Nissan - Pixo - Owners Manual - 2009 - 2009

Water Heater Feel the drive e1 Thermo Top E Parking Heater 00 0003 e1 Thermo Top C Parking Heater 00 0002 Thermo Top P Parking Heater 00 0104 e1 Installation instructions Nissan Pixo 1.0 Gasoline from Model Year 2009 Left-hand drive vehicle Manual air-conditioning system WARNING! Hazard warning: Incorrect installation or repair of Webasto heating systems may cause a fire or result in the emission of carbon monoxide, which can be fatal. Serious or fatal injuries can be caused as a result. Specialist company training, technical documentation, specialised tools and equipment are required to install and repair Webasto heating and cooling systems. NEVER attempt to install or repair Webasto heating or cooling systems if you have not successfully completed the company training and thereby acquired the required technical skills, or if you do not have access to the required technical documentation, tools and equipment needed to carry out correct installation and repairs. ALWAYS follow all Webasto installation and repair instructions and observe all warnings. Webasto does not accept any liability for defects and damage that are attributable to installation by untrained staff. Ident. No.: 1315218A_EN Fee Euro 10.00 © Webasto AG Nissan Pixo Table of Contents Validity Heater/Installation Kit Foreword General Instructions Special Tools Explanatory Notes on Document Preliminary Work Heater installation location Electrical system Fan controller Digital timer, summer/winter switch option Remote option (Telestart) 2 3 3 3 3 4 5 5 6 7 8 8 Preparing installation location Installing heater Coolant circuit Fuel Exhaust gas Combustion air Final Work Template for Fuel Standpipe Operating Instructions for End Customer 9 10 11 15 19 21 22 23 24 Validity Manufacturer Nissan Model Pixo Type HF EG-BE No./ABE e6 * 2001 / 116 * 0124 * ... Engine type K10B Engine model Gasoline Output in kW 50 Displacement in cm³ 996 Vehicle and engine types, equipment variants and national specifications not listed in these installation instructions have not been tested. However, installation according to these installation instructions may be possible. The installation location of a digital timer and summer/winter switch should be confirmed with the end customer before installation. 1315218A_EN 2 Nissan Pixo Heater/Installation Kit Quantity 1 1 1 Description Nissan-specific delivery scope Thermo Top E Gasoline Installation kit for Nissan Pixo 2009 1.0 Gasoline Heater control Order No.: See Nissan Price list 1315151A See Nissan Price list Heater recommended for the respective vehicle class: Vehicle Compact car Mid-size car, station wagon Full-size car, van, offroader Heater Thermo Top E Thermo Top C Thermo Top P The selection of the heater is based on the passenger compartment size of the vehicle and the level of comfort required by the customer! Foreword These installation instructions apply to vehicles Nissan Pixo 1.0 Gasoline - for validity, see page 2 from model year 2009 and later, assuming technical modifications to the vehicle do not affect installation, any liability claims excluded. Depending on the vehicle version and equipment, modifications may be necessary during installation with respect to these installation instructions. However, where this is the case the stipulations in the "installation instructions" and "operating and maintenance instructions" for the Thermo Top E/C/P should be observed. The corresponding rules of technology and any information from the vehicle manufacturer should be observed during the installation work. General Instructions Installation should be carried out according to the general, standard rules of technology. Unless specified otherwise, fasten hoses, lines and wiring harnesses to original vehicle lines and wiring harnesses using cable ties. Sharp edges must be provided with rub protection (cut-open fuel hose)! Spray unfinished body areas, e.g. drilled holes, with anti-corrosion wax (Tectyl 100K, Order No. 111329). Special Tools - Torque wrench for 2.0 - 10 Nm - Hose clamping pliers - Metric thread-setter kit 1315218A_EN 3 Nissan Pixo Explanatory Notes on Document To provide you with a quick overview of the individual working steps, you will find an identification mark on the outside top right corner of the page in question. Mechanical system Electrical system Coolant 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 or 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! 