Webasto Thermo Top C User manual

Water Heater Unit
Thermo Top C Additional Heater
Legend for Figure 1
1 Thermo Top C -B heater unit
2 Blade-type fuse holder
3 Exhaust muffler
4 Combustion-air intake pipe
5 Telestart receiver, Thermo Call
6 Metering pump
7 Gateway control unit
WARNING!
Hazard warning:
Incorrect installation or repair of Webasto heating and cooling 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.
Installation Instructions
Volvo XC 90
Gasoline
From model year 03
For left-hand drive vehicles only
See Page 2 for validity
Note:
Only in conjunction with Webasto Gateway!
Only in conjunction with the corresponding
Volvo vehicle software!
For combination with Telestart and/or Thermo
Call, the Volvo AEM must also be used with the
corresponding software!
1
63 14 2 5
4
7
Ident. No. 9010409D_EN Fee Euro 10 © Webasto AG
e1
00 0002

Thermo Top C XC 90
2
Table of Contents
Validity
Note:
Vehicle models, engine types, equipment variants as well as national specifications, which are not listed
in these installation instructions, have not been tested.
However, installation according to these installation instructions may be possible.
Manufacturer Typ
eModel EG-BE No.
Volvo T6 XC90 e9*2001/116*0046*..
Engine type Engine
model Output in kW Displacement in
cm3
B5254T2 Gasoline 154 2521
B6294T Gasoline 200 2922
B6324S Gasoline 175 3192
Volvo XC 90 1
Validity 2
Heater Unit/Installation Kit 3
Foreword 3
Special Tools 3
General Instructions 3
Preliminary Work 4
Heater Unit Installation Location 5
Electrical Connections 5
Gateway Wiring Harness up to 2004 Model 7
Gateway Wiring Harness from to 2005 Model 8
Gateway Wiring Harness 10
Wiring Diagram 11
Remote Option (Telestart) 12
Thermo Call option 13
Installing Heater Unit 14
Combustion-Air Intake Pipe 16
Exhaust System 17
Coolant Connection for 2.5 and 3.0 Liter Engine 18
Coolant Connection for 3.2 Liter Engine 21
Fuel Connection 25
Removing Fuel 27
Installing Software 29
Final Work 29
Template for Bracket 30
Operating Instructions for End Customer 31

XC 90 Thermo Top C
3
Heater Unit/Installation Kit
Depending on vehicle equipment, if not present:
When using Telestart and/or Thermo Call:
Foreword
These installation instructions apply to the Volvo XC 90gasoline passenger cars - for validity, see title page -
from model year 2003 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, where this is the case the stipulations in the "installation instructions" and "operating and
maintenance instructions" for the Thermo Top C should be observed.
The corresponding rules of technology and any information from the vehicle manufacturer should be
observed during the installation work.
Special Tools
Hose clamping pliers
Torque wrench for 2.0 - 10 Nm
General Instructions
- Provide bare areas on body, e.g. on holes, with corrosion protection
- Secure hoses, lines and wiring harnesses with cable ties and provide them with a protective hose in rubbing
areas
- Provide sharp edges with edge protection (cut-open fuel hose)
Quantity Description Volvo Order No.:
1Thermo Top C -B water heater unit with vehicle-specific delivery scope 12000093
Quantity Description Volvo Order No.:
1Volvo heater software in accordance with equipment Various
1Volvo AEM (if not present in vehicle equipment) up to Model Year ’04 8666691
1Volvo AEM (if not present in vehicle equipment) from Model Year ’05 30660541
1Volvo Y-Adapter Telestart-ThermoCall 12001637

Thermo Top C XC 90
4
Preliminary Work
General Preliminary Work
- Remove years that do not apply from the duplicate
label
- Attach duplicate label (type label) in an easily visible
place
- Apply the filling station sticker in an easily visible
location
Engine compartment
WARNING:
- Open radiator cap, release pressure and close
radiator cap again.
- Remove the wiper arms.
- Remove the coolant reservoir cap.
- Remove the wiper unit.
- Remove the air filter housing and the intake hose.
Outside of vehicle
- Open fuel tank cap, release pressure from fuel tank
system and close fuel tank cap again
- Remove left front wheel
- Remove the underride protection
- Remove left front wheel well trim
- Remove left bumper trim
- Remove the left-hand headlight.
Vehicle interior
- Remove left/right lower instrument panel cover (on
right only with installation of Thermo Call 1.1)
- Remove rear corner trim at left/right in cargo space
- Remove left rear and front door sill trim
- Remove floor cover in cargo space
- Remove bracket and battery cover
- Disconnect battery
- Remove cover of fuel-tank sending unit behind
second seat row at right
Heater unit installation location
- The heater unit (1) is installed at the front left
between the wheel well and the bumper. The
installation position is horizontal, lengthwise in the
driving direction.
2
1

