Fiat - Multijet - Workshop Manual - 2006 - 2006

Water Heater Thermo Top C Motorcaravan Parking Heater E1 00 0002 Installation Documentation Fiat Ducato 250 / Multijet Diesel From model year 2006 Left-hand drive vehicle Manual / automatic air-conditioning system WARNING! Hazard warning: 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. Only use genuine Webasto parts. See the Webasto air and water heaters accessories catalogue for this purpose. NEVER attempt to install or repair Webasto heating or cooling systems if you have not successfully completed the company training and thereby acquired the required technical skills, or if you do not have access to the required technical documentation, tools and equipment needed to carry out correct installation and repairs. ALWAYS follow all Webasto installation and repair instructions and observe all warnings. The initial startup is to be executed with the Webasto Thermo Test Diagnosis. Webasto does not accept any liability for defects and damage that are attributable to installation by untrained staff. Ident. No.: 9015695F_EN Status: 09.11.2015 © Webasto Thermo & Comfort SE Fiat Ducato 250 / Multijet Table of Contents Validity 2 Heater / Installation Kit 3 Foreword 3 General Instructions 3 Special Tools 3 Explanatory Notes on Document 4 Preliminary Work 5 Heater Installation Location 5 Dismantling Instructions from MY 2014 6 Preparing Electrical System 8 Electrical System 10 Fan Controller for Manual Air-Conditioning 11 Fan Controller for Automatic Air-Conditioning 12 Preparing Heater Installing Heater Fuel up to MY 2010 Fuel from MY 2011, Euro 5 Coolant Circuit Combustion Air Final Work Fuel Standpipe Template Operating Instructions for End Customer 15 15 16 18 20 26 27 28 29 Validity Manufacturer Fiat Fiat Fiat Model Ducato Ducato Ducato Engine model Diesel Diesel Diesel Diesel Diesel Diesel Diesel Output in kW 88 96 102 109 110 116 130 Type Multijet 250 250L EG-BE No. / ABE e3 * 2007 / 46 * 0044 * ... L 778 L 779 Displacement in cm³ 2287 2287 2287 2287 2999 2999 2999 Vehicle and engine types, equipment variants and national specifications not listed in this installation documentation have not been tested. However, installation according to this installation documentation may be possible. The installation location of a digital timer should be coordinated with the end customer before installation. 9015695F_EN 2 Fiat Ducato 250 / Multijet Heater / Installation Kit Quantity Description 1 Basic delivery scope of Thermo Top C Motorcaravan from MY 2006 1 Installation kit for Fiat Ducato 250 Diesel Trade Motorcaravan MY 2006 Multijet 130 and 140 1 Installation kit for Fiat Ducato 250 Diesel Trade Motorcaravan MY 2006 Multijet 120.150 and 160 from MY 2011 1 Installation kit for Thermo Top C Motorcaravan Diesel 12V RV Fiat Ducato Euro 5 MY 2011 Order No.: 9015824A 9015693F 9016330C 9026600B must also be ordered for automatic air-conditioning: Quantity 1 Description Automatic air-conditioning kit for Fiat Ducato 250 Order No.: 9017269C Foreword This installation documentation applies to Fiat Ducato 250 / Multijet Diesel vehicles - for 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 this ‘installation documentation’. However, the stipulations in this ‘installation documentation’, the ‘operating instructions’ and ‘installation instructions’ for the Thermo Top C 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. 