Water Heater - xn--80aejlqpaaj0acd6k.xn--p1aiавтоотопитель.рф/manual/Fiat/Dolbo/1315994C_EN_Fiat_Doblo+Doblo_Cargo... · Operating Instructions for Manual Air-Conditioning

Water Heater

Installation DocumentationFiat Doblo / Doblo Cargo

Thermo Top Evo Parking HeaterE1

00 0258

Validity

Manufacturer Model Type EG-BE No./ ABEFiat Doblo 263 e3 * 2007 / 46 * 0007 * ...Fiat Doblo Cargo 263 e3 * 2007 / 46 * 0002 * ...

Motorisation Fuel Transmission type Output in kW Displacement in cm³ Engine code1.3 JTD Diesel SG 66 1248 199 A3.0001.6 JTD Diesel SG 77 1598 198 A3.0002.0 JTD Diesel SG 99 1956 263 A1.000

SG = manual transmission

From Model Year 2010Left-hand drive vehicle

Verified equipment variants: Manual / automatic air-conditioning systemFront fog light

Not verified: Passenger compartment monitoring

Total installation time: approx. 8 hours

Ident. No.: 1315994C_EN Status: 23.11.2012 © Webasto Thermo & Comfort SE

Fiat Doblo / Doblo Cargo

Table of Contents

Necessary Components

Installation Overview

Information on Total Installation Time

Legend:

1. Heater2. Engine compartment fuse holder3. Passenger compartment fuse holder4. Circulating pump5. Digital timer6. Metering pump

Validity 1Necessary Components 2Installation Overview 2Information on Total Installation Time 2Information on Operating and Installation Instructions 3Information on Validity 4Technical Information 4Explanatory Notes on Document 4Preliminary Work 5Heater Installation Location 5Preparing Electrical System 6Electrical System 8Fan Controller for Manual Air-Conditioning 9Fan Controller for Automatic Air-Conditioning 11Digital Timer 13Remote Option (Telestart) 13

Preparing Bracket 14Preparing Heater 14Installing Heater 15Coolant Circuit 1.6 / 2.0 JTD 16Coolant Circuit 1.3 JTD 22Combustion Air 28Exhaust Gas 29Fuel 34Final Work 37Template for Bracket 38Template for Fuel Standpipe 39Operating Instructions for Manual Air-Conditioning 40Operating Instructions for Automatic Air-Conditioning 41

• Basic delivery scope of Thermo Top Evo in accordance with price list

• Installation kit for Fiat Doblo / Doblo Cargo 2010 Diesel: 1315993C

• To be ordered additionally in case of automatic air-conditioningAutomatic A/C kit 1316747A

• 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

1

4

2

3

56

The total installation time includes the time needed for mounting and demounting of the vehicle-specific components, 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.: 1315994C_EN Status: 23.11.2012 © Webasto Thermo & Comfort SE 2


Information on Operating and Installation Instructions


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 227).

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.

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).

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 an IPCU, the corresponding settings must be checked or adjusted before the installation.

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

For vehicles with an EU permit, no entry in accordance with § 19 Sub-Section 4 of Annex VIII b to the Road Traffic Act is required.

2.1 Excerpt from the directive 2001/56/EC Appendix VII for the installation of the heater

Beginning of excerpt.

ANNEX VII

REQUIREMENTS FOR COMBUSTION HEATERS AND THEIR IN-STALLATION

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 EvoHeating Directive ECE R122 E1 00 0258

EMC Directive ECE R10 E1 03 5627


Information on Validity

This installation documentation applies to Fiat Doblo / Doblo Cargo Diesel vehicles - for validity, see page 1 - from model year 2010 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 installa-tion 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 = 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.

Special features are highlighted using the following symbols: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

Combustion air

Fuel

Exhaust gas

Software

Specific risk of injury orfatal accidents

Specific risk of damage tocomponents

Specific risk of fire and explosion

Reference to general installation instructionsof the Webasto components or to themanufacturer's vehicle-specific documents.

Reference to a special technical feature

The arrow in the vehicle iconindicates the position on the vehicleand the viewing angle



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 air filter together with the intake hose.• Remove the coolant reservoir cap.• Remove the bumper.• Remove the left-hand headlight.• Remove the underride protection.• Remove the fuel tank in accordance with manufacturer's instructions (only in case of Doblo Cargo).• Remove the rear bench seat.• Open the tank-fitting service lid.• Remove the fuel-tank sending unit in accordance with the manufacturer's instructions.• Remove the lower instrument panel trim, driver and front passenger's side.

