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, specialised tools and equipment are
required to install and repair Webasto heating and cooling systems.
Only original Webasto parts must be used. For this, also see the catalog of air and water heat-
er accessories from Webasto.
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.
Webasto does not accept any liability for defects and damage that are attributable to installa-
tion by untrained staff.
Water Heater
Installation instructions
Ident. No.: 1315485A_EN Fee Euro 10.00 © Webasto AG
Subaru Legacy / Outback
2.0 and 2.5 Gasoline
from Model Year 2010
Left-hand drive vehicle
Automatic air-conditioning
Gear box / Lineartronic
Feel the drive
Thermo Top E Parking Heater
e1
00 0003
Thermo Top C Parking Heater
e1
00 0002

Subaru Legacy / Outback
1315485A_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.
Optional:
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 BM /BR e1 * 2007 / 46 * 0079 * ...
Subaru Legacy / Outback BM /BRS e13 * 2007 / 46 * 1074 * ...
Engine type Engine model Output in kW Displacement in cm³
EJ20 Gasoline 110 1994
EJ25 Gasoline 123 2457
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
Preparing electrical system 6
Electrical system 7
Fan controller 8
Digital timer and summer/winter switch option 11
Remote option (Telestart) 11
Preparing installation location 12
Preparing bracket 13
Preparing heater 14
Installing heater 15
Fuel 16
Coolant circuit 19
Combustion air 22
Exhaust gas 23
Final Work 26
Template for Fuel Standpipe 27
Template for Fuel sender 27
Operating Instructions for End Customer 28

Subaru Legacy / Outback
1315485A_EN 3
Heater/Installation Kit
Heater recommended for the relevant vehicle class:
The selection of the heater 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 the vehicles Subaru Legacy / Outback 2.0 and 2.5 Gasoline -
for validity, see page 2 - from model year 2010 and later, assuming technical modifications to the ve-
hicle 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 in-
structions.
However, the stipulations in these "installation instructions" and "operating and maintenance instruc-
tions" for the Thermo Top C/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 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
- Metric thread-setter kit
Quantity Description Order No.:
1 Retail accessories Thermo Top E / C See price list
1 Installation Kit for Subaru Legacy / Outback 2.0 and 2.5
Gasoline MY 2010 1315484A
1 Heater control See price list
Vehicle Heater
Compact car Thermo Top E
Mid-size car, station wagon Thermo Top C

Subaru Legacy / Outback
1315485A_EN 4
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.
ReferencetogeneralinstallationinstructionsofWebas-
tocomponentsortothemanufacturer'svehicle-specific
documents.
Reference to a special technical feature.
All dimensions are in mm!
Tightening torque of hose clamps = 2.0 + 0.5 Nm!
Tightening torque of Ejot screws, Ejot studs = 10 Nm!
Mechanical system
Electrical system
Coolant circuit
Fuel
Exhaust gas
Combustion air
Software
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
1315485A_EN 5
Preliminary Work
WARNING!
- Open fuel tank cap, ventilate 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 air filter together with the intake hose.
- Remove the engine cover
- Remove underride trim at the left in front of the tank
- Open the tank-fitting service lid on the right and left.
- Remove fuel-tank sending unit in accordance with manufacturer's instructions.
- Remove the instrument panel trim on the driver's side.
- Remove the instrument panel trim in the footwell on the front passenger side
- Remove the lateral trim of the instrument panel on the front passenger side (for Telestart only)
Remove page 28 "Operating Instructions for End Customer" and add to the vehicle operating instruc-
tions.
Heater installation location
1Heater
Installa-
tion loca-
tion
1
1

Subaru Legacy / Outback
1315485A_EN 6
Preparing electrical system
Replace 25 A fuse F3 with 10A fuse.
1Angle bracket
2M5x16 bolt, large diameter washer [2x] re-
taining plate for fuse holder, flanged nut
3F1-3 fuses mounted
4K3 relay
Pre-install-
ing fuse
holder
43
21

Subaru Legacy / Outback
1315485A_EN 7
Electrical system
Positive and ground connection
1Positive wire on positive battery terminal
2Ground wire on ground support point
Wiring harness pass through of lineartronic
1Protective rubber plug
Wiring har-
ness in-
stallation
routing
Fuse holder, K3 relay
1M6x20bolt,springlockwasher,largediameter
washer in existing threaded hole
2Angle bracket
Wiring harness pass through of gear box
Detach original vehicle wiring harness 2and put
it away.
1Protective rubber plug
2
1
2
3
1
Do not install the metering pump
cableharnessuntillatertogether
with fuel pipe along the original
vehicle fuel lines on the under-
body
4
21
5
12

