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 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.

Water Heater Unit

Installation Instructions

Ident. No.:1311875A_EN Fee Euro 10.00 © Webasto AG

Opel Vivaro

Diesel

from Model Year 2007

Left-hand drive vehicle

Feel the drive

Thermo Top E Additional Heater e1

00 0003

Thermo Top C

Additional Heater

00 0002

Thermo Top P Additional Heater e1

00 0104

Opel Vivaro

1311875A_EN 2

Table of Contents

Validity

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

instructionshavenotbeentested.However,installation according to these installationinstructions 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

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 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

Electrical Connections 6

Fan controller 7

Remote option (Telestart) 9

Preparing heater unit 10

Installing heater unit 12

Coolant connection 14

2.0 l dCi 15

2.5 l dCi 16

Combustion air 18

Fuel Connection 19

Installing trim pieces 21

Final Work 22

Operating Instructions for End Customer 23

Opel Vivaro

1311875A_EN 3

Heater Unit/Installation Kit

Optional heater control either:

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 Opel Vivaro Diesel vehicles - for validity, see page 2 - from

model year 2007 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,thestipulations in the "installationinstructions"and"operating and 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

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

harnesses using cable ties.

Sharp edges should be fitted with edge protectors (split-open plastic 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

- Torx E5 nut

Quantity Description Order No.:

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

1 Installation Kit for Opel Vivaro from 2001 TT/C Diesel 9002568H

Quantity Description Order No.:

1 Heater control See Opel 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 system

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.

Opel Vivaro

Specific risk of injury or fatal accidents.

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.

1311875A_EN 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

1311875A_EN 5

Preliminary Work

WARNING!

- Open the fuel tank cap, ventilate the tank.

- Close the tank cap again.

- Disconnect the battery "earth" or "ground" connection.

-Depressurizethe 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 23 "Operating Instructions for End Customer" and insert with vehicle operating

instructions.

Heater unit installation location

1Heater unit

Installation

location

Opel Vivaro

1311875A_EN 6

Electrical Connections

Digital timer and summer/winter switch

option

1Digital timer

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

Connection of positive wire

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

support point. Fasten retaining plate of fuse

holder with 3x9 self-tapping screw on battery

carrier. Mount fuse, F4 30 A 1.

Wiring

harness

installation

diagram

Fuse holder, relay K3

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

K3 relay

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

retaining plate, fuse holder

3Ground wire on ground 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

harness 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 metering

pump cable harness until

later together with fuel

pipe along the original

vehicle fuel lines on the

underbody

Opel Vivaro

1311875A_EN 7

Fan controller

Wiring

diagram

Webasto components Vehicle components Colors and symbols

Legend

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

X1 6-pin connector WG Resistor group X70 ws white

F3 Fuse, 25 A GS Fan switch S95 sw black

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

K3 Fan relay FC16 Fuse, 15 A 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 colors 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

Opel Vivaro

1311875A_EN 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

diagram.

1Yellow (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

Con-

nection to

fan switch

Connection to connector S70 3of switch for

rear-window heater.

Produce connections as shown in wiring

diagram.

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

2Insulate free yellow (ge) wire and tie back

4Yellow(ge)wiretoconnectorS70ofswitch

for rear-window heater

5Yellow (ge) wire from original vehicle fuse

FC16

Con-

nection of

switch for

rear-

window

heater

Connection to connector S95 3of fan switch.

Produce connections as shown in wiring

diagram.

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

Con-

nection to

fan switch

1 2

45 3

Opel Vivaro

1311875A_EN 9

Remote option (Telestart)

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

1Receiver

2M6x20 bolt in existing hole Installing

receiver

1Antenna

Installing

antenna

Temperature sensor for HTM100 only

1Fasten temperature sensor with suitable

means

2Ventilation duct Installing

temper-

ature

sensor

1311875A_EN 10

Opel Vivaro

Preparing heater unit

2.0 l dCi

a = 580 mm

b = 50 mm

c = 470 mm

Discard section X.

Push braided protection hose onto hose A

and C.

Cutting

coolant

hoses to

length

2.5 l dCi

a = 755 mm

b = 50 mm

c = 655 mm

Discard section X.

Push braided protection hose onto hose A

and C.

Cutting

coolant

hoses to

length

All vehicles

127 mm dia. spring clip

227 mm dia. hose clamp

320x20 connecting pipe Preassem-

bling

hose B

Ejot stud, tightening torque 10 Nm.

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

2Long Ejot stud, 5 mm shim, washer

3Hose section, 10 mm dia. hose clamp Preassem-

bling

heater unit

b c

B 1

3 2

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