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



Preparing Electrical System

Manual air-conditioning

Insert red (rt) wire 1 in K1/87a and black (sw) wire 2 in K1/30. Insert 25A fuse F4 into fuse carrier.

Preparing K1 relay and fuse F4

Drill out hole of fuse holder to 6.5mm dia.

Preparing passenger compart-ment fuse holder

Automatic air-conditioning

Install wire section 3 and 4 in protective sleev-ing provided.

Allocating wires

Connect the wires to the IPCU socket.IPCU view on contact side.The pre-programmed settings are to be checked during the function check on the ve-hicle and adjusted if necessary.

Duty cycle: 35%Frequency: 1200HzVoltage: 4.2VFunction: High-side

Premount-ing IPCU

86

85 30

87a87

K1

gn/ws0,75²

F4

br0,5²

rt4²

rt/sw0,5²

F3

1

2sw4²

rt4²

2

1

6br

0,5²

7rt

0,75²

5gn/ws

0,5²

4sw0,5²

3rt

0,5²

86 85

A

E

15

IPCU

7

3

4

6

A

1586 85

E

5



Drill out 6.5 mm dia. hole from fuse holder.

Preparing K1 relay and fuse F4

Produce connections as shown in wiring dia-gram.

Preparing IPCU K1 re-lay

All vehicles

Complete connector of metering pump after routing. Pin assignment is not relevant.

1 Connector housing2 Lock3 Blue/brown (bl/br) wires4 Coding5 Timer lock

Disassem-bling con-nector

3

1

86

85 30

87a87

K1

gn/ws0,75²

F4

br0,5²

rt4²

rt/sw0,5²

F3

1

2

A

EIPCU

15 85

86

76

4

3

5

rt4²

sw4²

4

1 43

5

5

2



Electrical System

Positive and earth wire

1 Positive wire on positive terminal of battery2 Earth wire on negative terminal of battery

Wiring harness pass through

1 Protective rubber plug

Wiring har-ness rout-ing diagram

Fuse holder of engine compartment

4.5 mm dia. hole at position 1 in coolant reservoir.

1 5.5x9.5 self-tapping screw; fuse holder re-taining plate

2 F1 and F2 fuses

Passenger compartment fuse holder

K1 relay pulled off for better display.

1 M6x12 bolt, existing threaded hole2 Passenger compartment fuse holder

52

1

6

1

Do not install the metering pump wiring harness until later togeth-er with fuel pipe along the origi-nal vehicle fuel lines on the underbody

72

1

8

1

2



Fan Controller for Manual Air-Conditioning

Wiring dia-gram

Webasto components Vehicle components Colours and symbols

Legend

HG TT-Evo heater GM Fan motor rt redX1 6-pin heater connector GS Fan switch ws whiteX2 2-pin heater connector GR Fan relay sw blackX10 4-pin connector

Heater controlWG Resistor group br brownFa Fuse gn green

K1 Fan relay Fb Fuse ge yellowF1 20A fuse or orangeF2 30A fuseF3 1A fuse X Cutting pointF4 25A fuse Wiring colours may vary.

Connect wiring harness of heater 2 to wiring harness of passenger compartment fuse holder 1 according to wiring diagram. Install wiring harness of fan control on the right vehi-cle side.

Connect-ing wiring harness of heater

Webasto

31

30

15

Fiat

Fa

GR

+

-

GMM

WG

GS

010203

04

0

Fb

or

HG

X2 1 2 X152F2 F1

br0,5²

gn/ws0,75²

ge0,5²

rt/sw0,5²

rt4²

br0,5²

X10

86

85 30

87a87

K1

gn/ws0,75²

F4

br0,5²

rt4²

rt/sw0,5²

F3

1

2

rt4²

sw4²

4²

or4²

9

2

1



Connection to 2-pin connector from the fan motor.Produce connections as shown in wiring dia-gram.

