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Water Heater Unit
e1
Thermo Top E Additional Heater
00 0003 e1
Thermo Top C Additional Heater
00 0002
Installation Instructions
Alfa Romeo 147
Gasoline and Diesel from Model Year 2001
Left-hand drive vehicle not for JTD 16V not with GTA
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, specialized tools and equipment are required to install and repair Webasto heating and cooling systems.
NEVER attempt to install or repair Webasto heating or cooling systems if you have not successfully completed the company training and thereby acquired the required technical skills, or if you do not have access to the required technical documentation, tools and equipment needed to carry out correct installation and repairs.
ALWAYS follow all Webasto installation and repair instructions and observe all warnings.
Webasto does not accept any liability for defects and damage that are attributable to installation by untrained staff.
Ident. No.:1313160A_EN Fee Euro 10.00
© Webasto AG
Alfa Romeo 147
Table of Contents
Heater unit installation location
Fan controller with switch-off function for passenger compartment monitoring
Preparing installation location
Operating Instructions for End Customer 27
Validity
Manufacturer
Fiat
Engine type
AR37203
AR32104
AR32310
937A2000
Model
Alfa 147
Engine model
Gasoline
Gasoline
Gasoline
Diesel
Type
937 (Alfa Romeo)
EG-BE No./ABE
e3 * 98/14 * 0070 * ...
Output in kW Displacement in cm³
77
88
1598
1598
110
85
1970
1910
Vehicle and engine types, equipment variants and national specifications not listed in these installation instructions have not been tested. However, installation according to these installation instructions may be possible.
The installation location of the digital timer should be confirmed with the end customer before installation.
1313160A_EN
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Alfa Romeo 147
Heater Unit/Installation Kit
1 or
1
Quantity Description
1 or
Retail Accessories for Thermo Top E Gasoline
Retail Accessories for Thermo Top E Diesel
Retail Accessories for Thermo Top C Gasoline or
1 and
1
Retail Accessories for Thermo Top C Diesel
Installation kit for Alfa Romeo 147 Gasoline and Diesel
Order No.:
See price list
See price list
See price list
See price list
1313097A
Foreword
These installation instructions apply to Alfa Romeo 147 Gasoline and Diesel vehicles - for validity, see page 2 - from model year 2001 and later, assuming technical modifications to the vehicle do not affect installation, any liability claims excluded. Depending on the vehicle version and equipment, modifications may be necessary during installation with respect to these installation instructions.
However, the stipulations in the "installation instructions" and "operating and maintenance instructions" for the Thermo Top C/E must always be observed.
The corresponding rules of technology and any information from the vehicle manufacturer should be observed during the installation work.
General Instructions
Installation should be carried out according to the general, standard rules of technology. Unless specified otherwise, fasten hoses, lines and wiring harnesses to original vehicle lines and wiring harnesses using cable ties.
Sharp edges should be fitted with edge protectors (split-open plastic hose).
Spray unfinished body areas, e.g. drilled holes, with anti-corrosion wax (Tectyl 100K, Order No.
111329).
Special Tools
- Torque wrench for 2.0 - 10 Nm
- Hose clamping pliers
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Alfa Romeo 147
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
Water
Fuel
Exhaust gas
Combustion air
Special features are highlighted using the following symbols:
Specific risk of injury or fatal accidents.
Specific risk of damage to components.
Specific risk of fire or explosion.
Reference to general installation instructions of
Webasto components or to the manufacturer's vehiclespecific 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!
1313160A_EN
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Alfa Romeo 147
Preliminary Work
WARNING!
- Open fuel tank cap, ventilate tank.
- Close the tank cap again.
- Disconnect the battery "earth" or "ground" connection.
- Depressurize 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 on the left.
- Remove the coolant reservoir cap on the right.
- Remove the complete intake hose.
- Disconnect the expansion tank and lay it aside.
- Expose the distributor B1 in the engine compartment.
- Remove the right-hand wheel well trim.
- Remove bumper
- Remove the horns.
- Remove the horn cable up from the wiring harness sleeve up to the frame side member.
