Webasto Thermo Top E 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.
Feel the drive
Mitsubishi Grandis
Gasoline and Diesel
from Model Year 2004
For left-hand drive vehicles only
Ident. No.: 1303003C_EN Fee Euro 10 © Webasto AG
Water Heater Unit
Thermo Top E Additional Heater
Thermo Top C Additional Heater
Thermo Top P Additional Heater
Installation Instructions
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2
Mitsubishi Grandis
Validity
Vehicle and engine types, equipment variants and national specifications not listed in these installation
instructionshavenotbeentested.However, installationaccordingtotheseinstallationinstructionsmay
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
Mitsubishi Grandis NAOW e1*2001/116*0269*00....
Engine type Engine model Output in kW Displacement in cm³
4G69 Gasoline 121 2378
BSY Diesel 100 1968
Validity 2
Heater Unit/Installation Kit 3
Foreword 3
Special Tools 3
Notes on Installation 3
Explanatory Notes on the Document 4
Preliminary Work 5
Heater Unit Installation Location 5
Electrical Connections 6
Telestart T100 HTM Option 7
Thermo Call TC1.1 Option 8
Fan Controller 9
Wiring Diagram 10
Preparing Installation Location 11
Preparing Heater Unit 12
Installing Heater Unit 13
Combustion Air 14
Installing Fuel Metering Pump 15
Fuel Removal, Gasoline 16
Fuel Removal, Diesel 17
Coolant, Gasoline 18
Coolant, Diesel 21
Exhaust Gas 24
Final Work 25
Operating Instructions for End Customer 26
Template for Fuel-Tank Sending Unit on
Gasoline Vehicles 27
Template for Fuel Standpipe on
Gasoline Vehicles 28
Template for Fuel Standpipe on
Diesel Vehicles 29
Table of Contents

3
Mitsubishi Grandis
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
The installation instructions apply to the Mitsubishi Grandis vehicles with a Gasoline and Diesel engine
- For the 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"operatingandmaintenanceinstructions"
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
Quantity Description Order No.:
1 Retail accessories with desired heater control See price list
1 Installation kit for Mitsubishi Grandis Gasoline and Diesel 1303000C
Vehicle Heater unit
Compact car Thermo Top E
Mid-size car, station wagon Thermo Top C
Full-size car, van, offroader Thermo Top P

4
Special features are highlighted using the following symbols:
Mechanical work
Electrical connection
Coolant connection
Fuel connection
Exhaust system
Combustion air
The arrow in the vehicle icon indicates the position on
the vehicle and the viewing angle.
Mitsubishi Grandis
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.
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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.

5
Mitsubishi Grandis
Preliminary Work
WARNING!
- 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 engine cover (diesel vehicles only).
- Completely remove the battery.
- Remove the air filter together with the intake hose.
- Detach the relay and fuse box in the engine compartment at the left (diesel vehicles only).
- Remove the left front wheel well trim and wheel.
- Remove the underride protection.
- Open the fuel tank cap.
- Remove the individual seat or seat row (depending on equipment) behind the driver's seat.
- Fold back the floor covering in the area of the service door.
- Open the tank-fitting service lid
- Remove the fuel-tank sending unit in accordance with the manufacturers specifications.
- Remove the A/C control panel.
- Remove the cover of the footwell trim on the driver's and front passenger side.
- Remove the lower cover from the instrument panel trim on the driver's side.
Heater unit installation location
(1) Heater unit
Heater
unit instal-
lation lo-
cation
11

6
Mitsubishi Grandis
Wiring harness pass through
(1) Protective rubber plug
Digital timer
(1) Digital timer (use wiring
harness extension)
Opt. summer/winter switch
(1) Summer/winter switch, hole
12 mm dia.
1
2
1
3
1
4
Fuse holder, relay K3
(1) K3 relay, M5x12 bolt,
washers, nut
(3) Fuse holder, M4x12 bolt,
washers, M4 nut
(2) Drill 6.5 mm dia. hole, angle
bracket, M6x20 bolt, spring
lockwasher
Telestart T70/80 Option
(1) Receiver
(2)Bracket,M5x12bolt,washer,
flanged nut
Antenna T70/80/90
(1) Antenna
2
3
1
5 6
21
7
1
Electrical
diagram
Do not install the
metering pump cable
harness until later
together with fuel
pipe along the
original vehicle fuel
lines on the
underbody
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Electrical Connections