XC 90 Thermo Top C
5
Electrical Connections
Preparing wiring harness for all vehicles
- Cut off brown (br) wire (4) to fan relay
- Insulate wire section to wiring harness and tie back
- Cut off green/white (gn/ws) wire (5) from fan relay
- Cut off red/white (rt/ws) wire (3) to blade fuse (2)
- Insulate wire section to wiring harness and tie back
- Cut open cable tie and discard entire fan relay (1)
together with blade fuse (2)
- Connect included purple (li) wire (3) to purple (li)
wire from wiring harness of digital timer (1) with
connector.
- Connect violet (li) wire (3) to connector of digital
timer (2).
Installing gateway control unit
- Connect wiring harness (2) to gateway control unit
(1) and route to left-hand side of vehicle.
- Glue wiring harness (2) onto control unit (1) with
socket (3).
- Fasten gateway control unit (1) with cable tie.
Only with Telestart
- If no AEM is installed, route AEMwiring harness and
connect in accordance with separate installation
instructions.
- Connect blue (bl) wire (2) from gateway wiring
harness with microtimer to Pin 3 of 50-pin connector
of AEM (1).
- Fasten AEM control unit with included bracket or
suitable means.
3
5
3
4
1 2


3
2
1
4
1
2
3
5
1
2
6

Thermo Top C XC 90
6
Routing wiring harness for gateway control unit
- Route wiring harness (1) behind battery to left-hand
side to REM.
- Route white (ws) 0.5 mm2wiring harness (branch)
to REM at rear left.
- Route wiring harness further under side trim to front,
along original vehicle wiring harness in left-hand
door sill into footwell on driver's side.
Gateway wiring harness up to 2004
model
- Unclip fuse box and fold forward
- Unlock secondary lock of fuse box
- Connect white (ws) wire with microtimer (2) to free
socket of fuse 16 (1) on back of fuse box
- Lock secondary lock of fuse box again and clip in
fuse box
- Fasten all wiring harnesses with cable ties
- Insert 5 ampere fuse in fuse slot 16
- Route green (gn) and green/white (gn/ws) wiring
harnesses (branch) through existing opening into
coolant reservoir
- Pull connector trim (2) off connector (3)
- Seal off cable pass through (grommet) (1) with butyl
tape, e.g. with following part numbers: 1161780,
1161783, 1161784.
- Cut off green/white (gn/ws) wire, Pin F13 (1) approx.
50 mm before connector
- Insulate green/white (gn/ws) wire end to wiring
harness and tie back
1
7
8
2
1
9
3
2
1
1
10

XC 90 Thermo Top C
7
- Connect green/white (gn/ws) wire end (4) to
connector and green/white (gn/ws) wiring harness
(3) from gateway with connector (crimp and shrink)
- Route green (gn) wire (8) from gateway through
cable pass throughs (1,2)
- Connect green (gn) wire (8) and green/white (gn/ws)
wire (7) from wiring harness of heater unit with
connector (crimp and shrink)
- Complete connector (6) with trim (5) and reconnect
Gateway wiring harness from to 2005
model
- Connect white (ws) wire (1) from gateway with
microtimer to Pin F from connector E of REM (lower
right socket, terminal 15).
- If Pin F is occupied (e.g. when a trailer towing device
is installed), then connect white (ws) wire (1) from
gateway to white (ws) 2.5 mm² wire from Pin F.
- Route green (gn) and green/white (gn/ws) wire from
gateway wiring harness through existing opening
from passenger compartment into coolant reservoir.
- Green (gn) wire will be routed to K3 relay later.
- Remove connector C (gray) (1) from CEM
- Pull compact housing (blue) (4) out of cover with
locking device (light blue)
- 36-pin connector C (gray) (3)
- Green/white (gn/ws) wire (2)
- Green (gn) wire (1)
11
6
54321
7
8
1
12
113
3
2
4
1
14

