Webasto Thermo Top E Installation Documentation
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Webasto Thermo Top E Installation Documentation

Water heater, parking heater, opel vivaro
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Download this manual See also: Instructions for Using, Installation Documentation
Water Heater
Thermo Top E Parking Heater
Thermo Top C Parking Heater
Installation Documentation
Opel Vivaro
Diesel
from model year 2007
Left-hand drive vehicle
WARNING!
Hazard warning:
The improper installation or repair of Webasto heating and cooling systems can cause fire or
the leakage of deadly carbon monoxide, leading to serious injury or death.
To install and repair Webasto heating and cooling systems you need to have completed a
special company training course and have the appropriate technical documentation, special
tools and special equipment.
Only use genuine Webasto parts. See the Webasto air and water heaters accessories cata-
logue for this purpose.
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 warnings.
The initial startup is to be executed with the Webasto Thermo Test Diagnosis.
Webasto does not accept any liability for defects and damage that are attributable to installa-
tion by untrained staff.
Ident. No.: 1311875B_EN
E
1
00 0002
E
1
00 0003
Status: 09.11.2012
© Webasto Thermo & Comfort SE

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Summary of Contents for Webasto Thermo Top E

  • Page 1 WARNING! Hazard warning: The improper installation or repair of Webasto heating and cooling systems can cause fire or the leakage of deadly carbon monoxide, leading to serious injury or death. To install and repair Webasto heating and cooling systems you need to have completed a special company training course and have the appropriate technical documentation, special tools and special equipment.

  • Page 2: Table Of Contents

    Opel Vivaro Table of Contents Validity Preparing Heater Heater / Installation Kit Installing Heater Foreword Coolant Circuit, One Heat Exchanger General Instructions Coolant Circuit, Two Heat Exchangers Special Tools 2.0 l dCi Explanatory Notes on Document 2.5 l dCi Preliminary Work Combustion Air Heater Installation Location Fuel...

  • Page 3: Heater / Installation Kit

    However, the stipulations in this "installation documentation" and "operating instructions" and the "in- stallation instructions" for the Thermo Top E / C should be observed. The corresponding rules of technology and any information from the vehicle manufacturer should be observed during the installation work.

  • Page 4: Explanatory Notes On Document

    All dimensions are in mm! Tightening torque of hose clamps = 2.0 + 0.5 Nm! Tightening torque of Ejot screws, Ejot studs = 10 Nm! Ident. No.: 1311875B_EN Status: 09.11.2012 © Webasto Thermo & Comfort SE...

  • Page 5: Preliminary Work

    - Remove the A-pillar trim in the driver's side footwell (only with Telestart). Remove page 26 "Operating Instructions for End Customer" and insert with vehicle operating instruc- tions. Heater Installation Location 1 Heater Installa- tion loca- tion Ident. No.: 1311875B_EN Status: 09.11.2012 © Webasto Thermo & Comfort SE...

  • Page 6: Electrical Connections

    F4 3 Earth wire on earth support point 3 Protective rubber plug 4 Extend positive wire with connector and red (rt) wire, 4mm² (crimp and shrink) Ident. No.: 1311875B_EN Status: 09.11.2012 © Webasto Thermo & Comfort SE...

  • Page 7: Fan Control

    Legend Fan relay FC16 Fuse 15A green K3.1 Isolating relay Switch for rear-window yellow heater, connector S70 Insulate wire end and tie back Cutting point Wiring colours may vary. Ident. No.: 1311875B_EN Status: 09.11.2012 © Webasto Thermo & Comfort SE...
  • Page 8 1 Black (sw) wire from K3/30 2 Red (rt) wire from K3/87a Connec- 4 Brown (br) wire to connector S95 of fan tion to fan switch switch 5 Brown (br) wire to resistor group Ident. No.: 1311875B_EN Status: 09.11.2012 © Webasto Thermo & Comfort SE...

  • Page 9: Remote Option (Telestart)

    2 M6x20 bolt in existing hole Mounting receiver 1 Antenna Mounting antenna Temperature sensor only in case of T100 HTM 1 Fasten temperature sensor with suitable means 2 Ventilation duct Installing tempera- ture sensor Ident. No.: 1311875B_EN Status: 09.11.2012 © Webasto Thermo & Comfort SE...

  • Page 10: Preparing Heater

    B 1 Short Ejot stud [2x], washer [2x each] 2 Long Ejot stud, 5 mm shim, washer 3 Hose section, 10 mm dia. hose clamp Premount- ing heater Ident. No.: 1311875B_EN Status: 09.11.2012 © Webasto Thermo & Comfort SE...
  • Page 11 2 M6x20 bolt, flanged nut Premount- ing ex- haust silencer 1 Hose clamp [3x] 2 Exhaust end section 3 Exhaust pipe 4 Spacer bracket Premount- ing ex- haust system Ident. No.: 1311875B_EN Status: 09.11.2012 © Webasto Thermo & Comfort SE...

