Alfa Romeo - Giulietta - Workshop Manual - 2010 - 2010

Water Heater Thermo Top Evo Parking Heater E1 00 0258 Installation Documentation Alfa Romeo Giulietta Validity Manufacturer Alfa Romeo Motorisation 1.4 TB 16V 2.0 JTDM 16V Model Giulietta Fuel Petrol Diesel Type 940 Transmission type Output in kW SG 88 SG 125 EG-BE No./ ABE e3 * 2007 / 46 * 0027 * ... Displacement in cm³ Engine code 1368 198A4000 1956 940A4000 SG = manual transmission From model year 2010 Left-hand drive vehicle Verified equipment variants: Manual / automatic air-conditioning system Front fog light Front fog lightBI-Xenon / headlight washer system Not verified: Passenger compartment monitoring Exclusion: TCT 6-speed dual clutch transmission Total installation time: approx. 7 hours Ident. No.: 1316616E_EN Status: 15.11.2013 © Webasto Thermo & Comfort SE Alfa Romeo Giulietta Table of Contents Validity Necessary Components Installation Overview Notes on Total Installation Time Information on Operating and Installation Instructions Notes on Validity Technical Instructions Explanatory Notes on Document Preliminary Work Heater Installation Location Preparing Electrical System Electrical System Fan Controller of All Vehicles Optional Heater Control 1 2 2 2 3 4 4 4 5 5 6 8 9 11 Preparing Bracket Preparing Installation Location Preparing Heater Installing Heater Combustion Air Fuel Coolant Circuit for Petrol Vehicles Coolant Circuit for Diesel Vehicles Exhaust Gas Final Work Fuel standpipe template Operating Instructions for Manual Air-Conditioning Operating Instructions for Automatic Air-Conditioning 12 13 15 15 16 17 21 26 33 36 37 38 39 Necessary Components • Basic delivery scope of Thermo Top Evo based on price list • Installation kit for Alfa Romeo Giulietta 2010 petrol: 1316615A • Installation kit for Alfa Romeo Giulietta 2010 diesel: 1316642A • 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 Installation Overview 3 Legend: 1. Heater 2. Fuse holder of engine compartment 3. Relay and fuse holder of passenger compartment 4. IPCU 5. Circulating pump 6. Digital timer 7. Metering pump 4 7 5 6 1 2 Notes on Total Installation Time 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.: 1316616E_EN Status: 15.11.2013 © Webasto Thermo & Comfort SE 2 Alfa Romeo Giulietta Information on Operating and Installation Instructions 1 Important Information (not complete) 1.1 Installation and Repair 2.1 The improper installation or repair of Webasto heating and cooling systems 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 appropriate technical documentation, special tools and special equipment. Excerpt from the directive 2001/56/EC Appendix VII for theinstallation of the heater Beginning of excerpt. ANNEX VII REQUIREMENTS FOR COMBUSTION HEATERS AND THEIR INSTALLATION 1. GENERAL REQUIREMENTS Installation and repair may ONLY be carried out by persons trained and certified in a Webasto training course. NEVER try to install or repair Webasto 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. 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 Only use genuine Webasto parts. See the Webasto air and water heaters accessories catalogue for this purpose. 2.1.1. Subject to paragraph 2.1.2. combustion heaters shall be installed according to the requirements of this Annex. 1.2 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 installation ensures an adequate distance to all parts and suitable ventilation, by the use of fire resistant materials or by the use of heat shields. 2.2.3. ALWAYS follow all Webasto installation and operating instructions and observe all warnings. 