- Insulate the horn cable and route it under the right-hand headlight.
- Remove the underride protection.
- Remove the trim of the fuel lines on the underbody.
- Remove the lighting unit for the passenger compartment (only with passenger compartment monitoring).
- Remove the rear bench seat (only for gasoline vehicles).
- Open the tank-fitting service lid (only for gasoline vehicles).
- Remove the fuel-tank sending unit according to the manufacturer's instructions (only for gasoline vehicles).
Remove page 27 "Operating Instructions for End Customer" and add to the vehicle operating
instructions.
1313160A_EN
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1
Heater unit installation location
1 Heater unit
Installation location
5
1
Alfa Romeo 147
Preparing electrical system
Cut away insulation 1 along marking in area of hole.
Cutting out insulation
2
90°
Bending perforated bracket
70
1
86 87 87a
85 30
K3
3
Only with passenger compartment monitoring
Produce connections as shown in wiring diagram. Also connect additional green/white
(gn/ws) wire 1 to K3/86 and pull into included protective sleeving.
Preparing
K3
br
2
86 87 87a
85 30
K3.1
4 3 rt rt
1313160A_EN
Produce connections as shown in wiring diagram.
Preparing
K3.1
6
Electrical system
Wiring harness pass through
1
2
Protective rubber plug
Wiring harness of digital timer, additional green/white (gn/ws) wire with passenger compartment monitoring
1
Digital timer
1
Digital timer
Alfa Romeo 147
2
4
1
5
Do not install the metering pump cable harness until later together with fuel pipe along the original vehicle fuel lines on the underbody
1 2
Wiring harness installation diagram
3
1
Wiring harness routing
1
Wiring harness of heater unit, fuel line
6
4
Fuse holder, relay K3
7
1
2
3
4
Angled-down perforated bracket
M6x20 bolt, M6 flanged nut on existing hole k3 relay, M5x12 bolt, washer, spring lockwasher, M5 nut
Retaining plate of fuse holder, M5x12 bolt, washer, spring lockwasher, M5 nut
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Alfa Romeo 147
Fan controller
Webasto Alfa Romeo
X1
HG
4 gn/ ws rt/ws
F3
86 87 87a
85 30
K3 sw rt
7
F31
A
B2 hbl/ rt
F39 F2
B1
F5
11 10
A hbl/ rt
M01
A
M
N85
B
30
15
Wiring diagram
M70
M72 br
31
Webasto components
HG Heater unit TT-C/E
X1
F3
6-pin heater unit connector
Replace 25 A with 7.5 A fuse.
K3 Fan relay
Vehicle components
N85 Fan motor
M01
M72
M70
B2
F31
F39
B1
F2
F5
Body computer
Fan controller
Air-conditioning control panel
Distributor in engine compartment
Fuse, 7.5 A br brown gn hbl green light blue
15 A fuse
Distributor in engine compartment
Fuse 40A
Fuse 40A
Colors and symbols
rt red ws white sw black
X
point
Wiring colors may vary.
1 2
Connection on connector A
5
, Pin 11 from distributor B1 in engine compartment.
Produce connections as shown in wiring diagram.
5
Legend
1
2
3
4
Light blue/red (hbl/rt) wire of connector
A/11
Black (sw) wire from K3/30
Red (rt) wire from K3/87a
Light blue/red (hbl/rt) wire of connector A/7 for distributor B2
Connecting fan-motor
4 3
8
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Alfa Romeo 147
Fan controller with switch-off function for passenger compartment monitoring
Webasto Alfa Romeo
30
15
X1
HG
4 gn/ ws rt/ws
F3
7 hbl/ rt
F31
A
B2
F39
F2
B1
F5
11 10
A
Wiring diagram
gn/ws rt
E
7
M01
86 87 87a
85 30
K3 sw hbl/rt
A
M
N85
B br
1
86 87 87a
85 30
K3.1
rt rt
2 sw/ vi
K62
1 br sw/ vi
M70
M72
31
Webasto components
HG Heater unit TT-C/E
X1
F3
6-pin heater unit connector
Replace 25 A with 7.5 A fuse.
