Water Heater Installation documentation Lexus LS 460 / LS 600h

Transcription

Water Heater
Feel the drive
e1
Thermo Top Evo 5KW Parking Heater
00 0258
Installation documentation
Lexus LS 460 / LS 600h
Petrol
from Model Year 2009
Left-hand drive vehicle
Automatic air-conditioning
Automatic transmission
WARNING!
Hazard warning:
Observe the instructions of the vehicle manufacturer, allow jobs to be performed by
electrical skilled persons only.
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.: 1316669A_EN
Fee Euro 10.00
© Webasto AG
Table of Contents
Validity
Heater/Installation Kit
Foreword
General Instructions
Special Tools
Explanatory Notes on Document
Preliminary Work
Heater installation location
Preparing electrical system
LS 460 electrical system
Electrical system LS600h
Fan control
Combination heater controls
Digital timer
2
3
3
3
3
4
5
5
6
7
8
9
12
13
Telestart
Preparing heater
Preparing installation location
Installing heater
Fuel
LS 460 coolant circuit
LS 600h coolant circuit
Final Work
Template for Fuel Standpipe
Operating Instructions for End Customer
13
15
17
18
20
25
32
40
41
42
Validity
Manufacturer
Lexus
Model
LS 460
Type
F4
EG-BE No./ABE
e6 * 2001 / 116 * 0108 * ...
Engine type
1UR-FSE
Engine model
Petrol
Output in kW
280
Displacement in cm³
4608
Manufacturer
Lexus
Model
LS 600h
Type
HF4
EG-BE No./ABE
e6 * 2001 / 116 * 0109 * ...
Engine type
2UR-FSE
Engine model
Petrol
Output in kW
290
Displacement in cm³
4969
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.
1316669A_EN
2
Heater/Installation Kit
Quantity
1
1
1
Description
Basic delivery scope of Thermo Top Evo 5KW
Installation kit Lexus LS 460 / LS 600h 2009 Petrol
Heater control
Order No.:
See price list
1316670A
See price list
Foreword
This installation documentation applies to the Lexus LS 460 / LS 600h Petrol vehicles - for validity, see
page 2 - from model year 2009 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.
However, the stipulations in this "installation documentation", the "operating instructions" and the "installation documentation" 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 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 plastic 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 are to be checked or adjusted before the installation.
Special Tools
- Torque wrench for 2.0 - 10 Nm
- Hose clamping pliers
- Metric thread-setter kit
1316669A_EN
3
Explanatory Notes on Document
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.
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! Install fuel connections without impacts.
Tightening torque of 5x13 heater bolts = 8Nm!
Tightening torque of 5x15 bolt of water connection piece retaining plate = 7Nm!
1316669A_EN
4
Preliminary Work
WARNING!
-
Open the fuel tank cap, ventilate the tank.
Close the fuel tank cap again.
Disconnect battery from on-board power supply network.
Drain the coolant from 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 air filter
Remove the engine cover
Remove coolant expansion tank
Remove the bumper trim
Remove the bumper.
Remove air duct for brake on the right
Remove underride protection
Remove underbody trim on the right
Remove the rear bench seat on the left
Open the tank-fitting service lid on the right
Remove the fuel-tank sending unit in accordance with manufacturer's instructions
Remove footwell trim on the right
Remove the glove compartment
Remove page 42 "Operating Instructions for End Customer" and insert with vehicle operating instructions.
Heater installation location
1
1 Heater
Installation location
1
1316669A_EN
5
Preparing electrical system
1
2
rt
0,5²
500
Cutting
wires to
length
3
sw
0,5²
4
br
0,5²
5
gn/ws
0,5²
Connect wires to IPCU socket.
IPCU view on contact side.
The pre-programmed settings are to be
checked during the function control on the vehicle, and adjusted if necessary.