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. 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. 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. 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 suffocation. Always switch off the heater before refuelling. The heater may only be used with the prescribed fuel Diesel (DIN EN 590) or petrol (DIN EN 227). The heater may not be cleaned with a high-pressure cleaner. 1.3 Please note 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. 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 labelled 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. 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 repairs, installations and repairs by untrained persons or in the case of a failure to use genuine spare parts. The liability due to culpable disregard to life, limb or health and due to damage or injuries caused by a wilful or reckless breach of duty remain unaffected, 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. Connectors on electronic components have to audibly click into place during installation. Sharp edges should be fitted with rub protection. 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 manufacturer for demounting and mounting vehicle specific components! 2.4. Exhaust system 2.4.1. The exhaust outlet must be located so as to prevent emissions from entering the vehicle through ventilators, heated air inlets or opening windows. 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. The initial startup is to be executed with the Webasto Thermo Test Diagnosis. When installing an IPCU, the corresponding settings must be checked or adjusted before the installation. 2 Statutory regulations governing installation Guidelines Thermo Top Evo Heating Directive ECE R122 EMC Directive ECE R10 E1 00 0258 E1 03 5627 Note 2.7. Heating air outlet 2.7.1. Any ducting used to route the hot air through the vehicle must be so positioned 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. 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. In multilingual versions the German language is binding. 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. Ident. No.: 1316616E_EN Status: 15.11.2013 © Webasto Thermo & Comfort SE 3 Alfa Romeo Giulietta Notes on Validity This installation documentation applies to Alfa Romeo Giulietta Petrol and 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 installation 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 Instructions 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 and 5x11 heater stud 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-theart-technology. 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. Special features are highlighted using the following symbols: Mechanical system Specific risk of injury or fatal accidents. Electrical system Specific risk of damage to components. Coolant circuit Specific risk of fire or explosion. Combustion air Reference to general installation instructions of the Webasto components or to the manufacturer's vehicle-specific documents Fuel Exhaust gas Reference to a special technical feature. The arrow in the vehicle icon indicates the position on the vehicle and the viewing angle Software Ident. No.: 1316616E_EN Status: 15.11.2013 © Webasto Thermo & Comfort SE 4 Alfa Romeo Giulietta Preliminary Work Vehicle • • • • • • • • • • • • • • • • • • • Open the fuel tank cap. Ventilate the fuel tank. Close the fuel tank cap again. Depressurise the cooling system. Remove the