Water Heater Installation documentation Chrysler Grand Voyager

Transcription

Water Heater Installation documentation Chrysler Grand Voyager
Water Heater
Feel the drive
e1
Thermo Top C Parking Heater
00 0002
Installation documentation
Chrysler Grand Voyager from model year 2008
Lancia Voyager from model year 2011
2.8 CRD
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 parts 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 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 installation by untrained staff.
Ident. No.: 1313868B_EN
Fee Euro 10.00
© Webasto AG
Chrysler Grand Voyager / Lancia Voyager
Table of Contents
Validity
Heater / Installation Kit
Foreword
General Instructions
Special tools
Explanatory Notes on Document
Preliminary Work
Heater installation location
Preparing Chrysler electrical system
Preparing electrical system for Lancia
Electrical system
Chrysler fan controller
Lancia fan controller
Remote option (Telestart)
2
3
3
3
3
4
5
5
6
7
8
9
12
15
Preparing installation location
Preparing heater
Installing heater
Coolant circuit
Fuel
Installing control unit
Final Work
Template for Fuel Standpipe
Operating Instructions for End Customer
16
18
19
20
24
27
28
29
30
Validity
Manufacturer
Chrysler (USA)
Lancia Voyager (USA)
Engine type
VM 64 C
5 / VM 25 D
Model
Grand Voyager
Voyager
Engine model
Diesel
Diesel
Type
rt
rt
Output in kW
120
120
EG BE No. / ABE
e11 * 2001/116 * 0144 * ...
e11 * 2001/116 * 0144 * ...
Displacement in cm³
2777
2776
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.
Note:
When the vehicle is delivered, the fuel tank should be filled with as little fuel as possible!
1313868B_EN
2
Chrysler Grand Voyager / Lancia Voyager
Heater / Installation Kit
Quantity
1
1
1
Description
Retail accessories Thermo Top C
Installation kit for Chrysler Grand Voyager Lancia Voyager 2.8 CRD
Heater control
Order No.:
See price list
1313748A
see price list
Foreword
This installation documentation applies to Chrysler Grand Voyager Lancia Voyager 2.8 CRD vehicles
- for validity, see page 2 - from model year 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."
In each case however, the specifications of this "installation documentation"; the "operating instructions" and the "installation instructions" of Thermo Top C must be followed.
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 rub protection (split-open fuel hose).
Spray unfinished body areas, e.g. drilled holes, with anti-corrosion wax (Tectyl 100K, Order No. 111329).
When installing an IPCU, the corresponding settings must be checked or adjusted before the installation.
Special tools
-
Torque wrench for 2.0 - 10 Nm
Hose clamping pliers
Metric thread-setter kit
Chrysler special tool number: 9340 (Installation and removal of fuel-tank sending unit)
1313868B_EN
3
Chrysler Grand Voyager / Lancia Voyager
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 hose clamps = 2.0 + 0.5 Nm!
Tightening torque of Ejot screws, Ejot studs = 10 Nm!
1313868B_EN
4
Chrysler Grand Voyager / Lancia Voyager
Preliminary Work
WARNING!
-
Open the fuel tank cap and vent the fuel tank.
Empty the fuel 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 the engine cover.
Completely remove the battery.
Remove the charge-air tube.
Detach the wheel well trim on the right and left.
Remove the bumper.
Remove the fuel tank according to the manufacturer's instructions.
Remove the lower instrument panel trim on the driver's side.
Remove the footwell trim on the front passenger's side.
Remove the A/C control panel in accordance with the manufacturer's instructions.
Remove page 30 "Operating Instructions for End Customer" and add to the vehicle operating instructions.
Heater installation location
1 Heater
1
Installation location
1
1313868B_EN
5
Chrysler Grand Voyager / Lancia Voyager
Preparing Chrysler electrical system
1
gn/ws
0,75²
2500
2
3
100
400
4
gn
0,75²
6
7
500
500
5
100
0,75²
gn/ws
500
10
11
10
1
87
85
30
sw
0,75²
Produce connections as shown in wiring diagram. Pull wire section 1 into protective
sleeving.
rt/ws
86
br
9
500
Cutting
wires to
length
0,75²
400
8
rt
Wire sections retain their numbering throughout the whole document!
