Webasto Thermo Top E Installation Instructions Manual
For opel 2007 corsa
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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
Thermo Top P Additional Heater
Installation Instructions
Opel Corsa
Diesel
from Model Year 2007
Left-hand drive vehicle
Manual transmission
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 suc-
cessfully 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 installa-
tion by untrained staff.
Ident. No.:1311770A_EN
e1
00 0003
e1
00 0002
e1
00 0104
Fee Euro 10.00
Feel the drive
© Webasto AG
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Table of Contents
Related Manuals for Webasto Thermo Top E
Summary of Contents for Webasto Thermo Top E
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Page 1: Installation Instructions
Manual transmission 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. -
Page 2: Table Of Contents
Opel Corsa Table of Contents Validity Preparing heater unit Heater Unit/Installation Kit Preparing installation location Foreword Installing heater unit General Instructions Combustion air Special Tools Exhaust system Explanatory Notes on Document Coolant connection Preliminary Work Fuel Connection Heater unit installation location Final Work Preparing electrical system Operating Instructions for End Customer... -
Page 3: Heater Unit/Installation Kit
Order No.: Retail accessories with desired heater control See price list For installation parts, see Webasto calculation program Foreword These installation instructions apply to Opel Corsa Diesel vehicles - for validity, see page 2 - from mod- el year 2007 and later, assuming technical modifications to the vehicle do not affect installation, any liability claims excluded. -
Page 4: Explanatory Notes On Document
Opel Corsa 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 connection Fuel connection Exhaust system Combustion air... -
Page 5: Preliminary Work
Opel Corsa Preliminary Work WARNING! - Open the fuel tank cap, ventilate the 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
Opel Corsa Preparing electrical system Only with automatic air-conditioning gn/ws Produce connection as shown in wiring dia- gram with tab receptacle. Pull line section 1 Cutting (2,000 mm long, 0.75 mm²) into protective wires to sleeving and install in passenger compart- length ment together with wiring harness for digital timer and fan controller. -
Page 7: Electrical Connections
Opel Corsa Electrical Connections Fuse holder, K3 relay with manual air condi- Digital timer tioning 1 Digital timer 1 7 mm dia. hole, M6x20 bolt, large diameter washer, flanged nut 2 Angle bracket 3 Retaining plate for fuse holder, M5x16 bolt, large diameter washer, K3 relay, flanged nut on angle bracket Wiring har-... -
Page 8: Fan Controller For Manual Air Conditioning
Opel Corsa Fan controller for manual air conditioning Webasto Opel Wiring dia- gram R1 A60 rt/ws S1 A60 Webasto components Vehicle components Colors and symbols Heater unit TT-C/E M1 A60 Fan motor 6-pin connector Fuse 40A white Fuse, 25 A... -
Page 9: Automatic Air-Conditioning Fan Controller
M1 A13 rt/ws XC33 XC32 Y1 A13 XC31 XC32 gn/ws XC42 XC42 Webasto components Vehicle components Colors and symbols Heater unit TT-C/E M1 A13 Fan motor 6-pin heater unit connector FU5 Fuse 40A white Fuse, 25 A Y1 A13 Fan controller... - Page 10 Opel Corsa Connection to connector 1 of fuse and relay box 2 . Produce connections as shown in wiring dia- gram. 3 Brown (br) wire to fan controller Y1 A13 Connect- 4 Black (sw) wire from K3/30 ing fan-mo- 5 Red (rt) wire to K3/87a 6 Brown (br) wire from fuse FU5 Connection to gray 32-pin connector 2 from the air conditioning control.