engine design cover. Completely remove the battery. Remove the battery carrier. Remove the intake air pipe at the engine according to the manufacturer's instructions (1.4 TB only). Remove the lower engine cover. Remove the lower cover of the bumper. Remove the cover of fuel lines on the right-hand side of the underbody. Drain the engine coolant according to the manufacturer's instructions. Remove the rear bench seat surface (screw fitting 2x at the front underneath the felt cover). Open the tank-fitting service lid. Remove the fuel-tank sending unit in accordance with the manufacturer's instructions. Remove the lower trim in the footwell on the front passenger's side. Remove the lateral trim of the centre console in the footwell. Remove the glove compartment. Remove the trim of the shift lever (for digital timer only). 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 Figure shows 1.4 TB 16V 1 Heater Installation location 1 Ident. No.: 1316616E_EN Status: 15.11.2013 © Webasto Thermo & Comfort SE 5 Alfa Romeo Giulietta Preparing Electrical System rt/sw rt gn/ws 0,5² 4² 0,75² Wire sections retain their numbering in the entire document. F3 F4 Connect wires to K1 relay socket. Insert 25A Inserting fuse F4. K1 relay will only be inserted after in- F4, preparstallation of the passenger compartment relay ing K1 relay and fuse holder. rt 1 86 87 85 30 4² 87a K1 br sw 2 0,5² 7 4² ge 0,75² 1000 4 sw Preparing wires 0,5² 500 6 br 3 rt 0,5² 100 5 300 0,5² gn/ws 0,75² 100 IPCU view on contact side. Check IPCU settings before start-up of heater and adjust if necessary. IPCU settings: 15 A 86 IPCU 15 85 E E 86 7 3 Duty cycle: Frequency: Voltage: Function: A 1 85 2 Attach IPCU socket 1 and passenger compartment relay and fuse holder 2 together. Detach/remove K1/85 and K1/86 contacts. Mount provided contacts on wires according to wiring diagram. 3 4 4 6 Ident. No.: 1316616E_EN 5 Checking IPCU 65% 400Hz 9V Low-side 3 Brown (br) wire of K1/85 4 Green/white (gn/ws) wire of K1/86 3 Red (rt) wire of IPCU/E 4 Black (sw) wire of IPCU/A 5 Green/white (gn/ws) wire of K1/86 and IPCU/86 6 Brown (br) wire of K1/85 and IPCU/85 7 Yellow (ge) wire of IPCU/15 2 Status: 15.11.2013 Premounting passenger compartment relay and fuse holder/IPCU socket © Webasto Thermo & Comfort SE 6 Alfa Romeo Giulietta rt/sw rt gn/ws 0,5² 4² 0,75² F3 F4 7 ge 0,75² 15 3 IPCU 87 87a 86 gn/ws K1 85 Premounting passenger compartment relay and fuse holder/IPCU socket A 5 86 E rt 0,5² 0,75² 30 85 br 4 sw 0,5² 0,5² 6 br 0,5² 2 1 sw 4² 1 2 rt 4² 3 Reassemble connector of metering pump after routing. Pin assignment is not relevant. 4 5 1 2 3 4 5 Connector housing Lock Blue/brown (bl / br) wires Coding Timer lock Dismantling connector 5 3 Ident. No.: 1316616E_EN Status: 15.11.2013 © Webasto Thermo & Comfort SE 7 Alfa Romeo Giulietta Electrical System Wiring harness pass through 1.4 TB Wiring harness pass through 2.0 JTDM 1 Protective rubber plug 1 Protective rubber plug 1 1 4 5 2 Wiring harness routing diagram Do not install the metering pump wiring harness until later together with the fuel pipe along the original vehicle fuel lines in a corrugated tube on the underbody. 