Red (rt) wire from K3/87a premounted
Black (sw) wire from K3/30 premounted
87a
Preparing
K3 relay
K3
br
11
2
Connect wires to IPCU socket. Pull wiring
sections 3 and 5 into protective sleeving.
IPCU view on contact side!
The IPCU provided in the kit is preprogrammed with the following adjustment values:
3
6
15
A
86
IPCU
15
E
85
A
E
86
85
4
8
Duty cycle:
Frequency:
Voltage:
Function:
55%
100Hz
5.0V
Low side
Preparing
IPCU and
K3.1 relay
On heater activation, the adjustment values
are to be controlled and corrective measures
are to be taken if necessary.
5
7
86
87 87a
85
30
K3.1
9
1313868B_EN
6
Chrysler Grand Voyager / Lancia Voyager
1
gn/ws
Preparing electrical system for
Lancia
0,75²
Wire sections retain their numbering throughout the whole document!
2
300
3
rt
0,75²
6
4
rt
0,75²
1000
7
8
0,75²
100
0,75²
300
br
5
sw
0,75²
1000
9
gn
100
gn/ws
900
10
11
10
1
87
85
30
0,75²
Produce connections as shown in wiring diagram. Pull wire section 1 into protective
sleeving.
rt/ws
86
Cutting
wires to
length
sw
Red (rt) wire from K3/87a premounted
Black (sw) wire from K3/30 premounted
87a
Preparing
K3 relay
K3
br
11
8
Connect wires to IPCU socket. Pull wiring
sections 2 and 4 into protective sleeving.
IPCU view on contact side!
The IPCU provided in the kit is preprogrammed with the following adjustment values:
9
2
15
A
86
IPCU
15
E
85
A
E
86
85
6
4
Duty cycle:
Frequency:
Voltage:
Function:
55%
100Hz
5.0V
Low side
Preparing
IPCU and
K3.1 relay
On heater activation, the adjustment values
are to be controlled and corrective measures
are to be taken if necessary.
7
3
86
87 87a
85
30
K3.1
5
1313868B_EN
7
Chrysler Grand Voyager / Lancia Voyager
Electrical system
Chrysler digital timer
Lancia digital timer
1 Digital timer
1 Digital timer
1
1
2
3
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
installation diagram
1
2
5
4
3
4
1
5
Fuse holder, K3 relay
Wiring harness pass through
1 Existing hole, 5.5x13 self-tapping screw
2 Angle bracket
3 Fuses pushed on
4 M5x16 bolt, retaining plate for fuse holder,
washer, flanged nut
5 K3 relay
Route wiring harnesss of digital timer, fan controller and green/white (gn/ws) wire with suitable
materials (fuel line) from engine compartment
through protective rubber plug 1 into passenger
compartment.
1313868B_EN
8
Chrysler Grand Voyager / Lancia Voyager
Chrysler fan controller
Webasto
Chrysler
30
15
HG
F3
VSV
4
X1
gn/
ws
bl
rt/ws
1
4²
10
86
87
85
30
Wiring diagram
rt
4²
87a
GM
K3
vi
0,75²
11
br
2
sw
4²
gn
3
C2
0,75²
A
8
sw
0,75²
2
GRr
4²
IPCU
C1
SD
4
3
2
sw
bl/hbl
E
0,75²
85
gn/ws
6
br
gn
bl/hbl
0,75²
0,75²
rt
7
0,75²
rt
0,75²
br
5
0,75²
0,75²
sw
0,75²
M
86
KM
87 87a
bl/rt
K3.1
85
4
1
bl
15
86
M
0,75²
30
9
sw
St A
0,75²
bl/rt
0,75²
21
23
32
KB
31
Webasto components
HG
Heater TT-C
X1
6-pin heater connector
F3
25A fuse
K3
Fan relay
K3.1 Additional relay
IPCU Pulse width modulator
IPCU adjustment values:
Duty cycle: 55%
Frequency: 100Hz
Voltage:
5.0V
Function:
Low side
1313868B_EN
Vehicle components
GM
Fan motor
KM
Valve motor
GRr
Fan controller
C1
4-pin connector, GRr
KB
A/C control panel
St A
32-pin connector KB
SD
Socket outlet of instrument panel
VSV
Power supply module
Colours and symbols
rt
red
ws
white
sw
black
br
brown
gn
green
bl
blue
hbl
light blue
vi
violet
Legend
X
Cutting point
Wiring colours may vary.