Thermo Top C XC 90
8
- Connect green/white (gn/ws) wire (1) from gateway
wiring harness to green/white (gn/ws) wire (2) from
connector C, Pin 32 as shown in wiring diagram.
- Produce connection according to wiring diagram
with included connector.
Installing fuse holder for all vehicles
- Drill 18 mm dia. hole in plastic trim and insert
protective rubber plug (3).
- Detach protective rubber plug (1).
- 10 mm dia. hole at Position (2). When drilling, watch
components located behind!
- Fasten fuse holder (2) with original vehicle stud bolt
and plastic nut (1).
- Fasten prepared K3 relay (7) on fuse holder (2) with
M5x16 bolt and flanged nut (3).
- Fasten retaining plate of fuse holder (5) on fuse
holder (2) with washer and flanged nut (4).
- Mount fuses F1 and F2 (6).
- Route wiring harness of digital timer (1) through
prepared protective rubber plugs into passenger
compartment.
- route green (gn) wire from gateway wiring harness
(2) along wiring harness of digital timer through
prepared protective rubber plugs to K3 relay and
connect to green /white (gn/ws) wire from heater
unit (3).
1
22 15
1
2
16
3
1
3
5
4
2
6
7
17
11
2
2
3
18

XC 90 Thermo Top C
9
- Connect connector (2) to wiring harness of
additional heater
- Connect connector (1) to Telestart receiver (see
Telestart option)
- Connect positive wire (8 mm dia. ring eye) (1) to
positive support point (2)
- Connect ground wire (3) to ground support point (4)
- Routewiring harness of heater unit(1) alongoriginal
vehicle lines to left-hand headlight and further to
installation location of heater unit.
- Fasten wiring harness with cable ties.
1
2
19
1
2
20
4
3
1
21

Thermo Top C XC 90
10
Gateway wiring harness
X3
gr 0,5mm² ws 0,5mm² vi 0,5mm² sw/ws 0,5mm² gn/ws 0,5mm²
X5
B A
X1
gn 0,5mm² ge 0,5mm² sw 0,5mm² bl 0,5mm² rt 0,75mm² rt 0,75mm² br 0,75mm²
X2 X4
B A
C
A
C
B
D
A
C
B
D
an REM (hinten links)
an Steckplatz vom Stecker AEM (hinten rechts)
A B E
C D H
F
G
1 6 4 5 3
rt 0,5mm²
br 0,5mm²
vi 0,5mm²
rt 0,5mm²
gr 0,5mm² br 0,5mm²
3 1 4 2
vi 0,5mm²
auf Leitung gn/ws vom Stecker C Pin 32 aufschleifen
sw 0,5mm²
mit Leitung gn/ws vom Heizgerät Stecker X1 Pin 4 verbinden
Stecker Thermo Call
(Option)
sw/ws 0,5mm²
12 4185
R 1kΩ
Stecker
Telestart Stecker Vorwahluhr

XC 90 Thermo Top C
11
Wiring diagram
Legend for wiring diagram:
Webasto components Volvo components Colors and symbols
HG Heater unit TT-C/E GW Gateway ws white
X1 Connector on heater
unit X3 Connector on gateway gn green
X4 Connector on gateway bl blue
X5 Connector on gateway
AEM Comfort electronics module
CEM Central electronics module
C36-pin connector, gray
REM Rear electronics module
EConnector on REM
ST01 Connector for CPM
A
Webasto
31
30
15
Volvo
3
AEM
bl
F
REM
E
ws
GW
C
gn/
ws
gn/ws
32
CEM
X5
gn/
ws
gn
gn/
ws
St 01 6
X3X4
HG
4
X1

Thermo Top C XC 90
12
Remote option (Telestart)
Note:
The installation location of the Telestart antenna (1) is
on the windshield at the lower left!
Produce connections according to general installation
instructions and fasten lines with cable ties.
- Clean and degrease bonding surface on windshield
- Glue on Telestart antenna (1)
Preparations only with Telestart T100 HTM
- Disconnect yellow (ge) wire (1) from 6-pin connector
(2) of Telestart T100 HTM Y-cable
- Cut yellow (ge) wire to length after approx. 60 mm
- Discard remaining Y-cable
- Cut off and discard connector of temperature sensor
(3)
- Engage yellow (ge) additional line ge (1) in Telestart
connector from gateway wiring harness
- Produce connections as shown in wiring diagram
1
22
23
X3 X2
B A
C
A
C
G
164
5
3
vi rt
gr br
sw
Stecker
Telestart Temperatur- sensor
2
br rt ge
ge
ϑ
24
2
1
3
25
1

