Webasto Thermo Top E Installation Instructions Manual
Additional heater.
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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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Table of Contents
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Summary of Contents for Webasto Thermo Top E
- Page 1 part number: 93199670 04/08...
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Page 2: Installation Instructions
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. -
Page 3: Table Of Contents
part number: 93199670 Opel Antara Table of Contents Validity Preparing heater unit Heater Unit/Installation Kit Preparing installation location Foreword Installing heater unit General Instructions Coolant connection Special Tools Fuel Connection Explanatory Notes on Document Combustion air Preliminary Work Exhaust system Heater unit installation location Final Work Electrical Connections... -
Page 4: Heater Unit/Installation Kit
1311923A 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 5: 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 6: Preliminary Work
part number: 93199670 Opel Antara 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 7: Electrical Connections
part number: 93199670 Opel Antara Electrical Connections 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 along the original vehicle fuel lines on the underbody Wiring harness... -
Page 8: Fan Controller For Manual Air Conditioning
2,5² bl/gn 4² bl/sw K3.1 bl/sw 2,5² 0,75² 4² Webasto components Components of Opel Antara Colors and symbols Heater unit TT-C/E Fan motor 6-pin connector Fan switch white Fuse, 25 A 40 A fan fuse black Fan relay... - Page 9 part number: 93199670 Opel Antara Preparing electrical system Preparing electrical system sw 4² 500mm Produce connections as shown in wiring rt 2,5² rt 2,5² diagram. 1000mm 500mm Cut 500 mm off included protective sleeving and push onto lines . Push Preparing remaining end of protective sleeving onto additional...
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Page 10: Automatic Air-Conditioning Fan Controller
2,5² diagram 4² gr/sw 4² K3.1 4² 0,75² 4² Webasto components Components of Opel Antara Colors and symbols Heater unit TT-C/E Fan motor 6-pin heater unit Fan controller white connector Fuse, 25 A Air-conditioning control black element... - Page 11 part number: 93199670 Opel Antara Preparing electrical system Produce connections as shown in wiring diagram. Crimp cable lug onto brown (br) wire 0.75² provided and onto brown (br) wire section 4². Cutting br 4² brown (br) wire to length Produce connections as shown in wiring diagram.
- Page 12 part number: 93199670 Opel Antara Connection to 2-pin connector 1 from fan motor. Produce connections as shown in wiring diagram (crimp and shrink). 2 Violet (vi) wire from connector 3 Violet (vi) wire to fan controller Con- 4 Black (sw) wire , 4²...
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Page 13: Remote Option (Telestart)
part number: 93199670 Opel Antara Remote option (Telestart) 1 Existing hole, M5x16 bolt, washer, flanged 2 Receiver 3 Telestart bracket Installing receiver 1 Antenna Installing antenna Temperature sensor for HTM100 only 1 Fasten temperature sensor with suitable means (here double-sided adhesive tape) Installing tempera- ture sensor... -
Page 14: Remote Option (Thermo Call)
part number: 93199670 Opel Antara Remote option (Thermo Call) 1 Fasten receiver with suitable means (here double-sided adhesive tape) Installing receiver 1 Antenna Installing antenna Pushbutton Installing push button... -
Page 15: Preparing Heater Unit
part number: 93199670 Opel Antara Preparing heater unit b = 240 mm c = 335 mm Discard section X Cutting coolant hoses to length Remove water pump 2 from heater unit. Hose section 1 and spring clip will be reused. Discard retaining clip 3 and bolt. - Page 16 part number: 93199670 Opel Antara 1 M6x12 bolt, angle bracket, M6 flanged nut 2 Water pump 3 Rubber-coated pipe clamp, 48 mm dia. 4 M6x20 bolt, M6 flanged nut Preassem- bling water pump Ejot screw 1 [3x], tightening torque 10 Nm! Connect adapter line of water pump 2 , cut to length and connect identical colors to wiring harness of water pump using connectors...
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Page 17: Preparing Installation Location
part number: 93199670 Opel Antara Preparing installation location 1 Cross member for battery carrier 2 Drill out thread to 10 mm dia. [2x] Drilling out thread Remove bracket 3 of hydraulic line 5 and mount as shown (depending on equipment). Original vehicle bolt 1 will be reused 2 Perforated bracket 3 M6x16 bolt, M6 flanged nut... - Page 18 part number: 93199670 Opel Antara 1 Original vehicle hose 2 Original vehicle spring clip mounting hose Completely remove control unit 1 with bracket 2 . Discard bracket 2 . Removing control unit 1 Self-tapping Torx screw [2x] 2 Additional bracket 3 Control unit Preassem- bling...
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Page 19: Installing Heater Unit
part number: 93199670 Opel Antara Installing heater unit 1 Loosely mount M8x30 bolt [2x] 2 Preassembled heater unit Installing heater unit Remove original vehicle screw 1 and discard. Removing screw 1 Bracket part 2 2 M6 flanged nut [3x] 3 M8x40 bolt, spring lockwasher, large diameter washer Installing bracket... -
Page 20: Coolant Connection
part number: 93199670 Opel Antara 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 21 part number: 93199670 Opel Antara Disconnect hose to engine outlet/heat exchanger inlet 2 at connection piece of engine outlet. Discard spring clip 1 . Cutting point When installing the coolant hose, ensure sufficient spacing to the vehicle gear shift mechanism. Con- nection to heater unit...
- Page 22 part number: 93199670 Opel Antara Before connecting, fill the coolant hoses with coolant. 1 Hose section of heat exchanger inlet Con- nection to heat exchanger inlet 1 Spacer bracket Installing spacer bracket...
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Page 23: Fuel Connection
part number: 93199670 Opel Antara 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 24 part number: 93199670 Opel Antara Connect fuel line 2 from heater unit to pressure side of metering pump [side with connector]. 1 Wiring harness of metering pump, connector mounted 3 Hose section, 10 mm dia. hose clamps Installing [2x]. metering pump 1 Separate 90°...
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Page 25: Combustion Air
part number: 93199670 Opel Antara Combustion air 1 Combustion air pipe 2 Hose clamp Installing com- bustion air pipe 1 Combustion air pipe 2 48 mm dia. p-clamp; rubber coating removed 3 Combustion-air intake muffler 4 Existing hole, M6 rivet nut, M6x20 bolt, spring lock washer Installing muffler... -
Page 26: Exhaust System
part number: 93199670 Opel Antara Exhaust system 1 Exhaust pipe a = 460 mm 2 Exhaust end section b = 230 mm Preparing exhaust Discard section X pipe Shape exhaust pipe 1 . 2 Red (rt) rubber isolator Preparing exhaust pipe Remove clip 2 from original vehicle wiring harness 1 . - Page 27 part number: 93199670 Opel Antara Bend perforated bracket upward by approx. 75° at bending line. 60mm Bending perforated bracket 50mm Biegelinie Bending line Check the position of the components; adjust if necessary. Check that they have free clearance. 1 Perforated bracket 2 Exhaust muffler 3 M6x20 bolt, flanged nut Installing...
- Page 28 part number: 93199670 Opel Antara Ensure sufficient spacing to neighboring components (wiring harness to exhaust system). 1 Cable tie 2 Exhaust end section 3 Hose clamp Installing 4 Original vehicle wiring harness exhaust section 1 Red (rt) rubber isolator 2 Red (rt) rubber isolator with groove Pushing on rubber isolator...
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Page 29: 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 02/07Printed by: Steffen... -
Page 30: Operating Instructions For End Customer
part number: 93199670 Opel Antara 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.