9
Chrysler Grand Voyager / Lancia Voyager
1
Produce wires according to wiring diagram.
Insert green/white (gn/ws) wire 1 from K3/86
into IPCU/86. Route down wiring harness 1
with brown (br) wire 5 and green (gn) wire 3
to socket outlet of instrument panel!
Connecting IPCU
1
6
1
Mount IPCU 2 and K3.1 1 with double-sided
adhesive tape.
2
Fastening
IPCU and
K3.1
7
Remove 32-pin connector 3 of A/C control
panel.
1
1 Blue/red (bl/rt) wire of 32-pin connector KB,
Pin 21
2 Blue/light blue (bl/hbl) wire of 32-pin connector KB, Pin 32
2
3
Connector
for A/C
control
panel
8
Connection of K3.1 relay on 32-pin connector
2 from A/C control panel. Produce connections as shown in wiring diagram.
7
9
1
1 Blue/red (bl/rt) wire of valve motor
3 Blue/red (bl/rt) wire of 32-pin connector KB,
Pin 21
7 Red (rt) wire to K3.1/87
9 Black (sw) wire to K3.1/30
Connecting A/C
control
panel
3
2
1313868B_EN
9
10
Chrysler Grand Voyager / Lancia Voyager
1
Connection to IPCU on 32-pin connector 3
from A/C control panel. Produce connections
as shown in wiring diagram.
8
1 Blue&light blue (bl/hbl) wire of fan controller
2 Blue/light blue (bl/hbl) wire of 32-pin connector KB, Pin 32
6 Red (rt) wire of IPCU/E
8 Black (sw) wire of IPCU/A
3
2
6
10
Connection on socket outlet of instrument
panel 2. Produce connections as shown in
wiring diagram.
3
5
1
3
10
Connecting A/C
control
panel
2
1 Grey/violet (gr/vi) wire of positive wire on
socket outlet (Terminal 15)
3 Black (sw) wire of earth wire on socket outlet
3 Green (gn) wire to K3.1/86
5 Brown (br) wire to K3.1/85
Connection of Terminal 15
11
Connection to 4-pin connector C1 3 from fan
controller. Produce connections as shown in
wiring diagram.
1
11
1 Socket of connector C1
2 Blue (bl) wire of terminal 15
4 Blue (bl) wire of connector C1, Pin 4
10 Red (rt) wire from K3/87a
11 Black (sw) wire K3/30
Connecting fan
controller
2
4
3
1313868B_EN
12
11
Chrysler Grand Voyager / Lancia Voyager
Lancia fan controller
Webasto
Lancia
30
15
HG
F3
Fa
Fb
Wiring diagram
Fc
4
X1
gn/
ws
ro/ge
rt/ws
0,5²
1
rt
10
4²
86
87
87a
rt/gr
0,5²
K3
85
30
sw
br
11
4²
8
9
0,5²
0,5²
0,75²
St A
15
A
IPCU
gn
rt/gr
ro/ge
gn
1
2
14
KB
4
bl
4²
0,75²
E
86
sw
85
0,75²
2
bl
rt
4²
0,75²
6
br
0,75²
7
rt
3
0,5²
1
2
1
2
0,75²
86
87 87a
85
30
K3.1
br
GM
M
bl/vi
5
St B
GR
bl/vi
0,5²
sw
St A
6
3
5
0,75²
0,75²
31
Webasto components
HG
Heater TT-C
X1
6-pin heater connector
F3
25A fuse
K3
Fan relay
K3.1 Additional relay
IPCU Pulse width modulator
IPCU adjustment values:
Duty cycle: 55%
Frequency: 100Hz
Voltage:
5.0V
Function:
Low side
1313868B_EN
Vehicle components
GM
N085 fan motor
GR
M072 fan controller
St A
6-pin connector GR
St B
2-pin connector GR
KB
M070 A/C control unit
St A
26-pin connector KB
Fa
Fuse
Fb
Fuse
Fc
Fuse
Colours and symbols
rt
red
ws
white
sw
black
br
brown
gn
green
bl
blue
gr
grey
ro
pink
vi
violet
ge
yellow
Legend
X
Cutting point
Wiring colors may vary.