Subaru Legacy / Outback
1315485A_EN 8
Fan controller
Wiring dia-
gram
Webasto components Vehicle components Colours and symbols
Legends
HG Heater TT-C/E F31 Fuse, 7.5 A rt red
X1 6-pin heater connector F22 Fuse, 15A ws white
F3 Replace 25 A fuse with
10A fuse F12 Fuse, 15A sw black
F4 Fan fuse br brown
K3 Fan relay F5 Fan fuse gn green
D1 Diode group ZE Central electrical box bl blue
A8 Connector A (i5) PIN 8 ZE ge yellow
A1 Connector A (i5) PIN 1 ZE vi violet
A3 Connector A (i5) PIN 3 ZE or orange
GRs Fan relay
GRr Fan controller
i183 5-pin connector, GRr
GM Fan motor Insulate wire ends and
tie back
A/C-V A/C booster
i80 26-pin connector A/C-V XCutting point
i181 24-pin connector A/C-V Wiring colours may vary.
Webasto
31
30
15
Subaru
F3
HG
X1 4
F4
gn/rt
0,5²
gn/or
0,5²
sw
4²
sw/rt
F5
sw bl
sw/
ws
sw bl
D1
ge/rt
0,5²
ge/rt
0,5²
A/C-V
5
1GRs 2
4
sw
0,75²
gn/rt
0,5²
ge
vi/ge
sw/
ge
bl/ge
gn/ws
+
-
GM
M
GRr
i183
4135
rt
4²
i80 2 3
F22F31
ZE
F1
A3
FB 38 MB 4
A1
FB 24
F12
A8
FB 31
i181
98
20
86
85 30
87a87
K3

Subaru Legacy / Outback
1315485A_EN 9
Connection on 20-pin connector A (i5) 1of
central electrical box.
Produce connections as shown in wiring dia-
gram.
2Green/orange (gn/or) wire of
connector A(i5), Pin 3
3Black (sw) wire of diode group D1
4Red (rt) wire from K3/87a
5Black (sw) wire from K3/30
6Green/orange (gn/or) wire of fan relay
Pin 2
Connec-
tion to cen-
tral
electrical
box
Connector A (i5) contact side
1Green/orange (gn/or) wire of Pin 3
Connector
A (i5)
Connection on 26-pin connector A (i80) 2
from A/C booster. Watch direction of flow of
diode group D1 6.
Produce connections as shown in wiring dia-
gram.
1Green/orange (gn/or) wire of
connector A(i80), Pin 2
3Green/red (gn/rt) wire of connector A(i80),
Pin 3
4Blue (bl) wire of diode group D1
5Black (sw) wire of diode group D1
Connect-
ing to A/C
booster
Produce connections as shown in wiring dia-
gram.
1Green/red (gn/rt) wire of fuse F12.
2Black (sw) wire of diode group D1
3White/black (ws/sw) wire of diode
group D1
4Additional black (sw) wire from K3/30
5Blue (bl) wire of diode group D1
6Yellow/red (ge/rt) wire of fuse F31.
Connect-
ing to A/C
booster
6
1
4
6
5
2
3
3 41 2 5 6 97 8
12 1310 11 16 1714 15 2018 19
7
1
8
1
4
2
3
56
9
1
2
4
3
5
6

Subaru Legacy / Outback
1315485A_EN 10
Connector A (i80) contact side
1Green/red (gn/rt) wire of Pin 2
2Yellow/red (ge/rt) wire of Pin 3
Connector
A (i80)
20 2118 19 22 23 2624 25
9107 8 13 1411 12 1715 16
3 41 2 5 6
10
1 2

Subaru Legacy / Outback
1315485A_EN 11
Digital timer and summer/winter
switch option
1Digital timer
212 mm dia. hole, summer/winter switch Installing
digital tim-
er
Remote option (Telestart)
Fasten receiver 1with adhesive tape.
Installing
receiver
1Antenna
Installing
antenna
Temperature sensor T100 HTM
Fasten temperature sensor 1with adhesive
tape.
Installing
tempera-
ture sensor
1
11
2
1
12
1
13
1
14

1315485A_EN 12
Subaru Legacy / Outback
Preparing installation location
Manual transmission
Removing plug. Drill out existing hole to 9.1
mm dia. and mount rivet nut 1Installing
rivet nut
Lineartronic
Remove clip at position 1drill hole up to
9.1mm dia and tighten rivet nut. Insulation
mat 2is retained.
Installing
rivet nut
All vehicles
Fasten original vehicle wiring harnesses 1,2
with cable tie.
Preparing
installa-
tion loca-
tion
Removing brake line bracket 1
Removing
bracket
15
1
16
1
2
1
2
17
2
1
18
1

1315485A_EN 13
Subaru Legacy / Outback
Cut and discard tab at position 2. Remount
brake line bracket 1.
Preparing
bracket
1Drill 9.1 mm dia. hole; install rivet nut
Installing
rivet nut
Detach radiator tank, lift and insert suitable
material 1in between
Detaching
radiator
tank
Preparing bracket
Only for bracket version 1310449C!
Drill out hole at position1to 8.5 mm dia.
2Bracket
3Discard section
47 mm dia. hole
Preparing
bracket
19
1
2
20
1
21
1
22
1
4
3
10
43
16
2
53

