Webasto Thermo Top E Bedienerhandbuch

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.

Water Heater

Installation Documentation

Opel Vivaro

Diesel

from model year 2007

Left-hand drive vehicle

Ident. No.: 1311875B_EN Status: 09.11.2012 © Webasto Thermo & Comfort SE

Thermo Top E Parking Heater

00 0002

Thermo Top C Parking Heater

00 0003

Opel Vivaro

1311875B 2

Table of Contents

Validity

Vehicle and engine types, equipment variants and national specifications not listed in this installation

documentationhavenot been tested. However, installationaccordingto thisinstallationdocumentation

may be possible.

The installation location of the digital timer must be coordinated with the end customer before the in-

stallation!

Manufacturer Model Type EG-BE-No. / ABE

Opel Vivaro X83 e1 * 98 / 14 * 0170 ...

Opel Vivaro F7 K830

Opel Vivaro E7 L048

Engine type Engine model Output in kW Displacement in cm³

M9R Diesel 66 1995

M9R Diesel 84 1995

G9U Diesel 107 2464

Validity 2

Heater / Installation Kit 3

Foreword 3

General Instructions 3

Special Tools 3

Explanatory Notes on Document 4

Preliminary Work 5

Heater Installation Location 5

Electrical Connections 6

Fan Control 7

Remote Option (Telestart) 9

Preparing Heater 10

Installing Heater 12

Coolant Circuit, One Heat Exchanger 14

Coolant Circuit, Two Heat Exchangers 15

2.0 l dCi 16

2.5 l dCi 17

Combustion Air 20

Fuel 21

Installing Trim Pieces 23

Final Work 25

Operating Instructions for End Customer 26

Opel Vivaro

1311875B 3

Heater / Installation Kit

Foreword

This installation documentation applies to the vehicles Opel Vivaro Diesel - for validity, see page 2 -

from model year 2007 and later, assuming technical modifications to the vehicle do not affect installa-

tion, any liability claims excluded. Depending on the vehicle version and equipment, modifications may

be necessary during installation with respect to this installation documentation.

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.

General Instructions

Installation should be carried out according to the general, standard rules of technology. Unless spec-

ified otherwise, fasten hoses, lines and wiring harnesses to original vehicle lines and wiring harnesses

using cable ties. Insulate loose wires and tie back.

Sharp edges must be provided with rub protection (cut-open fuel hose)!

Spray unfinished body areas, e.g. drilled holes, with anti-corrosion wax (Tectyl 100K, Order No. 111329).

While installing an IPCU, the corresponding settings must be checked or adjusted before the installa-

tion!

Special Tools

- Torque wrench for 2.0 - 10 Nm

- Hose clamping pliers

- Torx E5 nut

Quantity Designation Order No.:

1 Opel-specific heater delivery scope See Opel price list

1 Installation kit for Opel Vivaro starting with 2001 Diesel 9002568J

1 Heater control See Opel price list

Opel Vivaro

Special features are highlighted using the following symbols:

The arrow in the vehicle icon indicates the position on

the vehicle and the viewing angle.

Specific risk of injury or fatal accidents.

Specific risk of damage to components.

Specific risk of fire or explosion.

Referenceto general installationinstructionsof Webas-

tocomponentsortothemanufacturer'svehicle-specific

documents.

Reference to a special technical feature.

Mechanical system

Electrical system

Coolant circuit

Fuel

Exhaust gas

Combustion air

Software

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 4

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.

Opel Vivaro

Ident. No.: 1311875B_EN Status: 09.11.2012 © Webasto Thermo & Comfort SE 5

Preliminary Work

WARNING!

- Open the fuel tank cap and vent the fuel tank.

- Close the fuel tank cap again.

- Disconnect the battery earth connection.

-Depressurisethe 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.

- Remove the entire air filter box together with the intake hose.

- Remove the front apron.

- Remove the horn with the bracket.

- Remove the left-hand headlight.

- Detach and remove the right and left-hand wheel well trim.

- Remove the bumper with trim pieces.

- Remove the underride protection (2-piece).

- Remove the lower instrument panel trim on the front passenger side.

- Take off the left-hand side trim of the instrument panel (only with HTM 100).

- 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

1Heater

Installa-

tion loca-

tion

Opel Vivaro

Ident. No.: 1311875B_EN Status: 09.11.2012 © Webasto Thermo & Comfort SE 6

Electrical Connections

Digital timer, summer/winter switch option

1Digital timer

2Summer/winter switch, drilled hole 12 mm dia.