12
Chrysler Grand Voyager / Lancia Voyager
Produce wires according to wiring diagram.
Insert green/white (gn/ws) wire 1 from K3/86
into IPCU/86. Lock IPCU socket 2 and K3.1
relay socket 1 in place and mount using double-sided adhesive tape!
1
Connecting IPCU
2
13
1
Connection to 6-pin connector A 1 from fan
controller. Produce connections as shown in
wiring diagram.
1
2 Blue (bl) wire of connector A Pin 6
3 Blue (bl) wire from fuse Fc
10 Red (rt) wire from K3/87a
11 Black (sw) wire K3/30
3
10
2
11
14
Connection to 6-pin connector A 3 from fan
controller. Produce connections as shown in
wiring diagram.
1
2
3
2
Connecting fan
controller
Connection to 26-pin connector A 3 from A/C
control unit (see the next but one illustration).
Produce connections as shown in wiring diagram.
5
3
3
1 Blue/violet (bl/vi) wire of A/C control unit
connector A Pin 14
2 Blue/violet (bl/vi) wire of connector A Pin 3
2 Red (rt) wire of IPCU/E
4 Black (sw) wire of IPCU/A
15
4
1
1313868B_EN
Connecting fan
controller
2
1 Red/grey (rt/gr) wire from Fb fuse
2 Red/grey (rt/gr) wire from A/C control unit
connector A Pin 2
3 Red (rt) wire to K3.1/87
5 Black (sw) wire to K3.1/30
Connection of A/C
control
unit
16
13
Chrysler Grand Voyager / Lancia Voyager
9
Connection to 26-pin connector A 2 from A/C
control unit (see following illustration). Produce connections as shown in wiring diagram.
1
1 Pink/yellow (ro/ge) wire from Fa fuse
3 Pink/yellow (ro/ge) wire from A/C control
unit connector A Pin 1
9 Green (gn) wire to IPCU/15
Connection of A/C
control
unit
3
17
2
1
1 Red/grey (rt/gr) wire from Pin 2
2 A/C control unit connector A
3 Blue/violet (bl/vi) wire Pin 14
4 Pink/yellow (ro/go) wire Pin 1
2
4
View of A/C
control
unit connector A
3
18
1313868B_EN
14
Chrysler Grand Voyager / Lancia Voyager
Remote option (Telestart)
1
Fasten bracket on existing hole with M5x16
bolt and M5 flanged nut (see photo after
next).
1 Receiver
Installing
receiver
19
1 Antenna
1
Installing
antenna
20
Temperature sensor for T100 HTM only
1
1 Fasten temperature sensor with suitable
means
Installing
temperature sensor
21
1313868B_EN
15
Chrysler Grand Voyager / Lancia Voyager
Preparing installation location
Remove control unit with bracket 1. Original
vehicle bolts will be reused.
Removing
control
unit
22
1
Cut bracket of control unit 1 to length at markings.
1
2 Discard cut-off sections
2
Preparing
bracket of
control
unit
2
23
1 7 mm dia. hole
Hole in
bracket
95
7
24
1
1
Bracket will be installed later during "Final
Work".
1
1 Drill 5.5 mm dia. hole in centre [2x]
Hole in
bracket
37
63
25
1313868B_EN
16
Chrysler Grand Voyager / Lancia Voyager
Route original vehicle wiring harness 1 and
fasten with cable tie.
Cut away edge at marking.
1
2 Discard section
Routing
wiring harness
26
2
1 Bracket
2 M6x25 bolt, 8 mm shim, pin lock
3 M6x12 bolt, flanged nut [2x each]
4 Perforated bracket [2x]
1
Preparing
bracket
2
3
3
4
27
4
1
Loosely mount bracket 1 and align on lower
edge of frame side member!
2
2 Copy hole pattern [3x]
3 Original vehicle rivet nut, M6x25 bolt
Copying
hole pattern
3
2
28
2
Remove bracket.
1
1 Mount edge protection
2 9.1 mm dia. hole; mount rivet nut [2x each]
3 7 mm dia. hole
2
Installing
rivet nut
2
3
1313868B_EN
29
17
Chrysler Grand Voyager / Lancia Voyager
1
2
Preparing heater
2
Insert two washers between heater and
bracket 1 at position 3.
