Webasto SUBARU Legacy User manual

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.:1302628C_EN Fee Euro 10.00 © Webasto AG
SUBARU Legacy / Outback
Gasoline
from Model Year 2004
Left-hand drive vehicle
Feel the drive
Thermo Top E Additional Heater e1
00 0003
Thermo Top C Additional Heater
e1
00 0002

SUBARU Legacy / Outback
1302628C_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
SUBARU Legacy / Outback BL / BP e1 * 2001/116 * 0228 * ...
SUBARU Legacy / Outback BL / BPS e1 * 2001/116 * 0256 * ...
Engine type Engine model Output in kW Displacement in cm³
EJ20 Gasoline 101 1994
EJ20 Gasoline 110 1994
EJ20 Gasoline 121 1994
EJ25 Gasoline 121 2457
EJ25 Gasoline 127 2457
EZ30 Gasoline 180 3000
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 connection Version A 7
Fan connection Version B 9
Remote option (Telestart) 11
Preparing heater unit 12
Preparing installation location 13
Exhaust system with manual transmission 16
Exhaust system with automatic transmission 17
Installing heater unit 18
Combustion air 19
Coolant connection 20
Fuel Connection 23
Final Work 27
Operating Instructions for End Customer 28

SUBARU Legacy / Outback
1302628C_EN 3
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 applyto 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. 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).
Please ask customers to bring in the vehicle with as little fuel in the fuel tank as possible (max 1/4 full)!
Special Tools
- Torque wrench for 2.0 - 10 Nm
- Hose clamping pliers
- Metric thread-setter kit
Quantity Description Order No.:
1 Retail accessories with desired heater control See price list
1 Installation Kit for SUBARU Legacy / Outback Gasoline from
MY 04 1302625B
Vehicle Heater unit
Compact car Thermo Top E
Mid-size car, station wagon Thermo Top C

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.
SUBARU Legacy / Outback
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.
1302628C_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.

SUBARU Legacy / Outback
1302628C_EN 5
Preliminary Work
WARNING!
- Empty the fuel tank.
- 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 rear bench seat
- Open the right-hand fuel sender service lid.
- Remove the footwell trim on the driver's side.
- Remove the lower instrument panel trim on the driver's side.
- Remove the A-pillar trim in the footwell on the front passenger side.
- Remove the lower B-pillar trim on the front passenger side.
- Remove the door sill cover on the front passenger side.
- Remove the right-hand fuel tank trim.
Remove page 28 "Operating Instructions for End Customer" and add to the vehicle operating
instructions.
Heater unit installation location
1Heater unit
Installation
location
1
1

SUBARU Legacy / Outback
1302628C_EN 6
Electrical Connections
Pass through of fuel line and wiring harness
of metering pump
Leave approx. 50 cm of fuel line in engine
compartment.
1Protective rubber plug
2Metering pump wiring harness
3Mecanyl fuel line
Wiring harness pass through
With automatic transmission, use protective
rubber plug in firewall on driver's side.
1Protective rubber plug
2Original vehicle wiring harness
Wiring
harness
installation
diagram
Fuse holder, relay K3
Cutting out insulating mat.
1Fuse holder (replace F25A with 7.5 A)
2Retainingplateoffuseholder,4mmdia.hole,
5.5x9.5 self-tapping screw
3K3 relay, 4 mm dia. hole, 5.5x9.5 self-tapping
screw
Digital timer and summer/winter switch
option
1Summer/winter switch, drilled hole 12 mm dia.
2Digital timer
2
1
2
3
3
2
1
bl
br
Do not install the metering
pump cable harness until
later together with fuel pipe
along the original vehicle
fuel lines on the underbody
4
3
1 2
5
1 2

SUBARU Legacy / Outback
1302628C_EN 7
Fan connection Version A
1Remove central electrical box, back
2Socket of 10-pin connector
3Socket of 24-pin connector Discon-
necting
connector
from cen-
tral electri-
cal box
110-pin connector, gray D (B152)
disconnected
2Yellow/red (ge/rt) wire from PIN 7
10-pin
connector
124-pin connector white C (B52)
disconnected
2Green/yellow (gn/ge) or green/orange
(gn/or) wire from PIN 1
24-pin
connector
Make connections as shown in the wiring
diagram with the connectors provided.
124-pin connector white C (B52)
2Diode group D1
310-pin connector, gray D (B152) Connect-
ing diode
group
6
1
3
2
7
2
1
8
1
2
9
31
2