1
15
A
86
IPCU
15
Duty cycle:
Frequency:
Voltage:
Function:
E
2
85
3
A
E
86
60%
400Hz
9,0V
Low-side
Premounting IPCU
85
4
1 M5x12 bolt, washers [2x], nut
2 Fuse holder of passenger compartment
3 Angle bracket
1
3
Preparing
fuse holder
of passenger compartment
2
2
rt/sw
rt
gn/ws
0,5²
4²
0,75²
F3
F4
Insert K1 relay and F4 10A in the fuse holder
of the passenger compartment. Insert red (rt)
wire in the K1/87a socket and black (sw)
wire  in K1/30 socket
6
86
87
85
30
87a
rt
4²
Preparing
relay K1
and fuse
F4
K1
br
0,5²
1316669A_EN
7
sw
4²
6
LS 460 electrical system
Fuse holder of LS 460 engine compartment
1 M6x16 bolt, large diameter washer, flanged
nut, existing hole
2 Angle bracket
3 Fuses F1-2
4 M5x16 bolt, washers [2x], retaining plate of
fuse holder, nut
1
Wiring harness pass through of engine compartment, connection of earth wire LS 460
1 Protective rubber plug
2 Earth wire on earth support point
2
1
2
4
3
3
4
Wiring harness routing
diagram
Do not install the metering pump
wiring harness until later together with fuel pipe along the original vehicle fuel lines on the
underbody
1
1
2
5
6
Connecting LS 460 positive wire
Wiring harness pass through of passenger compartment
1 Positive wire on positive support point
2 Wiring harness of heater and heater control
1316669A_EN
7
Electrical system LS600h
Connecting earth wire LS 600
Connecting LS 600 positive wire
1 Original vehicle earth support point
1 Original vehicle positive support point
1
7
1
8
Wiring harness routing
diagram
Do not install the metering pump
wiring harness until later together with fuel pipe along the original vehicle fuel lines on the
underbody
1
1
2
3
4
9
10
Fuse holder of LS 600 engine compartment
Wiring harness pass through LS 600
1 Fuses F1-2
2 M5x16 bolt, washers [2x], retaining plate of
fuse holder, nut
3 Original vehicle flanged nut
4 Angle bracket
Protect wiring harnesses with corrugated tubes.
1316669A_EN
8
Fan control
Webasto
Lexus
30 (B+)
15 (IG)
HG
1
X2
F2
2 2
5
P-IG1-1
X1
HTR
Wiring diagram
F1
ge
0,5²
rt
gn/ws
4²
0,75²
rt/sw
rt
gn/ws
0,5²
4²
0,75²
rt/sw
0,5²
br
vi
0,5²
6
rt
rt
vi
ws
X10
F3
F4
86
87
L76 (A)
87a
30
br
rt
sw
0,5²
br
3
AC-V
K1
85
5
7
sw
2
0,5²
ws
rt
1
3
ws/sw
15
IPCU
E
Az3
3
2
1
A
bl
85
4
br
86
1
gn/ws
0,75²
2
GE
3
A40 (A)
M
5
31 (GND)
Webasto components
Vehicle components
HG
TT-Evo heater
GE
Fan unit
6-pin heater connector A40 (A) GE connector
X1
2-pin heater connector AC-V
A/C booster
X2
X10 4-pin connector
L76 (A) White (ws) 35-pin connecHeater control
tor A/C-V
K1
Fan relay
P-IG1-1 Fuse 10A
F1
Fuse 20A
HTR
50 A fan fuse
F2
Fuse 30A
Az3
3-pin connector
F3
Fuse 1A
F4
Fuse 10A
IPCU adjustment values:
Duty cycle: 60%
Frequency: 400Hz
Voltage:
9,0V
Function:
Low-side
1316669A_EN
Colours and symbols
rt
red
ws
white
sw
black
br
brown
gn
green
vi
violet
Legend
X
Cutting point
Wiring colours may vary.
