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Webasto Thermo Top Evo Installation Documentation

Opel astra 2016- parking heater
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Part numbers: 13437784_eng_astra / 13476204_eng_astra / 39123383
07 8

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Summary of Contents for Webasto Thermo Top Evo

  • Page 1 Part numbers: 13437784_eng_astra / 13476204_eng_astra / 39123383 07 8...
  • Page 2 Part numbers: 13437784_eng_astra / 13476204_eng_astra / 39123383...

  • Page 3: Validity

    Part numbers: 13437784_eng_astra / 13476204_eng_astra / 39 123 383 Water Heater Thermo Top Evo Parking Heater 00 0258 www.ifz-berlin.de Check NEW UPDATES 8,5 h Installation Documentation Opel Astra Validity Manufacturer Model Type EG-BE-No. / ABE Opel Astra e4 * 2007 / 46 * 0996*00...

  • Page 4: Table Of Contents

    Preparing Electrical System Template for Diesel Fuel Standpipe Necessary Components • Specific delivery scope of Thermo Top Evo petrol or diesel: GM parts No. for petrol: 13 437 784 GM Part No. diesel: 13 476 204 • Installation kit for Opel Astra 2016 petrol and diesel GM Part No.: 39 123 383...

  • Page 5: Information On Operating And Installation Instructions

    To ensure safe operation, we recommend having the heater checked every two years 2.2. Positioning of heater by an authorised Webasto dealer, especially when used over a long period and/or un- der extreme environmental conditions. 2.2.1. Body sections and any other components in the vicinity of the heater must be Do not operate the heater in closed rooms due to the danger of poisoning and protected from excessive heat and the possibility of fuel or oil contamination.

  • Page 6: Information On Validity

    • Torque wrench for 2.0 - 10 Nm • Deep-hole marker • Hose clamping pliers • Metric thread-setter kit • Webasto Thermo Test Diagnosis with current software Dimensions • All dimensions are in mm. Tightening torque values • Tightening torque values of 5x13 heater bolts and 5x11 heater stud bolts = 8Nm.

  • Page 7: Preliminary Work

    • Remove years that do not apply from the type and duplicate label. • Attach the duplicate label (type label) visibly in the appropriate place in the engine compart- ment. Heater Installation Location 1 Heater Installation location Ident. No.: 1324278F Status: 26.07.2018 © Webasto Thermo & Comfort SE...

  • Page 8: Preparing Electrical System

    4 Telestart receiver bracket Installing SVM module and receiver bracket Roll up temperature sensor wiring harness 2 at position 1 and fix with cable ties 3. Preparing tempera- ture sensor Ident. No.: 1324278F Status: 26.07.2018 © Webasto Thermo & Comfort SE...
  • Page 9 1 Temperature sensor connector 2 Wiring harness connector of passen- ger compartment (assigned 3x) Connect- ing passen- compart- ment wiring harness Stick 400mm foam 1 around aerial cable 2. Preparing aerial Ident. No.: 1324278F Status: 26.07.2018 © Webasto Thermo & Comfort SE...
  • Page 10 1 Telestart 5A fuse F1 2 SVM module 5A fuse F2 3 Heater 20A fuse F3 4 Retaining plate for fuse holder Preparing 5 Fuse holder wiring har- ness of heater Ident. No.: 1324278F Status: 26.07.2018 © Webasto Thermo & Comfort SE...
  • Page 11 Part numbers: 13437784_eng_astra / 13476204_eng_astra / 39123383 Opel Astra 1 M5x12 bolt, large diameter washer 2 Retaining plate 3 Fuse holder bracket Preparing fuse holder Ident. No.: 1324278F Status: 26.07.2018 © Webasto Thermo & Comfort SE...