K3
K3.1
Fan relay
Additional relay
Vehicle components
N85
M01
M72
M70
K62
B2
F31
F39
B1
F2
F5
Fan motor
Body computer
Fan controller
Air-conditioning control panel
Colors and symbols
rt red ws white sw black
Passenger compartment sensor gn green
Distributor in engine compartment
Fuse, 7.5 A
15 A fuse
Distributor in engine compartment
Fuse 40A
Fuse 40A br brown hbl light blue vi violet
X
point
Wiring colors may vary.
1 2 3 4
5
Passenger compartment monitoring is switched off on passenger compartment sensor K62 in lighting unit in passenger compartment. Produce connections as shown in wiring diagram. Connect green/white (gn/ws) wire from K3/86 to K3.1/86.
7
9
6
Note:
Passenger compartment monitoring will be deactivated while heating mode is active!
1
4
5
2
3
6
7
5.5x9.5 self-tapping screw
K3.1 relay
Red (rt) wire of K3/30
Red (rt) wire from K3/87a
Black/violet (sw/vi) wire K62/1
Black/violet (sw/vi) wire (original vehicle ground)
Brown (br) wire of K3.1/85 on ground point
Legend
Switching off passenger compartment monitoring
1313160A_EN
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2
1
3
1
1
1
2
4
1313160A_EN
1 2
Alfa Romeo 147
Preparing installation location
Remove original vehicle bolt
2
for plastic bracket
1
of servo cooling hose and discard.
Detaching plastic bracket
10
Remove plastic bracket from servo cooling hose
1
.
Removing plastic bracket
11
5
1
2
3
Copy hole pattern, drill 6.5 mm hole
[2x each]
Additional bracket
Plastic bracket
2
Copying hole pattern
12
3
Connect additional bracket
3
and plastic bracket
4
with M6x15 bolt
1
, large diameter washer, flanged nut [2x each]. Lay on additional bracket
3
flush with right-hand side and lower edge on cross member.
2
Copy hole pattern, drill 6.5 mm hole
[2x each]
Holes in cross member
13
10
65 mm
1
2
Alfa Romeo 147
1
2
3
Premounted additional bracket
M6x20 bolt, flanged nut
M6x20 bolt, large diameter washer, flanged nut
Installing additional bracket
3
40 mm
14
1
6.5 mm dia. hole [2x each]
Holes in cross member
1 1
1
15
1
6.5 mm dia. hole
65 mm
Drilling hole in cross member
6
16
1313160A_EN
11
B
X
X
B
X
A
Alfa Romeo 147
Preparing heater unit
a = 60 b = 1050 c = 1390
Discard sections
X
Cut heat protection hose in half and push onto hose
A
and
B
.
Cutting coolant hoses to length
C
X
1 1
1
2
3
Ejot stud [2x]
Hose section, 10 mm dia. clamp [2x]
Fuel line
Preparing heater unit
3
C
2
1
2
17
Hose
B
with 90° elbow on heater unit inlet
1
2
27 mm dia. spring clip
27 mm dia. hose clamp
Premounting coolant hoses
18
1313160A_EN
12
1
1
Alfa Romeo 147
Installing heater unit
1
Flanged nut [2x] on Ejot stud
Installing heater unit
1 2
5
4
19
In case of tolerance deviations, use 2x 5 mm shims at Position
5
.
1
2
4
5
Strut
M6x30 bolt, 15 mm spacer sleeve (see following photo), flanged nut
Ejot stud, flanged nut
5 mm shim
Installing strut
20
1
15 mm shim
1
Positioning shim
1
1
1313160A_EN
6
3
21
1
Wiring harness of heater unit
4
Connecting wiring harness
22
13
3
1 a
1
X
1
2
Alfa Romeo 147
Exhaust gas
1
2
Exhaust pipe a = 210
Exhaust end section b = 80
Discard section
X
Preparing exhaust pipe
b
1
2
3
Hose clamp [2x]
Position red (rt) rubber isolator
Exhaust pipe
Installing exhaust pipe
4
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2
1
23
1
2
Original vehicle bolt
Angle bracket
2
Installing angle bracket
25
1
2
24
1
2
3
4
M6x20 bolt, large diameter washer, flanged nut on angle bracket
Hose clamp
Exhaust end section
Muffler
Installing muffler and end section
14
1313160A_EN
1
1
Alfa Romeo 147
2
3
Installing cooling coil
Mount cooling coil
2
in prepared bracket
3
.