1 Orange (or) wire of 2-pin GM connector2 Orange (or) wire of GR3 Wire red (rt) K1/87a4 Wire black (sw) K1/30

Connect-ing fan mo-tor

10

1

3

2

4



Fan Controller for Automatic Air-Conditioning

Wiring dia-gram

Webasto components Vehicle components Colours and symbols

Legend

HG TT-Evo heater N085 Fan motor rt redX1 6-pin heater connector M070 A/C control panel sw blackX2 2-pin heater connector M072 Fan controller ge yellowX10 4-pin connector

Heater controlT08 Fan relay gn greenF08 40A fuse or orange

K1 Fan relay St A 1-pin connector M072 ws whiteF1 20A fuse St B 2-pin connector M072 br brownF2 30A fuse St C 2-pin connector M072 hbl light blueF3 1A fuseF4 25A fuseIPCU Pulse width modulatorIPCU adjustment values:Duty cycle: 35%Frequency: 1200HzVoltage: 4.2V X Cutting pointFunction: High-side Wiring colours may vary.

Webasto

31

3015

Fiat

HG

X2 1 2 X152

F2 F1

gn/ws0,75²

ge0,5²

rt/sw0,5²

rt4²X10

br0,5²

br0,5²

86

85 30

87a87

K1

gn/ws0,75²

F4

br0,5²

rt4²

rt/sw0,5²

F3

1

2

A

EIPCU

15 85

86

76

4

3

5

+ -

N085

M

M072

St B 1 2

St C 1 2

St A21

sw4²

rt4²

St A 5 29

M070

ws/bl0,5²

hbl/gn0,5²

hbl/gn0,5²

86

85 30

87a87

T08

F08

or4²

or4²

sw4²



K1 relay pulled off for better display!

1 M6x12 bolt, existing threaded hole2 Passenger compartment fuse holder

Installation of fuse holder

Connect wiring harness of heater 4 to wiring harness of fuse holder 1 according to wiring diagram. Route wiring harnesses of fan con-trol to the right vehicle side.

2 Brown (br) wire of IPCU/853 Green/white (gn/ws) wire of IPCU/86

Connect-ing wiring harness of heater

Connection of fan motor on connector B 1 from fan controller. Produce connection as shown in wiring diagram.

2 Orange (or) wire of connector B/2 IPCU/853 Black (sw) wire of K1/304 Red (rt) wire of K1/87a5 Orange (or) wire of fuse F08

Fan motor connection

Connection of IPCU to 2-pin connector A 4 of the fan controller. Produce connection as shown in wiring diagram.

1 Red (rd) wire of IPCU/E2 Black (sw) wire of IPCU/A3 Light blue/green (hbl/gn) wire of connec-

tor M072 A/1 5 Light blue (hbl/gr) wire of M070/5

Connec-tion of IPCU

11

1

2

12

4

1

2

3

13

5

1

24 3

14

3

21

5

4



Digital Timer

1 Digital timer

Installing digital tim-er

Remote Option (Telestart)

Fasten receiver 1 with adhesive tape.

Installing receiver

1 Antenna

Installing antenna

Temperature sensor T100 HTM

Fasten temperature sensor 1 with adhesive tape.

Installing tempera-ture sensor

151

1

16

1

17

181



Preparing Bracket

Separate bracket 1 at the marking and bend according to template.

2 Discard section Preparing bracket

1 Bracket2 M6x35 bolt, 20 shim, pin lock

Preparing bracket

1 Inclined perforated bracket, angled down

Preparing perforated bracket

Preparing Heater

1 Water connection pieces, sealing ring [2x each]

2 5x15 self-tapping bolt, retaining plate of water connection pieces Installing

water con-nection pieces

19

2

18

1

20

1

2

68

62

15°

1

1 21

1

2



1 5x13 self-tapping bolt [2x]2 90° moulded hose, 10 mm dia. clamp [2x]3 Fuel line4 Bracket

Installing bracket

Installing Heater

Replace original vehicle bolt at position 2 with M6x40 bolt, spring lock washer and large di-ameter washer.

1 Large diameter washer, flanged nut, ex-isting hole

Installing heater

Insert 20 mm shim between body and brack-et.