  • Page 12: Electrical System

    2 Positive wire on original vehicle positive support point 1 Fuse holder installed 3 Optional if chamber 7 is free, connect posi- 2 Large diameter washer, M5 flanged nut tive wire Ident. No.: 1324278F Status: 26.07.2018 © Webasto Thermo & Comfort SE...
  • Page 13 Route passenger compartment wiring har- ness 1 along original vehicle wiring har- ness 2 into the engine compartment. 3 Heater wiring harness Routing wiring har- ness Ident. No.: 1324278F Status: 26.07.2018 © Webasto Thermo & Comfort SE...
  • Page 14 Part numbers: 13437784_eng_astra / 13476204_eng_astra / 39123383 Opel Astra Route passenger compartment wiring har- ness 1 along original vehicle wiring har- ness to the firewall. Routing wiring har- ness Ident. No.: 1324278F Status: 26.07.2018 © Webasto Thermo & Comfort SE...

  • Page 15: Preparing Heater

    1 Combustion air pipe 2 Fuel line 3 90° moulded hose, 10 mm dia. clamp [2x] Installing combus- tion air pipe / fuel line 1 Bracket 2 Decoupling rubber Preparing bracket Ident. No.: 1324278F Status: 26.07.2018 © Webasto Thermo & Comfort SE...
  • Page 16 Part numbers: 13437784_eng_astra / 13476204_eng_astra / 39123383 Opel Astra CP1 Clamping plate 1 Intermediate plate CP2 Clamping plate 2 Preparing bracket Preparing bracket Preparing bracket Preparing bracket Ident. No.: 1324278F Status: 26.07.2018 © Webasto Thermo & Comfort SE...
  • Page 17 1 Circulating pump 2 Circulating pump mount 3 Circulating pump wiring harness con- nector, installed 4 Fasten circulating pump using M6 flanged nut Installing 5 Cable tie circulating pump Ident. No.: 1324278F Status: 26.07.2018 © Webasto Thermo & Comfort SE...
  • Page 18 1 10mm dia. 350mm long corrugated tube on fuel line 2 20x5 hose bracket between combus- tion air pipe and fuel line 3 Cable tie Fastening fuel line Ident. No.: 1324278F Status: 26.07.2018 © Webasto Thermo & Comfort SE...

  • Page 19: Installing Heater

    1 . 1 M8 flanged nut [2x] Installing heater 1 M6x16 bolt, large diameter washer, original vehicle hole, flanged nut 2 Wiring harness of heater, installed [2x] Installing heater Ident. No.: 1324278F Status: 26.07.2018 © Webasto Thermo & Comfort SE...

  • Page 20: Fan Controller

    Telestart HTM 100 green Legend Temperature sensor grey Push button white Diagnosis connector blue 5A fuse brown 5A fuse 20A fuse Special Vehicle Module Cutting point Wiring colours may vary. Ident. No.: 1324278F Status: 26.07.2018 © Webasto Thermo & Comfort SE...
  • Page 21 2 Large diameter washer, flanged nut Installing SVM module bracket 1 Diagnosis wire Routing wiring har- ness Wrap diagnosis connector 2 with foam. 1 Diagnosis wire Position di- agnosis connector Ident. No.: 1324278F Status: 26.07.2018 © Webasto Thermo & Comfort SE...
  • Page 22 4 Green/white (gn/ws) wire of Low Speed Can Drill 6 mm dia. hole at position 1 . 1 M5x12 bolt, flanged nut 2 Position of temperature sensor is hid- Installing temperature sensor Ident. No.: 1324278F Status: 26.07.2018 © Webasto Thermo & Comfort SE...

