Webasto Thermo Top E Bedienungsanleitung

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 equip-

ment 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 tech-

nical skills, or if you do not have access tothe 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 warn-

ings.

Webasto does not accept any liability for defects and damage that are attributable to

installation by untrained staff.

Feel the drive

Nissan Pathfinder and Navara

2.5 liter Diesel

from Model Year 2005

For left-hand drive vehicles only

Ident. No.: 1303637F_EN Fee Euro 10 © Webasto AG

Feel the drive

Water Heater Unit

Thermo Top E Additional Heater

Thermo Top C Additional Heater

Thermo Top P Additional Heater

Installation Instructions

00 0003

00 0002

00 0104

Nissan Pathfinder and Navara

Validity

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

instructionshave notbeen tested.However, installationaccordingto theseinstallationinstructions may

be possible.

The installation location of a digital timer and summer/winter switch should be confirmed with the end

customer before installation.

Manufacturer Model Type EG-BE No./ABE

Nissan Pathfinder R51 e9 * 2001/116 * 0051 * ...

Nissan Pathfinder R51 K492

Nissan Navara D40 L617

Engine type Engine model Output in kW Displacement in cm³

YD25 Diesel 128 2488

YD25 Diesel/DPF 126 2488

Validity 2

Heater Unit/Installation Kit 3

Foreword 3

General Instructions 3

Special Tools 3

Explanatory Notes on Document 4

Preliminary Work 5

Heater unit installation location 5

Preparing electrical system 6

Electrical Connections 7

Remote option (Telestart) 8

Remote Option (Telestart) 8

Remote option (Thermo Call) 9

Fan controller for manual air conditioning 10

Automatic air-conditioning fan controller 12

Switch-off function of passenger compartment

monitoring 14

Preparing installation location 16

Premounting heater unit 17

Installing Heater Unit 19

Coolant connection with manual transmission 20

Coolant connection for automatic transmission 24

Combustion air 28

Fuel Connection 29

Exhaust system 31

Final Work 34

Operating Instructions for End Customer 36

Table of Contents

Nissan Pathfinder and Navara

Heater Unit/Installation Kit

Heater unit recommended for the respective vehicle class:

The selection of the heater unit is based on the passenger compartment size of the vehicle and the

level of comfort required by the customer!

Foreword

These installation instructions apply to Nissan Pathfinder and Navara vehicles with 2.5 liter Diesel

engines - for validity, see page 2 - from model year 2005 and later, assuming technical modifications

to the vehicle do not affect installation, any liability claims excluded. Depending on the vehicle version

and equipment, modifications may be necessary during installation with respect to these installation

instructions.

However,the stipulations inthe "installationinstructions" and"operatingand maintenanceinstructions"

for the Thermo Top C/P/E must always 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.

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).

Special Tools

- Torque wrench for 2.0 - 10 Nm

- Hose clamping pliers

Quantity Description Order No.:

1 Nissan-specific heater unit delivery scope See Nissan price list

1 Installation Kit for Nissan Pathfinder 2.5 liter Diesel 1303633C

1 Heater control See Nissan price list

Vehicle Heater Unit

Compact car Thermo Top E

Mid-size car, station wagon Thermo Top C

Full-size car, van, offroader Thermo Top P

Special features are highlighted using the following symbols:

Mechanical work

Electrical system

Coolant connection

Fuel connection

Exhaust system

Combustion air

The arrow in the vehicle icon indicates the position on

the vehicle and the viewing angle.

Nissan Pathfinder and Navara

Specific risk of injury or fatal accidents.

Specific risk of damage to components.

Specific risk of fire or explosion.

Referenceto generalinstallationinstructions of Webas-

tocomponentsortothemanufacturer'svehicle-specific

documents.

Reference to a special technical feature.

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.

Nissan Pathfinder and Navara

Preliminary Work

WARNING!

- Copy the factory number from the original type label to the duplicate type label.

- Remove years that do not apply from duplicate label.

- Attach the duplicate label (type label) in the appropriate place.

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

- Close the tank cap again.

- Disconnect and remove the battery.

-Depressurizethe cooling system!

