Webasto Thermo Top E Operator's manual

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
E1
00 0002
Thermo Top C Parking Heater
E1
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
11

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
2
1
2
3
1
Do not install the meter-
ing pump wiring harness
until later together with
fuelline along the original
vehicle fuel lines on the
underbody
4
4
2
3
1
5
2
1
3

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
31
30
Opel
rt/ws
rt
gn/
ws
br
15
B4
B2
GS
S95
WG
X70
SH
S70
A1
5
ge
0,5mm²
ge
0,5mm²
ge
3 mm²
ge
3 mm²
br
2 mm²
br
2 mm²
ge 0,5mm²
br
86
85 30
87a87
K3
F3
HG
X1 4
85
86 30
87a87
K3.1
+
-
GM
M
!
FC25 FC16
ge
4 mm²
ge
1,5 mm²
F4
rt
rt
rt
4 mm²
sw
4 mm²
ge
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.
1 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
5 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
6
3
2
1
7
1
3
2
4
8
1 2
5
4
3
9
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
1
2
3
10
1
11
1
12
2

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
A
C
BX
XX
A
C
BX
XX
3
13
B 1
2
3 2
11
14

Opel Vivaro
Ident. No.: 1311875B_EN Status: 09.11.2012 © Webasto Thermo & Comfort SE 11
Before installing, insert M8x20 bolt 1 in bracket 3 .
2Flanged nut (3x)
Premount-
ingbracket
on heater
1Exhaust pipe
a = 330mm
2Exhaust end section
b = 140mm
Discard section X.Preparing
exhaust
pipe
1Exhaust silencer
2M6x20 bolt, flanged nut
Premount-
ing ex-
haust
silencer
1Hose clamp [3x]
2Exhaust end section
3Exhaust pipe
4Spacer bracket
Premount-
ing ex-
haust
system
15
1 2
2
32
a b
1 2
X
16
2
1
17
1
3
2
4
1
1

Opel Vivaro
Ident. No.: 1311875B_EN Status: 09.11.2012 © Webasto Thermo & Comfort SE 12
1Strut
2Loosely premount Ejot screw [2x]
Premount-
ingstruton
heater
Installing Heater
1Remove air ducting trim
Removing
trim
1Remove trim
Removing
trim
Remove control unit 1(if present). Connector
plugs may remain mounted. Discard fasten-
ing bolts [2x].
1Control unit of electrical auxiliary heater Removing
control unit
18
1 2 2
19
1
20
1
21
1

Opel Vivaro
Ident. No.: 1311875B_EN Status: 09.11.2012 © Webasto Thermo & Comfort SE 13
Remove and discard thread insert 1[2x].
Removing
thread in-
sert
1M8x20 bolt, flanged nut [2x each] on exist-
ing holes
Mounting
heater
Tighten Ejot screws on heater.
Connect wiring harness on heater.
1Premounted strut
2M10x16 bolt, spring lockwasher in existing
threaded hole Mounting
bracket
Ensure sufficient distance from neighbouring
components.
1M8x12 bolt in existing threaded hole
2Horn with bracket Installing
horn
22
1
1
23
1 1
24
1
2
25
1
2

Opel Vivaro
Ident. No.: 1311875B_EN Status: 09.11.2012 © Webasto Thermo & Comfort SE 14
Coolant Circuit, One Heat Exchanger
WARNING!
Any coolant running off should be collected using an appropriate container.
Route coolant hoses 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:
Hose in-
stallation
diagram
Spring clip = 27 mm dia. All hose clamps = 20-27 mm dia.!
All connecting pipes = dia. 20x20.
1 = Black (sw) rubber isolator . 2 = Electrical auxiliary heater (option).
3= original vehicle spring clip (only 2.5 l dCi)
B
A
C
1
1
2
3