1 20 mm shim, flanged nut

Installing heater

1 Flanged nut, existing bolt2 Perforated bracket3 5x13 self-tapping bolt

Installing heater

22

1

1

4

3 2

232

1

241

25

2

1

3



Coolant Circuit 1.6 / 2.0 JTD

WARNING!Any coolant running off should be collected in an appropriate container. Install hoses so that they are kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that other hose 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 rout-ing dia-gram

All spring clips = 25 mm dia. All hose clamps = 20-27 mm dia.! 1 = Original vehicle hose 2 = Black (sw) rubber isolator . Connecting pipe = 18x18mm dia.Connecting pipe = 15x18 mm dia.

B

A

C

2

D1 Ø 22



Discard section X.Hose D = 18x20 moulded hose

A = 870B = 220C = 1050 Cutting

hoses to length

Push braided protection hoses onto hose A and C and cut to length.Cut heat shrink plastic tubing to length.

1 25 mm long heat shrink plastic tubing [4x]

Preparing hoses

Shape 48 mm dia. rubber-coated p-clamp 1. Insert 10 mm shim between vehicle carrier and rubber-coated pipe clamp.

2 M6x25 bolt, 10 mm shim, flanged nut, ex-isting hole Installing

rubber-coated pipe clamp

Remove original vehicle hose of engine outlet / heat exchanger inlet 1 completely!

Cutting point

A X C B

X X

D

C

A

1 1

1 1

26

1

2

1

27

1



Separate original vehicle hose 2 at the mark-ings [2x].

1 Heat exchanger inlet coupling (is reused)3 Discard hose sections4 Discard clamp Preparing

hose

1 Coupling on heat exchanger inlet2 Apply black (sw) rubber isolator

Premount-ing hose C and D

Push coupling 1 onto the heat exchanger in-let. Fasten black (sw) rubber isolator with ca-ble tie 2 on brake line!

Connect-ing heat ex-changer inlet

Install hose C through rubber-coated pipe clamp 1.

Routing in engine compart-ment

28

1

3

4

80

10

2

3

29

C

2

1

D

30C

D

1

2

31

C 1



Connect-ing heater outlet

1 Combustion air silencer2 51 mm dia. pipe clamp3 M5x16 bolt, flanged nut4 Angle bracket5 29 mm dia. rubber-coated p-clamp

Premount-ing silencer

1 Angle bracket2 Original vehicle nut

Installing silencer

Install M6x40 spacer nut 1 on original vehicle bolt.

Installing spacer nut

32C

333

5

1

4 2

34

2

1

35

1



1 48 mm dia. rubber-coated p-clamp2 M6x25 bolt3 Circulating pump

Installing circulating pump

Mount wiring harness on circulating pump 1 and on heater 2.

Mounting wiring har-ness

In the original vehicle hose 2 cut a notch 1 of 3mm width and 5mm length.

Premount-ing hose A

1 Original vehicle hose

Connect-ing engine outlet

36

2

1

3

37

1

2

38

A

2

11

39

A1



Install hose A through rubber-coated p-clamp 1.



Install hose A through rubber-coated p-clamp 1.

Connect-ing circu-lating pump

Align hoses. Ensure sufficient distance from neighbouring components.

Connect-ing heater inlet

40

C A1

41A

42

1 A

43B



Coolant Circuit 1.3 JTD

WARNING!Any coolant running off should be collected in an appropriate container. Install hoses so that they are kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that other hose 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 rout-ing dia-gram

All spring clips = 25 mm dia. 1 = AGR.Connecting pipe = 18x18mm dia. Connecting pipe = 18x20 mm dia.

C

B

D

AØ 27

1

Ø 27



Discard section X.Hose A = 180°, 18x18mm dia. moulded hose

B = 725C = 220D = 810 Cutting

hoses to length

Push braided protection hoses onto hose B and D and cut to length.Cut heat shrink plastic tubing to length.

1 25 mm long heat shrink plastic tubing [4x]

Preparing hoses

Detach retaining clip 2 from original vehicle wiring harness 1. Route original vehicle wir-ing harness 1 as shown.

Relocating wiring har-ness

Remove and discard spring clip 1. Pull hose of engine outlet / heat exchanger inlet 2 off connection piece of engine outlet.