9
1
1 Original vehicle bolt
2 Angle bracket
2
Installation of fuse
holder in
passenger
compartment
11
Connect same colour wires of wiring harness
of passenger compartment fuse holder 3 with
wiring harness of heater 1 according to the
wiring diagram. Connect additional
green/white (gn/ws) wire  2 with
green/white (gn/ws) wire of wiring harness of
the passenger compartment fuse holder 3 .
1
Connecting wiring
harnesses
3
2
12
Connection on white (ws) 35-pin
connector L76 (A) 1, Pin 5 from A/C booster.
Produce connections as shown in wiring diagram.
1
2
6
3
5
2
3
4
5
6
Violet (vi) wire of connector L76 (A)
Black (sw) wire  of K1/30
Red (rt) wire  of K1/87a
Red (rt) wire  to IPCU/15
Violet (vi) wire from fuse P-IG1-1
Connecting A/C
booster
13
4
Connector L76 (A) on contact side.
1
8
2
3
4
5
6
Connector
assignment
L76 (A)
7
9 10 11 12 13 14 15 16 17 18 19
20 21 22 23
24 25
26 27
28 29 30 31
32 33
34 35
14
1316669A_EN
10
1
1 Angle bracket
2 M5x16 bolt, washers [2x], nut
3 IPCU socket
2
Premounting IPCU
socket
15
3
1
Before installation, mount the green/white
(gn/ws) wire  1 in the socket of IPCU/86.
Mount IPCU.
IPCU installation
16
2
1
Connection to 3-pin connector A3 1 of fan unit.
Produce connections as shown in wiring diagram.
2
3
5
4
2
3
4
5
White (ws) wire to connector Az3
White (ws) wire from A/C heater control Pin 3
Red (rt) wire  to IPCU/E
Black (sw) wire  to IPCU/A
Connecting IPCU
17
1 Brown (br) wire  to IPCU/85, cable lug
2 Original vehicle earth support point
1
2
1316669A_EN
Connecting earth
wire
18
11
Combination heater controls
1
Only for "silver" transmitter.
See provided installation instructions for
"black" transmitter.
Telestart T91 with and without keys.
Preparing
connector
Figure 11 (Y-adapter of connector)
2
Detach violet (vi) wire 2 from 6-pin connector 1
Pin5 and insert it in Pin2
19
4
1
3
2
1
Digital timer and Telestart T91.
2
Figure 20a (Y-adapter coupling, wire-side
view)
5
3
Detach, insulate and tie back violet (vi) wire 4
from 4-pin coupling 1 Pin1.
Detach black (sw) wire 5 from 4-pin coupling 1
Pin2 and insert it in Pin1.
Preparing
connector
Figure 20b (Y-adapter of connector)
Detach black (sw) wire 3 from 6-pin connector 2
20a
20b
4
Telestart T100 HTM with and without keys.
1
Figure 21 (Y-adapter of connector)
Detach violet (vi) wire 2 from 6-pin connector 1
Pin5. Cut yellow (ge) wire 3 approx. 50mm before connector 1. Connect violet (vi) wire 2 and
yellow (ge) wire 3 to connector.
3
21
2
4
1
3
2
Preparing
connector
1
Digital timer and Telestart T100 HTM!
2
Figure 22a (Y-adapter coupling, wire-side
view)
3
6
Detach, insulate and tie back violet (vi) wire 5
from 4-pin coupling 1 Pin1.
Detach black (sw) wire 6 from 4-pin coupling 1
Preparing
connector
Figure 22b (Y-adapter of connector)
22a
1316669A_EN
5
4
22b
Detach black (sw) wire 4 from 6-pin connector 2
Pin3. Cut yellow (ge) wire 3 approx. 50mm before connector 2. Connect black (sw) wire 4 and
yellow (ge) wire 3 to connector.
12
Kabelbaum
Heizgerät
9004584A
Heater
controls diagram
Vorwahluhr
Telestart
Taster
Digital timer
1
1 Digital timer
Installing
digital timer
23
Telestart
1
Detach player 2 and fasten receiver 1 with adhesive tape.
Installing
receiver
24
2
Paste antenna 1 in the black area of the windscreen.