SUBARU Legacy / Outback
1302628C_EN 8
Wiring
diagram
for Version
A
Webasto components Vehicle components Colors and symbols
Legend
HG Heater unit TT-C/P F31 Fuse, 7.5 A rt red
X1 6-pin connector F22 15 A fuse ws white
F3 Replace 25 A fuse with
7.5 A fuse ZE Central electrical box sw black
A1 Connector A (i5) PIN 1 br brown
K3 Fan relay D7 Connector D (B152) PIN 7 gn green
D1 Diode group1 A3 Connector A (i5) PIN 3 bl blue
C1 Connector C (B52) PIN 1 ge yellow
KB Air-conditioning control
panel or orange
A2 Connector A (B282) PIN 2 Insulate wire ends and
tie back
A9 Connector A (B282) PIN 9 XCutting point
Wiring colors may vary.
Webasto
31
30
15
Subaru Legacy / Outback
HG
X1 4F3
86
85 30
87a87
K3
F31 F22
ZE
A1
FB 28 D7 FB 29 A3 FB 45 C1 FB 46
KB
A9A2
!
D1
br sw
ws/sw
bl
bl
sw
sw
ge/rt
ge/rt
gn/ge
(gn/or)
gn/ge
(gn/or)
rt
rt/wsgn/ws

SUBARU Legacy / Outback
1302628C_EN 9
Fan connection Version B
1Remove central electrical box, back
2Socket of 24-pin connector
Discon-
necting
connector
from cen-
tral electri-
cal box
124-pin connector white C (B52)
disconnected
2Green/yellow (gn/ge) or green/orange
(gn/or) wire from PIN 1
24-pin
connector
Make connections as shown in the wiring
diagram with the connectors provided.
1Black (sw) wire from K3/30
2Diode group D1
324-pin connector white C (B52) Connect-
ing diode
group
10
1
3
2
10
1
2
11
1
2
12
3
21

SUBARU Legacy / Outback
1302628C_EN 10
Wiring
diagram
for Version
B
Webasto components Vehicle components Colors and symbols
Legend
HG Heater unit TT-C/P F31 Fuse, 7.5 A rt red
X1 6-pin connector F22 15 A fuse ws white
F3 Replace 25 A fuse with
7.5 A fuse ZE Central electrical box sw black
A1 Connector A (i5) PIN 1 br brown
K3 Fan relay D7 Connector D (B152) PIN 7 gn green
D1 Diode group1 A3 Connector A (i5) PIN 3 bl blue
C1 Connector C (B52) PIN 1 ge yellow
KB Air-conditioning control
panel or orange
A9/21*Vehicle-dependent
Connector B282 (16-pin)
PIN 9 or connector B282
(40-pin) PIN 21
Insulate wire ends and
tie back
XCutting point
Wiring colors may vary.
Webasto
31
30
15
Subaru Legacy / Outback
HG
X1 4F3
86
85 30
87a87
K3
F31 F22
ZE
A1
FB 28 D7 FB 29 A3 FB 45 C1 FB 46
KB
A9/21
!
D1
br sw
ws/sw
bl bl sw
sw
gn/ge
(gn/or)
gn/ge
(gn/or)
rt
rt/wsgn/ws
! !
*

SUBARU Legacy / Outback
1302628C_EN 11
Remote option (Telestart)
1Receiver
2Original vehicle bolt
3Bracket, angle down 90° Installing
receiver
1Antenna
Installing
antenna
1
213 3
1
14

1302628C_EN 12
SUBARU Legacy / Outback
Preparing heater unit
1Exhaust pipe
a = 150 mm
2Exhaust end section
b = 450 mm
Discard section X
Preparing
exhaust
pipe
Loosely mount lower hose clamp.
1Hose clamp [2x]
2Exhaust pipe
3Red (rt) rubber isolator with groove Preassem-
bling ex-
haust pipe
Loosely mount outer hose clamp.
1Hose section, 10 mm dia. hose clamps
[2x].
2Precut thread with Ejot screw. Premount-
ing fuel
connec-
tion on
heater unit
Loosely mount Ejot screws.
1Bracket
2Ejot screw [2x]
Preassem-
bling
bracket on
heater unit
a B
1 2
X
1
2
3
1
15
16
1 2
122
17

