Water Heater Unit Installation Instructions Iveco Daily Thermo Top C Motorcaravan

Water Heater Unit Installation Instructions Iveco Daily Thermo Top C Motorcaravan
Water Heater Unit
Feel the drive
e1
Thermo Top C Motorcaravan Additional Heater 00 0002
Installation Instructions
Iveco Daily
Diesel
from Model Year 2006
For left-hand drive vehicles only
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.: 9016374A_EN
Fee Euro 10
© Webasto AG
Iveco Daily
Table of Contents
Validity
Heater Unit/Installation Kit
Foreword
General Instructions
Special Tools
Explanatory Notes on Document
Preliminary Work
Heater unit installation location
Preparing heater unit
2
3
3
3
3
4
5
5
6
Combustion air
Preparing installation location
Installing heater unit
Fuel Connection
Coolant connection
Electrical Connections
Final Work
7
9
9
11
12
15
17
Validity
Manufacturer
Model
Iveco
Daily
Engine type
3.0
3.0
Engine model
Diesel
Diesel
Output in kW
110
130
Displacement in cm³
3000
3000
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 a digital timer and changeover switch should be confirmed with the end
customer before installation.
2
Iveco Daily
Heater Unit/Installation Kit
Quantity
1
1
Description
Basic delivery scope of Thermo Top C Motorcaravan
Installation kit of Iveco Daily 3.0 liter Diesel
Order No.:
9015824A
9016323B
Foreword
The installation instructions apply to the Iveco Daily vehicles with a Diesel engine
- For the validity, see page 2 - from model year 2006 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, where this is the case the stipulations in the "installation instructions" and "operating and
maintenance instructions" for the Thermo Top C Motorcaravan should 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
- Riveting pliers
3
Iveco Daily
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 connection
Fuel connection
Exhaust system
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.
i
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.
4
Iveco Daily
Preliminary Work
WARNING!
-
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.
Open the fuel tank cap, ventilate the tank.
Close the tank cap again.
Remove the glove compartment
Remove the coolant expansion tank
Heater unit installation location
1
1 Heater unit
Installation
location
1
5
Iveco Daily
Preparing heater unit
E
X
e = 620 mm
d = 520 mm
D
Discard section X
e
d
1
Cutting
20 mm
coolant
hose to
length
X
Push braided protection hose onto hose D
and E and cut to length.
Cut heat shrink plastic tubing to length.
1
1 25 mm heat shrink plastic tubing [4x]
D
1
1
Preparing
coolant
hoses
E
c = 1000 mm
f = 1000 mm
Discard section X
C
F
Cutting
20 mm
coolant
hose to
length
f
X
c
B
a = 420 mm
g = 180 mm
A
G
Discard section X
X
Cutting
18 mm
molded
hose to
length
a
g
6
Iveco Daily
1
1 Exhaust pipe
a = 230 mm
2 Exhaust end section
b = 770 mm
2
Preparing
exhaust
pipe
a
b
Combustion air
1
1 Combustion air pipe
a = 250 mm
Discard section X
Cutting
combustion air
pipe to
length
a
X
1
1 Exhaust muffler
2 M6x20 bolt, flanged nut
3 Angle bracket
2
Preassembling
exhaust
muffler
3
2
1 Stud bolt, large diameter washer, M6
flanged nut
1
Installing
exhaust
muffler
3
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Iveco Daily
1
Tighten EJOT screws to 10 Nm!
2 2
1 Bracket
2 Ejot screw [3x]
Preassembling
bracket on
heater unit
2
4
1
Ensure proper installation position of air
intake muffler, see "Installation Instructions“.
2 3
1
2
3
4
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Combustion-air intake pipe
Combustion-air intake muffler
Cable tie
27 mm dia. hose clamp
Installing
intake
muffler
5
4
1
1 Hose clamp
2 Exhaust insulation, 200 mm long
3 Exhaust pipe
1
Preassembling
exhaust
pipe
3
6
2
1 Preassembled exhaust pipe
2 Hose section, 10 mm dia. hose clamp [2x]
3 Mecanyl fuel line, 1,000 mm long
Preassembling fuel
line on
heater unit
and
installing
exhaust
pipe
3
2
1
7
8
Iveco Daily
E
Tighten EJOT screws to 10 Nm!
Mark hose. Shown without braided protection
hose!
1
2
1
2
3
D
E
27 mm dia. spring clip [2x]
Ejot screw, rubber-coated p-clamp
Cable tie [2x]
Hose on heater unit water inlet
Hose on heater unit water outlet
1
3
D
1
Preassembling
coolant
hoses on
heater unit
8
3
Braided protection hose not shown!
2
1 Red (rt) rubber isolator
2 Exhaust end section
3 Hose clamp
Preassembling
exhaust
end
section
3
9
1
Preparing installation location
1
2
1 Insert M8 hexagon rivet nuts [4x] in
existing holes
2 Bracket mount
Installing
rivet nut
2
1
1
10
Installing heater unit
2
1
1
Mount wiring harness of heater unit before
installation on heater unit, hook bracket into
bracket mount with lugs and route through
exhaust end section between vehicle floor
and frame.