  • Page 23: Fuel

    1 Wiring harness of metering pump and fuel line in corrugated tube attached to original vehicle fuel lines with cable ties Routing lines Ident. No.: 1324278F Status: 26.07.2018 © Webasto Thermo & Comfort SE...
  • Page 24 Unclip ABS connector 2 . 1 Copy hole pattern, drill 6.5 mm dia. hole Preparing installation location of metering pump Connector X7 Complet- ing meter- ing pump connector Pin assignment is not relevant. Ident. No.: 1324278F Status: 26.07.2018 © Webasto Thermo & Comfort SE...
  • Page 25 Diesel vehicles with engine codes: LVK / LVL / LWQ/ LWV Bend fuel standpipe 1 according to tem- plate and cut to length. Installing fuel stand- pipe Ident. No.: 1324278F Status: 26.07.2018 © Webasto Thermo & Comfort SE...
  • Page 26 Install fuel tank in accordance with manu- facturer's instructions. Ensure sufficient distance from neighbouring components, correct if necessary. 1 10 mm dia. clamp Connect- 2 Fuel line of fuel standpipe ing meter- ing pump Ident. No.: 1324278F Status: 26.07.2018 © Webasto Thermo & Comfort SE...

  • Page 27: Coolant Circuit/ Petrol/ Engine: Le1/ Le2

    The connection should be modelled on an ‘inline’ circuit and based on the following diagram: Hose rout- ing diagram All spring clips without a specific designation = 27 mm dia. 1 = Black (sw) rubber isolator 2 = Original vehicle spring clip Ident. No.: 1324278F Status: 26.07.2018 © Webasto Thermo & Comfort SE...

  • Page 28: Coolant Circuit/ Diesel/ Engine: Lvk/ Lvl/ Lwq/ Lwv

    The connection should be modelled on an ‘inline’ circuit and based on the following diagram: Hose rout- ing diagram Ø 15x18 Ø 25 Ø 23 Ø 18x18 Ø 25 Ø 25 All spring clips without a specific designation = 27 mm dia. Ident. No.: 1324278F Status: 26.07.2018 © Webasto Thermo & Comfort SE...
  • Page 29 4 Hose C=Petrol, D=Diesel, heat ex- changer inlet connection 1 180° moulded hose B=Petrol, C=Diesel 2 Circulating pump inlet connection 3 Heater outlet connection Moulded hose B / C Ident. No.: 1324278F Status: 26.07.2018 © Webasto Thermo & Comfort SE...
  • Page 30 1 Hose A with 15mm dia. connection piece in hose B Connect- ing hoses A and B All vehicles Route hose group along frame side mem- ber in the engine compartment Routing hose group Ident. No.: 1324278F Status: 26.07.2018 © Webasto Thermo & Comfort SE...
  • Page 31 / heater Installation info for next figure. 1 30 mm spacer 2 25 mm rubber-coated p-clamp 3 M6x50 bolt 4 Large diameter washer [2x] Installing rubber-coat- ed pipe clamp Ident. No.: 1324278F Status: 26.07.2018 © Webasto Thermo & Comfort SE...
  • Page 32 Petrol vehicles with engine codes: LE1 / LE2 1 Hose of engine outlet / heat exchang- er inlet 2 Disassemble hose bracket, will be re- Removing installed later hose bracket Ident. No.: 1324278F Status: 26.07.2018 © Webasto Thermo & Comfort SE...
  • Page 33 1 Coupling of hose C on heat exchang- er inlet Connect- ing heat ex- changer inlet 1 Brake line 2 20x5mm dia. hose bracket between hose C and brake line Routing Ident. No.: 1324278F Status: 26.07.2018 © Webasto Thermo & Comfort SE...
  • Page 34 (at least 20mm). Routing 1 8x25mm dia. hose bracket between hose C and A/C line [3x] Routing 1 25x25mm dia. hose bracket between hose A and hose C Routing Ident. No.: 1324278F Status: 26.07.2018 © Webasto Thermo & Comfort SE...
  • Page 35 / LVL / LWQ / LWV Cut hose of engine outlet/heat exchanger inlet as shown. Detach section X on heat exchanger and discard. Cutting point 1 Cutting point 2 Engine outlet hose section Ident. No.: 1324278F Status: 26.07.2018 © Webasto Thermo & Comfort SE...
  • Page 36 2 Coupling of hose D on heat exchang- er inlet 3 Brake line 4 5x25mm dia. hose bracket between Connect- hose D and brake line ing heat ex- changer inlet Ident. No.: 1324278F Status: 26.07.2018 © Webasto Thermo & Comfort SE...

