Webasto THERMO TOP E Installation Instructions Manual
Nissan pathfinder and navara
Hide thumbs
Also See for THERMO TOP E:
- Installation documentation (41 pages) ,
- Installation instructions manual (35 pages) ,
- Manual (31 pages)
Table of Contents
Advertisement
Quick Links
Water Heater Unit
Thermo Top E Additional Heater
Thermo Top C Additional Heater
Thermo Top P Additional Heater
Installation Instructions
Nissan Pathfinder and Navara
2.5 liter Diesel
from Model Year 2005
For left-hand drive vehicles only
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 equip-
ment 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 tech-
nical 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 warn-
ings.
Webasto does not accept any liability for defects and damage that are attributable to
installation by untrained staff.
Ident. No.: 1303637F_EN
e1
00 0003
e1
00 0002
e1
00 0104
Fee Euro 10
Feel the drive
Feel the drive
© Webasto AG
Advertisement
Table of Contents
Subscribe to Our Youtube Channel
Related Manuals for Webasto THERMO TOP E
Summary of Contents for Webasto THERMO TOP E
-
Page 1: Installation Instructions
Specialist company training, technical documentation, specialized tools and equip- ment 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 tech- nical skills, or if you do not have access to the required technical documentation, tools and equipment needed to carry out correct installation and repairs. -
Page 2: Table Of Contents
Nissan Pathfinder and Navara Table of Contents Validity Preparing installation location Heater Unit/Installation Kit Premounting heater unit Foreword Installing Heater Unit General Instructions Coolant connection with manual transmission Special Tools Coolant connection for automatic transmission Explanatory Notes on Document Combustion air Preliminary Work Fuel Connection Heater unit installation location... -
Page 3: Heater Unit/Installation Kit
See Nissan 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
Nissan Pathfinder and Navara 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 work Electrical system Coolant connection Fuel connection Exhaust system... -
Page 5: Preliminary Work
Nissan Pathfinder and Navara Preliminary Work WARNING! - Copy the factory number from the original type label to the duplicate type label. - Remove years that do not apply from duplicate label. - Attach the duplicate label (type label) in the appropriate place. - Open the fuel tank cap and vent the fuel tank. -
Page 6: Preparing Electrical System
Nissan Pathfinder and Navara Preparing electrical system All equipment Cutting 1mm² wire to 2900 length Produce connections as shown in wiring dia- gram. Cut included protective sleeving to length of gn/ws 2,500 and push onto wire Only with passenger compartment moni- toring Connect- ing fuse... -
Page 7: Electrical Connections
Nissan Pathfinder and Navara Electrical Connections Fuse holder, relay K3 Fuse holder, relay K3 WARNING: ( 3 ) M6x12 bolt, angle bracket, flanged nut Do not damage tank ( 4 ) Retaining plate, M5x12 bolt, large diameter washer, flanged nut ( 1 ) 6.5 mm dia. -
Page 8: Remote Option (Telestart)
Nissan Pathfinder and Navara Remote option (Telestart) ( 1 ) Receiver ( 2 ) 4 mm dia. hole; 5.5x13 self-tapping screw [2x] Installing receiver Produce all connections in accordance with general installation instructions provided and fasten wires with cable ties. ( 1 ) Antenna Installing antenna... -
Page 9: Remote Option (Thermo Call)
Nissan Pathfinder and Navara Remote option (Thermo Call) ( 1 ) Receiver ( 2 ) 4 mm dia. hole; 5.5x13 self-tapping screw [4x] Installing receiver ( 1 ) Antenna Installing antenna Produce all connections in accordance with general installation instructions provided and fasten wires with cable ties. -
Page 10: Fan Controller For Manual Air Conditioning
Nissan Pathfinder and Navara Fan controller for manual air conditioning Webasto Nissan rt/ws ws/sw Wiring dia- gram for manual air condition- Webasto components Nissan components Colors and symbols Heater unit Fan motor 6-pin heater unit con- Fan relay white nector 25 A fuse... - Page 11 Nissan Pathfinder and Navara Connection to 2-pin connector from blower motor. Cut off white (ws) wire approx. 50 mm before connector. Produce connections as shown in wiring diagram. (3) 2-pin connector of fan motor, disconnected Connect- ( 1 ) Red (rt) wire from K3/87a ing fan ( 2 ) Black (sw) wire from K3/30 motor...
