR INSTALLATION 1. GENERAL REQUIREMENTS 1.7.1. A clearly visible tell-tale in the operator's field of view shall inform when the combustion heater is switched on or off. 2. VEHICLE INSTALLATION REQUIREMENTS 2.1. Scope 2.1.1. Subject to paragraph 2.1.2. combustion heaters shall be installed ac- cording to the requirements of this Annex. 2.1.2. Vehicles of category O having liquid fuel heaters are deemed to comply with the requirements of this Annex. 2.2. Positioning of heater 2.2.1. Body sections and any other components in the vicinity of the heater must be protected from excessive heat and the possibility of fuel or oil contamination. 2.2.2. The combustion heater shall not constitute a risk of fire, even in the case of overheating. This requirement shall be deemed to be fulfilled if the in- stallation ensures an adequate distance to all parts and suitable ventila- tion, by the use of fire resistant materials or by the use of heat shields. 2.2.3. In the case of M2 and M3 vehicles, the heater must not be positioned in the passenger compartment. However, an installation in an effectively sealed envelope which also complies with the conditions in paragraph 2.2.2 may be used. 2.2.4. The label referred to in paragraph 1.4 or a duplicate, must be positioned so that it can be easily read when the heater is installed in the vehicle. 2.2.5. Every reasonable precaution should be taken in positioning the heater to minimise the risk of injury and damage to personal property. 2.3. Fuel supply 2.3.1. The fuel filler must not be situated in the passenger compartment and must be provided with an effective cap to prevent fuel spillage. 2.3.2. In the case of liquid fuel heaters, where a supply separate to that of the vehicle is provided, the type of fuel and its filler point must be clearly la- belled. 2.3.3. A notice, indicating that the heater must be shut down before refuelling, must be affixed to the fuelling point. In addition a suitable instruction must be included in the manufacturer's operating manual. 2.4. Exhaust system 2.4.1. The exhaust outlet must be located so as to prevent emissions from en- tering the vehicle through ventilators, heated air inlets or opening win- dows. 2.5. Combustion air inlet 2.5.1. The air for the combustion chamber of the heater must not be drawn from the passenger compartment of the vehicle. 2.5.2. The air inlet must be so positioned or guarded that blocking by rubbish or luggage is unlikely. 2.6. Heating air inlet 2.6.1. The heating air supply may be fresh or recirculated air and must be drawn from a clean area not likely to be contaminated by exhaust fumes emitted either by the propulsion engine, the combustion heater or any other vehicle source. 2.6.2. The inlet duct must be protected by mesh or other suitable means. 2.7. Heating air outlet 2.7.1. Any ducting used to route the hot air through the vehicle must be so po- sitioned or protected that no injury or damage could be caused if it were to be touched. 2.7.2. The air outlet must be so positioned or guarded that blocking by rubbish or luggage is unlikely. End of excerpt. In multilingual versions the German language is binding. Guidelines Thermo Top Evo Heating Directive ECE R122 E1 00 0258 EMC Directive ECE R10 E1 04 5627 Information on Operating and Installation Instructions

You will find an identification mark on the outside top right corner of the page in question to provide you with a quick overview of the individual working steps. Skoda Rapid Ident. No.: 1319165B_EN Status: 19.02.2015 © Webasto Thermo & Comfort SE 4 Mechanical system Electrical system Coolant circuit Combustion air Fuel Exhaust gas Software Specific risk of injury or fatal accidents Specific risk due to electrical voltage Specific risk of damage to components Specific risk of fire or explosion Reference to general installation instructions of the 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 Tightening torque according to the manufacturer's vehicle-specific documents Nm ! Information on Validity This installation documentation applies to Skoda Rapid Diesel vehicles - for validity, see page 1 - from model year 2013 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. Vehicle and engine types, equipment variants and other specifications not listed in this installation documentation have not been tested. However, installation according to this installation documentation may be possible. Technical Information Explanatory Notes on Document Special tools • Hose clamp pliers for self-clamping hose clamps • Hose clamp pliers for Clic hose clamps of type W • Automatic wire stripper 0.2 - 6mm² • Crimping pliers for cable lug / tab connector 0.5 - 6mm² • Torque wrench for 2.0 - 10 Nm • Hose clamping pliers • Metric thread-setter kit • Webasto Thermo Test Diagnosis with current software Dimensions • All dimensions are in mm Tightening torque values • Tightening torque values of 5x13 heater bolts and 5x11 heater stud bolts = 8Nm. • Tightening torque values of 5x15 retaining plate of water connection piece bolts = 7Nm. • Tighten other bolt connections in accordance with manufacturer's instructions or in accordance with state-of-the- art-technology.