1
2
Spacer bracket
Original vehicle spacer bracket
Installing cooling coil
26
1
2
Installing horns
1
2
M6x20 bolt, flanged nut on strut
Angle bracket
Installing horns
5
4
1
27
Install horn bracket with original vehicle bolt
2
on angle bracket
1
.
Installing horns
2
28
15
Alfa Romeo 147
Coolant for gasoline engine
WARNING!
Any coolant running off should be collected using an appropriate container. Install hoses so that they are kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that no other hose can be damaged! When installing the coolant hose, the heater unit must be filled with coolant.
The connection should be "inline" based on the following diagram:
Coolant routing diagram
Ø 18x20
A
Ø 18x20
3
2
C
B
1
Undesignated connecting pipes
1
= Spring clip = 27 mm dia.
2
= Black (sw) rubber isolator
= dia. 20x20. All hose clamps = 20-27 mm dia.!
(2.0 liter only)!
3
= Black (sw) rubber isolator (1.6 liter only)!
1313160A_EN
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1313160A_EN
Alfa Romeo 147
B
Routing in engine compartment
C
B
29
Routing in engine compartment
1
C
30
1
2
Engine-outlet hose section
Hose section of heat exchanger inlet
Cutting point
1
2
31
1
Engine-outlet hose section
Connecting engine outlet
A
32
17
3
1
C
1
1 C 2
Alfa Romeo 147
3
2.0 liter gasoline
Ensure sufficient distance to neighboring components.
1
2
3
Spacer bracket [3x]
Position black (sw) rubber isolator
Hose section of heat exchanger inlet
Connection on engine outlet and heat exchanger inlet
B
B
1
1 A
33
A
1.6 liter gasoline
Ensure sufficient distance to neighboring components.
Route hose
A
under original vehicle lines.
1
2
3
Hose section of heat exchanger inlet
Position black (sw) rubber isolator
Spacer bracket
Connection on engine outlet and heat exchanger inlet
2
34
All gasoline vehicles
1
Spacer bracket [2x]
Installing spacer bracket
1
35
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Alfa Romeo 147
Coolant for diesel engine
WARNING!
Any coolant running off should be collected using an appropriate container. Install hoses so that they are kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that no other hose can be damaged! When installing the coolant hose, the heater unit must be filled with coolant.
The connection should be "inline" based on the following diagram:
Coolant routing diagram
2
A
Ø 18x20
C
B
1
Undesignated connecting pipes
1
= Spring clip
= dia. 20x20. All hose clamps
= 27 mm dia.
2
= Original vehicle hose clamp .
= 20-27 mm dia.!
1313160A_EN
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Alfa Romeo 147
B
Routing in engine compartment
C
B
36
Routing in engine compartment
1
C
2
37
Pull hose on engine outlet/heat exchanger inlet
2
off connection piece of engine outlet
1
.
Spring clip
3
will be reused.
Cutting point
3
A
38
1
Original vehicle spring clip
Connecting engine outlet
39
1313160A_EN
1
20
1
B 1
1 C
A
Alfa Romeo 147
Ensure sufficient distance to neighboring components.
1
2
Spacer bracket [2x]
Hose section of heat exchanger inlet
Connection on engine outlet and heat exchanger inlet
2
40
1
Spacer bracket [2x]
Installing spacer bracket
1
41
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Alfa Romeo 147
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 in as shown in the wiring harness routing diagram.