1
Installing
antenna
25
1316669A_EN
13
Temperature sensor T100 HTM
Fasten temperature sensor 1 with adhesive
tape.
1
Installing
temperature sensor
26
1316669A_EN
14
1
Preparing heater
2
1 Exhaust pipe
a = 130
2 Exhaust end section
b = 25
Discard section X
a
Preparing
exhaust
pipe
b
X
1 Combustion air pipe
a = 300
1
Discard section X
Cutting
combustion air
pipe to
length
a
X
LS 460
A
B
C
D
F
E
K
J
I
Hose I and H will be cut to length later. Discard section X
G
X
X
X
H
1
=
=
=
=
=
=
=
=
=
110
730
170
60
120
860
90
55
270
Cutting
hoses to
length
Push braided protection hose onto hose B, F
and K and cut to length.
Cut heat shrink plastic tubing to length.
1
B
1
A
B
C
D
E
F
G
J
K
1
1 Heat shrink plastic tubing, 50 mm long [6x]
Preparing
hoses
F
K
1
1
1316669A_EN
15
LS 600h
A
B
C
E
D
Hose G and H will be cut to length later. Discard section X
F
A
B
C
D
E
F
I
I
H
X
X
X
G
1
500
170
60
120
750
90
240
Cutting
hoses to
length
Push braided protection hose onto hose A
and E and cut to length.
Cut heat shrink plastic tubing to length.
1
A
1
=
=
=
=
=
=
=
1
1 Heat shrink plastic tubing, 50 mm long [6x]
Preparing
hoses
E
I
1
1
All vehicles
1
2
1
1
1 Coolant connection piece, sealing ring [2x
each]
2 5x15 self-tapping bolt, retaining plate of
coolant connection piece
Installing
coolant
connection piece
27
Hose D = heater inlet LS 460h
Hose E = heater outlet LS 460h
Hose C = heater inlet LS 600h
Hose D = heater outlet LS 600h
2 C/D 2
1 18x18mm, 90° connecting pipe [2x]
2 25mm dia. spring clip [4x]
Premounting hoses
2
D/E
1316669A_EN
2
28
16
1 90° moulded hose, 10mm dia. clamp [2x]
2 Fuel line
Premounting fuel
line
2
29
1
1
3mm dia. drain hole 4 in exhaust silencer 3.
Mount exhaust end section 5 and lock with 4
blows of a staking punch.
2
1
1 Hose clamp [2x]
2 Exhaust pipe
3
Premounting exhaust
system
4
30
5
Bend tab 2 of bracket 1 by 90°. Apply corrosion protection at bending point.
1
Preparing
bracket
31
2
1
Preparing installation location
2
Position bracket 2 and align it parallel to
bumper edge 3.
15
1 Bumper
4 Copy hole pattern, 7mm dia. hole [3x]
Copying
hole pattern
4
80
3
1316669A_EN
32
17
1
1 M6x20 bolt, pin lock [3x each]
1
Premounting bolts
1
33
1
2
1
2
3
4
5
3
Combustion air pipe
Flanged nut [3x]
Bracket
48mm p-clamp
Silencer
Installing
bracket
4
2
5
1
2
34
Installing heater
1
1 5x15 Self-tapping bolt [3x]
2 M6x25 bolt, spring lockwasher, 15mm
spacer nut
Installing
heater
1
2
35
1 25mm dia. spring clip
2 Combustion air pipe
Installing
combustion air
pipe
1
2
1316669A_EN
36
18
Wrap bumper and air cleaner housing 1 with
insulation material 2.
Installing
bumper
1
37
2
Position air filter 1 laterally in bumper.
Installing
air filter
38
1
1 Wiring harness of circulating pump
2 Wiring harness of heater [2x]
1
Mounting
wiring harnesses
2
1316669A_EN
2
39
19
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.