Additional fuse F4

Connect red (rt) positive wire, 4mm², to positive

support point. Fasten retaining plate of fuse hold-

er with 3x9 self-tapping screw on battery carrier.

Mount fuse, F4 30A 1.

Diagram of

wiring har-

ness rout-

ing

Fuse holder, K3 relay

14mm dia. hole, 5.5x13 self-tapping screw

K3 relay

24mm dia. hole, 5.5x13 self-tapping screw

Retaining plate, fuse holder

3Earth wire on earth support point

4Extend positive wire with connector and red

(rt) wire, 4mm² (crimp and shrink)

Wiring harness pass through

1Wiring harness of fan controller, wiring har-

ness of digital timer

2Route extended positive wire in protective

sleeving to battery box and connect to fuse F4

3Protective rubber plug

Do not install the meter-

ing pump wiring harness

until later together with

fuelline along the original

vehicle fuel lines on the

underbody

Opel Vivaro

Ident. No.: 1311875B_EN Status: 09.11.2012 © Webasto Thermo & Comfort SE 7

Fan Control

Wiring dia-

gram

Webasto components Vehicle components Colours and symbols

Legend

HG Heater TT-C/E GM Fan motor rt red

X1 6-pin connector WG Resistor group X70 ws white

F3 Fuse 25A GS Fan switch S95 sw black

F4 Additional fuse, 30 A FC25 25A fan fuse br brown

K3 Fan relay FC16 Fuse 15A gn green

K3.1 Isolating relay SH Switch for rear-window

heater, connector S70 ge yellow

Insulate wire end and tie

back

XCutting point

Wiring colours may vary.

Webasto

Opel

rt/ws

gn/

S95

X70

S70

0,5mm²

3 mm²

2 mm²

ge 0,5mm²

85 30

87a87

X1 4

86 30

87a87

K3.1

FC25 FC16

4 mm²

1,5 mm²

4 mm²

Opel Vivaro

Ident. No.: 1311875B_EN Status: 09.11.2012 © Webasto Thermo & Comfort SE 8

1Isolating relay K3.1, M5x16 bolt, flanged

nut on existing hole

2Mount M8x16 bolt, flanged nut in existing

hole

3Brown (br) wire from K3.1/85, 8 mm dia.

cable lug Installing

isolating

relay

Connection to connector S95 4of fan switch.

Produce connections as shown in wiring dia-

gram.

Yellow (ge) wire from original vehicle fuse FC25

2Yellow (ge) wire from K3.1/87

3Yellow (ge) wire to connector S95 of fan

switch, Pin B4

Connec-

tion to fan

switch

Connection to connector S70 3of switch for

rear-window heater.

Produce connections as shown in wiring dia-

gram.

1Yellow (ge) wire from K3.1/86

2Insulate free yellow (ge) wire and tie back

4Yellow (ge)wireto connectorS70 of switch

for rear-window heater

Yellow (ge) wire from original vehicle fuse FC16

Connec-

tion of

rear-win-

dow heat-

er switch

Connection to connector S95 3of fan switch.

Produce connections as shown in wiring dia-

gram.

1Black (sw) wire from K3/30

2Red (rt) wire from K3/87a

4Brown (br) wire to connector S95 of fan

switch

5Brown (br) wire to resistor group

Connec-

tion to fan

switch

1 2

45 3

Opel Vivaro

Ident. No.: 1311875B_EN Status: 09.11.2012 © Webasto Thermo & Comfort SE 9

Remote Option (Telestart)

Drill out bracket 3to 6.5 mm dia. at position 2.

1Receiver

2M6x20 bolt in existing hole Mounting

receiver

1Antenna

Mounting

antenna

Temperature sensor only in case of T100 HTM

1Fasten temperature sensor with suitable

means

2Ventilation duct Installing

tempera-

ture sensor

Opel Vivaro

Ident. No.: 1311875B_EN Status: 09.11.2012 © Webasto Thermo & Comfort SE 10

Preparing Heater

2,0 l dCi

Discard section X.

A=650

B=120

C=470

Cutting

coolant

hoses to

length

2.5 l dCi

Discard section X.

A=825

B=120

C=655 Cutting

coolant

hoses to

length

All vehicles

127 mm dia. spring clip

227 mm dia. hose clamp

320x20 connecting pipe Premount-

ing hose B

1Short Ejot stud [2x], washer [2x each]

2Long Ejot stud, 5 mm shim, washer

3Hose section, 10 mm dia. hose clamp

Premount-

ing heater

B 1

3 2

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