Cutting point

CX

DB

X

A

D

B

1 1

1 1

44

1

2

45

1

2



1 Install 90° connecting pipe

Connect-ing engine outlet

1 Install connecting pipe2 Hose on heat exchanger inlet

Connect-ing heat ex-changer inlet


1 Hose on heat exchanger inlet2 Cable tie


46

A

1

47

1

2

48

B

A

49D

1

2



1 Cable tie


Connect-ing heater outlet

1 Combustion air silencer2 51 mm dia. pipe clamp3 M5x16 bolt, flanged nut4 Angle bracket5 29 mm dia. rubber-coated p-clamp

Premount-ing silencer

1 Angle bracket2 Original vehicle nut

Installing silencer

50

1

D1

B

51D

523

5

1

4 2

53

2

1



Install M6x40 spacer nut 1 on original vehicle bolt.

Installing spacer nut

1 48 mm dia. rubber-coated p-clamp2 M6x25 bolt3 Circulating pump

Installing circulating pump

Mount wiring harness on circulating pump 1 and on heater 2.

Mounting wiring har-ness


54

1

55

2

1

3

56

1

2

57B



Route hose B through rubber-coated p-clamp 1.

Connect-ing circu-lating pump

Align hoses. Ensure sufficient distance from neighbouring components.

Connect-ing heater inlet

58

1 B

59C



Combustion Air

Discard section X.

1 Combustion air pipea = 300 Cutting

combus-tion air pipe to length

Route fuel line 1 and wiring harness of meter-ing pump to the engine compartment and onto the underbody along original vehicle lines.

2 Combustion air pipe3 Mount wiring harness of heater.

Installing combus-tion air pipe

Secure wiring harnesses and combustion air pipe with cable tie.

1 Silencer2 Combustion air pipe

Installing combus-tion air pipe

a

1

X

603 2 1

61

21



Exhaust Gas

Discard section X.

1 Exhaust pipe2 Exhaust end section Preparing

exhaust pipe

1 Angle down perforated bracket.


1 Perforated bracket2 Flanged nut, original vehicle bolt

Installing perforated bracket

Remove retaining clip at position 1 (to be re-used later) and drill 6.5 mm dia. hole in cutout centre.

Hole in cross member

a b

1 2

X

a =b =

1.6 / 2.0 JTD

620240

1.3 JTD

620145

58

90°

1

622

1

63

1



1 Angle bracket2 Silencer3 M6x12 bolt, spring lockwasher

Installing silencer

Reinsert retaining clip 2 after installation.

1 M6x20 cap screw, flanged nut3 Angle bracket

Installing silencer

1 Hose clamp2 Exhaust pipe3 Exhaust-gas insulation

Installing exhaust pipe

1.6 / 2.0 JTD

Insert 10mm shim between perforated brack-et and pipe clamp.

1 M6x25 bolt, 10 mm shim, pipe clamp, flanged nut

2 Exhaust pipe

Routing ex-haust pipe

64

1

3 2

65

1

3 2

3 66

1

2

1 672



1 Hose clamp2 Exhaust pipe


1 9.1 mm dia. hole; rivet nut

Installing rivet nut

Ensure sufficient distance from neighbouring components.

1 Hose clamp2 Exhaust end section3 M6x60 bolt, spring lockwasher, large di-

ameter washer, pipe clamp, 40mm shimInstalling exhaust end section

1 Underride protection2 60mm dia. hole

Cutting out underride protection

1 682

1

69

185

1 2

3 70

71

1

2



Align the exhaust end section 2 at the centre of the hole.

1 Underride protection mounted

Aligning exhaust end section

1.3 JTD

Insert 10mm shim between perforated brack-et 4 and pipe clamp 2.

1 Exhaust pipe3 M6x25 bolt, 10mm shim, flanged nut

Routing ex-haust pipe

1 Align spacer bracket on charge-air hose.

Pushing on spacer bracket

1 Hose clamp2 Exhaust pipe


722

1

2

734 3

1

74

1

1

1 752



1 9.1 mm dia. hole; rivet nut

Installing rivet nut

Ensure sufficient distance from neighbouring components.

1 Hose clamp2 Exhaust end section3 M6x60 bolt, spring lockwasher, large di-

ameter washer, pipe clamp, 40mm shimInstalling exhaust end section

1 Underride protection2 60mm dia. hole

Cutting out underride protection

Align the exhaust end section 2 at the centre of the hole.

