Fuel integration
The fuel filler must not be situated in the passenger compartment and must be provided with an effective cap to prevent fuel spillage.
Requirement from ECE-R 122, point 5.3.3.1. See eur-lex.europa.eu document 42010X0630(08) for more information.
In the case of liquid fuel heaters, where a supply separate from that of the vehicle is provided,the type of fuel and its filler must be clearly labelled.
Requirement from ECE-R 122, point 5.3.3.2. See eur-lex.europa.eu document 42010X0630(08) for more information.
The fuel integration is carried out either in the supply or return line or by a special tank extraction unit.
Integration in the motor supply or return line
On vehicles with their own fuel feed pump in the fuel tank, the fuel must not be removed from the fuel supply line!
- If the vehicle is equipped with a non-return valve to the tank, the fuel must not be extracted from the return line.
- It must be ensured that no zero shut-off occurs in the vehicle system when extracting fuel.
- When removing fuel from the swirl pot, it must be ensured that it is not completely empty.
Proper installation is carried out as shown in figure:
1 | from fuel tank |
2 | to fuel pump |
3 | to motor |
Integration via vehicle's own fuel delivery unit
See also Installation example in the vehicle.
The tank extracting device is installed in the fuel extraction unit of the tank.
1 | Tank extracting device |
2 | Vehicle's own fuel delivery unit with hole |
The mounting surface of the tank extracting device must be clean, level and free of burrs. Make sure the standpipe is carefully routed when inserting the tank extracting device into the fuel extraction unit. It must not adversely affect the function of the fuel extraction unit parts, including the fill level indicator, during any of the operating states. The length of the standpipe should be selected such that, in the installed state, a minimum clearance of 10 mm above the floor of the tank or 20 mm above the floor of the fuel delivery unit is ensured.
The safeguarding measures and the corresponding torque specified by the vehicle manufacturer must be observed.
The tank extracting device must under no circumstances be mounted in the tank body, but only in the vehicle's fuel delivery unit.
Fuel line
The fuel line is divided into an intake and a pressure line. Here, the intake line forms a connection between tank and fuel pump, and the pressure line forms a connection between fuel pump and heater.
Only lines approved by Webasto may be used as fuel lines.
Installing lines
When installing the fuel line make sure that it is kept as short as possible.
Length of intake pipe [m] | max. 3.0m |
Intake height [m] (height difference between tank and fuel pump) | max. 1.0m |
Length of pressure pipe | max. 9.0m |
The line must be protected against damage (e.g. stone chips) in all areas.
It is essential that the fuel line is installed in cool areas to avoid bubbles being formed by the effect of heat. High fuel temperatures can cause the heater to malfunction. The line must therefore not be directed past heat sources (e.g. exhaust gas) and also not in the region of trapped heat zones. Moreover, the fuel line should be installed with as much of an incline as possible from the tank to the heater.
Fuel lines must be secured in accordance with the state of the art so that sagging of the lines is avoided. An abrasion guard should be fitted at transition points with sharp edges.
Do not route the fuel lines through the vehicle interior.
Connecting 2 lines using a hose
1 | Hose clip | 2 | Air bubble |
Make sure there are no leaks!
Only Webasto-approved fastening and connecting parts may be used.
Fuel pump
The fuel pump is a combined delivery, metering and a shut-off system and is subject to certain installation criteria.
The Thermo Top Evo heater must only be operated with the fuel pump DP 42.
Installation and attachment fuel pump
The fuel pump must be secured with a vibration-damping mounting. The installation position is restricted (maximum inclination angle and axial installation position of fuel pump) as illustrated in to ensure effective automatic bleeding.
The arrow indicates the direction the fuel is flowing.
The fuel pump must not be installed within the radiated heat range of hot vehicle components. Fit a heat shield if necessary. The fuel pump should be preferably installed close to the fuel tank.
Permissible ambient temperature depending on the fuel used: see Technical data.
Sticker
A notice, indicating that the heater must be shut down before refuelling, must be affixed to the filler neck of the vehicle. [...]
Requirement from ECE-R 122, point 5.3.3.3. See eur-lex.europa.eu document 42010X0630(08) for more information.
The enclosed sticker “Switch off heater when fuelling” should be attached in the region of the vehicle filler neck.
The image shows an example.