1
2
3
Detach external connector housing 1 by
opening lock 2 of the connector of metering
pump 6. Remove coding 4. Remove blue (bl)
wire 3 and brown (br) wire 7 from the connector of the metering pump 6 by opening the
lock 5 [2x]. Will be inserted again later. Pin assignment is not relevant.
4
Removing
wires
5
5
7
6
40
Pull fuel line 3 and wiring harness of metering
pump 1 into 2100mm long corrugated tube 2
and route to the engine compartment (see
wiring harness routing to engine compartment).
Installing
lines
3
1
2
41
Route wiring harness of metering pump and
fuel line into 10mm dia., 2100mm long corrugated tube 1 to the firewall (see fuel).
1
Installing
lines
42
1316669A_EN
20
Cut open 17mm dia., 200mm long corrugated
tube 2 lengthwise and slide onto wiring harnesses of heater, heater control and earth
wire. Route wiring harness of heater control
in 10mm dia., 1130mm long corrugated tube
1 to the firewall.
1
Installing
lines
43
2
1
2
3
4
Route 10mm dia., 2100mm long corrugated
tube 1 and 10mm dia., 1130mm long corrugated tube 4 through rubber-coated pipe
clamp 2. Route corrugated tube 1 further on
the firewall to the underbody.
3 M6x20 bolt, spring lock washer, 29mm dia.
rubber-coated p-clamp, existing threaded
hole
Installing
lines
44
1 Fuel line and wiring harness for metering
pump in corrugated tube
Installing
lines
45
1
1 Fuel line and wiring harness for metering
pump in corrugated tube
1
Installing
lines
46
1316669A_EN
21
1
2
1 Perforated bracket section 2
2 Cutting line
3
Cutting
perforated
bracket to
size
60
1
Angling
down perforated
bracket
section 1
25
55°
1
Angling
down perforated
bracket
section 2
28
50°
Discard rubber plug at position 1.
1 M6 rivet nut, existing hole
Installing
rivet nut
1
1316669A_EN
47
22
1 M6x20 bolt, spring lockwasher
3 M6x25 detent-edged bolt, pin lock
1
Installing
perforated
bracket
section 2
2
48
3
1
1
2
3
4
2
Metering pump
Receptacle for metering pump
Perforated bracket section 1
M6 flanged nut
Installing
metering
pump
3
4
1
49
Check the position of the components; adjust
if necessary. Check that they have freedom of
movement.
2
1 Fuel line of heater
2 Hose section, 10 mm dia. clamp [2x]
3 Wiring harness of metering pump, connector mounted
3
Connecting metering pump
50
Remove and dismantle fuel-tank sending unit
1 according to manufacturer's instructions.
2 Large diameter washer, dia. da = 14,8 mm
3 Copy hole pattern, 6 mm dia. hole
1
Removing
fuel
3
2
1316669A_EN
51
23
Shape fuel standpipe 1 according to template, cut to length and install.
1
Installing
fuel standpipe
52
1
Install fuel-tank sending unit according to
manufacturer's instructions.
2
1 2100mm long corrugated tube
2 Fuel line
3
Connecting fuel
line
53
Check the position of the components; adjust
if necessary. Check that they have freedom of
movement.
1
2 Fuel line of fuel standpipe
Connecting metering pump
2
54
1316669A_EN
24
LS 460 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. When installing the hoses, the heater must be filled with coolant.
The connection should be "inline" based on the following diagram:
Coolant
routing diagram
A
1
1
I
H
3
B
J
2
2
G
4
C
K
F
D
2
2
E
All spring clips
= 25mm dia. 1 = Original vehicle spring clip
2 = Black (sw) rubber isolator
All connecting pipes
and
4 = Check valve
.
1316669A_EN
. 3 = 90° T-piece
= 18x18mm dia.
.
25
1 Discard clip
2 Cutting point
3 Discard section
H
70
Cutting
coolant
hose H to
length
3
2
55
1
1 Discard section
2 Cutting point
I
Cutting
coolant
hose I to
length
10
2
1
1
56
1 Slide spring clip onto hose [2x]
2 T-piece
A
Premounting T-piece
1
J
2
57
1
H
Pay attention to the direction of flow of check
valve 3. Slide 100mm heat shrink plastic tubing 1 onto hose H and shrink.