1 Underride protection mounted

Aligning exhaust end section

1

76

115

1 2

3 77

78

1 2

340

70

792

1



Fuel

CAUTION!Open the vehicle's fuel tank cap, ventilate the tank and then re-close the tank lock.

Catch any fuel running off in an appropriate container.

Install fuel line and metering pump wiring harness so that they are protected against stone impact. Un-less 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 rout-ing diagram.

Install fuel line and wiring harness of the me-tering pump in corrugated tube 1 at the instal-lation location of the metering pump.

Installing lines

1 Angle down perforated bracket


1 Original vehicle nut2 Perforated bracket

Installing perforated bracket

80

1

1

90°

80

1

81

1

2



Fix mounting of metering pump 1 with cable tie 3 on the perforated bracket.

2 M6x25 bolt, support angle, flanged nut4 Metering pump

Mounting metering pump

Check the position of the components; adjust if necessary. Check that they have freedom of movement.

1 Wiring harness of metering pump, con-nector mounted

2 Hose section, 10 mm dia. clamp [2x]3 Fuel line of heater

Connect-ing meter-ing pump

The fuel tank has to be removed in accord-ance with manufacturer's instructions for ve-hicles without service lid. Remove fuel-tank sending unit 1 in accordance with the manu-facturer's instructions. Remove sticker 2.

Fuel ex-traction

Mount large diameter washer 1 on reference edge (broken line).

2 Copy hole pattern, 6 mm dia. hole

Hole in fuel-tank sending unit

82

1

234

83

1

3 2

84

1

2

852

1

18



Shape fuel standpipe 1 according to tem-plate, cut to length and install.

Installing fuel stand-pipe

Image shows vehicle with service lid. Install fuel-tank sending unit 4 according to manu-facturer's instructions.

1 Fuel line2 Hose section, 10 mm dia. clamp [2x]3 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 of fuel standpipe2 Hose section, 10 mm dia. clamp [2x] Connect-

ing meter-ing pump

86

1

1

1

87

3

1 2

4

882

1



Final Work

WARNING!Mount removed parts 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 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.• Adjust digital timer, teach Telestart transmitter.• Make settings on A/C control panel according to the "Operating Instructions for the End

Customer".• Place the "Switch the parking heater off before refueling" signboard in the area of the filler

neck.• For initial startup and function check, please see installation instructions.

Align exhaust pipe 1 towards front fog light 2. Ensure sufficient distance from neighbouring components, correct if necessary.

Aligning exhaust pipe

892

1

Webasto Thermo & Comfort SEPostfach 141082199 GilchingGermanyInternet: www.webasto.comTechnical Extranet:http://dealers.webasto.com



Template for Bracket


15

18

18

35°5

5

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.


Template for Fuel Standpipe


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.


Operating Instructions for Manual Air-Conditioning

Please remove this page in case of manual air-conditioning and add it to the vehicle operating instructions.

Note:We recommend matching the heating time to the driving time.Heating time = driving timeExample: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 instructions on deactivation, please refer to the operating instructions of the vehicle.

Before parking the vehicle, make the following settings:

1 Air outlet to windscreen2 Set temperature to "max."3 Set fan to level "1", or max. "2"

A/C control panel

1 30A main fuse F1 of passenger compart-ment

2 20A heater fuse F2

Fuses of engine compart-ment

1 1A fuse F3 of heater control 2 25A fan fuse F4

Fuses of passenger compart-ment

902

3

1

912

1

922

1


Operating Instructions for Automatic Air-Conditioning

Please remove this page in case of automatic air-conditioning and add it to the vehicle operating instructions.

Note:We recommend matching the heating time to the driving time.Heating time = driving timeExample: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 instructions on deactivation, please refer to the operating instructions of the vehicle.

Before parking the vehicle, make the following settings:

1 Air outlet to windscreen2 Set temperature to "max."

A/C control panel

1 30A main fuse F1 of passenger compart-ment

2 20A heater fuse F2

Fuses of engine compart-ment

1 1A fuse F3 of heater control 2 25A fan fuse F4

Fuses of passenger compart-ment

932

1

942

1

952

1

Documents

Water Heater - xn--80aejlqpaaj0acd6k.xn--p1aiавтоотопитель.рф/manual/Fiat/Dolbo/1315994C_EN_Fiat_Doblo+Doblo_Cargo... · Operating Instructions for Manual Air-Conditioning