1302628C_EN 13
SUBARU Legacy / Outback
Preparing installation location
1Cut out insulating mat
2Original vehicle wiring harness
36 mm dia. hole Hole in
firewall
1Cable clip
Tie back
wiring
harness
1Hole for protective rubber plug
Removing
rubber
grommet
Remove protective rubber plug from hole 2.
If hole is not present, drill new hole next to
retaining clip for brake line 1.
2Drill 9.1 mm dia. hole; install rivet nut Installing
rivet nut
18
2
3
1
19
1
20
1
21
2 1
17 mm

1302628C_EN 14
SUBARU Legacy / Outback
1Original vehicle hole
27 mm dia. hole
Hole in
wheel well
1M6x30 bolt, largediameter washer, 10 mm
shim, pin lock
2M6x20 bolt, large diameter washer, pin
lock
Mounting
bolts
Looselymountandalignheaterunitandstrut.
Check the position of the components; adjust
if necessary. Check that they have free
clearance.
1Copy hole pattern
2Strut
3M6 flanged nut [2x]
Copying
hole
pattern to
strut
Check line routing and correct if necessary.
Ensure sufficient spacing (at least 20 mm)
between heater unit and steering line 1.
Checking
line routing
22
1
2
23
1
2
24
2
3
3
1
25
1

1302628C_EN 15
SUBARU Legacy / Outback
Ensure sufficient spacing (at least 5 mm)
between bracket 1 and brake line 2. Cut out
bracket 1along marking if necessary.
Remove heater unit.
Cuttingout
bracket
17 mm dia. hole
Hole in
coolant
reservoir
26
1
2
27
1

SUBARU Legacy / Outback
1302628C_EN 16
Exhaust system with manual
transmission
1Exhaust muffler
2Angle bracket, M6x20 bolt, flanged nut
3M6x20 bolt, spring lockwasher Installing
exhaust
muffler
1Perforated bracket
2M6x20 bolt, large diameter washer, M6
flanged nut
Installing
perforated
bracket
1Red (rt) rubber isolator with groove
2Exhaust end section
325 mm dia. p-clamp, M6x20 bolt, flanged
nut
Installing
exhaust
end
section
Ensure sufficient distance to neighboring
components. Position rubber isolator.
Aligning
exhaust
pipe
28
2
3
29
2
1
30
1 2 3
31

SUBARU Legacy / Outback
1302628C_EN 17
Exhaust system with automatic
transmission
1Exhaust muffler
2Angle bracket, M6x20 bolt, flanged nut
3M6x20 bolt, spring lockwasher Installing
exhaust
muffler
1Drill 9.1 mm dia. hole; install rivet nut
Installing
rivet nut
120 mm spacer
2Red (rt) rubber isolator with groove
3Exhaust end section
425 mm dia. p-clamp, M6x40 bolt, spring
lockwasher Installing
exhaust
end
section
Ensure sufficient distance to neighboring
components. Position rubber isolator.
Aligning
exhaust
pipe
32
2
3
1
33
1
34
2 31
4
35

1302628C_EN 18
SUBARU Legacy / Outback
Installing heater unit
Connectexhaustpipe beforeinstallingheater
unit on muffler.
Alignheaterunit.Ensuresufficientdistanceto
neighboring components. Tighten Ejot
screws; tighening torque 10 Nm.
1M6x20 bolt, large diameter washer,
flanged nut
2M6 flanged nut [2x]
Installing
heater unit
1Exhaust pipe
2Red (rt) rubber isolator with groove
3Exhaust muffler
4Hose clamp
Installing
exhaust
pipe on
heater unit
36
1
2
2
37
1
4
2
3

SUBARU Legacy / Outback
1302628C_EN 19
Combustion air
1Combustion-air intake muffler
2Retaining clip in hole
3Combustion-air intake pipe
427 mm dia. hose clamp
5Hole Installing
combus-
tion air
pipe
38
1
4
2
3
5

SUBARU Legacy / Outback
1302628C_EN 20
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.
Position hose clamps and spring band clamps so that no other hose can be damaged.
The connection should be "inline" based on the following diagram:
Coolant
routing
diagram
All clamps without a specific designation = 20-27 mm dia. hose clamps!
All connecting pipes = 15x20 dia..
B
A