  • Page 12: Installing Heater

    1 Remove trim Removing trim Remove control unit 1 (if present). Connector plugs may remain mounted. Discard fasten- ing bolts [2x]. 1 Control unit of electrical auxiliary heater Removing control unit Ident. No.: 1311875B_EN Status: 09.11.2012 © Webasto Thermo & Comfort SE...
  • Page 13 2 M10x16 bolt, spring lockwasher in existing threaded hole Mounting bracket Ensure sufficient distance from neighbouring components. 1 M8x12 bolt in existing threaded hole 2 Horn with bracket Installing horn Ident. No.: 1311875B_EN Status: 09.11.2012 © Webasto Thermo & Comfort SE...

  • Page 14: Coolant Circuit, One Heat Exchanger

    All connecting pipes = dia. 20x20. 1 = Black (sw) rubber isolator . 2 = Electrical auxiliary heater (option). 3 = original vehicle spring clip (only 2.5 l dCi) Ident. No.: 1311875B_EN Status: 09.11.2012 © Webasto Thermo & Comfort SE...

  • Page 15: Coolant Circuit, Two Heat Exchangers

    3 = Electrical auxiliary heater (option). 4 = Fuel-driven auxiliary heater (option). 5 = in case of 2.5l dC, original vehicle spring clip , in case of 2.0l dCi, hose clamp = 20-27mm dia. Ident. No.: 1311875B_EN Status: 09.11.2012 © Webasto Thermo & Comfort SE...

  • Page 16: 2.0 L Dci

    1 Hose section of heat exchanger inlet 2 Discard hose section 3 Engine outlet hose section Cutting original ve- hicle hose to length Ident. No.: 1311875B_EN Status: 09.11.2012 © Webasto Thermo & Comfort SE...

  • Page 17: L Dci

    1 Hose section of heat exchanger inlet tion on heat ex- changer in- 2.5 l dCi Connect hose B and C . 1 Spacer bracket Connec- tion to heater Ident. No.: 1311875B_EN Status: 09.11.2012 © Webasto Thermo & Comfort SE...
  • Page 18 Turn bleeder valve 2 towards front. 1 Hose section of heat exchanger inlet Turning valve 1 Hose section of heat exchanger inlet 2 Original vehicle spring clip Connec- tion on heat ex- changer in- Ident. No.: 1311875B_EN Status: 09.11.2012 © Webasto Thermo & Comfort SE...
  • Page 19 Opel Vivaro Before connecting, fill the coolant hoses with coolant. 1 Bleeder valve 2 Spacer bracket Connec- tion on en- gine outlet Ident. No.: 1311875B_EN Status: 09.11.2012 © Webasto Thermo & Comfort SE...

  • Page 20: Combustion Air

    1 Retaining clip in hole of strut 2 27 mm dia. hose clamp 3 Combustion air pipe 4 Silencer Mounting combus- tion air pipe Ident. No.: 1311875B_EN Status: 09.11.2012 © Webasto Thermo & Comfort SE...

  • Page 21: Fuel

    Route fuel line 1 and wiring harness of meter- ing pump 2 along original vehicle fuel lines on underbody to installation location of metering pump. Routing lines Ident. No.: 1311875B_EN Status: 09.11.2012 © Webasto Thermo & Comfort SE...
  • Page 22 1 Hose section, 10 mm dia. hose clamp [2x] 3 Hose section, 10 mm dia. hose clamp [2x] 4 8x5x8 fuel standpipe, 10 mm dia. hose clamp [2x] Ident. No.: 1311875B_EN Status: 09.11.2012 © Webasto Thermo & Comfort SE...

  • Page 23: Installing Trim Pieces

    1 M6x25 bolt, 5mm shim 2 Perforated bracket 3 M6x20 bolt, pin lock Preparing perforated bracket Align perforated bracket 1 and fasten using bolt 2 . 2 M6x20 bolt Mounting perforated bracket Ident. No.: 1311875B_EN Status: 09.11.2012 © Webasto Thermo & Comfort SE...
  • Page 24 1 M6 flanged nut 3 M6x25 bolt, 8mm shim, flanged nut Installing control unit Cut out trim 1 in area of markings. Cutting out trim 1 Trim Mounting trim Ident. No.: 1311875B_EN Status: 09.11.2012 © Webasto Thermo & Comfort SE...

  • Page 25: Final Work

    - For initial start-up and function check, see installation instructions. Webasto Thermo & Comfort SE Postfach 1410 82199 Gilching Germany Internet: www.webasto.com Technical Extranet: http://dealers.webasto.com Ident. No.: 1311875B_EN Ident. No.: 1311875B_EN Status: 09.11.2012 Status: 09.11.2012 © Webasto Thermo & Comfort SE © Webasto Thermo & Comfort SE...

  • Page 26: 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.

This manual is also suitable for:

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