Status: 19.02.2015 © Webasto Thermo & Comfort SE 5 Preliminary Work Vehicle • Open the fuel tank cap. • Ventilate the fuel tank. • Close the fuel tank cap again. • Depressurise the cooling system. • Disconnect and remove the battery. • Remove the windscreen wiper. • Remove the coolant reservoir cap. • Remove the coolant reservoir partition wall. • Remove the windscreen wiper motor. • Remove the air filter together with the intake hose. • Remove the underride protection. • Remove the right vehicle underbody trim. • Fold up the seating surface of the rear bench seat. • Open the tank-fitting service lid. • Remove the light switch. • Detach the central electrical box under the steering wheel. • Remove the side instrument panel trim on the left. • Remove the A/C control panel (only with automatic air-conditioning). Heater • Remove years that do not apply from the type and duplicate label. • Attach the duplicate label (type label) in the appropriate place in the engine compartment. Heater Installation Location 1 Heater Installation location 1 1

Status: 19.02.2015 © Webasto Thermo & Comfort SE 6 Preparing Electrical System Wire sections retain their numbering in the entire document. Produce all following electrical connections as shown in the wiring diagram. Red (rt) wire of fan wiring harness Black (sw) wire of fan wiring harness Assigning wires 5.5 mm dia. hole at position 2. When drilling, watch components located behind! 1 Retaining plate for engine compartment fuse holder 2 M5x16 bolt, large diameter washer [2x], nut Installing retaining plate Connecting wires to pas- senger com- partment relay and fuse holder 2 rt 4² sw 4² 1 2 1 2 3 1 2 2 3 4 5 6 7 8 9 10 13 11 12 14 15 1 rt/sw 0,5² gn/ws 0,75² rt 4² br 0,5² 87 6.3 30 6.3 86 6.3 85 6.3 87a 6.3 F4 4.8 F4 4.8 F3 4.8 F5 4.8 F5 4.8 F3 4.8 __ 2.8 __ 2.8 __ 2.8 __ 2.8 rt 4² 2 1 sw 4² 4

Status: 19.02.2015 © Webasto Thermo & Comfort SE 7 1 Passenger compartment relay and fuse holder 2 Angle bracket 3 M5x16 bolt, large diameter washer [2x], nut Premount- ing relay and fuse holder Only in case of automatic air-conditioning Pull wire sections and into provided protective sleeving. Assigning wires The settings must be checked during the start-up of the heater and adjusted if neces- sary. Settings: Duty cycle: 100% Frequency: not relevant Voltage: 3.6V Function: High-side Checking IPCU 5 3 1 2 1000 4 sw 0,5² 6 100 br 0,5² 5 100 gn/ws 0,75² 1000 3 rt 0,5² 6 3 4 E 86 A 15 85 7

Status: 19.02.2015 © Webasto Thermo & Comfort SE 8 Preparing relay and fuse holder of passen- ger com- partment Interlocking socket of IPCU and re- lay and fuse holder of passenger compart- ment and connecting wires 1. 2. 3. 4. 5. 2 3 4 5 6 7 8 9 10 13 11 12 14 15 1 rt/sw 0,5² gn/ws 0,75² rt 4² br 0,5² 87 6.3 30 6.3 86 6.3 85 6.3 87a 6.3 F4 4.8 F4 4.8 F3 4.8 F5 4.8 F5 4.8 F3 4.8 __ 2.8 __ 2.8 __ 2.8 __ 2.8 2 sw 4² rt 4² 1 2 3 4 5 6 7 8 9 10 13 11 12 14 15 1 87 6.3 30 6.3 86 6.3 85 6.3 87a 6.3 F4 4.8 F4 4.8 F3 4.8 F5 4.8 F5 4.8 F3 4.8 __ 2.8 __ 2.8 __ 2.8 __ 2.8 rt/sw 0,5² gn/ws 0,75² rt 4² br 0,5² 2 sw 4² rt 4² 1 8 2 3 4 5 6 7 8 9 10 13 11 12 14 15 1 87 6.3 30 6.3 86 6.3 85 6.3 87a 6.3 F4 4.8 F4 4.8 F3 4.8 F5 4.8 F5 4.8 F3 4.8 __ 2.8 __ 2.8 __ 2.8 __ 2.8 rt/sw 0,5² gn/ws 0,75² rt 4² br 0,5² sw 4² rt 4² rt 0,5² sw 0,5² 5 3 4 2 1 6 br 0,5² gn/ws 0,75² 85 6.3 86 6.3 E 6.3 __ 2.8 __ 2.8 __ 2.8 __ 2.8 A 6.3 15 6.3 9

