Table of Contents
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Water Heater Unit
Thermo Top E Additional Heater
Thermo Top C Additional Heater
Installation Instructions
SUBARU Legacy / Outback
Gasoline
from Model Year 2004
Left-hand drive vehicle
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 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.
ALWAYS follow all Webasto installation and repair instructions and observe all warnings.
Webasto does not accept any liability for defects and damage that are attributable to
installation by untrained staff.
Ident. No.:1302628C_EN
e1
00 0003
e1
00 0002
Fee Euro 10.00
Feel the drive
© Webasto AG
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Table of Contents
Related Manuals for Webasto SUBARU Legacy
Summary of Contents for Webasto SUBARU Legacy
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Page 1: Installation Instructions
Left-hand drive vehicle 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. -
Page 2: Table Of Contents
SUBARU Legacy / Outback Table of Contents Validity Preparing heater unit Heater Unit/Installation Kit Preparing installation location Foreword Exhaust system with manual transmission General Instructions Exhaust system with automatic transmission 17 Special Tools Installing heater unit Explanatory Notes on Document... -
Page 3: Heater Unit/Installation Kit
Foreword These installation instructions apply to SUBARU Legacy / Outback Gasoline vehicles - for validity, see page 2 - from model year 2004 and later, assuming technical modifications to the vehicle do not affect installation, any liability claims excluded. -
Page 4: 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 5: Preliminary Work
SUBARU Legacy / Outback Preliminary Work WARNING! - Empty the fuel tank. - 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. -
Page 6: Electrical Connections
SUBARU Legacy / Outback Electrical Connections Pass through of fuel line and wiring harness Wiring harness pass through of metering pump Leave approx. 50 cm of fuel line in engine With automatic transmission, use protective compartment. rubber plug in firewall on driver's side. -
Page 7: Fan Connection Version A
SUBARU Legacy / Outback Fan connection Version A 1 Remove central electrical box, back 2 Socket of 10-pin connector 3 Socket of 24-pin connector Discon- necting connector from cen- tral electri- cal box 1 10-pin connector, gray D (B152) disconnected... - Page 8 SUBARU Legacy / Outback Webasto Subaru Legacy / Outback Wiring diagram for Version gn/ws rt/ws FB 28 FB 29 FB 45 FB 46 gn/ge ge/rt (gn/or) ws/sw gn/ge ge/rt (gn/or) Webasto components Vehicle components Colors and symbols Heater unit TT-C/P Fuse, 7.5 A...
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Page 9: Fan Connection Version B
SUBARU Legacy / Outback Fan connection Version B 1 Remove central electrical box, back 2 Socket of 24-pin connector Discon- necting connector from cen- tral electri- cal box 1 24-pin connector white C (B52) disconnected 2 Green/yellow (gn/ge) or green/orange... - Page 10 SUBARU Legacy / Outback Webasto Subaru Legacy / Outback Wiring diagram for Version gn/ws rt/ws FB 28 FB 29 FB 45 FB 46 gn/ge (gn/or) ws/sw gn/ge (gn/or) A9/21 Webasto components Vehicle components Colors and symbols Heater unit TT-C/P Fuse, 7.5 A...
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Page 11: Remote Option (Telestart)
SUBARU Legacy / Outback Remote option (Telestart) 1 Receiver 2 Original vehicle bolt 3 Bracket, angle down 90° Installing receiver 1 Antenna Installing antenna 1302628C_EN... -
Page 12: Preparing Heater Unit
SUBARU Legacy / Outback Preparing heater unit 1 Exhaust pipe a = 150 mm 2 Exhaust end section b = 450 mm Preparing exhaust Discard section X pipe Loosely mount lower hose clamp. 1 Hose clamp [2x] 2 Exhaust pipe... -
Page 13: Preparing Installation Location
SUBARU Legacy / Outback Preparing installation location 1 Cut out insulating mat 2 Original vehicle wiring harness 3 6 mm dia. hole Hole in firewall 1 Cable clip Tie back wiring harness 1 Hole for protective rubber plug Removing rubber grommet Remove protective rubber plug from hole 2 . - Page 14 SUBARU Legacy / Outback 1 Original vehicle hole 2 7 mm dia. hole Hole in wheel well 1 M6x30 bolt, large diameter washer, 10 mm shim, pin lock 2 M6x20 bolt, large diameter washer, pin lock Mounting bolts Loosely mount and align heater unit and strut.