1 1 2 2 6 Fuse holder of engine compartment Positive and earth wire 1 Positive wire on positive battery terminal 2 8mm dia. cable lug, earth wire on original vehicle earth support point Ident. No.: 1316616E_EN 7 3 1 Angle bracket, drill out hole in short leg to 8.5mm dia 2 Original vehicle stud bolt 3 Fuse holder, M5x16 bolt, washer [2x], nut Status: 15.11.2013 © Webasto Thermo & Comfort SE 8 Alfa Romeo Giulietta Fan Controller of All Vehicles Webasto Alfa Romeo 30 15 1 X2 F2 2 2 Wiring diagram F01 HG 5 X1 20 F1 86 30 85 87 M001 T08 ge 0,5² br rt/sw 0,5² 0,5² F08 0,75² 4² X10 rt/sw rt 0,5² gn/ws 4² F3 gr/rt gn/ws rt 0,5² 36 F4 gr/rt 21 M070 5 gn/ws rt 0,75² 4² 86 87 87a 5 br 86 85 85 IPCU br E rt 0,5² sw 4² 3 sw 4 ge 1 2 2 1 2 0,5² 15 6 30 0,5² A ws/rt K1 6 3 M072 ws/rt 0,5² 4 1 M N85 7 0,75² br 0,5² Webasto components HG Heater TT-Evo X1 6-pin heater connector X2 2-pin heater connector X10 4-pin connector of heater control K1 Fan relay F1 20A fuse F2 30A fuse F3 1A fuse F4 25A fuse IPCU Pulse width modulator IPCU settings: Duty cycle: 65% Frequency: 400Hz Voltage: 9V Function: Low-side Ident. No.: 1316616E_EN 31 Vehicle components F01 Fuse M001 Body computer T08 Relay F08 Fuse M070 A/C control panel M072 Fan controller N85 Fan unit Colours and symbols rt red sw black ge yellow gn green gr grey ws white br brown Legend X Cutting point Wiring colours may vary. Status: 15.11.2013 © Webasto Thermo & Comfort SE 9 Alfa Romeo Giulietta Mount K1 relay 3 and IPCU 5 first after installing angle bracket on relay and fuse holder. 1 Angle bracket, washer [2x], M5x16 bolt, nut 2 Original vehicle hole, M6x35 bolt, 20mm shim, flanged nut 5 4 1 3 Mounting relay and fuse holder of passenger compartment 8 2 Connect wiring harness of passenger compartment relay and fuse holder 1 with wiring harness of heater 2 in accordance with wiring diagram in such a way that same colour wires are connected to each other. 1 Connecting wiring harness 9 2 1 Produce connections as shown in wiring diagram. 4 1 Green/red (gr/rt) wire of fan controller 2 Green/red (gr/rt) wire of fuse F08 1 Red (rt) wire of K1/87a 2 Black (sw) wire of K1/30 4 Yellow (ge) wire of IPCU/15 Connecting fan controller 1 2 2 10 Produce connections as shown in wiring diagram. 1 4 1 White/red (ws/rt) wire of fan controller 2 White/red (ws/rt) wire of A/C control panel 3 Red (rt) wire of IPCU/E Connect4 Black (sw) wire of IPCU/A ing fan controller 3 2 Ident. No.: 1316616E_EN 11 Status: 15.11.2013 © Webasto Thermo & Comfort SE 10 Alfa Romeo Giulietta Optional Heater Control 1 1 Receiver 2 Original vehicle hole, M5x16 bolt, flanged nut Installing receiver 2 12 1 Antenna 1 Installing antenna 13 Temperature sensor T100 HTM 1 Fasten temperature sensor 1 with adhesive tape. Installing temperature sensor 14 Digital timer 1 Digital timer Installing digital timer 1 Ident. No.: 1316616E_EN 15 Status: 15.11.2013 © Webasto Thermo & Comfort SE 11 Alfa Romeo Giulietta 35 Preparing Bracket 15 1 1 Perforated bracket Bending perforated bracket at an angle 50° 50° Drill 5.5mm dia. hole 1 into bracket 2 as shown. 1 Preparing bracket 20 48 16 2 Drill 5.5mm dia. hole 1 into bracket 2 as shown. 1 Preparing bracket 20 48 17 2 1 2 Combustion air pipe 1 shortened to 280mm. 3 4 5 2 51mm dia. clamp, M5x16 bolt, flanged nut 3 Intake silencer 4 Perforated bracket 5 Perforated bracket, M6x16 bolt, flanged nut Premounting 1.4 TB bracket 5 6 Ident. No.: 1316616E_EN 18 Status: 15.11.2013 © Webasto Thermo & Comfort SE 12 Alfa Romeo Giulietta 1 Shorten combustion air pipe 5 to 300mm and mould as shown. 2 5 3 4 1 51mm dia. clamp, M5x16 bolt, flanged nut, perforated bracket 2 Intake silencer 3 Bracket 4 Perforated bracket, M6x16 bolt, flanged nut Premounting bracket 2.0 JTDM 19 4 Preparing Installation Location 1 Align bracket 1, note dimensioning. Aligning bracket 235mm 1.4TB 10 180mm 2.0JTDM 1 20 Copy hole pattern 1 [2x] for 9.1mm dia. hole. 1 1 21a Copying hole pattern 21 1 1 Copy hole pattern 1 [2x] for 9.1mm dia. hole. 1 Copying hole pattern 22 Ident. No.: 1316616E_EN Status: 15.11.2013 © Webasto Thermo & Comfort SE 13 Alfa Romeo Giulietta Slit 8x12 hose 1 longitudinally and slide on to vacuum line, secure with cable ties (2.0 JTDM only). 