Status: 19.02.2015 © Webasto Thermo & Comfort SE 9 Electrical System Positive wire 1 Positive distributor of battery 2 Positive wire Wiring harness pass through of passenger compartment 1 Protective rubber plug 2 Wiring harnesses of heater, heater control Wiring har- ness rout- ing diagram Fuse holder of engine compartment 1 Retaining plate for fuse holder 2 F1-2 fuses mounted Earth wire 1 Earth wire on original vehicle earth support point 10 1 2 2 11 2 1 Do not install the me- tering pump wiring harness until later to- gether with fuel pipe along the original ve- hicle fuel lines on the underbody 12 1 2 13 1 Nm !

Status: 19.02.2015 © Webasto Thermo & Comfort SE 10 Manual Air-Conditioning Fan Controller Wiring dia- gram Webasto components Vehicle components Colours and symbols Legend HG Heater TT-Evo SB39 30A fuse rt red X1 6-pin heater connector T... Connector ws white X2 2-pin heater connector E9 Switch unit sw black F1 20A fuse V2 Fan motor br brown F2 30A fuse N24 Resistor group gn green X10 4-pin connector of heater control ge yellow F3 1A fuse F4 25A fuse X Cutting point K1 Fan relay Wiring colours may vary. 31 30 15 (75x) VW SB 39 sw/rt 2,5² sw/rt 2,5² T10d/1 E9 5 T5h T5h 4 3 2 1 rt/ws 4² N24 T4aa 2 3 1 4 + - V2 M rt br Webasto HG X2 1 2 X1 5 2 F2 F1 br 0,5² gn/ws 0,75² ge 0,5² rt/sw 0,5² rt 4² br 0,5² X10 86 85 30 87a 87 K1 gn/ws 0,75² F4 br 0,5² rt 4² rt/sw 0,5² F3 sw 4² 1 2 rt 4²

Status: 19.02.2015 © Webasto Thermo & Comfort SE 11 1 Wiring harness of passenger compart- ment relay and fuse holder 2 Wiring harness of heater Connecting wiring har- nesses us- ing same colour wires Insert 10mm shim between body and angle bracket at position 4. 1 25A fuse F4 2 Passenger compartment relay and fuse holder 3 K1 relay 4 M6x25 bolt, large diameter washer, exist- ing hole, 10mm shim, angle bracket, flanged nut Mounting passenger compart- ment relay and fuse holder 1 Black/red (sw/rt) wire of fan unit 2 Black/red (sw/rt) wire of fuse SB39 3 Fuse carrier of passenger compartment Red (rt) wire from K1/87a fan wiring har- ness Black (sw) wire from K1/30 fan wiring harness Connecting passenger compart- ment fuse carrier 14 1 2 15 2 4 1 3 16 2 1 3 1 2 1 2

Status: 19.02.2015 © Webasto Thermo & Comfort SE 12 Automatic Air-Conditioning Fan Controller Wiring dia- gram Webasto components Vehicle components Colours and symbols Legend HG Heater TT-Evo SB39 30A fuse rt red X1 6-pin heater connector T... Connector ws white X2 2-pin heater connector J126 Fan unit sw black F1 20A fuse J255 A/C control panel br brown F2 30A fuse gn green X10 4-pin connector of heater control ge yellow F3 1A fuse F4 25A fuse K1 Fan relay IPCU Pulse width modulator IPCU settings: Duty cycle: 100% Frequency: not relevant Voltage: 3.6 V X Cutting point Function: High-side Wiring colours may vary. 31 30 15 (75x) Skoda sw sw SB39 T6aa 2 6 J126 M 0,35² 0,35² 2,5² sw/rt 2,5² sw/rt Webasto HG X2 1 2 X1 5 2 F2 F1 gn/ws 0,75² ge 0,5² rt/sw 0,5² rt 4² br 0,5² X10 86 85 30 87a 87 K1 gn/ws 0,75² F4 br 0,5² rt 4² rt/sw 0,5² F3 1 2 sw 4² rt 4² 6 3 4 rt 0,5² sw 0,5² 5 gn/ws 0,75² br 0,5² T16d 14 J255 br 0,5² 86 85 E A IPCU