7
Mitsubishi Grandis
Remote option (Telestart)
(1) Receiver
(2) Bracket, M5x12 bolt, washer, flanged nut
Installing
receiver
1
8
2
i
(1) Antenna of Telestart T100 HTM
Installing
antenna
1
9
(1) Temperature sensor of Telestart T100
HTM
(2) Dual Lock, self-adhesive
(3) Air distribution for passenger
compartment fan
Tempera-
ture sen-
sor
1
10
2 3 
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8
Mitsubishi Grandis
Remote option (Thermo Call)
Cut out insulation mat.
(1) Thermo Call receiver, M5x20 bolts,
flanged nut, washers [4x]
(2) Lower footwell cover on front passenger
side Installing
receiver
1
11
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(1) Antenna TC 1.1
Installing
antenna
1
12
(1) Push button
Installing
push
button
1
13
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9
Mitsubishi Grandis
Automatic air-conditioning fan
controller
Connection to 2-pin connector from blower
motor.
Make connections as shown in the wiring
diagram with the connectors provided.
(1) Connector, 2-pin Fan
controller
1
14
Connection of diode group 8on 26-pin
connector 5from A/C control panel.
Insulate wire ends 9[2x].
(1) White/black (ws/sw) wire
(2) Black (sw) wire
(3) Black (sw) wire from fuse F4
(4) Blue/red (bl/rt) wire from +15
(6) Blue/red (bl/rt) wire from Pin 8
(7) Black (sw) wire
Fan
controller
5
15
31 2
67
4
8
9
26-pin connector from A/C control panel
(1) Connector, 26-pin
The pin assignment (Pin 8) does not match
the wiring diagram from the Rep. Manual!!!!
1
Pin 8
13
1

10
Mitsubishi Grandis
Wiring
diagram
gn/
ws
sw
br
rt/ws
Webasto
31
30
15
Mitsubishi
rt
4
HG
X1 F3 Fbl/rt
K3
87a
87
86
85 30
F4
sw
sw
8
KB
ST 1
M
+
-
GM
bl/rt
rt/ws
rt/ws
GR ws/sw sw
0,5²
0,5²
sw
D1
bl bl
!
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Webasto components Mitsubishi components Colors and symbols
Legend
HG Heater unit TT-C/E GM Fan motor rt red
X1
6-pin heater unit connector GB Fan relay ws white
F3 25 A fuse ST 1 26-pin connector KB sw black
F4 Fuse, 7.5 A KB
Air-conditioning control panel br brown
K3 Fan relay F Fuse gn green
D1 Diode group GR Fan relay bl blue
Insulate wire ends
and tie back
XCutting point

11
Mitsubishi Grandis
Preparing installation location
(1) Bracket
(2) Drill out existing hole to 8.5 mm dia.
Preparing
bracket
21
16
(1) Remove original vehicle bolt
Preparing
installa-
tion loca-
tion
1
17
(3) Install bracket and align
(2) M8x30 bolt
(1, 4, 5) Copy hole pattern
Preparing
installa-
tion loca-
tion
3
4
2
518
1
(1) 9.1 mm dia. hole, M6 rivet nut
(2) 7.0 mm dia. hole
Preparing
installa-
tion loca-
tion
1
19
2

12
Mitsubishi Grandis
(2) Bracket
(1) M6x35 bolt, spring lockwasher,5 mm shim
(3) M8x35 bolt, 5 mm shim, 8 mm dia. washer
(4) M6x35 bolt, 5 mm shim, flanged nut
(5) M6x35 bolt, 5 mm shim, flanged nut
Installing
bracket
4
5
31 2
20
Preparing heater unit
(1) Exhaust pipe
a = 250 mm
(2) Exhaust end section
b = 145 mm
Discard section 8
Preparing
exhaust
pipe
2
X
1
a b
Tighten EJOT screws to 10 Nm!
(1) Heater unit
(4) Perforated bracket, Ejot screw
(3) Exhaust muffler, M6x20 bolt, flanged nut
(2) 250 mm exhaust pipe, hose clamp [2x]
(4) Bend perforated bracket Premount-
ing ex-
haust pipe
and ex-
haust muf-
fler
2
3
1
4
21

13
Mitsubishi Grandis
Tighten EJOT screws to 10 Nm!
Insert two washers between heater unit and
bracket at position 3.
(2) Heater unit
(4) Bracket
(3) Ejot screw
(5) Ejot screws [2x]
(1) Exhaust system, watch spacing to other
components!
Installing
heater unit
3
4
2
5
23
1
Installing heater unit
Tighten EJOT screws to 10 Nm!
Mount heater-unit wiring harness.
(2) Bracket, Ejot screw
(1) Heater unit Installing
heater unit
2
1
22