1 2 Rivet nut [2x] Installing rivet nuts 2 23 2 1 1 Rivet nut [2x] 1 Installing rivet nuts 24 A 1 M6x20 bolt, spring lockwasher [2x] Installing bracket 1 1 25 1 M6x20 bolt, spring lockwasher [2x] 1 1 Ident. No.: 1316616E_EN Installing bracket 26 Status: 15.11.2013 © Webasto Thermo & Comfort SE 14 Alfa Romeo Giulietta Preparing Heater 1 1 Water connection piece, sealing ring [2x each] 2 5x15 self-tapping bolt, retaining plate of water connection pieces 2 27 1 1 1 1 Mounting water connection piece Screw 5x13 self-tapping bolts 1 [4x] in existing holes by a max. of 3 thread turns. 1 Premounting bolts loosely 28 1 Installing Heater 2 Insert heater 1 in bracket 3 and align. 2 5x15 Self-tapping bolt [2x] Installing heater 2 3 1 29 1 5x15 Self-tapping bolt [2x] 1 Installing heater 30 Ident. No.: 1316616E_EN Status: 15.11.2013 © Webasto Thermo & Comfort SE 15 Alfa Romeo Giulietta Combustion Air 1 Ensure sufficient distance from neighbouring components. 1 Intake hose 2 Heater Installing 2.0 JTDM combustion air pipe 2 31 Ensure sufficient distance from neighbouring components. 1 1 Intake hose 2 Heater Installing 1.4 TB combustion air pipe 2 32 Ident. No.: 1316616E_EN Status: 15.11.2013 © Webasto Thermo & Comfort SE 16 Alfa Romeo Giulietta 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. Discard section X. 1 1 180° moulded hose Preparing heater connection X 15 33 1 Image shows 2.0 JTDM Attach connector of heater wiring harness 4 [2x] to the heater and secure/fasten it using cable ties 3. Ensure sufficient distance from neighbouring components. 2 3 4 1 Fuel line, metering pump cable, 10mm dia. corrugated tube 2 Moulded hose, 10 mm dia. clamp [2x] Connecting heater 34 1 Route fuel line and wiring harness of metering pump in 10mm dia. corrugated tube 2 to the right side of the vehicle and secure it with cable ties 1 [2x]. 1 Routing on underbody 2 Ident. No.: 1316616E_EN 35 Status: 15.11.2013 © Webasto Thermo & Comfort SE 17 Alfa Romeo Giulietta 1 Route fuel line and wiring harness of metering pump in 10mm dia. corrugated tube 1 to underbody and secure with cable ties. 1 Routing in engine compartment 36 Route fuel line and wiring harness of metering pump in 10mm dia. corrugated tube 1 on underbody and secure using cable ties. Routing on underbody 1 37 1 1 Perforated bracket 2 Drill hole to 8.5mm dia. 2 Preparing perforated bracket 80 90° 1 2 3 4 1 Perforated bracket M6x25 bolt, flanged nut Cable tie Mounting of metering pump 2 4 3 Ident. No.: 1316616E_EN Preinstalling metering pump mounting 38 Status: 15.11.2013 © Webasto Thermo & Comfort SE 18 Alfa Romeo Giulietta 1 Original vehicle bolt 2 Mounting of metering pump 1 Installation of metering pump mounting 39 2 Insert metering pump 2 into mounting 1. 1 Metering pump installation 40 2 1 Wiring harness of metering pump, connector mounted 2 Fuel line 3 Hose section, 10 mm dia. clamp [2x] 1 Connecting metering pump 3 1 41 2 The design of the fuel standpipe is identical for the shown fuel tank sending units. Remove fuel-tank sending unit 1 in accordance with manufacturer's instructions. Remove sticker 2! 1 Fuel extraction 2.0 JTDM 2 1.4 TB 2 Ident. No.: 1316616E_EN 42 Status: 15.11.2013 © Webasto Thermo & Comfort SE 19 Alfa Romeo Giulietta Place large diameter washer 1 against the reference edge (dotted marking). 