2 Position black (sw) rubber isolator
3
G
K
Premounting check
valve
2
58
1316669A_EN
26
1 70mm long narrow edge protection
2 50mm long broad edge protection
Installing
edge protection
2
1
59
1 Discard hose section on heat exchanger
outlet
2 Discard hose section on engine outlet
1
Cutting
point
2
60
Bend pipe of heat exchanger inlet 1 if necessary
towards the engine.
1
Connecting hose H
H
61
Install hose I with shortened side on connection piece of engine outlet 1.
1
Connecting hose I
I
62
1316669A_EN
27
1
Align T-piece and ensure sufficient distance
from pulley at position 2.
I
1 Pipe of heat exchanger outlet
A
Connecting T-piece
J
63
2
1 Align black (sw) rubber isolator
I
Connecting hose K
K
64
1
1
Install hose B on T-piece. Fasten black (sw)
rubber isolator 3 with cable tie 1 [2x].
2
2 Hose H fastened with cable tie
H
Connecting hose B
D
65
B 3
H
Ensure sufficient distance between pulley 2
and hose B at position 1.
1
Checking
the distance from
pulley
B
2
1316669A_EN
66
28
1 M6 rivet nut in existing hole
1
Installing
rivet nut
67
1 Dismantle original vehicle bolt
Preparing
installation of circulating
pump
68
1
1 Shorten large diameter washer
Preparing
pump
1
69
1 Perforated bracket
1
20
Angling
down perforated
bracket 2x
90°
50
70
1316669A_EN
29
1
2
3
4
1
48mm dia. rubber-coated p-clamp
Mount M6x20 bolt, flanged nut loosely
Perforated bracket
Circulating pump
2
Preparing
circulating
pump
3
71
4
Aligning circulating pump. Tighten M6x20
bolt, flanged nut.
1
1 Mount wiring harness of circulating pump
Installing
circulating
pump
72
2
B
Connecting hose B
73
1 Hose D with 90° connecting pipe
1
E
Connecting hose C
C
74
1316669A_EN
30
1 Cable tie
F
Connecting hose F
C
1
75
Shape rubber-coated 48mm dia. p-clamp 1 as
shown.
Shaping
rubbercoated pclamp
76
1
1
2
1
2
3
4
5
B
M6x20 bolt, spring lockwasher
M6x20 bolt, flanged nut M6
Cable tie
Rubber-coated pipe clamp
Angle bracket
Routing in
engine
compartment
3
5
4
F
77
Ensure sufficient distance to neighbouring
components.
B
1 Spacer bracket
G
F
1316669A_EN
1
Connecting hose F
78
31
LS 600h 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. When installing the hoses, the heater must be filled with coolant.
The connection should be "inline" based on the following diagram:
Hose routing diagram
H
1
G
3
I
2
B
F
4
2
E
C
2
D
A
5
All spring clips
= 25mm dia. 1 = Original vehicle spring clip
2 = Black (sw) rubber isolator
All connecting pipes
and
4 = Check valve
. 5 = 90° T-piece
!
1316669A_EN
. 3 = Original vehicle water pump.
= 18x18mm dia.
32
1
2
1 Original vehicle spring clips will be required
again [2x]
2 Dismantle pipe group
3 Remove and discard hose section on heat
exchanger outlet
Cutting
point
3
1
79
Align pipe end1 by 15mm in the direction of
the arrow, see following Figure.
Prevent breaking of pipe.
Aligning
pipe group
80
1
1 Pipe group installed
Installing
pipe group
1
81
1 Discard clip
2 Cutting point
3 Discard section
G
80
Cutting
coolant
hose G to
length
3
1316669A_EN
2
1
82
33
1 Discard section
2 Cutting point
H
Cutting
coolant
hose H to
length
10
2
1
1
83
2
G
5
3
F
I
4
2
Pay attention to the direction of flow of check
valve 5. Slide 100mm heat shrink plastic tubing 1 onto hose G and shrink. Cut 300mm
braided protection hose 3 to length and slide
onto hose I.