- Remove the engine cover.

- Remove the intake hose between the intercooler and the engine.

- Detach the fuel filter.

- Remove the right front wheel.

- Remove the right-hand wheel well trim.

- Remove the underride protection.

- Remove the lower footwell trim on the front passenger side (not with automatic air-conditioning).

- Remove the A-pillar trim on the front passenger side (with passenger compartment monitoring)

- Remove front interior lighting and monitoring sensors (with passenger compartment monitoring)

- Expose the A/C control panel (only with automatic air-conditioning).

Heater unit installation location

1Heater unit

Installa-

tion loca-

tion

Nissan Pathfinder and Navara

Preparing electrical system

All equipment

Cutting

wire to

length

Produce connections as shown in wiring dia-

gram.

Cut included protective sleeving to length of

2,500 and push onto wire .

Only with passenger compartment moni-

toring

Also connect 3,000 mm long red (rt) wire

to K3/86 and pull into protective sleeving.

Connect-

ing fuse

Cut off tab connector at Position 3and crimp

on connector.

(2) Diode group

(1) Connector [2x]

(4) Insulate blue (bl) wire [2x] and tie back

Preparing

diode

group

Only with automatic air-conditioning

Wire sections and will be used later.

Cutting

wire to

length

2900

100

2sw

1mm²

85 30

87a87

1 2

gn/ws

rt 52

2,5mm²

3 4

Nissan Pathfinder and Navara

Electrical Connections

Fuse holder, relay K3

WARNING:

Do not damage tank

(1) 6.5 mm dia. hole

Fuse holder, relay K3

(3) M6x12 bolt, angle bracket, flanged nut

(4) Retaining plate, M5x12 bolt, large diameter

washer, flanged nut

(5) Fuse holder mounted

(2) K3 relay, M5x12 bolt, large diameter washer,

flanged nut

(1) Positive wire on positive support point

(6) Ground wire on battery terminal

Wiring

harness

installa-

tion dia-

gram

Wiring harness pass through

(1) Protective rubber plug Digital Timer and Summer/Winter Switch

(1) Summer/winter switch, hole 12 mm dia.

(2) Digital timer with extension wiring harness,

drilling template

41 2 3 5

Donotinstallthemeteringpump

cable harness until later togeth-

er with fuel pipe along the origi-

nal vehicle fuel lines on the

underbody

1 2

Nissan Pathfinder and Navara

Remote option (Telestart)

(1) Receiver

(2)4 mm dia.hole; 5.5x13 self-tappingscrew

[2x]

Installing

receiver

Produce all connections in accordance with

general installation instructions provided and

fasten wires with cable ties.

(1) Antenna

Installing

antenna

Nissan Pathfinder and Navara

Remote option (Thermo Call)

(1) Receiver

(2)4 mm dia.hole; 5.5x13 self-tappingscrew

[4x]

Installing

receiver

(1) Antenna

Installing

antenna

Produce all connections in accordance with

general installation instructions provided and

fasten wires with cable ties.

(1) Push button

Installing

push but-

ton

Nissan Pathfinder and Navara

Fan controller for manual air conditioning

Wiring dia-

gram for

manual air

condition-

ing

Webasto components Nissan components Colors and symbols

Legend

HG Heater unit GM Fan motor rt red

X1 6-pin heater unit con-

nector gr Fan relay ws white

F3 25 A fuse WG Resistor group sw black

K3 Fan relay M95 4-pin connector WG br brown

F4 3 A fuse GS Fan switch gn green

D Diode group M59 8-pin connector GS bl blue

F24 15 A fuse gr gray

*Red (rt) wire only on

veh. with passenger

compartment monitoring

F27 15 A fuse vi violet

F8 10 A fuse pk pink

KB A/C control panel Insulate wire ends and

tie back

M98 26-pin connector KB XCutting point

Wiring colors may vary.

gn/

rt/ws

Webasto Nissan

vi vi

X1 4F3

85 30

87a87

F4 2

GM M

3GR

2 7

3 2 4 1

2378

F24 F27

ws/sw

M95

M59

M98 18 6 20

BCM

rt*5

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