2 Copy hole pattern, 6 mm dia. hole Hole in fuel-tank sending unit 15 1 2 43 1 1 Shape fuel standpipe 1 according to template and cut to length. Installing fuel standpipe 1 44 Install fuel-tank sending unit 1 in accordance with manufacturer's instructions. 1 2 Hose section, 10 mm dia. clamp [2x] 3 Fuel line 4 Fuel standpipe Connecting fuel line 2 3 45 4 1 Metering pump 2 Hose section, 10 mm dia. clamp [2x] 3 Fuel line, corrugated tube 1 Connecting metering pump 3 2 Ident. No.: 1316616E_EN 46 Status: 15.11.2013 © Webasto Thermo & Comfort SE 20 Alfa Romeo Giulietta Coolant Circuit for Petrol Vehicles 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 hoses cannot be damaged. The heater must be filled with coolant when installing the hoses. The connection should be "inline" based on the following diagram: Hose routing diagram Ø 22 A Ø 22 Ø 16x18 Ø 27 Ø 18x20 B C All spring clips without a specific designation Ident. No.: 1316616E_EN D = 25 mm dia. Status: 15.11.2013 © Webasto Thermo & Comfort SE 21 Alfa Romeo Giulietta Discard section X. Hose A = 180° moulded hose B C D B = C = D = X 380 390 630 Cutting hoses to length A 1 Push braided protection hoses onto hose C and D and cut to length. Cut heat shrink plastic tubing to length. 1 1 50 mm long heat shrink plastic tubing [4x] C Preparing hoses D 1 1 1 Circulating pump 2 Mounting of circulating pump 3 Angle bracket, M6x25 bolt, flanged nut 1 Premounting circulating pump 2 3 47 Cut provided 50 mm edge protection in the middle. 1 1 25mm edge protection [2x] Inserting edge protection 1 48 Ident. No.: 1316616E_EN Status: 15.11.2013 © Webasto Thermo & Comfort SE 22 Alfa Romeo Giulietta 1 1 Battery carrier console 2 Original vehicle hole, M6x20 bolt, large diameter washer, flanged nut 3 Circulating pump premounted 2 Circulating pump installation 3 49 Pull hose 1 of engine outlet off connection piece 2 discard original vehicle hose clamp. 1 Cutting point 50 2 Separate provided rub protection 1 in the middle and paste on hose clamp of hose 2 on heat exchanger outlet. 1 Placing rub protection 2 51 Route hose D in the engine compartment. 1 Connection piece of heater outlet D Connecting heater 1 52 Ident. No.: 1316616E_EN Status: 15.11.2013 © Webasto Thermo & Comfort SE 23 Alfa Romeo Giulietta 1 1 Cable tie [2x] 2 Hose section of heat exchanger inlet 2 1 D Connection of heat exchanger inlet 53 1 1 Connection piece on engine outlet A Connecting engine outlet 54 Route hose C to the circulating pump in the engine compartment. 1 Connection piece of heater outlet Connecting heater C 55 1 1 Connection piece of circulating pump 1 Connecting circulating pump C Ident. No.: 1316616E_EN 56 Status: 15.11.2013 © Webasto Thermo & Comfort SE 24 Alfa Romeo Giulietta 1 Attach wiring harness of circulating pump 1 to heater 2 and circulating pump 3 and secure with cable ties. 1 3 Attaching wiring harnesses 2 57 1 Connection piece of circulating pump 1 B Connection of heat exchanger inlet 58 B B A Connecting hose B and hose A 59 After installing the air intake pipe 1 check the position of hoses B and D. Align hoses. Ensure sufficient distance from adjacent components; correct if necessary. 