14
Mitsubishi Grandis
(2) Combustion-air intake pipe
(3) Combustion-air intake muffler
(1) Battery carrier, drill 7.0 mm dia. hole
(4) Cable tie
Installing
combus-
tion-air in-
take
muffler
3
2
4
25
1
i
Combustion air
Ensure proper installation position of air
intake muffler, see "Installation Instructions“.
(3) Heater unit
(2) 27 mm dia. hose clamp
(1) Combustion-air intake pipe Installing
combus-
tion-air in-
take
muffler
3
1
24
2
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15
Mitsubishi Grandis
(3) Heater unit
(2) Mecanyl fuel line
(1) Hose section, 10 mm dia. hose clamp [2x]
Fuel on
heater unit
3
2
26
1
Ensure proper installation position of metering
pump, see "Installation Instructions“.
Installation location on left in front of vehicle
fuel tank!
Fuel line from heater unit on pressure side of
metering pump [side with connector].
(6) Silent block, flanged nut
(5) Angle bracket
(2) Rubber-coated p-clamp, flanged nut
(3) Metering pump
(7) Hose section, fuel line, 10 mm dia. hose
clamps [2x]
( 1 ) Wiring harness of metering pump, protective
rubber plug, tab connector, connector housing
(4) Original vehicle bolt
Installing
metering
pump
5
3
7
2
27
1
4
6
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(1) Metering pump
(2)Moldedhose180°elbow, 10mm dia.hose
clamp [2x]
(3) Mecanyl fuel line
Installing
metering
pump
2
3
1
28
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Fuel
CAUTION!
Open the vehicle's fuel tank cap, ventilate the tank and then re-close the tank lock.
Catch any fuel running off with an appropriate container.
Install fuel line and wiring harness so that they are protected against stone impact.
Mount the fuel line and wiring harness with rub protection on sharp edges.
WARNING!
The fuel line and wiring harness are routed to the metering pump in as shown in the electrical diagram.

16
Mitsubishi Grandis
Shape fuel standpipe according to template,
cut to length and install, see "installation
instructions".
(1) Fuel-tank sending unit
(2) Fuel standpipe
Installing
fuel
standpipe
1
2
30
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Install fuel-tank sending unit according to
manufacturer's specifications. Shorten
molded hose with 3.5 mm dia. by 10 mm.
(1) Fuel-tank sending unit
(5) Fuel standpipe
(2) Molded hose
(3) Mecanyl fuel line
(6) 8 mm dia. Caillau clamp
(4) 10 mm dia. Caillau clamp
Connect-
ing fuel
line
5
3
4
1
6
2
31
Gasoline vehicles only
Remove fuel-tank sending unit in accordance
with manufacturer's instructions.
(1) Fuel-tank sending unit
(3) Drilling template
(2) Copy hole pattern, 6 mm dia. hole Preparing
fuel-tank
sending
unit
3
21
29

17
Mitsubishi Grandis
Shape fuel standpipe according to template,
cut to length and install, see "installation
instructions".
(1) Fuel-tank sending unit
(2) Fuel standpipe
Installing
fuel
standpipe
1
2
33
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Install fuel-tank sending unit according to
manufacturer's specifications. Shorten
molded hose with 3.5 mm dia. by 10 mm.
(1) Fuel-tank sending unit
(5) Fuel standpipe
(2) Molded hose
(3) Mecanyl fuel line
(6) 8 mm dia. Caillau clamp
(4) 10 mm dia. Caillau clamp
Connect-
ing fuel
line
5
3
4
1
6
2
34
Diesel vehicles only
Remove fuel-tank sending unit in accordance
with manufacturer's instructions.
Layon large diameter washer ash shownand
copy hole pattern.
(1) Fuel-tank sending unit
(2) Large diameter washer
(3) Copy hole pattern, 6 mm dia. hole
Preparing
fuel-tank
sending
unit
3
21
32

18
Mitsubishi Grandis
Coolant
Diagram
Motor
Heat-
exchanger
Ø 17x20
A B
Ø 17x20
All clamps without a specific designation are 20-27 mm dia. hose clamps.
Coolant for gasoline engine
WARNING!
Tighten all hose clamps to 2.0 + 0.5 Nm.
Any cold water running off should be collected using an appropriate container!
Install hoses so that they are kink-free.
Position hose clamps so that no other hose can be damaged!
The connection should be "inline" based on the following diagram:

19
Mitsubishi Grandis
(1) Hose section on engine outlet
Connec-
tion
on
engine
outlet
37
A
1
a = 950 mm
b = 860 mm
Discard section 8
Cutting
coolant
hoses to
length
ba
BA
X
X
X
Push braided protection hoses onto hose A
and B
Preparing
coolant
A
B35
(2) Hose on heat exchanger inlet
(1) Hose on engine outlet
Cutting
point
1 2
36

20
Mitsubishi Grandis
Fill heater unit with coolant before installing
coolant hoses.
Connec-
tion on
heater unit
B
A
41
(1) Hose section on heat exchanger inlet
Connec-
tion
on heat
exchang-
er inlet
B
38
1
Secure coolant hoses with cable ties.
Routing in
engine
compart-
ment
A
B
39
Secure coolant hoses with cable ties.
Routing in
engine
compart-
ment
BA
40