1315218A_EN 4 Nissan Pixo Preliminary Work WARNING! - Open fuel tank cap, ventilate tank. Close the tank cap again. Disconnect the battery "earth" or "ground" connection. Depressurize the cooling system! Copy the factory number from the original type label to the duplicate type label. Remove years that do not apply from the duplicate label. Attach the duplicate label (type label) in the appropriate place. Remove battery Remove the air filter together with the intake hose Detach the wheel well trim on the right and left. Remove bumper trim Remove fuel-tank in accordance with manufacturer's instructions. Remove the fuel-tank sending unit in accordance with the manufacturers specifications. Remove footwell trim on the driver side Remove page 24 "Operating Instructions for End Customer" and add to the vehicle operating instructions. Heater installation location 1 Heater Installation location 1 1315218A_EN 1 5 Nissan Pixo Electrical system Plus wire Wiring harness pass through 1 Positive wire to positive battery terminal 1 Protective rubber plug 1 1 2 3 Do not install the metering pump cable harness until later together with fuel pipe along the original vehicle fuel lines on the underbody 1 Wiring harness installation diagram 2 3 5 4 4 1 5 Fuse holder, K3 relay Ground wire 1 Mount M6x20 bolt, spring lockwasher, flanged nut, existing hole 2 Angle bracket 3 M5x16 bolt, washers, fuse holder retaining plate, flanged nut 4 K3 relay 5 F1-3 fuses mounted 1 Groundwire to original vehicle ground support point 1315218A_EN 6 Nissan Pixo Fan controller Webasto Nissan 30 15 F3 HG X1 Wiring diagram F2 4 GR rt 86 87 85 30 4² sw/ ge sw sw/ ge 87a K3 4² KB + M GM - 31 Webasto components HG Heater TT-E/C/P X1 6-pin heater connector K3 Fan relay F3 25A fuse Vehicle components GM Fan motor GR Fan relay KB A/C control panel F2 30A fuse Colours and symbols rt red ge yellow sw black Legend X Cutting point Wiring colours may vary. 1 Connection to 2-pin connector 5 from fan motor. Produce connections as shown in wiring diagram. 2 3 5 1315218A_EN 4 1 2 3 4 Black / yellow (se/ge) wire to fan relay Black (sw) wire from K3/30 Red (rt) wire from K3/87a Black / yellow (se/ge) wire to connector Connecting fan-motor 6 7 Nissan Pixo Digital timer, summer/winter switch option 1 12 mm dia. hole, summer/winter switch 2 Digital timer Installing digital timer 2 7 1 Remote option (Telestart) 1 Fasten receiver 1 with adhesive tape. Installing receiver 8 1 Antenna Installing antenna 1 9 Temperature sensor HTM100 1 Fasten temperature sensor 1 with adhesive tape. Installing temperature sensor 10 1315218A_EN 8 Nissan Pixo Preparing installation location 1 Angle down perforated bracket 1 2x by 90°. 32 Angling down perforated bracket 53 11 1 Bracket 2 Perforated bracket, mount loosely 3 M6x12 bolt, flanged nut Preassembling bracket 1 3 2 12 Drill out existing hole to 9.1mm dia and tighten rivet nut! Installing rivet nut 1 13 1 Align bracket 2, mount loosely and copy hole pattern to Position 1 [3x]! 2 3 M6x20 bolt 30 3 1 1315218A_EN 1 Copying hole pattern 14 9 Nissan Pixo Remove bracket! 1 1 9.1 mm dia. hole; rivet nut [3x each] 2 Drill out hole to 9.1 mm dia, river nut 1 Installing rivet nut 1 2 15 Insert one 15mm spacer nut each between bracket and side member at Position 1 and 3, and a large diameter washer at Position 3! 1 2 1 3 1 M6x35 bolt, spring lockwasher, 15mm shim [2x each] 2 M6x20 bolt, spring lockwasher 3 M6x35 bolt, spring lockwasher, 15mm spacer nut, large diameter washer Installing bracket 16 Installing heater 1 Connect wiring harness 1 on heater before installation. 