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). When installing a programmable control module (e.g. a PWM Gateway), the corresponding settings must be checked or adjusted before the installation. Special Tools - Torque wrench for 2.0 - 10 Nm - Hose clamping pliers 9015695F_EN 3 Fiat Ducato 250 / Multijet Explanatory Notes on Document You will find an identification mark on the outside top right corner of the page in question to provide you with a quick overview of the individual working steps. Mechanical System Electrical System Coolant Circuit Fuel Exhaust Gas Combustion Air Software Special features are highlighted using the following symbols: Specific risk of injury or fatal accidents. Specific risk of damage to components. Specific risk of fire and explosion. Reference to general installation instructions of Webasto components or to the manufacturer's vehicle-specific documents. Reference to a special technical feature. The arrow in the vehicle icon indicates the position on the vehicle and the viewing angle. All dimensions are in mm. Tightening torque of hose clamps = 2.0 + 0.5 Nm. Tightening torque of Ejot screws, Ejot studs = 10 Nm. Ident. No.: 9015695F_EN Status: 09.11.2015 © Webasto Thermo & Comfort SE 4 Fiat Ducato 250 / Multijet Preliminary Work WARNING! • • • • • • • • • • • • • Open the fuel tank cap. Ventilate the fuel tank. Close the fuel tank cap again. Depressurise the cooling system. Disconnect the battery. Remove the air filter with the temperature sensor. Remove the underride protection on the right and on the left, if present. If the wing trim is present, remove the wheel well trim on the left and on the right, otherwise detach only on the front left side (see the dismantling instructions). Detach the upper wing trim on the left and right, if present (see the dismantling instructions). Remove the left and right-hand headlight (see the dismantling instructions). Remove the front grille and bumper trim (see the dismantling instructions). Open the fuse box at the front left in the engine compartment. Remove the lower footwell trim on the front passenger's side (only with automatic air-conditioning). The following work should only be performed during the corresponding installation sequence: • Open the tank-fitting service lid. • Remove the fuel tank sending unit in accordance with the manufacturer's instructions. Heater • Remove years that do not apply from the type and duplicate label. • Attach the duplicate label (type label) visibly in the appropriate place in the engine compartment. Please remove page 29 ‘Operating Instructions for End Customer’ and add to the operating instructions. Heater Installation Location 1 1 Heater Installation location 1 Ident. No.: 9015695F_EN Status: 09.11.2015 © Webasto Thermo & Comfort SE 5 Fiat Ducato 250 / Multijet Dismantling Instructions from MY 2014 1 Only needed if there is wing trim. Remove retaining clip 1 [2x] at position 2 and take care not to damage the locking tab! 2 Detaching upper wing trim on the left and right 2 2 1 Further dismantling instructions are demonstrated on a Citroen Jumper but also apply for a Fiat Ducato! 