Webasto Thermo Top E Installation Instructions Manual
Opel 2007 vivaro
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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 Vivaro
Diesel
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.:1311875A_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
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
Opel Vivaro Table of Contents Validity Preparing heater unit Heater Unit/Installation Kit Installing heater unit Foreword Coolant connection General Instructions 2.0 l dCi Special Tools 2.5 l dCi Explanatory Notes on Document Combustion air Preliminary Work Fuel Connection Heater unit installation location Installing trim pieces Electrical Connections Final Work... -
Page 3: Heater Unit/Installation Kit
See Opel price list Heater unit recommended for the respective vehicle class: Vehicle Heater unit Compact car Thermo Top E Mid-size car, station wagon Thermo Top C Full-size car, van, offroader Thermo Top P 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
Opel Vivaro 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: Electrical Connections
Opel Vivaro Electrical Connections Digital timer and summer/winter switch Connection of positive wire option Connect red (rt) positive wire, 4mm², to positive support point. Fasten retaining plate of fuse 1 Digital timer holder with 3x9 self-tapping screw on battery 2 Summer/winter switch, drilled hole 12 mm dia. carrier. -
Page 7: Fan Controller
4 mm² 3 mm² 0,5mm² rt/ws ge 0,5mm² 2 mm² 1,5 mm² 0,5mm² 2 mm² K3.1 Webasto components Vehicle components Colors and symbols Heater unit TT-C/E Fan motor 6-pin connector Resistor group X70 white Fuse, 25 A Fan switch S95... - Page 8 Opel Vivaro 1 Isolating relay K3.1, M5x16 bolt, flanged nut on existing hole 2 Mount M8x16 bolt, flanged nut in existing hole 3 Brown (br) wire from K3.1/85, 8 mm dia. cable lug Installing isolating relay Connection to connector S95 4 of fan switch. Produce connections as shown in wiring diagram.
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Page 9: Remote Option (Telestart)
Opel Vivaro Remote option (Telestart) Drill out bracket 3 to 6.5 mm dia. at position 2 . 1 Receiver 2 M6x20 bolt in existing hole Installing receiver 1 Antenna Installing antenna Temperature sensor for HTM100 only 1 Fasten temperature sensor with suitable means 2 Ventilation duct Installing... -
Page 10: Preparing Heater Unit
Opel Vivaro Preparing heater unit 2.0 l dCi a = 580 mm b = 50 mm Cutting c = 470 mm coolant hoses to Discard section X . length Push braided protection hose onto hose A and C . 2.5 l dCi a = 755 mm b = 50 mm c = 655 mm... - Page 11 Opel Vivaro Before installing, insert M8x20 bolt 1 in bracket 3 . 2 Flanged nut (3x) Preassem- bling bracket on heater unit 1 Exhaust pipe a = 330 mm 2 Exhaust end section b = 140 mm Discard section X Preparing exhaust pipe...
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Page 12: Installing Heater Unit
Opel Vivaro 1 Strut 2 Loosely premount Ejot screw [2x] Preassem- bling strut on heater unit Installing heater unit 1 Remove air ducting trim Removing trim 1 Remove trim Removing trim 1 M8x20 bolt, flanged nut [2x each] on existing holes Installing heater unit 1311875A_EN... - Page 13 Opel Vivaro Tighten Ejot screws on heater unit, tightening torque 10 Nm. Connect wiring harness on heater unit. 1 Premounted strut 2 M10x16 bolt, spring lockwasher in existing Installing threaded hole bracket Ensure sufficient distance to neighboring components. 1 M8x12 bolt in existing threaded hole 2 Horn with bracket Installing horn...
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Page 14: Coolant Connection
Opel Vivaro 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. Position hose clamps and spring band clamps so that no other hose can be damaged. -
Page 15: 2.0 L Dci
Opel Vivaro 2.0 l dCi Connect hose B and C . Con- nection to heater unit Slide rubber isolator 1 onto hose C . Slide rubber isolator onto hose A (hidden in photo). 2 Spacer bracket Routing in engine compart- ment 1 Original vehicle hose of engine outlet/heat exchanger inlet... -
Page 16: L Dci
Opel Vivaro 1 Engine-outlet hose section Con- nection on engine outlet Before connecting, fill the coolant hoses with coolant. Position rubber isolator on hose A and C on original vehicle wiring harness. 1 Hose section of heat exchanger inlet Con- nection on heat exchanger... - Page 17 Opel Vivaro Pull original vehicle hose 3 of heat exchanger inlet off bleeder valve 2 . Spring clip 1 will be reused. Pulling off original vehicle hose Turn bleeder valve 2 toward front. 1 Hose section of heat exchanger inlet Turning valve 1 Hose section of heat exchanger inlet...
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Page 18: Combustion Air
Opel Vivaro Combustion air 1 Combustion air pipe a = 300 mm Discard section X Cutting com- bustion air pipe to length 1 Retaining clip in hole of strut 2 27 mm dia. hose clamp 3 Combustion-air intake pipe 4 Combustion-air intake muffler Installing intake pipe 1311875A_EN... -
Page 19: Fuel Connection
Opel Vivaro 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. Unless specified otherwise, always fasten using cable ties. - Page 20 Opel Vivaro Ensure proper installation position of metering pump 4 , see "Installation Instructions“. Connect fuel line from heater unit 1 to pressure side of metering pump [end with connector]. Installing metering 2 Wiring harness of metering pump, single- pump wire seal, tab connector, connector housing 3 Flanged nut...
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Page 21: Installing Trim Pieces
Opel Vivaro Installing trim pieces Cut out trim piece 1 in area of markings. Cutting out trim piece 1 Trim piece Installing trim piece Cut out trim piece 1 in area of markings. Cutting out trim piece 1 Trim piece Installing trim piece 1311875A_EN... -
Page 22: 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 23: Operating Instructions For End Customer
Opel Vivaro 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.