- Page 15 SUBARU Legacy / Outback Ensure sufficient spacing (at least 5 mm) between bracket 1 and brake line 2 . Cut out bracket 1 along marking if necessary. Remove heater unit. Cutting out bracket 1 7 mm dia. hole Hole in...
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Page 16: Exhaust System With Manual Transmission
SUBARU Legacy / Outback Exhaust system with manual transmission 1 Exhaust muffler 2 Angle bracket, M6x20 bolt, flanged nut 3 M6x20 bolt, spring lockwasher Installing exhaust muffler 1 Perforated bracket 2 M6x20 bolt, large diameter washer, M6 flanged nut Installing... -
Page 17: Exhaust System With Automatic Transmission
SUBARU Legacy / Outback Exhaust system with automatic transmission 1 Exhaust muffler 2 Angle bracket, M6x20 bolt, flanged nut 3 M6x20 bolt, spring lockwasher Installing exhaust muffler 1 Drill 9.1 mm dia. hole; install rivet nut Installing rivet nut 1 20 mm spacer... -
Page 18: Installing Heater Unit
SUBARU Legacy / Outback Installing heater unit Connect exhaust pipe before installing heater unit on muffler. Align heater unit. Ensure sufficient distance to neighboring components. Tighten Ejot Installing screws; tighening torque 10 Nm. heater unit 1 M6x20 bolt, large diameter washer,... -
Page 19: Combustion Air
SUBARU Legacy / Outback Combustion air 1 Combustion-air intake muffler 2 Retaining clip in hole 3 Combustion-air intake pipe 4 27 mm dia. hose clamp Installing 5 Hole combus- tion air pipe 1302628C_EN... -
Page 20: Coolant Connection
SUBARU Legacy / Outback 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. - Page 21 SUBARU Legacy / Outback a = 330 mm b = 430 mm Discard section X Cutting coolant hoses to length Push braided protection hoses onto hose A and B and cut to length. Cut heat shrink plastic tubing to length.
- Page 22 SUBARU Legacy / Outback 1 Original vehicle hose on engine outlet Connec- tion to heater unit inlet Before connecting, fill the coolant hoses with coolant. 1 Original vehicle hose on heat exchanger inlet Connec- tion to heater unit outlet 1302628C_EN...
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Page 23: Fuel Connection
SUBARU Legacy / Outback 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. - Page 24 SUBARU Legacy / Outback Installation location behind vehicle fuel tank! 1 Metering pump 2 Mecanyl fuel line from heater unit 3 Metering pump wiring harness Installation location of metering pump 1 Existing hole Mounting metering pump Ensure proper installation position of metering pump, see "Installation...
- Page 25 SUBARU Legacy / Outback Cut off tank ventilation line at marking as shown. 1 Ventilation line 2 Cutting point Cutting point Bend fuel standpipe, but do not shorten. Ensure correct position of standpipe. 1 Standpipe 2 Fuel standpipe Bending fuel...
- Page 26 SUBARU Legacy / Outback Remove fuel-tank sending unit in accordance with manufacturer's instructions. Align end of standpipe, 5-7mm, to bottom of fuel tank. 1 Fuel standpipe Installing 2 8 mm dia. hose clamp hose 3 Hose section section Fuel line from fuel standpipe on intake side of metering pump [side without connector].
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Page 27: Final Work
SUBARU Legacy / Outback Final Work WARNING! Reassemble the disassembled components in reverse order. Check all hoses, clamps and all electrical connections for firm seating. Secure all loose cables using cable ties. Only use manufacturer-approved coolant. Spray the heater unit components with anti-corrosion wax (Tectyl 100K, Order No. 111329). -
Page 28: Operating Instructions For End Customer
SUBARU Legacy / Outback 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.