1 1 Remove bolts [4x] 2 Left headlight 3 Right headlight Removing headlights on the right and on the left 3 2 1 1 1 1 3 1 1 1 1 1 1 1 Remove bolts [8x] 2 Remove bolts (hidden) [2x] Removing radiator grille 2 4 2 1 1 1 1 1 1 1 1 1 Remove bolts [13x] 2 Remove bolts (hidden) [2x] 1 1 1 1 2 Ident. No.: 9015695F_EN 1 2 Removing middle section of front bumper trim 5 Status: 09.11.2015 © Webasto Thermo & Comfort SE 6 Fiat Ducato 250 / Multijet 1 1 1 1 1 Remove bolts (hidden) [9x] 1 1 Removing left section of front bumper trim 1 1 Ident. No.: 9015695F_EN 1 6 Status: 09.11.2015 © Webasto Thermo & Comfort SE 7 Fiat Ducato 250 / Multijet Preparing Electrical System 1 gn/ws 2 Only with automatic air-conditioning 0,75² 2500 Wire sections retain their numbering throughout the entire document. Assigning / preparing Pull wire 1 into provided protective sleeving. wires rt 0,75² 500 3 sw 0,75² 500 4 br 1² 1000 7 gn/ws br sw rt 0,75² 0,75² 4² 4² gn/ws rt/sw rt/sw 0,75² 0,75² Connecting green/white (gn/ws) wire 1 to K3 relay socket of heater wiring harness 0,75² br 0,75² 30 30 6.3 6.3 85 87a 6.3 6.3 86 6.3 85 87a 86 6.3 6.3 6.3 87 87 6.3 6.3 _ 87b E2 2.8 6.3 2.8 31 87a 30 6.3 6.3 6.3 _ 87 E1 2.8 6.3 2.8 rt/sw sw 0,75² 0,75² rt/sw rt/ws 0,75² 2,5² br sw ws/sw 0,75² 0,75² 0,75² 30 30 6.3 6.3 85 87a 86 6.3 85 87a 86 6.3 6.3 6.3 6.3 6.3 87 87 6.3 gn/ws 6.3 0,75² 1 8 Ident. No.: 9015695F_EN Status: 09.11.2015 © Webasto Thermo & Comfort SE 8 Fiat Ducato 250 / Multijet Check the PWM Gateway settings when starting up the heater and adjust if necessary. Settings: Duty cycle: Frequency: Voltage: Function: IN KL 15 GND 35% 1200Hz 4.2V High side View of PWM-GW SH OUT 9 rt 0,75² 2 __ 2.8 br 4 GND KL15 __ 2.8 6.3 6.3 __ 2.8 OUT __ 2.8 6.3 Connecting wires to PWM GW socket SH 6.3 1² sw IN 6.3 3 0,75² 10 All vehicles 1 If possible, switch power supply of heater to existing second battery. 4 2 3 Ident. No.: 9015695F_EN 11 Connection on grey (gr) 3-pin connector 1, Pin C from central electrical box in engine compartment. Produce connections as shown in wiring diagram. Insulate red (rt) wire from K3/87a and tie back. Connecting central electrical box 2 Black (sw) wire from K3/30 3 Wire (blue [bl] or red [rt] or grey/white [gr/ws]) of fan motor 4 Wire (blue [bl] or red [rt] or grey/white [gr/ws]) of 3-pin connector Pin C, central electrical box (fan relay) Status: 09.11.2015 © Webasto Thermo & Comfort SE 9 Fiat Ducato 250 / Multijet Electrical System Installation of fuse holder Fuse holder, K3/K4/K5 relay 1 2 3 4 5 6 7 1 M6x16 bolt, washers, premounted angle bracket, flanged nut M5x16 bolt, washers, nut [2x] Retaining plate of fuse holder K5 relay K3 relay, K4 relay Angle bracket M6x16 bolt, washers, flanged nut Perforated bracket 1 2 3 1 7 4 1 6 12 5 13 Wiring harness routing diagram 1 1 14 Wiring harness pass through 1 Protective rubber plug Ident. No.: 9015695F_EN 15 Digital timer 1 Digital timer, changeover switch Status: 09.11.2015 © Webasto Thermo & Comfort SE 10 Fiat Ducato 250 / Multijet Fan Controller for Manual Air-Conditioning Webasto Fiat 30 15 X2 F1 F2 F3 HG 2 br 2,5² 1 rt GR 1 gn/ws sw sw 0,5² 3 0,75² 0,5² gn/ws 0,5² ! rt 4² 0,75² 86 87 87a 85 30 86 87 87a 85 30 K3 X9 br C St 01 0,75² 0,75² br 4 rt/ws rt/ws Wiring diagram ZE F08 2,5² X1 rt 0,5² F31 bl * rt ** gr/ws*** 4² 0,75² sw sw sw 0,5² 0,75² 4² K4 br 0,75² S6 sw br 0,75² bl * rt ** gr/ws*** 0,75² 4² 2 M GM 1 ws/sw E1 31 WG 87 K5 0,5² 87b E2 rt/sw 0,75² 30 87a rt/sw 0,75² 31 Webasto components HG TT-C 300 heater X1 6-pin heater connector X2 2-pin heater connector F1 Fuses 1A F2 Fuse 20 F3 25A fuse X9 Connector of heater controls K3 Fan relay K4 Additional relay S6 Changeover switch K5 Electronic relay Ident. No.: 9015695F_EN Components Fiat Ducato 250 F31 7.5A fuse ZE Central electrical box GR Fan relay F08 40A fuse ST01 3-pin connector, grey GM Fan motor WG Resistor group Colours and symbols rt red ws white sw black br brown gn green bl blue gr grey Legend * ** *** up to MY 2010 MY 2011 from MY 2012 Insulate wire ends and tie back Wiring colours may vary. Status: 09.11.2015 © Webasto Thermo & Comfort SE 11 Fiat Ducato 250 / Multijet Fan Controller for Automatic Air-Conditioning Webasto Fiat 30 15 X2 2,5² F1 F2 F3 br 4 3 sw 0,5² 0,75² 86 C St 01 gn/ws 0,75² rt 0,5² gn/ws Wiring diagram F51 GR 1 0,75² sw F39 1 rt 0,75² 0,5² F08 rt/ws rt/ws 0,5² F31 2,5² X1 rt ZE HG 2 br ! 4² 87 87a bl * rt ** gr/ws*** 4² K3 X9 85 br 0,75² 30 sw sw 4² 0,5² sw 0,75² 86 87 87a bl * rt ** gr/ws*** K4 S6 85 br 30 ws/sw St A 4² 0,75² 30 KB 0,5² br St A rt/sw 0,75² 29 5 40 39 0,75² sw br/gn 0,75² 31 E1 87 K5 87b E2 87a 30 gn/ws 1 0,75² 0,75² PWM GW br/gn IN 0,75² OUT 3 0,75² br 0,75² 0,75² rt SH rt/sw 4 2 sw 3 GND 2 4 GE 1 St B M 0,75² 31 Webasto components HG TT-C 300 heater X1 6-pin heater connector X2 2-pin heater connector F1 Fuses 1A F2 Fuse 20 F3 25A fuse X9 Connector of heater controls K3 Fan relay S6 Changeover switch K4 Additional relay K5 Electronic relay PWM Pulse width modulator GW Ident. No.: 9015695F_EN Vehicle components F31 7.5A fuse ZE Central electrical box GR Fan relay F08 40A fuse St 01 3-pin, grey connector of ZE F39 10A fuse F51 7.5A fuse KB A/C control panel St A Connector of KB GE Fan unit St B 6-pin connector of GE Settings of PWM GW: Duty cycle: 35% Frequency: 1200Hz Voltage: 4.2V Function: High side Status: 09.11.2015 Colours and symbols rt red ws white sw black br brown gn green bl blue gr grey Legend * ** *** up to MY 2010 MY 2011 from MY 2012 Insulate wire end and tie back X Cutting point Wiring colours may vary. © Webasto Thermo & Comfort SE 12 Fiat Ducato 250 / Multijet 1 Automatic air-conditioning 2 1 Original vehicle bolt of fan motor 2 PWM GW socket 1 Green/white (gn/ws) additional wire of K3/86 and PWM GW/SH 1 Installing PWM GW socket 16 1 PWM GW 1 Inserting PWM GW 17 1 Original vehicle earth point 4 Brown (br) wire of PWM GW/GND Connecting earth wire 1 4 18 1 Blue (bl) wire of 6-pin GE connector, pin 4 2 6-pin connector of fan controller 3 Brown/green (br/gn) wire of GE connector, pin 2 1 3 2 Ident. No.: 9015695F_EN View of fan unit connector up to MY 2011 19 Status: 09.11.2015 © Webasto Thermo & Comfort SE 13 Fiat Ducato 250 / Multijet 1 3 1 Grey/white (gr/ws) wire of 6-pin GE connector, pin 4 2 6-pin connector of fan controller 3 Brown/green (br/gn) wire of GE connector, pin 2 View of fan unit connector from MY 2012 2 20 1 2 Connection to 6-pin connector 3 from fan controller, pin 2. Produce connections as shown in wiring diagram. 