Webasto Thermo Top E Installation Instructions Manual
Ford 2007 500
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Also See for Thermo Top E:
- Installation documentation (41 pages) ,
- Installation instructions manual (36 pages) ,
- Manual (31 pages)
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Water Heater Unit
Thermo Top E Additional Heater
Thermo Top C Additional Heater
Installation Instructions
Fiat 500
Gasoline
from Model Year 2007
Left-hand drive vehicle
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, specialized 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.:1313401A_EN
e1
00 0003
e1
00 0002
Fee Euro 10.00
Feel the drive
© Webasto AG
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Summary of Contents for Webasto Thermo Top E
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Page 1: Installation Instructions
Left-hand drive vehicle 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. -
Page 2: Table Of Contents
Fiat 500 Table of Contents Validity Fuel Heater Unit/Installation Kit Coolant routing Foreword Coolant on 1.2 liter General Instructions Coolant on 1.4 liter Special Tools Combustion air Explanatory Notes on Document Exhaust gas Preliminary Work 1.2 liter engine Heater unit installation location 1.4 liter engine Preparing electrical system Vehicle with underride protection... -
Page 3: Heater Unit/Installation Kit
Heater unit recommended for the respective vehicle class: Vehicle Heater unit Compact car Thermo Top E Mid-size car, station wagon Thermo Top C The selection of the heater unit is based on the passenger compartment size of the vehicle and the... -
Page 4: Explanatory Notes On Document
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 angle. -
Page 5: Preliminary Work
Fiat 500 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. -
Page 6: Preparing Electrical System
Fiat 500 Preparing electrical system Only with automatic air-conditioning Cutting wires to length O,75² Produce connections as shown in wiring diagram. Install wire section 2 in the protective sleeving provided. Preparing fuse F4 1313401A_EN... -
Page 7: Electrical System
Fiat 500 Electrical system Wiring harness pass through Digital timer 1 Protective rubber plug 1 Digital timer Do not install the metering pump cable harness until later together with fuel pipe Wiring along the original vehicle harness fuel lines on the underbody installation diagram Fuse holder, relay K3... -
Page 8: Fan Controller For Manual Air Conditioning
M001 B001 gr/ws O030 4² gr/ws 4² T° N086 N085 H080 Webasto components Vehicle components Colors and symbols Heater unit TT-C/E M001 Body computer 6-pin heater unit connector B001 Central electrical box in white engine compartment 25 A fuse O030... -
Page 9: Automatic Air-Conditioning Fan Controller
Fiat Wiring diagram M001 B001 bl/gn 4² gr/ws gr/ws 4² bl/gn N085 M070 Webasto components Vehicle components Colors and symbols Heater unit TT-C/E M001 Body computer 6-pin heater unit B001 Central electrical box in white connector engine compartment Fan relay... - Page 10 Fiat 500 Connection on fan relay T08 of central electrical box in engine compartment 4 . Produce connections as shown in wiring diagram. 1 Black (sw) wire from K3/30 Connec- 2 Gray/white (gr/ws) wire of fan motor N085, tion to fan Pin 4 relay 3 Gray/white (gr/ws) wire of connector B...
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Page 11: Remote Option (Telestart)
Fiat 500 Remote option (Telestart) Drill out bracket 1 to 6.5 mm dia. at position 2 . 2 M6 flanged nut on original vehicle stud bolt 3 Receiver Installing receiver 1 Antenna Installing antenna 1313401A_EN... -
Page 12: Preparing Heater Unit
Fiat 500 Preparing heater unit Bend perforated bracket C according to template. Precut thread at position 2 . 1 Ejot stud Premount- 3 Ejot screw ing heater 4 Perforated bracket C unit Preparing installation location Remove horn 2 with bracket. Original vehicle bolt 1 will be reused. -
Page 13: Installing Heater Unit
Fiat 500 1 Edge protection 100 [2x] Installing edge protection Cut out template 2 and lay on cross member (see marking). 1 7 mm dia. hole [3x] Holes in cross member Bend perforated bracket A and B according to template. 1 Loosely mount M6x20 bolt, flanged nut [2x each] 2 Perforated bracket A... - Page 14 Fiat 500 1 Loosely mount M6x20 bolt, flanged nut 2 Perforated bracket C Installing heater unit Check position of all components and adjust if necessary. Check that they have free clearance. Align heater unit and tighten all bolts. Connect wiring harness of heater unit 1 . Installing heater unit 1313401A_EN...