2 Ejot screw [2x] Installing heater 2 2 17 1 48 mm dia. p-clamp 2 Ejot screw, mount loosely 1 Installing heater 2 1315218A_EN 18 10 Nissan Pixo Coolant circuit WARNING! Any coolant running off should be collected using an appropriate container! Install hoses so that they are kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that no other hose can be damaged! When installing the coolant hose, the heater must be filled with coolant. The connection should be "inline" based on the following diagram: Coolant circuit diagram Ø 20x18 A Ø 20x18 3 1 D B 2 All connecting pipes without a specific designation All hose clamps without a specific designation 25.5 mm 3 = Black (sw) rubber isolator dia = 22mm 1315218A_EN 2 C = dia. 20x20 mm. 1 = Original vehicle spring clip . dia = = 20-27 mm dia 2 = Black (sw) rubber isolator 11 Nissan Pixo Discard section X Hose A = 180°, 18x18mm moulded hose D C B = 635 C = 450 D = 100 B X Cutting coolant hoses to length X X A Push braided protection hose onto hose B and cut to length! Cut heat shrink plastic tubing to length. 1 1 50 mm long heat shrink plastic tubing [2x] A Preparing hoses A and B 1 19 B 1 2 2 Push braided protection hose onto hose D and cut to length! Cut heat shrink plastic tubing to length. 1 1 50 mm long heat shrink plastic tubing [2x] 2 = Black (sw) rubber isolator [2x] C Preparing hoses C and D 20 D Detach engine outlet/heat exchanger inlet hose 1 on neck of engine outlet. Spring clip 2 will be reused. Cutting point 2 1 1315218A_EN 21 12 Nissan Pixo A Connecting engine outlet 22 B Routing in engine compartment 23 B B D Connecting heater C 24 D Routing in engine compartment D 1315218A_EN 25 13 Nissan Pixo Slide black (sw) rubber isolator dia = 22 1 onto hose of heat exchanger inlet 3 and align with air filter box. 2 Original vehicle spring clip 3 Connecting heat exchanger inlet 1 2 D 26 Ensure sufficient distance from neighbouring components. Align black (sw) rubber isolator 1 [2x] on expansion tank! Aligning rubber isolator 1 1315218A_EN 1 D 27 14 Nissan Pixo Fuel CAUTION! Open the vehicle's fuel tank cap, ventilate the tank and then re-close the tank lock. Catch any fuel running off with an appropriate container. Install fuel line and metering-pump wiring harness so that they are protected against stone impact. Unless specified otherwise, always fasten using cable ties. Mount the fuel line and wiring harness with rub protection on sharp edges. WARNING! The fuel line and wiring harness are routed to the metering pump in as shown in the wiring harness routing diagram. Slide protective hose 1 onto fuel line 2 1 3 Hose section, 10 mm dia. clamp [2x] Connecting heater 2 28 3 Detach corrugated tube 1. Route fuel line and wiring harness of metering pump in corrugated tube 1 to firewall! 1 Installing lines 29 Route fuel line and wiring harness of metering pump in corrugated tube 1 to original vehicle lines at the installation location of the metering pump! 1 Installing lines 1 30 1315218A_EN 15 Nissan Pixo 1 Remove fuel-tank in accordance with manufacturer's instructions. Remove fuel-tank sending unit 1 according to manufacturer's specifications. Remove fuel pump, level indicator and charcoal filter connecting pieces. Drill 6mm dia hole 2 at the centre of the circular elevation. Pay attention to the components at the rear when drilling! 2 Removing fuel 31 Shape fuel standpipe 1 according to template, cut to length and install according to the following figures. 1 Installing fuel standpipe 1 32 1 Fuel standpipe 1 Installing fuel standpipe 1 33 Complete the fuel tank sending unit. Check the position of the components; adjust if necessary. Check that they have free clearance. 1 1 Fuel standpipe Installing fuel standpipe 1 1315218A_EN 34 16 Nissan Pixo Ensure sufficient distance between fuel tank standpipe 1 and connector 2. 