Status: 19.02.2015 © Webasto Thermo & Comfort SE 13 1 Wiring harness of passenger compart- ment relay and fuse holder 2 Wiring harness of heater Connecting wiring har- nesses us- ing same colour wires Insert 10mm shim between body and angle bracket at position 5. 1 Passenger compartment relay and fuse holder 2 25A fuse F4 3 IPCU 4 K1 relay 5 M6x25 bolt, large diameter washer, exist- ing hole, 10mm shim, angle bracket, flanged nut Mounting passenger compart- ment relay and fuse holder 1 Black/red (sw/rt) wire of fan unit 2 Fuse carrier of passenger compartment 3 Black/red (sw/rt) wire of fuse SB39 Red (rt) wire from K1/87a fan wiring har- ness Black (sw) wire from K1/30 fan wiring harness Connecting passenger compart- ment fuse carrier 1 Black (sw) wire of T6aa, Pin 6 2 Connector of A/C control unit 3 Black (sw) wire of connector T16d, Pin14 Red (rt) wire of IPCU/E Black (sw) wire of IPCU/A Connec- tion of A/C control unit 17 1 2 18 1 5 2 3 4 19 2 1 3 1 2 1 2 20 1 3 3 4 2 3 4

Status: 19.02.2015 © Webasto Thermo & Comfort SE 14 Digital Timer 1 Digital timer Installing digital tim- er Remote Option (Telestart) 1 M6x20 bolt, flanged nut, existing hole 2 Bracket 3 Receiver Installing receiver 1 Antenna Installing antenna Temperature sensor T100 HTM Fasten temperature sensor 1 with double-sid- ed adhesive tape. Installing tempera- ture sensor 1 21 2 22 1 3 1 23 1 24

Status: 19.02.2015 © Webasto Thermo & Comfort SE 15 Preparing Bracket 1 8mm dia. hole 2 Bracket Hole in bracket Shift hole pattern for attachement of heater at position 2 by 25mm. Shift hole pattern for at- tachement of exhaust silencer at position 3 by 13mm. 1 Bracket 2 6mm dia. hole [3x] 3 7mm dia. hole Holes in bracket Preparing Installation Location Route wiring harness of metering pump and wiring harness of heater in heat protection hose. Place heat shield plate 1 on the tunnel in the area of the bracket. 2 Remove and discard retaining clamp Removing clamp Adjust tab 4 of bracket to contour of under- body. Insert bracket 2 at position 1 and hori- zontally adjust it upwards as far as possible. 1 Original vehicle stud bolt 3 Copy hole pattern to heat shield plate [4x] Copying hole pat- tern 25 1 14 39 2 26 2 2 1 2 25 25 25 13 3 27 2 1 28 3 2 3 3 1 3 4

Status: 19.02.2015 © Webasto Thermo & Comfort SE 16 Remove bracket. Use 10mm drilling depth limitation. Enlarge holes in the heat shield plate to 12mm. 1 9.1mm dia. hole in body; rivet nut [4x each] Installing rivet nut Preparing Heater 1 Water connection piece, sealing ring [2x each] 2 5x15 self-tapping bolt, retaining plate of water connection piece Installing water con- nection piece 1 Moulded hose (fuel) 2 10 mm dia. clamp Premount- ing heater Discard section X. Hose B =90°, 18 mm dia. moulded hose A = 420 C = 170 D = 80 E = 115 F = 140 G = 60 H = 485 Cutting hoses to length 29 1 1 1 1 3 1 2 30 31 1 2 A C D E F G H X B 32

Status: 19.02.2015 © Webasto Thermo & Comfort SE 17 All spring clips = 25mm dia. 1 90°, 18x18mm dia. connecting pipe [2x] Premount- ing heater All spring clips = 25 mm dia. 1 90°, 18x18mm dia. connecting pipe [2x] Premount- ing heater 1 Circulating pump 2 Circulating pump mounting 3 M6x25 bolt, large diameter washer, flanged nut 4 Bracket Premount- ing circu- lating pump 1 5x13 self-tapping bolt [3x] Installing bracket 33 1 F G 1 34 1 E C D 1 35 2 1 3 4 1 1 1 36

Status: 19.02.2015 © Webasto Thermo & Comfort SE 18 1 Combustion air pipe Installing combus- tion air pipe 1 Wiring harness of circulating pump [2x] Connect- ing circu- lating pump 1 Exhaust pipe a = 100 2 Exhaust end section b = 50 Preparing exhaust pipe 1 Exhaust pipe 2 Hose clamp [3x] 3 Exhaust silencer 4 Exhaust end section 5 M6x16 bolt, spring lockwasher Installing exhaust system 37 1 38 1 1 C a b 1 2 39 40 2 2 1 2 5 4 3