1 2 Cable tie D Routing in engine compartment 2 B Ident. No.: 1316616E_EN 60 Status: 15.11.2013 © Webasto Thermo & Comfort SE 25 Alfa Romeo Giulietta Coolant Circuit for Diesel Vehicles 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 hoses cannot be damaged. The heater must be filled with coolant when installing the hoses. The connection should be "inline" based on the following diagram: Hose routing diagram Ø 24/27 A Ø 27 Ø 15x20 Ø 22 Ø 15x18 Ø 22 Ø 15x18 Ø 22 1 Ø 16/24 B C E D All spring clips without a specific designation All connecting pipes = 18x18 mm dia. Ident. No.: 1316616E_EN = 25 mm dia. 1 = Black (sw) rubber isolator Status: 15.11.2013 [4x]. © Webasto Thermo & Comfort SE 26 Alfa Romeo Giulietta Discard section X. Hose A = 180° moulded hose B C D E B C D E X = = = = 650 65 350 950 Cutting hoses to length A 1 1 1 Push braided protection hose onto hose B, D and E and cut to length. Cut heat shrink plastic tubing to length. B 1 1 50 mm long heat shrink plastic tubing [6x] Preparing hoses D E 1 1 1 Black (sw) rubber isolator 2x on hoses B and E E Preparing hoses 1 B C D 61 1 Circulating pump 2 Mounting of circulating pump 3 Angle bracket, M6x25 bolt, flanged nut 1 2 3 Ident. No.: 1316616E_EN Premounting circulating pump 62 Status: 15.11.2013 © Webasto Thermo & Comfort SE 27 Alfa Romeo Giulietta 1 1 Battery carrier console 2 Original vehicle hole, M6x20 bolt, large diameter washer, flanged nut 3 Circulating pump premounted 2 Circulating pump installation 3 63 Remove hose section 1 of engine outlet. 1 2 Discard hose clamp Cutting point 64 2 1 Remove quick-release coupling 3 from hose 1 discard clamp 2. 2 Preparing hose 3 65 1 2 3 4 1 150 Engine outlet hose section Connection quick-release coupling Hose section of heat exchanger inlet Connection of engine outlet Preparing hose 4 3 Ident. No.: 1316616E_EN 2 66 Status: 15.11.2013 © Webasto Thermo & Comfort SE 28 Alfa Romeo Giulietta 1 1 Quick-release coupling 2 Hose section of heat exchanger inlet 3 Connection for hose E 2 Preparing hose of heat exchanger inlet 3 67 A 1 Connection of engine outlet connection piece 2 Connection for hose B 1 Preparing hose of engine outlet 2 68 1 Hose group of engine outlet 2 Connection piece on engine outlet Connecting engine outlet 1 69 2 1 1 Hose group of heat exchanger inlet 2 Connection of heat exchanger inlet 2 Connection of heat exchanger inlet 70 Ident. No.: 1316616E_EN Status: 15.11.2013 © Webasto Thermo & Comfort SE 29 Alfa Romeo Giulietta Route hose E in the engine compartment. E 1 Connection piece of heater outlet Connecting heater 71 1 Route hose E to heat exchanger connection. Routing 72 E Route hose E to heat exchanger connection. E Routing in engine compartment 73 1 Hose group of heat exchanger inlet 1 E Connection of heat exchanger inlet 74 Ident. No.: 1316616E_EN Status: 15.11.2013 © Webasto Thermo & Comfort SE 30 Alfa Romeo Giulietta E Align black (sw) rubber isolator 1 to cable bracket 2. 1 Aligning rubber isolator 2 75 Align black (sw) rubber isolator 2 to clamp 1 on engine outlet. E 1 Aligning rubber isolator 2 76 Route hose D to the circulating pump. 1 Connection piece of heater inlet Connecting heater D 1 77 1 Connection piece of circulating pump 2 Cable tie [2x] 1 E D 2 Ident. No.: 1316616E_EN Connecting circulating pump 78 Status: 15.11.2013 © Webasto Thermo & Comfort SE 31 Alfa Romeo Giulietta B 1 Connection piece of circulating pump 1 Connecting circulating pump 79 C 1 Route hose B to engine outlet connection. 1 1 Cable tie [2x] 2 Align rubber isolator [2x] 2 Routing 2 80 B B A Connecting engine outlet 81 Align hoses. Ensure sufficient distance from adjacent components; correct if necessary. 