2 Slide on 50mm heat shrink plastic tubing [2x]
and shrink
Premounting check
valve
84
Premounting hose E
E
85
1
1 Pipe of heat exchanger inlet
1
Connecting hose G
G
86
1316669A_EN
34
Install hose H with shortened side on connection piece of engine outlet 1.
H
Connecting hose H
1
I
87
1
Fasten hose I with cable tie 1.
I
2 Fasten check valve with cable tie [2x]
3 Remove original vehicle hose
4 Align black (sw) rubber isolator
Fastening
hoses
2
3
4
88
2
Ensure sufficient distance between pulley 1
and hose G at position 2.
1
Checking
the distance from
pulley
2
G
89
1 Discard section
70
20
1
1316669A_EN
Cutting
original vehicle hose
to length
90
35
1 Original vehicle hose
2 T-piece
1
Premounting T-piece
A
91
2
1 Original vehicle hose [2x]
2 T-piece
1
Installing
original vehicle hose
2
1
92
Shape rubber-coated 48mm dia. p-clamp 1
as shown.
Shaping
rubbercoated pclamp
93
1
1
Discard original vehicle bolt at position 3. Install 5mm shim between angle bracket 1 and
body.
2
2 M6x20 bolt, 48mm dia. rubber-coated pclamp, flanged nut
3 M6x20 bolt, spring lockwasher, 5mm shim,
original vehicle threaded hole
3
1316669A_EN
Installing
rubbercoated pclamp
94
36
1 70mm long narrow edge protection
2 50mm long broad edge protection
Installing
edge protection
2
1
95
Route hose A and E through rubber-coated
p-clamp 1.
1
Routing
hose A and
E
E
A
96
1 Dismantle original vehicle bolt
Preparing
pump
1
97
1 Shorten large diameter washer
1
Preparing
pump
98
1316669A_EN
37
1 Perforated bracket
1
20
Angling
down perforated
bracket 2x
90°
50
99
1
2
3
4
1
48mm dia. rubber-coated p-clamp
Mount M6x20 bolt, flanged nut loosely
Perforated bracket
Circulating pump
2
Preparing
circulating
pump
3
100
4
Aligning circulating pump. Tighten M6x20
bolt, flanged nut.
1
1 Mount wiring harness of circulating pump
Installing
circulating
pump
101
2
A
Connecting hose A
102
1316669A_EN
38
1 Hose C with 90° connecting pipe
1
D
Connecting hose B
B
103
1 Cable tie
E
Connecting hose E
B
1
104
1316669A_EN
39
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 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.
Set the digital timer.
Make settings on A/C control panel according to the "Operating Instructions for End Customer".
- Apply the sticker "Switch off parking heater before refilling" in the area of the filler neck.
- For initial startup and function test, see installation instructions
Cut out wheel-well inner panel 1 at the markings. Discard section 2.
1
Cutting out
wheel-well
inner panel
105
2
1 Position exhaust end section at the centre
of the recess
1
Exhaust
end section
106
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: [email protected]
http://www.webasto.com
1316669A_EN
Printed in Germany
08/2011
Printing: Steffen
40
Template for Fuel Standpipe
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 margins” and 100% of the normal size.
100mm
0
1316669A_EN
41
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.
For vehicles with passenger compartment monitoring this must be deactivated in addition to defining
the vehicle settings for the heating operation.
Instructions on deactivation can be taken from the operating instructions of the vehicle.
Before parking the vehicle, make the following settings:
1 Set temperature to "HI" [2x]
2 Air outlet to windscreen on both sides
Automatic
air-conditioning
1
1
2
1316669A_EN
107
42

Water Heater Installation documentation Lexus LS 460 / LS 600h

Transcription

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