2 Ejot screw [2x]
3 Ejot screw, washer [2x]
Mounting
bracket on
heater
30
3
1 Combustion air pipe
a = 220
1
Discard section X
Cutting
combustion air
pipe to
length
a
X
Punch through perforation on heater cover at
position 2.
4
1
2
1 Silencer
2 Retaining clip in hole
3 27 mm dia. clamp
4 Combustion air pipe
Mounting
silencer
3
31
1 Loosely mount angle bracket [2x]
2 Ejot screw, large diameter washer [2x each]
3 Ejot stud
1
1
Loosely
mounting
angle
bracket
2
1313868B_EN
3
2
32
18
Chrysler Grand Voyager / Lancia Voyager
1
1 Exhaust pipe
a = 200
2 Exhaust end section
b = 180
2
Discard section X
a
Preparing
exhaust
pipe
b
X
1
2
1 Hose clamp [3x]
2 M6x20 bolt, flanged nut
3 Exhaust-pipe end section
4 Exhaust silencer
5 Exhaust pipe
1
Premounting exhaust pipe
5
3
1
4
33
Installing heater
1 M6x40 bolt, spring lockwasher, 20 mm
shim, rivet nut
2 M6x25 bolt, original vehicle rivet nut
Mounting
heater
2
1
34
1 M6x40 bolt, spring lockwasher, 20 mm
shim, rivet nut
2 M6x50 bolt, spring lockwasher, 30 mm
shim, flanged nut
1
Mounting
heater
2
1313868B_EN
35
19
Chrysler Grand Voyager / Lancia Voyager
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 other
hoses cannot be damaged. The heater must be filled with coolant when installing the hose.
The connection should be "inline" according to the following diagram:
Hose installation
diagram
A
2
D
1
C
B
All connecting pipes
= 18x20 mm dia. All hose clamps
1 = T-piece
! 2 = Check valve
!
1313868B_EN
= 20-27 mm dia.
20
Chrysler Grand Voyager / Lancia Voyager
Hose A = 90° elbow, 18x18
Hose D = 90° elbow, 18x18
Discard section X!
B
X
B = 1260
C = 1140
Cutting
hoses to
length
X
C
A
X
D
1
Divide braided protection hose in middle.
Push one and a half braided protection hose
each onto hose B and C.
Cut heat shrink plastic tubing to length.
1
C
1 50 mm long heat shrink plastic tubing [6x]
1
Preparing
hoses
B
1
1
1
Route hose B and C under original vehicle
wiring harness into engine compartment.
Connecting heater
B
C
1313868B_EN
36
21
Chrysler Grand Voyager / Lancia Voyager
B
Routing in
engine
compartment
C
37
C
B
Routing in
engine
compartment
C
B
38
Remove protective hoses on hose on engine
outlet 2 and heat exchanger inlet 1.
Cutting
point
2
1
39
1
2
5
1 Hose section on heat exchanger outlet
2 Hose section of heat exchanger inlet
3 Engine outlet hose section
4 Hose section on engine inlet
5 Discard 60 mm hose section
Cutting
point
60
80
50
4 3
1313868B_EN
40
22
Chrysler Grand Voyager / Lancia Voyager
1
Observe direction of flow of check valve 2.
2
1 T-piece
3 18x20 connecting pipe
A
D
Preparing
hose A
and D
3
3
41
1 Hose on heat exchanger inlet
2 Hose of engine outlet
1
D
Connecting engine
outlet
C
2
42
Fill coolant hoses with coolant. Ensure sufficient distance to neighbouring components.
1
1 Hose for heat exchanger outlet
2 Hose on engine inlet
A
2
Connecting heat
exchanger
inlet
B
43
1313868B_EN
23
Chrysler Grand Voyager / Lancia Voyager
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. 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 as shown in the wiring harness routing diagram.
Remove fuel tank. Remove fuel-tank sending
unit 1 in accordance with manufacturer's instructions.
Place large diameter washer 2 on bars.
1
3 Copy hole pattern, 6 mm dia. hole
Fuel extraction
2
3
44
Shape fuel standpipe 1 according to template, cut to length and install.