1315485A_EN 14
Subaru Legacy / Outback
Preparing heater
1Perforated bracket
Angling
down per-
forated
bracket
1M6x12 bolt, spring lockwasher
2Perforated bracket
3Ejot screw
4Hose section, 10 mm dia. clamp [2x]
5Fuel line Preassem-
bling heat-
er
Discard section X
Manual transmission
1Exhaust pipe
a = 220
2Exhaust end section
b =500
Lineartronic
1Exhaust pipe
a = 220
2Exhaust end section
b =440
Preparing
exhaust
pipe
1Ejot screw [2x]
2Exhaust pipe
3Hose clamp, install loosely
4Hose clamp
Preassem-
bling heat-
er
90°
80
23
1
24
2
1
4
3
5
a b
1 2
X
25
1 1
3
2
4

1315485A_EN 15
Subaru Legacy / Outback
Installing heater
1Large diameter washer, flanged nut on ex-
isting hole
Installing
heater
Slide one 10mm shim 1[2x] on each ejot
screw.
Installing
heater
Ensure free movement between bracket of
heater 3and brake lines at position 1
2Flanged nut [2x]
4M6x20 bolt, spring lockwasher
5Large diameter washer, original vehicle
bolt Installing
heater
Mount wiring harness of heater 1and close
radiator tank again. Check the position of the
components; adjust if necessary. Check that
they have free clearance.
Mounting
wiring har-
ness
26
1
27
1
1
28
2
1
3
2
4
5
29
1

Subaru Legacy / Outback
1315485A_EN 16
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 metering-pump wiring harness so that they are protected against stone impact. Un-
less specified otherwise, always fasten using cable ties.
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 wiring harness
routing diagram.
Route wiring harness of heater and fuel
pipe 1to original vehicle wiring harness on
the left side of vehicle.
Installing
lines
Divide corrugated tube at the centre. Route
fuelline and wiringharness ofmeteringpump
in corrugated tube 1of underbody
Installing
lines
Route fuel line and wiring harness of meter-
ing pump to the installation location of meter-
ing pump
1Pasting socket, cable tie [5x each] Installing
lines
30
1 1
31
1
1
1
32
1 11 1 1

Subaru Legacy / Outback
1315485A_EN 17
Drill out perforated bracket 2at position 1 to
8.5 mm dia. and install loosely
3Silent block, flanged nut [2x]
4Rubber-coated pipe clamp
5Metering pump Pre-install-
ing meter-
ing pump
Align metering pump, tighten nut at
position 2.
1M8x20 bolt, spring lockwasher, existing
threaded hole
3Perforated bracket Installing
metering
pump
1Hose section, 10 mm dia. clamp [2x]
2Fuel line
3Wiring harness of metering pump, connec-
tor mounted
Connect-
ing meter-
ing pump
Remove fuel-tank sending unit 1in accord-
ance with manufacturer's specifications. Cut
out template 2and lay on.
3Copy hole pattern, 6 mm dia. hole Removing
fuel
33
4
3
321
2
5
34
1
3
2
35
2
3
1
36
1 2
3

Subaru Legacy / Outback
1315485A_EN 18
Shape fuel standpipe 1according to tem-
plate, cut to length andinstall. At position 2in-
sert five plane washers da = 12mm as height
compensation.
Installing
fuel stand-
pipe
Install fuel-tank sending unit 2in accordance
with manufacturer's instructions. Slide pro-
tective hose 1onto fuel line 5and route to the
left vehicle side.
3Fuel standpipe
4Hose section, 10 mm dia. clamp [2x] Connect-
ing fuel
line
Route fuel line in corrugated tube 1to meter-
ing pump.
Installing
fuel line
Check the position of the components; adjust
if necessary. Check that they have free clear-
ance.
1Hose section, 10 mm dia. clamp [2x]
2Fuel line Connect-
ing meter-
ing pump
2
1
37
1
1
38
3
5
4
1
2
39
5
1
40
1
2

Subaru Legacy / Outback
1315485A_EN 19
Coolant circuit
WARNING!
Any coolant running off should be collected using an appropriate container. Install coolant hoses kink-
free. Unless specified otherwise, always fasten using cable ties. Position clamps so that no other hose
can be damaged! When installing the hoses, the heater must be filled with coolant.
The connection should be "inline" based on the following diagram:
Hose-rout-
ing dia-
gram
All hose clamps = 20-27 mm dia.!
1= Black (sw) rubber isolator . 2= Original vehicle spring clip .
All connecting pipes = 15x20 dia..
A
B
1
2

Subaru Legacy / Outback
1315485A_EN 20
Discard section X
A= 380
B= 360
Cutting
coolant
hoses to
length
Push braided protection hoses onto hose A
and Band cut to length.
Cut heat shrink plastic tubing to length.
125 mm long heat shrink plastic tubing [4x] Preparing
coolant
hoses
Remove hose section of heat exchanger inlet
1. Spring clip will be reused. Adjust original
vehicle spacer bracket 3as shown
2Engine outlet hose section
4Discard hose section Cutting
point
Connect-
ing heater
inlet
AB
X
X
B
A
1 1
1 1
41
1
4
2
3
42
A