XC 90 Thermo Top C
13
- Lay receiver (3) on trim as shown and copy hole
pattern 1,2)
- Drill two 5.5 mm dia. holes
- Fasten receiver and bracket with two M5x12 bolts,
washers, spring lockwashers and nuts
- Connect antenna cable and Telestart connector to
receiver
- Reinstall trim
Note:
To teach the Telestart, the connector must be
disconnected at the Telestart receiver so that the
connection to the gateway is separated!
Remote option (Thermo-Call)
Note:
Observe the included general installation instructions
for the Thermo Call option.
- Copy hole pattern (1,2,4,5) of receiver (3) to footwell
trim on driver's side as shown
- Drill hole in accordance with bolts to be used
- Fasten receiver bracket with suitable bolts (1,2,4,5)
- Connect receiver (3) to bracket
Note:
Clean and degrease the bonding surface for the
antenna prior to mounting.
- Glue antenna (1) onto windshield at upper right as
shown
- Route antenna cable downward through trim of A-
pillar and then into footwell on driver's side
- Produce connections to adapter wiring harness
Order No. 12001637, or connect Thermo Call as
shown in wiring diagram, Pg. 10. Fasten all wiring
harnesses with cable ties.
- When installing Telestart and Thermo Call,
installation location of Telestart receiver must be
specified in coordination with customer.
28
1
27
5
2
1
4
3
26
3
12

Thermo Top C XC 90
14
29
1 2
34
30
1
2
3
31
12
Installing Heater Unit
Preparing installation location
- Lay on included template (1) as shown
- Copy hole pattern (2,3,4)
- Drill three 7.0 mm dia. holes
- Pry off central cover (1) on heater unit
- Cut off connector of circulating pump
- Remove circulating pump (/3) and coolant hose (2)
on heater unit
- Connect adapter wiring harness of circulating pump
on heater unit connector of circulating pump and
route through groove in heater unit
Note:
When mounting the central cover, ensure freedom of
movement of the adapter wiring harness of the
circulating pump!
- Mount central cover (1) on heater unit again
Note:
Use only special boltof the type EJOTPTto fasten the
strut (1) on the heater unit (Tightening torque 10 Nm)!
Fasten strut (1) on heater unit with special bolt of the
type EJOT PT (2) as shown
Note:
Use only the special bolts and special stud bolts of
type EJOT PT included in the delivery scope to fasten
the bracket on the heater unit (Tightening torque 10
Nm)!
Insert two washers between bracket and heater unit at
Position (3).
- Screw Ejot stud (3) into heater unit
- Lay 2 B6.3 washers on stud bolt (3)
- Mount bracket (4) on stud bolt (3)
- Fasten bracket (4) on heater unit with 2 Ejot screws
(1,2) (tightening torque 10 Nm)
32
3
1 2
4

XC 90 Thermo Top C
15
- Fasten 30 mm spacer nut (1) on stud bolt
Installing heater unit
- Drill 7 mm dia. hole (1) as shown
- Connect wiring harness of heater unit
- Fasten premounted heater unit with four M6x20
bolts ( 1,2,4,5), A7.4 washers and flanged nuts
- Fasten strut to hole with M6x20 bolt (3) and flanged
nut
- Wiring harness of heater unit (1)
36
1
35
5
4
12 3
33
1
34
1
22 mm
12 mm

Thermo Top C XC 90
16
- Angle down perforated bracket (4) by 45° at center
- Fasten water pump (1) on existing hole on engine
support with M6x85 bolt, rubber-coated p-clamp (4),
15 mm spacer nut (5), perforated bracket (4), A7.4
washer and flanged nut
- Drill out hole to 7 mm dia. if necessary
- Connect water pump wire with extension (3) to
same color
Combustion-Air Intake Pipe
Note:
Ensure proper installation position of combustion-air
intake muffler, see "Installation Instructions"!
- Mount combustion-air intake pipe (1) with slotted
side on heater unit combustion-air connection piece
and secure with hose clamp
- Route combustion-air intake pipe as shown
- Fasten mecanyl fuel line (2) on heater unit with hose
section and hose clamps
- Screw combustion-air intake muffler (1) as far as
possible into combustion-air intake pipe (2)
- Fasten combustion-air intake muffler and
combustion-air intake pipe with cable ties
37
4
3
1 2
5
38
1
2
39
2
1