1 Brown/green (br/gn) wire 2 Brown/green (br/gn) wire of 6-pin connector, Pin 2 2 Red (rt) wire of PWM GW/IN 3 Black (sw) wire of PWM GW/OUT Connecting fan controller 3 3 Ident. No.: 9015695F_EN 2 21 Status: 09.11.2015 © Webasto Thermo & Comfort SE 14 Fiat Ducato 250 / Multijet 1 Preparing Heater 2 Discard section X. 1 Exhaust pipe a = 140 2 Exhaust end section b = 160 a Preparing exhaust pipe b 22 X 1 1 Hose section, 10 mm dia. hose clamp 2 Ejot screw [3x] 3 Bracket 2 Mounting bracket on heater 2 2 23 3 1 2 2 5 1 2 3 4 5 Exhaust pipe Hose clamp [3x] Exhaust silencer Exhaust-pipe end section Flanged nut Installing exhaust pipe 3 2 4 24 1 Installing Heater 2 1 Washer, spring lockwasher, nut [2x each], hidden 2 M8x20 bolt, washer, spring lockwasher, hidden 1 Ident. No.: 9015695F_EN Installing bracket with heater 25 Status: 09.11.2015 © Webasto Thermo & Comfort SE 15 Fiat Ducato 250 / Multijet Fuel up to MY 2010 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. Route fuel line and metering pump wiring harness so that they are protected against stone impact. Unless specified otherwise, always fasten using cable ties. Provide rub protection for fuel line and wiring harness in areas where there are sharp edges. WARNING! The fuel line and wiring harness are routed to the metering pump as shown in the wiring harness routing diagram. 1 2 All vehicles 3 1 800mm long fuel line 2 Hose section [2x], 10mm dia. hose clamp [4x] 3 Metering pump 4 300 mm long fuel line 5 Metering pump mount Premounting metering pump 4 5 26 2 1 7 mm dia. hole, M6x20 bolt, washer, flanged nut 2 Metering pump wiring harness 1 Installing metering pump 27 2 1 Fuel line 2 10 mm dia. hose clamp 1 Connecting heater 2 Ident. No.: 9015695F_EN 28 Status: 09.11.2015 © Webasto Thermo & Comfort SE 16 Fiat Ducato 250 / Multijet 1 2 Only for 2.3 D 3 1 8x5x8 fuel standpipe 2 Hose section, 10 mm dia. hose clamp [2x], hose section 3 Fuel line 4 Original vehicle fuel return line 5 10 mm dia. hose clamp 5 29 4 1 2 Only for 3.0 D 3 8x5x8 fuel standpipe 10 mm dia. hose clamp [2x] Fuel line to metering pump 90° hose section, 10mm dia. hose clamp [2x] 5 Original vehicle fuel return line 1 2 3 4 5 4 Ident. No.: 9015695F_EN Fuel extraction Fuel extraction 30 Status: 09.11.2015 © Webasto Thermo & Comfort SE 17 Fiat Ducato 250 / Multijet Fuel from MY 2011, Euro 5 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. Route fuel line and metering pump wiring harness so that they are protected against stone impact. Unless specified otherwise, always fasten using cable ties. Provide rub protection for fuel line and wiring harness in areas where there are sharp edges. WARNING! The fuel line and wiring harness are routed to the metering pump as shown in the wiring harness routing diagram. 1 10 mm dia. hose clamp 2 Fuel line 3 Cable tie 1 3 2 Connecting heater 31 1 Metering pump mount 2 Angle bracket 3 M6x20 bolt, washer, flanged nut 1 Preparing metering pump mounting 3 32 2 1 Installation location between vehicle fuel tank and battery box. 2 1 Metering pump 2 M6x20 bolt, large diameter washer, flanged nut on existing hole Installing 3 Premounted metering pump bracket metering 4 Single wire seals, tab connector, connec- pump tor housing 5 Hose section, 10 mm dia. hose clamps [2x] 6 Metering pump wiring harness 7 Fuel line of heater 7 6 5 Ident. No.: 9015695F_EN 4 3 33 Status: 09.11.2015 © Webasto Thermo & Comfort SE 18 Fiat Ducato 250 / Multijet Remove fuel tank sending unit 2 in accordance with manufacturer's instructions. 