1 1 Cable tie E E Ident. No.: 1316616E_EN Routing in engine compartment 82 Status: 15.11.2013 © Webasto Thermo & Comfort SE 32 Alfa Romeo Giulietta 1 Exhaust Gas 2 Discard section X. 1 Exhaust pipe a = 350 2 Exhaust end section b = 100 a Preparing exhaust pipe b X 1 Perforated bracket 1 10 Bending perforated bracket at an angle 35 100° 90° 1 Silencer 2 M6x16 bolt, spring lockwasher 3 Perforated bracket 1 Premounting silencer 2 83 3 1 9.1mm dia. hole ; Rivet nut 1 Installing rivet nut 240 15 84 Ident. No.: 1316616E_EN Status: 15.11.2013 © Webasto Thermo & Comfort SE 33 Alfa Romeo Giulietta Insert 5mm shim between perforated bracket and cross member. 1 1 Silencer premounted with perforated bracket 2 M6x25 bolt, spring lockwasher, 5mm shim Installing silencer 2 85 1 Hose clamp [2x] 2 Exhaust pipe 1 2 Installing exhaust pipe 86 1 1 Ensure sufficient distance from neighbouring components. 2 1 Exhaust end section 2 Hose clamp Installing exhaust end section 87 Cut out sound insulation 1 and discard. 1 2 Lower engine cover Processing lower engine cover 2 88 Ident. No.: 1316616E_EN Status: 15.11.2013 © Webasto Thermo & Comfort SE 34 Alfa Romeo Giulietta 1 Lower engine cover 2 60mm dia. hole 1 35 Hole in lower engine cover 75 2 Ident. No.: 1316616E_EN 89 Status: 15.11.2013 © Webasto Thermo & Comfort SE 35 Alfa Romeo Giulietta Final Work WARNING! Mount removed parts in reverse order. Check all hoses, clamps and all electrical connections for firm seating. Insulate and tie back all loose wires. Only use manufacturer-approved coolant. Spray heater components with anti-corrosion wax (Tectyl 100K, Order No. 111329). • • • • Connect the battery. Fill and bleed the coolant circuit according to the vehicle manufacturer’s specifications. Adjust digital timer, teach Telestart transmitter Make settings on A/C control panel according to the "Operating Instructions for End Customer". • Affix "Switch off parking heater before refueling" caution label in area of filler neck. • See installation instructions for notes on initial operation and functional test Cut out marked layer 2 in cover 1. 1 Processing lower cover of bumper 2 90 Align exhaust end section 1 to the centre. 3 Lower engine cover 1 2 Aligning exhaust end section 91 Webasto Thermo & Comfort SE Postfach 1410 82199 Gilching Germany Internet: www.webasto.com Technical Extranet: http://dealers.webasto.com Ident. No.: 1316616E_EN Status: 15.11.2013 © Webasto Thermo & Comfort SE 36 Alfa Romeo Giulietta Fuel standpipe template 100 mm Scale 1:1 Compare the size of the printed version with dimension lines. Permitted tolerance a maximum of 2%. Set the printer settings to “no margin” or “minimise margins” and 100% of the normal size. 100 mm 0 Ident. No.: 1316616E_EN Status: 15.11.2013 © Webasto Thermo & Comfort SE 37 Alfa Romeo Giulietta Operating Instructions for Manual Air-Conditioning 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. 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: Note: No need to pre-select the fan speed. 1 1 Set temperature to "HI" 2 Air outlet to windscreen A/C control panel 2 92 1 20A heater fuse F1 2 30A main fuse F2 of passenger compartment Engine compartment fuses 2 93 1 1 1A fuse F3 of heater control 2 25A fan fuse F4 2 Passenger compartment fuses 1 94 Alfa Romeo Giulietta Operating Instructions for Automatic Air-Conditioning 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. 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: 2 1 Note: No need to pre-select the fan speed. 1 1 Set temperature to "HI" 2 Air outlet to windscreen A/C control panel 95 1 20A heater fuse F1 2 30A main fuse F2 of passenger compartment Engine compartment fuses 2 96 1 1 1A fuse F3 of heater control 2 25A fan fuse F4 2 Passenger compartment fuses 1 97