-
Page 12: Automatic Air-Conditioning Fan Controller
Automatic air-conditioning fan controller Nissan Webasto rt/ws rt/ws ws/sw Automatic air-condi- tioning cir- cuit diagram Webasto components Nissan components Colors and symbols Heater unit 15 A fuse 6-pin heater unit con- 15 A fuse white nector 25 A fuse 10 A fuse... - Page 13 Nissan Pathfinder and Navara Fan motor is connected on original vehicle fan relay for front in engine compartment. ( 1 ) Fan relay, front ( 2 ) Relay carrier Fan relay View of fan relay socket! Seen from above! Imprint on relay or socket may differ from original vehicle wiring diagram, and is there- fore irrelevant! View of re-...
-
Page 14: Switch-Off Function Of Passenger Compartment Monitoring
( 6 ) Black (sw) wire from diode group ( 7 ) White/black (ws/sw) wire to diode group Switch-off function of passenger compartment monitoring Webasto components: K3.1 = Additional relay = Red (rt) wire from K3/86 Vehicle components:... - Page 15 Nissan Pathfinder and Navara Connection is carried out on 2-pin connector of ultrasound sensor R6 ( 1 ). Disconnect black (sw) wire from 2-pin connector ( 1 ) and con- nect to black (sw) wires ( 2 ) and ( 3 ) provided (solder and insulate).
-
Page 16: Preparing Installation Location
Nissan Pathfinder and Navara Preparing installation location ( 1 ) Line from steering reservoir ( 2 ) Line to automatic-transmission oil cooler ( 3 ) Bolts from bracket of steering reservoir [2x] Original state ( 1 ) Bracket aligned as shown ( 3 ) Bolts from bracket of steering reservoir [2x] ( 2 ) Copy hole pattern... -
Page 17: Premounting Heater Unit
Nissan Pathfinder and Navara Premounting heater unit Spring clips [2x] will be reused! Removing circulat- ing pump x = 60 mm Remaining sections will be used later ( 1 ) Hose on heater unit outlet Cutting coolant hose on heater unit output to length Ejot screws, tightening torque 10 Nm! - Page 18 Nissan Pathfinder and Navara ( 1 ) Exhaust pipe a = 550 mm ( 2 ) Exhaust end section b = 350 mm Discard section X Cutting exhaust pipe to length ( 1 ) M6x12 bolt (from below), pin lock (from above) [2x] Preassem- bling...
-
Page 19: Installing Heater Unit
Nissan Pathfinder and Navara Installing Heater Unit Connect wiring harness on heater unit. ( 1 ) Heater unit Installing heater unit ( 3 ) Original vehicle bolt replaced with M6x20 bolt, washer ( 2 ) Heater unit ( 1 ) Strut loosely mounted on bolt (3) with flanged nut Installing heater unit... -
Page 20: Coolant Connection With Manual Transmission
Nissan Pathfinder and Navara Coolant connection with manual transmission WARNING! Tighten all hose clamps to 2.0 + 0.5 Nm. Any cold water running off should be collected using an appropriate container! Route coolant hoses kink-free! Unless specified otherwise, always fasten using cable ties. Position hose and spring clips so that no other hose can be damaged! The connection should be "inline"... - Page 21 Nissan Pathfinder and Navara Preparing coolant connection Hose D is already mounted on heater unit! a = 270 mm b = 300 mm c = 50 mm Cutting e = 430 mm coolant hoses to Discard sections X length Push braided protection hose onto hose A , B, C and E and cut to length.
- Page 22 Nissan Pathfinder and Navara Coolant connection ( 1 ) Hose section on engine outlet ( 2 ) Discard section ( 3 ) Hose section on heat exchanger inlet Cutting point ( 1 ) Hose section on engine outlet ( 2 ) Hose section on heat exchanger inlet Mounting connec- tion pipes...
- Page 23 Nissan Pathfinder and Navara Observe direction of flow. Pressure side fac- es toward heater unit! Connect wiring harnesses to same colors with red (rt) shrink connectors (crimp and shrink). ( 5 ) Circulating pump, premounted Installing ( 1 ) M6x12 bolt, large diameter washer, circulat- flanged nut ing pump...