1 Position large diameter washer with outer dia. da = 21.6mm. 3 Copy hole pattern, 6mm dia. hole 1 3 Fuel extraction 34 2 Shape fuel standpipe 1 according to template and cut to length. 1 Installing fuel standpipe 1 35 1 Install fuel tank sending unit according to manufacturer's instructions. 1 1 2 3 4 5 5 4 3 2 Fuel standpipe 9 mm dia. Caillau clamp 90°, 3.5x4.5mm dia. moulded hose 10 mm dia. Caillau clamp Fuel line Connecting fuel line 36 Fuel line from fuel standpipe 1 on intake side of metering pump [side without connector]. Check the position of the components; adjust if necessary. Check that they have freedom of movement. 1 Connect1 Fuel line of fuel standpipe ing meter2 Hose section, 10 mm dia. hose clamp [2x] ing pump 2 Ident. No.: 9015695F_EN 37 Status: 09.11.2015 © Webasto Thermo & Comfort SE 19 Fiat Ducato 250 / Multijet Coolant Circuit WARNING! Any coolant running off should be collected in an appropriate container. Route hoses 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 modelled on an ‘inline’ circuit and based on the following diagram: Hose routing diagram Ø 15x18 Ø 25 F E D Ø 25 Ø 25 1 Ø 25 3 Ø 25 A 2 B C Ø 15x18 G All spring clips without a specific designation = 27mm dia. All hose clamps = 20-27 mm dia. All connecting pipes without a specific designation = 20x20mm dia. 1 = check valve and 2 = thermostat for passenger compartment coolant circuit. 3 = T-piece for engine coolant circuit. Ident. No.: 9015695F_EN Status: 09.11.2015 © Webasto Thermo & Comfort SE 20 Fiat Ducato 250 / Multijet Discard section X. D X c = 440 d = 400 C Cutting hoses to length d c X 38 Twist perforated bracket 1 in longitudinal direction by 90°. 1 Preparing perforated bracket 39 1 E Watch direction of flow of check valve 1. 2 B = 20/18 mm dia. moulded hose E = 20/18 mm dia. moulded hose 2 Perforated bracket 3 Thermostat 4 Rubber-coated p-clamp, M6x20 bolt, washer, flanged nut B G F 4 Installation of hose group 40 3 F = 90° moulded hose, 350 long (98455B) G = Moulded hose C 1 Black rubber isolator Installation of hose group 1 D 41 Ident. No.: 9015695F_EN Status: 09.11.2015 © Webasto Thermo & Comfort SE 21 Fiat Ducato 250 / Multijet 120 Multijet A A = Moulded hose (98454A) 1 18/15 connecting pipe, 25mm dia. spring clip (to engine outlet) 2 18/15 connecting pipe, 25mm dia. spring clip (to heat exchanger inlet) 3 18x15x18 T-piece, 27 mm dia. hose clamp (in return line) 3 2 Completing hose group 42 1 1 1 Original vehicle fuel return line 2 Original vehicle fuel supply line 2 Cutting points 43 1 Original vehicle stud bolt and flanged nut 1 Routing in engine compartment 44 G F Mount T-piece in original vehicle return hose and secure with hose clamps. Fix hoses with spacer bracket and cable tie. A Connecting heat exchanger 45 Ident. No.: 9015695F_EN Status: 09.11.2015 © Webasto Thermo & Comfort SE 22 Fiat Ducato 250 / Multijet 130 and 140 Multijet A A = Moulded hose (98454A) 1 18/15 connecting pipe, 25mm dia. spring clip (to engine outlet) 2 18/15 connecting pipe, 25mm dia. spring clip (to heat exchanger inlet) 3 22x15x22 T-piece, 27 mm dia. hose clamp (in return line) 3 2 Completing hose group 46 1 1 1 Original vehicle fuel return line 2 Original vehicle fuel supply line 2 Cutting points 47 1 Original vehicle stud bolt and flanged nut 1 