Opel Vivaro
Ident. No.: 1311875B_EN Status: 09.11.2012 © Webasto Thermo & Comfort SE 15
Coolant Circuit, Two Heat Exchangers
WARNING!
Any coolant running off should be collected using an appropriate container.
Route coolant hoses 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:
Hose in-
stallation
diagram
Spring clip = 27 mm dia. All hose clamps = 20-27 mm dia.!
All connecting pipes = dia. 20x20. 1= Black (sw) rubber isolator . 2= Solenoid valve .
3= Electrical auxiliary heater (option). 4= Fuel-driven auxiliary heater (option).
5 = in case of 2.5ldC, original vehicle springclip , in case of 2.0ldCi, hose clamp = 20-27mm dia.
B
A
C
1
1
2
4
35

Opel Vivaro
Ident. No.: 1311875B_EN Status: 09.11.2012 © Webasto Thermo & Comfort SE 16
2.0 l dCi
Connect hose Band C.
Connec-
tion to
heater
Slide black(sw)rubberisolator 1 ontohose C .
Slide black (sw) rubber isolator onto hose
A
(hidden in image).
2Spacer bracket Routing in
engine
compart-
ment
Cutting point, variant 1
Clamps will be re-used.
1Originalvehiclehoseofengineoutlet/heat
exchanger inlet Removing
original ve-
hicle hose
After cutting to length, remount both hose
section ends at their old position.
1Hose section of heat exchanger inlet
2Discard hose section
3Engine outlet hose section Cutting
original ve-
hicle hose
to length
26
A
C
B
27
A
C
2
B
1
28
1
1
29
1
2
3

Opel Vivaro
Ident. No.: 1311875B_EN Status: 09.11.2012 © Webasto Thermo & Comfort SE 17
Cutting point, variant 2
Separate original vehicle hose 1at the mark-
ings. Discard section 2.
1Hose section of heat exchanger inlet
2Discard hose section
3Engine outlet hose section
Cutting
original ve-
hicle hose
to length
All variants
1Engine outlet hose section
Connec-
tion on en-
gine outlet
Before connecting, fill the coolant hoses with
coolant.
Position rubber isolator 2on hose Aand rub-
ber isolator 3(hidden) on hose Con original
vehicle wiring harness.
1Hose section of heat exchanger inlet Connec-
tion on
heat ex-
changer in-
let
2.5 l dCi
Connect hose Band C.
1Spacer bracket Connec-
tion to
heater
30
1
1
23
31
1
A
32
C
1
23
A
33
A
BC
1

Opel Vivaro
Ident. No.: 1311875B_EN Status: 09.11.2012 © Webasto Thermo & Comfort SE 18
Slide rubber isolator 1 [2x] onto hose A and C .
1Rubber isolator [2x]
2Cable tie
Routing in
engine
compart-
ment
Pulloriginalvehiclehose3ofheat exchanger
inlet off bleeder valve 2. Spring clip 1will be
reused.
Pulling off
original ve-
hicle hose
Turn bleeder valve 2towards front.
1Hose section of heat exchanger inlet
Turning
valve
1Hose section of heat exchanger inlet
2Original vehicle spring clip
Connec-
tion on
heat ex-
changer in-
let
34
1
AC
1
2
35
1
3
2
36
2
1
37
1 C2

Opel Vivaro
Ident. No.: 1311875B_EN Status: 09.11.2012 © Webasto Thermo & Comfort SE 19
Before connecting, fill the coolant hoses with
coolant.
1Bleeder valve
2Spacer bracket Connec-
tion on en-
gine outlet
38
1
A
2

Opel Vivaro
Ident. No.: 1311875B_EN Status: 09.11.2012 © Webasto Thermo & Comfort SE 20
Combustion Air
1Combustion air pipe
a = 300mm
Discard section X.Cutting
combus-
tionairpipe
to length
1Retaining clip in hole of strut
227 mm dia. hose clamp
3Combustion air pipe
4Silencer
Mounting
combus-
tion air
pipe
a
1
X
39
2
1
34