  • Page 37: Coolant Circuit/ Petrol/ Engine: Lwc

    Ø 23 Ø 23 All spring clips without a specific designation = 25 mm dia. All connecting pipes without a specific designation = 15x15 1 = Black (sw) rubber isolator Ident. No.: 1324278F Status: 26.07.2018 © Webasto Thermo & Comfort SE...
  • Page 38 1 Remove hose bracket [2x] Preparing hose group Remove an approx. 20mm wide section of braided protection from hose A at both cutting points 1 . Discard section X . Preparing hose A Ident. No.: 1324278F Status: 26.07.2018 © Webasto Thermo & Comfort SE...
  • Page 39 [2x] Premount- ing hose C Remove an approx. 20mm wide section of braided protection from hose A at cutting point 1 . Discard section X . Preparing hose A Ident. No.: 1324278F Status: 26.07.2018 © Webasto Thermo & Comfort SE...
  • Page 40 2 Circulating pump inlet connection 3 Heater outlet connection Moulded hose B / C Route hose group along frame side mem- ber in the engine compartment Routing hose group Connect- ing heater inlet Ident. No.: 1324278F Status: 26.07.2018 © Webasto Thermo & Comfort SE...
  • Page 41 3 M6x50 bolt 4 Large diameter washer [2x] Installing rubber-coat- ed pipe clamp 1 Flanged nut 2 25 mm rubber-coated p-clamp (see previous figure) Routing in engine compart- ment Ident. No.: 1324278F Status: 26.07.2018 © Webasto Thermo & Comfort SE...
  • Page 42 Fasten hose C with cable tie 2 to coolant reservoir. Routing in engine compart- ment Place hose C at position 2 against the body and fasten using cable tie 1 . Routing in engine com- partment Ident. No.: 1324278F Status: 26.07.2018 © Webasto Thermo & Comfort SE...
  • Page 43 1 8x25mm dia. hose bracket between hose A and fuel line [2x] Routing Remove and discard section X . 1 Cutting point 2 Hose of engine outlet / heat exchang- er inlet Cutting point Ident. No.: 1324278F Status: 26.07.2018 © Webasto Thermo & Comfort SE...
  • Page 44 Part numbers: 13437784_eng_astra / 13476204_eng_astra / 39123383 Opel Astra 1 Align black (sw) rubber isolator with brake booster 2 25mm dia. spring clip 3 Engine outlet hose section Connect- ing hoses A and C Ident. No.: 1324278F Status: 26.07.2018 © Webasto Thermo & Comfort SE...

  • Page 45: Exhaust Gas

    1 Underride protection 2 60 mm dia. hole Cutting out underride protection Install underride protection 1 . Align ex- haust end section 2 . Aligning ex- haust end section Ident. No.: 1324278F Status: 26.07.2018 © Webasto Thermo & Comfort SE...

  • Page 46: Final Work

    F1 1 . 1 Telestart 5A fuse F1 2 SVM module 5A fuse F2 3 Heater 30A fuse F3 Inserting fus- 1 Type label Sticking on type label Ident. No.: 1324278F Status: 26.07.2018 © Webasto Thermo & Comfort SE...

  • Page 47: Template For Petrol Fuel Standpipe

    Compare the size of the printed version with dimension lines. Permitted tolerance a maximum of 2%. Set the printer settings to 'no margin' or 'minimise mar- gins' and 100% of the normal size. 100mm Ident. No.: 1324278F Status: 26.07.2018 © Webasto Thermo & Comfort SE...

  • Page 48: Template For Diesel Fuel Standpipe

    Compare the size of the printed version with dimension lines. Permitted tolerance a maximum of 2%. Set the printer settings to 'no margin' or 'minimise mar- gins' and 100% of the normal size. 100mm Ident. No.: 1324278F Status: 26.07.2018 © Webasto Thermo & Comfort SE...

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