Routing in engine compartment 48 G F Mount T-piece in original vehicle return hose and secure with hose clamps. Fix hoses with spacer bracket and cable tie. A Connecting heat exchanger 49 Ident. No.: 9015695F_EN Status: 09.11.2015 © Webasto Thermo & Comfort SE 23 Fiat Ducato 250 / Multijet 150 and 160 Multijet A A = Cut moulded hose (98454A), 90° elbow to size 1 18/18 connecting pipe, 25mm dia. spring clip (to engine outlet) 2 Connection to heat exchanger inlet 3 18x15x18 T-piece, 27 mm dia. hose clamp (in return line) 3 2 Completing hose group 50 1 1 Original vehicle hose of heat exchanger outlet 2 Original vehicle hose of engine inlet 1 Cutting point 2 51 1 1 Remove original vehicle clamp and remount hose after twisting it by 180° 2 Original vehicle hose of engine outlet/heat exchanger inlet 2 Cutting point 52 1 Original vehicle stud bolt and flanged nut 1 Routing in engine compartment 53 Ident. No.: 9015695F_EN Status: 09.11.2015 © Webasto Thermo & Comfort SE 24 Fiat Ducato 250 / Multijet 1 2 G 3 Mount T-piece in original vehicle return hose and secure with hose clamps. F 1 2 3 4 4 A Connection of heat exchanger inlet Position black rubber isolator Position spacer bracket Original vehicle hose of engine outlet Connecting heat exchanger inlet/ outlet and engine outlet 54 All vehicles D Connecting heater C Ident. No.: 9015695F_EN 55 Status: 09.11.2015 © Webasto Thermo & Comfort SE 25 Fiat Ducato 250 / Multijet 1 2 Combustion Air 2 3 1 2 3 4 4 Combustion air pipe Cable tie [2x] Silencer 27 mm dia. hose clamp Installing combustion air pipe 56 Ident. No.: 9015695F_EN Status: 09.11.2015 © Webasto Thermo & Comfort SE 26 Fiat Ducato 250 / Multijet Final Work WARNING! Reassemble the components in reverse order. Check all hoses, clamps and all electrical connections for firm seating. Insulate and tie back all loose lines. 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 End Customer’. • Place the ‘Switch off parking heater before refuelling’ caution label near the filler neck. • For initial startup and function check, please see installation instructions. Webasto Thermo & Comfort SE Postfach 1410 82199 Gilching Germany Internet: www.webasto.com Technical Extranet: http://dealers.webasto.com Ident. No.: 9015695F_EN Status: 09.11.2015 © Webasto Thermo & Comfort SE 27 Fiat Ducato 250 / Multijet Fuel Standpipe Template Watch length! Shown cut in straight section! 295mm 100mm Scale 1:1 Compare size of printout with dimension lines. Allowed tolerance a maximum of 2%. Set the printer settings to 'no margin' or 'minimise margins' and 100% of the normal size. 100mm 0 Ident. No.: 9015695F_EN Status: 09.11.2015 © Webasto Thermo & Comfort SE 28 Fiat Ducato 250 / Multijet Operating Instructions for End Customer Please remove page and add to the vehicle operating instructions. Note: We recommend matching the heating time to the driving time. Heating time = driving time Example: For a driving time of approx. 20 min. (in one direction), we recommend not exceeding a switch-on time of 20 min. 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 1 Set temperature to ‘max.’ 2 Air outlet to windscreen 3 Set fan to level ‘1’, or possibly ‘2’ 2 Manual A/C 3 57 The fan speed need not be preset! 1 1 Air outlet to windscreen 2 Set temperature to ‘HI’ Automatic air-conditioning 2 58