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Page 15: Fuel
Fiat 500 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. - Page 16 Fiat 500 Short standpipe 1 by 210 mm and shape as shown. Bend connection piece 2 by 90°. Removing fuel Remove fuel-tank vent line 1 from bracket and cut off approx. 200 mm before fuel tank connection piece. Remove section on connection piece.
- Page 17 Fiat 500 Insert fuel-tank vent line in bracket again. Route fuel line 1 to metering pump. Aligning fuel-tank vent line 1 Silentblock, flanged nut 2 Angle bracket 3 Original vehicle bolt Installation location of metering pump Check the position of the components; adjust if necessary.
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Page 18: Coolant Routing
Fiat 500 Coolant routing 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 unit must be filled with coolant. -
Page 19: Coolant On 1.2 Liter
Fiat 500 Coolant on 1.2 liter b = 655 c = 720 Hose A = 17x20 180° molded hose Cutting Discard section X coolant hoses to length Push braided protection hoses onto hose B and C and cut to length. Cut heat shrink plastic tubing to length. - Page 20 Fiat 500 1 Cable tie Routing in engine compart- ment Disconnect hose to engine outlet/heat exchanger inlet 2 at connection piece of engine outlet. Discard clamp 1 Cutting point Fasten hose A with small diameter on connection piece on engine outlet. Connect- ing engine outlet...
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Page 21: Coolant On 1.4 Liter
Fiat 500 Coolant on 1.4 liter b = 630 c = 720 Hose A = 17x20 180° molded hose Cutting Discard section X coolant hoses to length Push braided protection hoses onto hose B and C and cut to length. Cut heat shrink plastic tubing to length. - Page 22 Fiat 500 1 Cable tie [4x] Routing in engine compart- ment Disconnect hose to engine outlet/heat exchanger inlet 2 at connection piece of engine outlet. Discard clamp 1 Cutting point Fasten hose A with small diameter on connection piece on engine outlet. 1 Black (sw) rubber isolator Connect- ing engine...
- Page 23 Fiat 500 1 Hose on heat exchanger inlet 2 Black (sw) rubber isolator 3 Spacer bracket Connect- ing heat exchanger inlet Align black (sw) rubber isolator 1 [2x]. Ensure sufficient distance to neighboring components. 2 Spacer bracket Aligning hoses 1313401A_EN...
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Page 24: Combustion Air
Fiat 500 Combustion air 1 Combustion air pipe a = 240 Discard section X Cutting combus- tion air pipe to length 1 Combustion air pipe 2 27 mm dia. clamp Installing combus- tion air pipe 1 Flanged nut 4 , 48 mm dia. clamp, 10 mm shim 5 on Ejot stud 3 2 Muffler Installing... -
Page 25: Exhaust Gas
Fiat 500 Exhaust gas 1 Exhaust pipe a = 270 2 Exhaust end section b = 95 Preparing exhaust Discard section X pipe 1 Exhaust pipe 2 Red (rt) rubber isolator 3 Hose clamp Installing exhaust pipe 1.2 liter engine 1 Existing hole;... -
Page 26: 1.4 Liter Engine
Fiat 500 1.4 liter engine 1 Angle bracket 2 Original vehicle bolt Installing angle bracket 1 Hose clamp [2x] 2 Muffler, M6x20 bolt, large diameter washer, flanged nut on angle bracket 3 Exhaust end section 4 Red (rt) rubber isolator with groove Installing muffler and section... -
Page 27: Final Work
- Check the proper operation of the additional heater, see the operating instructions/installation instructions. - Attach the "Switch off additional heater before refueling" sticker to the left-hand B-pillar. Feel the drive Webasto AG Postfach 80 - 82132 Stockdorf Hotline 01805 / 932278 - Hotfax 0395 / 5592-353 http://www.webasto.de... -
Page 28: Template For Perforated Bracket A
Fiat 500 Template for Perforated Bracket A bend upwards on bending line by approx. 123° Template for Perforated Bracket B bend upwards on bending line by approx. 123° Template for Perforated Bracket C 100 mm bend downwards on bending line by approx. 90° bend upwards on bending line by approx. -
Page 29: Template For Bracket
Fiat 500 Template for Bracket Ø 7mm Ø 7mm 100 mm Ø 7mm 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 “minimize margins”... -
Page 30: Operating Instructions For End Customer
Fiat 500 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.
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