Webasto thermo top e Installation Instructions Manual
Subaru impreza 1.5r; 2.0r
Hide thumbs
Also See for thermo top e:
- Installation documentation (41 pages) ,
- Installation instructions manual (36 pages) ,
- Manual (31 pages)
Table of Contents
Advertisement
Quick Links
Water Heater Unit
Thermo Top E Additional Heater
Thermo Top C Additional Heater
Installation Instructions
SUBARU Impreza 1.5R; 2.0R
Gasoline
Impreza 2.0R from Model Year 2006
Impreza 1.5R from Model Year 2007
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.: 1311020B
e1
00 0003
e1
00 0002
Fee Euro 10.00
Feel the drive
© Webasto AG
Advertisement
Table of Contents
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
SUBARU Impreza 1.5R; 2.0R Table of Contents Validity Coolant connection Heater Unit/Installation Kit Combustion air Foreword Fuel Connection General Instructions Exhaust system Special Tools Final Work Explanatory Notes on Document Operating Instructions for End Customer Preliminary Work Template with Hole Pattern for Spring Strut Dome 30 Heater unit installation location Template for Bracket Preparing electrical system... -
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
SUBARU Impreza 1.5R; 2.0R 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... -
Page 5: Preliminary Work
SUBARU Impreza 1.5R; 2.0R Preliminary Work WARNING! - 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. - Attach the duplicate label (type label) in the appropriate place. -
Page 6: Preparing Electrical System
SUBARU Impreza 1.5R; 2.0R Preparing electrical system Install wire section 2 in the protective sleeving provided. sw 1² Cutting wires to length Make connections as shown in the wiring dia- gram with the tab receptacles provided. Preparing fuse F4... -
Page 7: Electrical Connections
SUBARU Impreza 1.5R; 2.0R Electrical Connections Wiring harness pass through Digital timer 1 Protective rubber sleeve 1 Digital timer (match installation location) sw rt Do not install the metering-pump wir- ing harness until lat- er together with the fuel line along the Wiring har- original vehicle fuel ness in-... -
Page 8: Automatic Air-Conditioning Fan Controller
SUBARU Impreza 1.5R; 2.0R Automatic air-conditioning fan controller Connection to the 2-pin connector 3 from the fan motor. Make connections as shown in the wiring dia- gram with the wire connectors provided. Connect- ing fan mo- 1 Red (rt) wire from K3/87a 2 Black (sw) wire from K3/30 3 2-pin connector of B87 fan motor Connection to the 16-pin connector 1 from... - Page 9 FB17 rt/ws Automatic sw/rt air-condi- tioning cir- cuit gn/ge diagram sw/rt B282 B283 Webasto components Components of SUBARU Colors and symbols Impreza 1.5R; 2.0R Heater unit TT-C/E Fan motor 6-pin connector Fan amplifier white Fuse, 15 A Fan relay yellow...
-
Page 10: Remote Option (Telestart)
SUBARU Impreza 1.5R; 2.0R Remote option (Telestart) 1 Receiver, Dual Lock, self-adhesive Installing receiver 1 Antenna Installing antenna Temperature sensor for HTM100 only 1 Temperature sensor, cable tie Installing tempera- ture sensor... -
Page 11: Remote Option (Thermo Call)
SUBARU Impreza 1.5R; 2.0R Remote option (Thermo Call) 1 Receiver, Dual Lock, self-adhesive Installing receiver 1 Antenna Installing antenna Pushbutton Installing push but-... -
Page 12: Preparing Heater Unit
SUBARU Impreza 1.5R; 2.0R Preparing heater unit d = 360 mm a = 450 mm c = 90 Discard section X Cutting coolant hoses to length Slide braided protection hose onto hose D and cut to length. Cut shrinkdown plastic tubing to length. 1 Shrinkdown plastic tubing, 25 mm 2 Rubber isolator, black Preparing... -
Page 13: Preparing Installation Location
SUBARU Impreza 1.5R; 2.0R Preparing installation location Remove retaining clip for brake line, drill out hole, 9.1 mm dia., install M6 rivet nut 1 Retaining clip Preparing installa- tion loca- tion Bend perforated bracket as shown! 1 Perforated bracket Preparing perforated bracket 65 mm... -
Page 14: Preassembling Heater Unit
SUBARU Impreza 1.5R; 2.0R Position drilling template as shown and copy hole pattern 1 Drilling template 2 Copy hole pattern, 7 mm dia. drilled hole 3 Threaded insert on vehicle 4 Threaded insert on vehicle Copying hole pat- tern Preassembling heater unit Discard retaining clip 2 and molded hose 1 Removing circulating... -
Page 15: Installing Heater Unit
SUBARU Impreza 1.5R; 2.0R Tighten EJOT screws to 10 Nm! Connect circulating pump harness and en- sure freedom of movement. 1 Ejot bolt, spacer nut, M6x30 4 Circulating pump 3 Rubber-coated pipe clamp, 48 mm dia. Preassem- 2 M6x12 bolt, spring lockwasher bling heat- 5 Hose clamp er unit... - Page 16 SUBARU Impreza 1.5R; 2.0R 1 Bracket 2 7 mm dia. hole, M6x20 bolt, 5 mm shim, M6 flanged nut 3 M6x20 bolt, spring lockwasher, 5 mm shim, M6 threaded insert already on vehicle Installing heater unit 1 M6x20 bolt, large diameter washer Installing heater unit Tighten all loose mounting hardware.