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Page 11: Remote Option (Telestart)
Opel Corsa Remote option (Telestart) Fasten receiver 1 with suitable means (dou- ble-sided adhesive tape). Installing receiver 1 Antenna Installing antenna Temperature sensor for HTM100 only Fasten temperature sensor 1 with suitable means (double-sided adhesive tape). Installing tempera- ture sensor 1311770A_EN... -
Page 12: Opel Corsa
Opel Corsa Preparing heater unit b1 = 250 mm b2 = 20 mm c = 80 mm d = 330 mm Cutting coolant Discard section X hoses to length 1 20x20 connecting pipe 2 27 mm dia. hose clamp [2x] Preassem- bling hose C on heater... - Page 13 Opel Corsa 1 Loosely screw M6x30 bolt into rivet nut 2 Copy hole pattern 3 Bracket Copying hole pat- tern 1 Copy hole pattern [2x], remove bracket Copying hole pat- tern 1 Drill 9.1 mm hole; install rivet nut [3x each] Installing rivet nut Insert one 5 mm shim each between bracket...
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Page 14: Installing Heater Unit
Opel Corsa 1 Mount M6x20 bolt, spring lockwasher on rivet nut [2x each] Installing bracket Installing heater unit Ejot screw bolt, tightening torque 10 Nm! 1 Ejot screw [2x] Installing heater unit Ejot screw bolt, tightening torque 10 Nm! 1 Ejot screw Installing heater unit 1 Wiring harness of heater unit... -
Page 15: Combustion Air
Opel Corsa Combustion air 1 Combustion air pipe a = 250 mm Discard section X Cutting combus- tion air pipe to length Route combustion-air intake pipe 1 under battery carrier 2 Combustion-air intake muffler 3 27 mm dia. hose clamp Installing intake pipe and muffler... -
Page 16: Exhaust System
Opel Corsa Exhaust system 1 Exhaust pipe a = 280 mm 2 Exhaust end section b = 80 mm Preparing exhaust Discard section X pipe 1 Muffler 2 M6x20 bolt, flanged nut 3 Perforated bracket 4 Mount M6x20 bolt, large diameter washer, flanged nut in existing hole Installing muffler... -
Page 17: Coolant Connection
Opel Corsa Coolant connection WARNING! Tighten all hose clamps to 2.0 + 0.5 Nm. 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. Po- sition hose clamps and spring band clamps so that no other hose can be damaged. - Page 18 Opel Corsa Disconnect hose to heat exchanger inlet 1 on connection piece of engine outlet. Discard spring clip 2 . Cutting point Slide black (sw) rubber isolator 1 onto original vehicle hose to heat exchanger inlet 2 and position. 3 Slide black (sw) rubber isolator onto hose D and position Connect- ing heat...
- Page 19 Opel Corsa Connect hose A and B . Connect- ing engine outlet 1311770A_EN...
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Page 20: Fuel Connection
Opel Corsa Fuel Connection 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. Un- less specified otherwise, always fasten using cable ties. - Page 21 Opel Corsa Connect fuel line 2 from heater unit to pres- sure side of metering pump [side with con- nector]. 1 Wiring harness of metering pump, connec- tor mounted Connect- 3 Hose section, 10 mm dia. hose clamps [2x] ing meter- ing pump Remove fuel-tank sending unit 3 in accor- dance with manufacturer's specifications.
- Page 22 Opel Corsa Fuel line 1 from fuel standpipe on intake side of metering pump [side without connector]. Check the position of the components; adjust if necessary. Check that they have free clear- ance. Connect- 2 Hose section, 10 mm dia. hose clamp [2x] ing meter- ing pump 1311770A_EN...
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Page 23: Final Work
Opel Corsa Final Work WARNING! Reassemble the disassembled components 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 unit 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. -
Page 24: Operating Instructions For End Customer
1 Set temperature to "max." 2 Air outlet to windshield Automatic air-condi- tioning Feel the drive Webasto AG Postfach 80 - 82132 Stockdorf Hotline 01805 / 932278 - Hotfax 0395 / 5592-353 http://www.webasto.de Printed in Germany 02/2007 Printing: Steffen... -
Page 25: Template For Fuel Standpipe
Opel Corsa Template for Fuel Standpipe 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 “minimize mar- gins” and 100% of the normal size. 100 mm 1311770A_EN...
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