-
Page 24: Coolant Connection For Automatic Transmission
Nissan Pathfinder and Navara Coolant connection for automatic transmission WARNING! Tighten all hose clamps to 2.0 + 0.5 Nm. Any cold water running off should be collected using an appropriate container! Route coolant hoses kink-free! Unless specified otherwise, always fasten using cable ties. Position hose and spring clips so that no other hose can be damaged! The connection should be "inline"... - Page 25 Nissan Pathfinder and Navara Preparing coolant connection Hose C is already mounted on heater unit! b = 200 mm d = 450 mm Cutting Discard sections X coolant hoses to length Push braided protection hose onto hose B and D and cut to length! ( 1 ) Heat shrink plastic tubing [4x] Premount- ing cool-...
- Page 26 Nissan Pathfinder and Navara Coolant connection Remove hose A . Hose A and clamp (1) will be reused! Removing original hose ( 1 ) Discard section Cutting point Side of hose A cut to length is connected to intake side of circulating pump ( 1 ) Engine outlet ( 2 ) 27x27 double clip ( 3 ) Intake side of circulating pump...
- Page 27 Nissan Pathfinder and Navara Align line (1) and rubber profile (2) as shown. ( 1 ) 50 mm edge protection ( 2 ) Line from steering reservoir ( 3 ) Rubber profile (premounted) Connec- tion to heater unit inlet ( 1 ) 8x25 double clip on D and A/C line Connec- tion to heater unit...
-
Page 28: Combustion Air
Nissan Pathfinder and Navara Combustion air ( 1 ) Combustion-air intake pipe (slotted side on heater unit) ( 2 ) 27 mm dia. hose clamp Installing combus- tion air pipe For improved overview, fuse holder is not shown! Shape combustion-air intake pipe as shown in picture. -
Page 29: Fuel Connection
Nissan Pathfinder and Navara 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 30 Nissan Pathfinder and Navara Ensure proper installation position of meter- ing pump, see "Installation Instructions“. Fuel line from heater unit on pressure side of metering pump [side with connector]. Route Mecanyl line and wiring harness of me- tering pump in included protective pipe (4) . ( 2 ) Premounted metering pump ( 3 ) Original vehicle bolt, flanged nut Installing...
-
Page 31: Exhaust System
Nissan Pathfinder and Navara Exhaust system Bend perforated bracket as shown! Bending perforat- 20° ed bracket ( 1 ) 6.5 mm dia. hole Hole in un- derride protection First guide preshaped exhaust pipe to heater unit, then insert bracket. ( 1 ) Heater unit ( 2 ) Hose clamp ( 3 ) Exhaust pipe (premounted) Installing... - Page 32 Nissan Pathfinder and Navara Fasten long hole spacing of perforated brack- et (4) on muffler. ( 2 ) Exhaust pipe ( 1 ) P-clamp [2x] Installing ( 8 ) Flanged nut on premounted bolt [2x] exhaust ( 5 ) Hose clamp pipe and ( 7 ) Muffler muffler...
- Page 33 Nissan Pathfinder and Navara Installing wheel well trim Cut out wheel well trim as shown. ( 1 ) Discard section Cutting out wheel well trim Rework cut-out if necessary. Installing wheel well trim Ensure sufficient distance of wheel well trim from exhaust system.
-
Page 34: Final Work
Nissan Pathfinder and Navara Final Work Position rubber profiles and lines as shown. ( 1 ) Black (sw) rubber profile positioned on hose of heater unit inlet (2) (4) Red (rt) rubber profile positioned on line (3) Position- ( 3 ) Line to automatic-transmission oil cooler ing rubber ( 5 ) Line from steering reservoir profiles... - Page 35 - Attach the "Switch off additional heater before refueling" sticker to the left-hand B-pillar. Feel the drive Webasto AG Postfach 80 - 82132 Stockdorf, Germany - Hotline +49- (0)1805-932278 Hotfax +49-(0)395-5592-353 - http://www.webasto.de Printed in Germany 04/09Printed by: Steffen...
-
Page 36: Operating Instructions For End Customer
Nissan Pathfinder and Navara Operating Instructions for End Customer Please remove page and add to the vehicle operating instructions. On vehicles with passenger compartment monitoring, the ultrasound passenger compartment moni- toring is deactivated simultaneously with the control of the passenger compartment fan to prevent an alarm from being triggered.
Need help?
Do you have a question about the THERMO TOP E and is the answer not in the manual?
Questions and answers