-
Page 17: Coolant Connection
SUBARU Impreza 1.5R; 2.0R 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! The connection should be "inline"... - Page 18 SUBARU Impreza 1.5R; 2.0R For all vehicles Remove existing spacer from coolant hose and retain for later use.. 1 Turn hose section of engine outlet to right- hand side of vehicle Cutting point Only for 1.5R Shorten hose section of engine outlet 2 on connection piece for heat exchanger inlet by 40 mm and remount.
- Page 19 SUBARU Impreza 1.5R; 2.0R Before connecting, fill the coolant hoses with coolant. 1 Hose section on heat exchanger inlet Connec- tion to heat exchanger inlet 1 Cable tie Routing of coolant hoses 1 Black (sw) rubber isolator [3x] Aligning rubber iso- lator Only for 2.0R 1 Black (sw) rubber isolator [2x]...
- Page 20 SUBARU Impreza 1.5R; 2.0R 1 Hose on heat exchanger inlet 2 Spacer bracket 3 Spacer bracket already on vehicle Installing spacer bracket Only for 1.5R Ensure sufficient distance for clutch actua- tion! 2 Black (sw) rubber isolator 1 Cable tie Aligning rubber iso- lator...
-
Page 21: Combustion Air
SUBARU Impreza 1.5R; 2.0R Combustion air 1 Combustion air pipe a = 235 mm Cutting Discard section X combus- tion air pipe to length 2 Heater unit 4 Combustion-air intake pipe 1 Combustion-air intake silencer 3 27 mm dia. hose clamp Installing intake pipe Punch through pre-punched hole in cover. -
Page 22: Fuel Connection
SUBARU Impreza 1.5R; 2.0R 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 23 SUBARU Impreza 1.5R; 2.0R 1 Metering pump, rubber-coated clamp 2 Noise isolation mounts, flanged nut M6 [2x] 3 Hole, angle bracket, large diameter wash- er, M6x20 bolt, existing M6x20 flanged nut Installing metering pump Install fuel sender according to manufactur- er's instructions.
- Page 24 SUBARU Impreza 1.5R; 2.0R 1 fuel line already present in vehicle 2 fuel line already present in vehicle 4 Grommet 3 Mecanyl fuel line, metering-pump wiring harness Routing through into pas- senger compart- ment Route Mecanyl fuel line and wiring harness along fuel lines already present in vehicle.
- Page 25 SUBARU Impreza 1.5R; 2.0R Route Mecanyl fuel line along existing lines and secure with cable ties! 1 Mecanyl fuel line Routing in engine compart- ment to heater unit 1 Heater unit 2 Hose section, 10 mm dia. hose clamp [2x] 3 Mecanyl fuel line Connec- tion on...
-
Page 26: Exhaust System
SUBARU Impreza 1.5R; 2.0R Exhaust system 1 Exhaust pipe a = 650 mm 2 Exhaust end section b = 85 mm Preparing exhaust Discard section X pipe Ensure sufficient distance to neighboring components. 1 Heater unit 3 Exhaust pipe, 650 mm long 2 Hose clamp Installing exhaust... - Page 27 SUBARU Impreza 1.5R; 2.0R Ensure sufficient distance to neighboring components. 2 Exhaust pipe 1 Red (rt) rubber isolator 7 Hole, M6 rivet nut, M6x20 bolt, spring lock- washer already present in vehicle 6 Perforated bracket Installing 4 Exhaust silencer, M6x20 bolt, M6 flanged exhaust si- lencer 3 Hose clamp [2x]...
-
Page 28: Final Work
- 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 10/06Printed by: Steffen... -
Page 29: Operating Instructions For End Customer
SUBARU Impreza 1.5R; 2.0R Operating Instructions for End Customer Please remove page and add to the vehicle operating instructions. Rule of thumb for operating additional heater: driving time = heating time! Before parking the vehicle, make the following settings: 1 Air outlet to windshield 2 Set fan to approx. -
Page 30: Template With Hole Pattern For Spring Strut Dome
SUBARU Impreza 1.5R; 2.0R Template with Hole Pattern for Spring Strut Dome 7.0 mm dia. 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 margins” and 100% of the normal size. -
Page 31: Template For Bracket
SUBARU Impreza 1.5R; 2.0R Template for Bracket Bending line Biegelinie 50mm 100 mm 7.0 mm dia. Scale 1:1 20mm Compare the size of the printed version with di- mension lines. Permitted tolerance a maximum of 2%. Set the printer settings to “no margin” or “minimize margins” and 100% of the normal size. -
Page 32: Template For Perforated Bracket A
SUBARU Impreza 1.5R; 2.0R Template for Perforated bracket A 8.5 mm dia. Template for Perforated bracket B 8.5 mm dia. 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”... -
Page 33: Template For Fuel Sender
SUBARU Impreza 1.5R; 2.0R Template for Fuel sender 6 mm dia. 100 mm Scale 1:1 100 mm 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” and 100% of the normal size. -
Page 34: Template For Fuel Standpipe
SUBARU Impreza 1.5R; 2.0R Template for Fuel Standpipe 100 mm Scale 1:1 100 mm 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” and 100% of the normal size.