XC 90 Thermo Top C
17
Exhaust system
WARNING:
Ensure sufficient spacing to hoses and lines when
installing exhaust system.
- Cut exhaust pipe (1) and exhaust-pipe end section
(2) to length as shown
- Mount 370 mm long exhaust pipe (1,4) on exhaust
muffler (2) and secure with hose clamp
- Shape exhaust pipe as shown and push on rubber
isolator (5)
- Push heat shield (2) onto muffler
- Fasten 370 mm long exhaust pipe (1,4) on
premounted spacer nut withp-clamp (3), M6x16 bolt
and A6 spring lockwasher
- Connect exhaust pipe to heater unit and secure with
hose clamp
- Connect 300 mm long exhaust-pipe end section (2)
to exhaust muffler (3) and fasten with hose clamp
- Connect red (rt) rubber isolator (1) to exhaust-pipe
end section
- Fasten 300 mm long exhaust-pipe end section (1)
on perforated bracket with p-clamp (2), M6x20 bolt
and flanged nut
Exhaust pipe
370 300
12
40
41
4
1
5
3
2
42
21
3
43
1
2

Thermo Top C XC 90
18
Integration in Water Circuit
Note:
Tighten all hose clamps to 2.0 + 0.5 Nm. Any coolant
running off should be collected with an appropriate
container!
Install hoses so that they are kink-free.
The connection of the heater unit "in series" (inline) in
the vehicle coolant circuit is described in the following.
Legend:
1 Expansion tank
2 Radiator thermostat
3 Vehicle engine
4 Circulating pump (heater unit)
5 Heater unit
6 Heater heat exchanger (vehicle)
7 Radiator
Coolant connection for 2.5 liter and 3.0
liter engine
Cut off hose sections from included coolant hoses as
shown in Figure 45 and 46:
1 x 500 mm long + 90° elbow (1)
(from engine outlet to water-pump coolant inlet)
1 x 900 mm long + 180° elbow (2)
(from heater-unit coolant outlet to heat-exchanger
coolant inlet)
- Push included braided protection hose onto 500 mm
long coolant hose (1), cut to length and fasten ends
with heat shrink plastic tubing
- Push included braided protection hose onto 900 mm
long coolant hose (2), cut to length and fasten ends
with heat shrink plastic tubing
1 x 240 mm long + 90° elbow (1)
(from water-pump coolant outlet to heater-unit coolant
inlet)
a = section
ϑ
44
900
1A2
500
45
A
1A
240
A
46

XC 90 Thermo Top C
19
- Cut off original vehicle coolant hose (1,2) as shown
- Connect cut-off 90° elbow (1) to engine outlet, turn
toward front in driving direction and fasten with hose
clamp
- Connect coolant hose, 900 mm long (1) to heater-
unit coolant outlet with 180° elbow, align and fasten
with hose clamp as shown
- Connect coolant hose, 240 mm long (2) to heater-
unit coolant inlet with 90° elbow, align and fasten
with hose clamp as shown
- Connect 240 mm long coolant hose (1) with straight
end to water-pump coolant outlet and fasten with
hose clamp
47
1 2
48
1
49
1
2
50
1

Thermo Top C XC 90
20
- Connect 500 mm long coolant hose (1) with 90°
elbow to water-pump coolant inlet, route to cutting
point and fasten with hose clamp as shown
- Connect 500 mm long coolant hose (1) from water-
pump coolant inlet and original vehicle 90° elbow (2)
with 18/20 connecting pipe and spring clips
- Connect 900 mm long coolant hose (2) from heater-
unit coolant inlet and coolant hose (1) to heat-
exchanger coolant inlet with 18/20 connecting pipe
and spring clips
- Align coolant hoses (1,2) in engine compartment
and fasten with cable ties as shown
51
12
52
1 2
53
21
54
2
1