Status: 19.02.2015 © Webasto Thermo & Comfort SE 19 Installing Heater 1 Mount wiring harness of heater [2x] 2 Heat shield plate 3 M6x20 bolt, spring lockwasher, large di- ameter washer 4 Wiring harness of heater and wiring har- ness of metering pump in heat protection hose 6 Loosely install M6x30 bolt (will be re- moved again later) Installing heater 1 M6x20 bolt, spring lockwasher, large di- ameter washer [2x each] Installing heater 41 6 3 2 1 1 4 42 1 1

Status: 19.02.2015 © Webasto Thermo & Comfort SE 20 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. Un- less specified otherwise, always fasten using cable ties. Provide rub protection for fuel line and wiring harness in areas where there are sharp edges. WARNING! The fuel line and wiring harness are routed to the metering pump as shown in the wiring harness rout- ing diagram. Disman- tling con- nector of metering pump Remove grease from gluing point! 1 Cable tie [2x] 2 Moulded hose (premounted), 10 mm dia. clamp, fuel line 3 Adhesive base, clip-type cable tie 4 Fuel line, metering pump wiring harness Heater con- nection and routing Route fuel line and wiring harness of meter- ing pump 2 to the installation location of the metering pump along original vehicle fuel lines. Remove grease from gluing points 1 Adhesive base, cable tie [2 each] Connect- ing heater Connector X7 43 44 3 1 2 4 1 45 1 2 1

Status: 19.02.2015 © Webasto Thermo & Comfort SE 21 1 Perforated bracket 2 Drill hole to 8.5mm dia. Preparing perforated bracket 1 Perforated bracket 2 Metering pump mount 3 M6x25 bolt, support angle bracket, flang- ed nut Preassem- bling mount of metering pump 1 Original vehicle bolt 2 Perforated bracket Installing metering pump mount 1 Hose section, 10 mm dia. clamp [2x] 2 Metering pump mount 3 Metering pump Installing metering pump 70 76 90° 1 2 46 47 1 2 3 48 1 2 49 2 3 1 1

Status: 19.02.2015 © Webasto Thermo & Comfort SE 22 Complet- ing connec- tor of metering pump Check the position of the components; adjust if necessary. Check that they have freedom of movement. 1 10 mm dia. clamp [2x] 2 Fuel line of heater 3 Wiring harness of metering pump, con- nector mounted Connect- ing meter- ing pump Remove fuel-tank sending unit 1 in accord- ance with manufacturer's instructions. 2 Align washer, outer dia. da = 21.6mm 3 Copy hole pattern, 6 mm dia. hole Fuel ex- traction Shape fuel standpipe 1 according to tem- plate, cut to length and install. Installing fuel stand- pipe Pin assignment is not relevant. Connector X7 50 51 2 1 3 52 9 3 2 1 53 1 1

Status: 19.02.2015 © Webasto Thermo & Comfort SE 23 Install fuel-tank sending unit 1 in accordance with manufacturer's instructions. 2 Fuel line 3 Hose section, 10 mm dia. clamp [2x] 4 Fuel standpipe Connect- ing fuel line Check the position of the components; adjust if necessary. Check that they have freedom of movement. 1 fuel line, fuel standpipe 2 10 mm dia. clamp [2x] Connect- ing meter- ing pump 54 3 1 4 2 55 2 1

Status: 19.02.2015 © Webasto Thermo & Comfort SE 24 Combustion Air 1 Insulation strip Gluing on insulation strip Glue on insulation strips 3 as shown. 1 Original vehicle stud bolt, 51mm dia. p- clamp, plastic nut 2 Silencer 4 Fuel line Installing silencer 56 1 57 2 1 3 4

Status: 19.02.2015 © Webasto Thermo & Comfort SE 25 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 modelled on an "inline" circuit and based on the following diagram: Hose rout- ing dia- gram All spring clips without a specific designation = 25 mm dia. 1 = Original vehicle hose section. 2 = Original vehicle spring clip . 3 = original vehicle quick-release coupling! All connecting pipes without a specific designation and = 18x18mm dia. F G C H B Ø 22 Ø 22 Ø 18x16 1 A Ø 18x16 2 3 D E