2 Installing fuel standpipe 1 35 1 Install fuel-tank sending unit 2 in accordance with manufacturer's specifications. 2 1 Fuel standpipe 3 Hose section, 10 mm dia. clamp [2x] 4 Fuel line 4 3 36 4 1 1 2 3 4 2 Silent block, flanged nut Metering pump Hose section, 10 mm dia. clamp [2x] Rubber-coated pipe clamp Premounting metering pump 3 3 4 Connecting fuel line 37 Remove fuel-tank in accordance with manufacturer's instructions. 1 1 Angle bracket 2 Original vehicle bolt, flanged nut Installing metering pump 2 1315218A_EN 38 17 Nissan Pixo 1 Flanged nut 1 Installing metering pump 39 1 Route fuel line from fuel tank standpipe 3 to metering pump. Check the position of the components; adjust if necessary. Check that they have free clearance. 2 1 Wiring harness of metering pump, connector mounted 2 Fuel line of heater, 10mm dia clamp 4 10 mm dia. clamp 4 3 1315218A_EN Connecting metering pump 40 18 Nissan Pixo 1 Exhaust gas 2 Discard section X 1 Exhaust pipe a = 145 2 Exhaust end section b = 145 a Preparing exhaust pipe b X 1 1 42 mm dia. hole 2 Wheel well inner panel 2 Cutting out wheel well inner panel 41 Angle down perforated bracket1 by 90°. 80 Angling down perforated bracket 42 1 1 1 Exhaust muffler 2 M6x35 bolt, spring lockwasher, 20 mm shim, flanged nut 3 Perforated bracket 4 M6x55 bolt, spring lockwasher, 40 mm shim 2 Installing muffler 3 4 1315218A_EN 43 19 Nissan Pixo 1 1 Hose clamp [3x] 2 Exhaust manifold 3 Exhaust pipe 2 1 Installing exhaust pipe 3 1 1 44 Slide red (rt) rubber isolator 1 and red (rt) rubber isolator with groove 3 on to exhaust end section 4. Position red (rt) rubber isolator 1 along side member. 2 2 Hose clamp Installing exhaust end section 4 3 1 45 Ensure sufficient distance to neighbouring components. Align exhaust end section 3 flush on red rubber isolator 1. 2 2 Wheel well inner panel 3 1315218A_EN Mounting rubber isolator 46 20 Nissan Pixo Combustion air 1 Discard section X 1 Combustion air pipe a = 220 Cutting combustion air pipe to length a X 1 2 3 4 5 1 2 5 1315218A_EN 4 3 Combustion air pipe 27 mm dia. clamp Muffler Tighten Ejot screw 48 mm dia. p-clamp Installing muffler 47 21 Nissan Pixo Final Work WARNING! Mount removed parts in reverse order. Check all hoses, clamps and all electrical connections for firm seating. Secure all loose cables using cable ties. Only use manufacturer-approved coolant. Spray the heater components with anti-corrosion wax (Tectyl 100K, Order No. 111329). - Connect the battery. Fill and bleed the coolant circuit according to the vehicle manufacturer’s specifications. Set the digital timer. Make settings on A/C control panel according to the "Operating Instructions for End Customer". Check the proper operation of the parking heater, see the operating instructions/installation instructions. - Apply the sticker "Switch off parking heater before refilling" in the area of the filling neck Feel the drive Webasto AG Postfach 80 D-82131 Stockdorf / Germany National Hotline: 01805 93 22 78 (14 Cent aus dem deutschen Festnetz) Hotfax: 0395 5592 353 Hotmail: [email protected] http://www.webasto.de 1315218A_EN Printed in Germany 07/2010 Printing: Steffen Nissan Pixo Template for Fuel Standpipe 100mm Top view 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. 100mm 0 1315218A_EN 23 Nissan Pixo 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. The passenger compartment monitoring is to be deactivated in vehicles equipped with anti-theft alarm system. Deactivation instructions can be taken from the operating instructions of the vehicle! If the summer/winter switch option has been installed, this must be switched in accordance with the time of year. The heater will then only switch on the vehicle fan to ventilate the vehicle interior in the position Winter heat and in the position Summer . Before parking the vehicle, make the following settings: 1 Air outlet to windshield 2 Set temperature to "max." 3 Set fan to level "1“ or max. "2" 3 Manual air conditioning 2 1315218A_EN 1 48 24