1 M8x30 bolt, washer, spring lockwasher [4x]
2 Bracket assembly with heater
Installing
heater unit
1
1
11
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Iveco Daily
Align red (rt) rubber isolator 1
1
Aligning
exhaust
pipe
12
1
1 Original vehicle hole
2 Pipe clamp, M6x20 bolt, flanged nut
2
Fastening
exhaust
pipe
13
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Iveco Daily
Fuel Connection
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.
1
2
3
4
Ensure proper installation position of
metering pump, see "Installation
Instructions“.
1
8
5
7
6
14
1 Hose section, 10 mm dia. hose clamp [2x]
2 Metering pump connector
3 Metering pump mounting, M6x30 bolt,
flanged nut
4 Metering pump
5 Mecanyl fuel line, 250 mm long
6 Molded hose, 10 mm dia. Calliau clamp [2x]
7 8x5x8 fuel standpipe, 10 mm dia. hose
clamp [2x]
8 Mecanyl fuel line from heater unit
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Installation
location of
metering
pump
11
Iveco Daily
Coolant connection
WARNING!
Tighten all hose clamps to 2.0 + 0.5 Nm.
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 hose clamps and spring band clamps so that no other hose can be damaged.
The connection should be based on the following diagram:
Coolant
routing
diagram
Coolant circuit in passenger compartment
Coolant circuit in passenger compartment and engine
12
Iveco Daily
G
1 Check valve (watch direction of flow)
2 Rubber-coated p-clamp, perforated
bracket, M6x20 hexagon bolt, flanged nut
3 Thermostat valve
4 Spacer bracket
5 T-piece, 18x15x18
B
A
1
2
3
5
4
1
Preparing
hose group
H
1
2
1
1
2
1
2
3
4
3
Spring clip 25 [4x]
Connecting pipe 18/20 [2x]
Spring clip 27 [3x]
Spring clip 22
3
Preparing
hose group
3
15
4
1
2
3
4
5
1
5
4
Heater unit outlet (F,E)
Heater unit inlet (C,D)
Original vehicle return line
From engine outlet
To heat exchanger inlet
Connections
2
3
16
1 Original vehicle hose from engine outlet to
heat exchanger inlet
2 Original vehicle return hose
b
a
a = 15 mm
b = 100 mm
Discard hose sections
2
1
Cutting
points
17
13
Iveco Daily
1 Hose clamp 20...27 [4x]
1 1
1
18
1
G
1
Connection on
vehicle
side
1 Spring clip 27 [2x]
2 Original vehicle bolt
2 F
1
Connect hose F to hose G
Connect hose C to thermostat valve
Push black (sw) rubber isolator onto hose C
C
Routing in
engine
compartment
19
F
Mark hoses C and F and route downward
C
1 Position black (sw) rubber isolator
1
Connection to
engine
outlet
20
Secure hoses and wiring harness of metering
pump with cable ties while watching distance
to steering spindle.
1
1 Spring clip 27, hose C and D
2 Spring clip 27, hose E and F
Connection on
heater unit
2
21
14
Iveco Daily
Electrical Connections
Wiring harness pass through
Digital timer
1 Protective rubber plug
1 Changeover switch
2 Digital timer
1
1
2
22
1
2
23
3
1
4
5
6
24
Preassembling fuse holder
1
2
3
4
5
6
K3 relay
M5x16 bolt, washers, M5 nut [2x]
K4 relay
Perforated plate angled downward
Fuse holder
K5 relay
25
Installing fuse holder
1 M6x20 bolt, washer, flanged nut
15
Iveco Daily
1
Connection to 6-pin connector 2 from fan
motor.
Make connections as shown in the wiring
diagram with the tab receptacles provided.
2
3
5
Red (rt) wire from fan motor
Read (rt) wire to connector, to fuse
Red (rt) wire from K3/87a
Black (sw) wire from K3/30
1
3
4
5
Connecting fan
motor
26
4
Webasto
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Iveco Daily
30
15
F3
F
HG
X1 4
rt/ws
gn/
ws
86
87
85
rt
87a
K3
30
Wiring
diagram
for manual
air conditioning
rt
sw
rt
+
M
GM
WG
br
31
Webasto components
HG
Heater unit TT-C/E
X1
6-pin connector
F3
Fuse, 25 A
K3
Fan relay
Components of Iveco Daily
GM
Fan motor
WG
Resistor group
F
Fan fuse
Colors and symbols
rt
red
ws
white
sw
black
br
brown
gn
green
Legend
X
Cutting point
Wiring colors may vary.
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Iveco Daily
Final Work
WARNING!
Reassemble the disassembled components in reverse order.
Check all hoses, hose, spring and Caillau clamps, as well as 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
- Start the engine, bleed the coolant circuit according to the vehicle manufacturer's instructions and
top up coolant
- Set the digital timer.
- 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.
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Feel the drive
Webasto AG
Postfach 80 - 82132 Stockdorf, Germany - Hotline +49(0)1805-932278
Hotfax +49-(0)395-5592-353 - http://www.webasto.de
Printed in Germany
10/06Printed by: Steffen
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