Status: 19.02.2015 © Webasto Thermo & Comfort SE 26 Detach original vehicle quick-release cou- pling 3 at connection piece. 1 Engine outlet hose section 2 Hose section of heat exchanger inlet 4 Cutting point Cutting point Discard section X. A = 350 B = 50 H = 400 Cutting heat pro- tection hose to length Sliding on heat pro- tection hoses Install original vehicle hose section 4 as shown on original vehicle quick-release cou- pling 3. 1 Connection of engine outlet 2 Connection of circulating pump Preparing hoses 58 4 1 3 2 A H B 59 A H B 60 2 H 61 1 B A 3 4

Status: 19.02.2015 © Webasto Thermo & Comfort SE 27 1 Circulating pump Connect- ing heater 1 Black (sw) rubber isolator Routing in engine compart- ment 1 Engine outlet hose section Connect- ing engine outlet Connect- ing heater 62 1 B 63 A 64 1 A 65 G H

Status: 19.02.2015 © Webasto Thermo & Comfort SE 28 Ensure sufficient distance from neighbouring components. 1 Cable tie (temperature resistant) Routing in engine compart- ment 1 Original vehicle quick-release coupling at heat exchanger inlet 2 Original vehicle hose section. Connect- ing heat ex- changer inlet 66 H A 1 1 H 2 67

Status: 19.02.2015 © Webasto Thermo & Comfort SE 29 Underbody Trim 1 Underbody trim 2 Discard section Cutting out underbody trim 1 Underbody trim 2 Discard section Cutting out underbody trim Ensure sufficient distance from neighbouring components. 1 Underbody trim Mounting underbody trim 1 Perforated bracket 2 Discard section Preparing perforated bracket 68 2 1 69 1 2 60 70 70 1 60 5x45° 1 2 71

Status: 19.02.2015 © Webasto Thermo & Comfort SE 30 Guard Plate Prior to installation, adjust guard plate 1 to heater, mind hole coverage, correct if neces- sary. 2 5x13 self-tapping bolt [3x] Installing guard plate Align guard plate 1 so that there is a maxi- mum distance between the plate and the ex- haust pipe. Aligning heater Remove M6x30 bolt at position 6 . Insert 10mm shim between bracket of heater and perforated bracket 1. 2 M6x12 bolt, flanged nut 3 100 mm edge protection 4 8mm dia. rubber-coated p-clamp 5 Plastic nut, original vehicle stud bolt 6 M6x30 bolt, spring lockwasher, large di- ameter washer, 10mm shim Installing guard plate 72 2 2 2 1 73 1 74 4 6 3 2 1 5

Status: 19.02.2015 © Webasto Thermo & Comfort SE 31 Webasto Thermo & Comfort SE Postfach 1410 82199 Gilching Germany Internet: www.webasto.com Technical Extranet: http://dealers.webasto.com 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 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 transmitter. • Make settings on A/C control panel according to the "Operating Instructions for End Cus- tomer". • Place caution label "Switch off parking heater before refuelling" in the area of the filler neck • For initial start-up and function test, refer to installation instructions

Status: 19.02.2015 © Webasto Thermo & Comfort SE 32 Template for Fuel Standpipe Top view 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.

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. 20 min. (in one direction), we recommend not exceeding a switch-on time of 20 min. Passenger compartment monitoring, if installed, must be deactivated in addition to the vehicle settings for the heating operation. For information on deactivation, please see the vehicle owner's manual. Before parking the vehicle, make the following settings: 1 Set fan to level "1", max. "2" 2 Direct air outlet towards windscreen 3 Set temperature to "max." A/C control panel 1 30A main fuse F2 of passenger compart- ment 2 20A heater fuse F1 Engine com- partment fus- es 1 1A fuse F3 of heater control 2 25A fan fuse F4 Passenger compart- ment fuses 75 3 1 2 76 2 1 77 2 1

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. 20 min. (in one direction), we recommend not exceeding a switch-on time of 20 min. Passenger compartment monitoring, if installed, must be deactivated in addition to the vehicle settings for the heating operation. For information on deactivation, please see the vehicle owner's manual. Before parking the vehicle, make the following settings: 1 Set temperature to "HI" 2 Direct air outlet towards windscreen A/C control panel 1 30A main fuse F2 of passenger compart- ment 2 20A heater fuse F1 Engine com- partment fus- es 1 1A fuse F3 of heater control 2 25A fan fuse F4 Passenger compart- ment fuses 78 2 1 79 2 1 80 2 1