1
2
M8 nut on existing stud bolt
Angle bracket
1
Installing angle bracket
1 2
2
3
1
6 5
42
4
Fuel removal on gasoline engines
1
2
3
4
5
6
Metering pump
Silent block, flanged nut [2x] on angle bracket
Hose section, 10 mm dia. clamp [2x]
Fuel line
Wiring harness of metering pump, connector mounted
Rubber-coated pipe clamp
Installing metering pump
43
2
Remove fuel-tank sending unit
1
in accordance with manufacturer's specifications.
2
3
Cut out template and lay on
Copy hole pattern, 6 mm dia. hole
Removing fuel
3
44
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2
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1
1
1
Alfa Romeo 147
Shape fuel standpipe
1
according to template, cut to length and install.
Installing fuel standpipe
1
1 2
2
45
3
Shorten 90° molded hose
1
by 10 mm at
3.5 mm dia. (shortened side on fuel standpipe).
2
3
9 mm dia. Caillau clamp
Fuel standpipe
Connecting 90° molded hose
46
3
Install fuel-tank sending unit
4
in accordance with manufacturer's specifications.
1
2
3
Fuel line
10 mm dia. Caillau clamp
90° molded hose
Connecting fuel line
4
47
Check the position of the components; adjust if necessary. Check that they have free clearance.
1
2
Hose section, 10 mm dia. clamp [2x]
Fuel line
Connecting metering pump
48
23
4
3
1
Alfa Romeo 147
2 3 4
5
Fuel removal on diesel engines
1
2
3
4
5
6
Metering pump
Silent block, flanged nut [2x] on angle bracket
Hose section, 10 mm dia. clamp [2x]
Fuel line
Wiring harness of metering pump, connector mounted
Rubber-coated pipe clamp
Installing metering pump
1
1
6
2 3 2
5 4
49
Cut fuel return line
1
at Position
3
and insert support sleeves in line ends.
Shorten molded hose
4
by 10 mm at
3.5 mm dia.
2
3
4
5
Hose section (inside dia. = 8 mm) [2x],
12 mm dia. clamp [4x]
8x5x8 mm fuel standpipe
90° molded hose (shortened side on fuel standpipe), 10 mm dia. clamp [2x]
Fuel line
Removing fuel
50
Insert fuel line
4
in line holder
2
.
Check the position of the components; adjust if necessary. Check that they have free clearance.
1
3
Hose section, 10 mm dia. clamp [2x]
Cable tie
Connecting metering pump
2
51
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1313160A_EN
1
2
Combustion air
1
2
Intake pipe
27 mm dia. clamp
Alfa Romeo 147
Installing intake pipe
1 2
52
1
2
3
Intake pipe
Cable tie
Intake muffler
3
53
Installing muffler
25
Alfa Romeo 147
Final Work
WARNING!
Reassemble the disassembled components 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 unit 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".
- Check the proper operation of the additional heater, see the operating instructions/installation instructions.
- Attach the "Switch off additional heater before refueling" sticker to the left-hand B-pillar.
WARNING:
During heating, three "sporadic errors" are stored in the A/C control unit:
- Coolant temperature
- Outside temperature sensor
- Engine speed
These are irrelevant and can be deleted when performing vehicle service (inspection)!
1
1
2
Underride protection
Exhaust end section
Aligning exhaust end section
2
54
1313160A_EN
Feel the drive
Webasto AG
Postfach 80 - 82132 Stockdorf
Hotline 01805 / 932278 - Hotfax 0395 / 5592-353 http://www.webasto.de
Printed in Germany 01/2008 Printing:
Steffen
Alfa Romeo 147
Operating Instructions for End Customer
Please remove page and add to the vehicle operating instructions.
WARNING!
Passenger compartment monitoring will be deactivated while heating mode is active!
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.
Before parking the vehicle, make the following settings:
1
2
3
Air outlet to windshield
Set fan to level "2"
Set temperature to "max."
Manual air conditioning
3 2
3
55
1
1
2
3
Air outlet to windshield
Set temperature on both sides to "HI".
Set fan to level "2"
2 2
1
Automatic air-conditioning
3
56
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Alfa Romeo 147
Template for Fuel Standpipe
Template for Fuel sender
Ø 6mm
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 “minimize margins” and 100% of the normal size.
100 mm
0
1313160A_EN
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