1
Installing
fuel standpipe
1
45
1
Install fuel-tank sending unit 1 in accordance
with manufacturer's instructions. Cut 1,000
mm off fuel line 2.
2
3 Fuel standpipe
4 3.5 x 4.5 mm dia. hose section; 8 mm dia.
clamp, 10 mm dia. clamp
4
3
1313868B_EN
Connecting fuel
line
46
24
Chrysler Grand Voyager / Lancia Voyager
1
Fasten fuel line 1 to original vehicle fuel line
with cable tie!
1
Routing
fuel line
47
Drill out angle bracket 2 at position 1 to 10.5
mm dia.
1
1 Original vehicle bolt of tank mount
Mounting
angle
bracket
48
2
1
2
1 Metering pump
2 Silent block, flanged nut [2x]
3 Hose section, 10 mm dia. clamp [2x]
4 Fuel line of fuel standpipe
5 Rubber-coated pipe clamp
3
Mounting
metering
pump
4
5
49
1 Hose section, 10 mm dia. clamp [2x]
2 Fuel line
Connecting heater
2
1
1313868B_EN
50
25
Chrysler Grand Voyager / Lancia Voyager
1 Fuel line, wiring harness of metering pump
1
Installing
lines
1
51
Slide fuel hose 1 onto fuel line as rub protection.
1
2 Fuel line, wiring harness of metering pump
2
Installing
lines
52
1
Slide fuel hose 1 onto fuel line as rub protection.
Check the position of the components; adjust
if necessary. Check that they have freedom of
movement.
2
2 Wiring harness of metering pump, connector mounted
3 Fuel line, hose section, 10 mm dia. clamp [2x]
3
1313868B_EN
Connecting metering pump
53
26
Chrysler Grand Voyager / Lancia Voyager
1
2
Installing control unit
2
Tighten Ejot screw at position 3 [2x].
1 Control unit bracket
2 M5x16 bolt, flanged nut [2x each]
4 Ejot stud, 20 mm shim, flanged nut
3
3
4
Installing
control
unit bracket
54
Install control unit 1 with original vehicle bolts
on bracket and complete with connector.
Installing
control
unit
1
1
55
Ensure sufficient distance to adjacent components; shorten bolt at position 2 if necessary.
C
1 Cable tie
Fixing hoses B and C
in place
B
2
1313868B_EN
56
27
Chrysler Grand Voyager / Lancia Voyager
Final Work
WARNING!
Mount removed parts in reverse order.
Check all hoses, clamps and all electrical connections for firm seating.
Secure all loose cables using cable ties.
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 Customer".
- Place message signboard "Switch off parking heater before refilling" in the area of the filler
neck.
- For start-up and function check, see Installation instructions
1
42mm dia. hole wheel-well inner panel 2 at
position 3. Align exhaust end section 3 flush
with red (rt) rubber isolator 1!
2
Mounting
rubber isolator
3
57
Feel the drive
Webasto AG
Postfach 80
D-82132 Stockdorf / Germany
National Hotline: 01805 93 22 78
(14 Cent aus dem deutschen Festnetz)
Hotfax: 0395 5592 353
Hotmail: technikcenter@webasto.com
http://www.webasto.com
1313868B_EN
Printed in Germany
06/2012
Printing: Steffen
28
Chrysler Grand Voyager / Lancia Voyager
Template for Fuel Standpipe
100 mm
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 margins” and 100% of the normal size.
100 mm
0
1313868B_EN
29
Chrysler Grand Voyager / Lancia Voyager
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. 20 min. (in one direction), we recommend not exceeding a switch-on time
of 20 min.
The passenger compartment monitoring must be deactivated during heating. It will not be armed if the
doors are locked manually using the locking button!
If the summer/winter switch option has been installed, it must be switched in accordance with the time
of year. The heater will then heat in the position Winter
and in the position Summer
it will only
switch on the vehicle fan to ventilate the vehicle interior.
Before parking the vehicle, make the following settings:
2
1
Chrysler
2
1 Direct air outlet toward windscreen
2 Set temperature on both sides to "HI".
3 Switch off rear ventilation
Automatic
air-conditioning
58
3
2
1
Lancia
2
1 Direct air outlet toward windscreen
2 Set temperature on both sides to "HI".
Automatic
air-conditioning
59
1313868B_EN
30