Webasto Thermo Top E User manual

part number: 93199670 04/08

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
Opel Antara
3.2 Gasoline
from Model Year 2007
Left-hand drive vehicle
Automatic transmission
Ident. No.: 1311938A_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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part number: 93199670

22
Opel Antara
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
Opel Antara L-A e4 * 2001 / 116 * 0118
Engine type Engine model Output in kW Displacement in cm³
10HM Gasoline 167 3195
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 controller for manual air conditioning 7
Automatic air-conditioning fan controller 9
Remote option (Telestart) 12
Remote option (Thermo Call) 13
Preparing heater unit 14
Preparing installation location 16
Installing heater unit 18
Coolant connection 19
Fuel Connection 22
Combustion air 24
Exhaust system 25
Final Work 28
Operating Instructions for End Customer 29
Table of Contents
part number: 93199670

33
Opel Antara
Heater Unit/Installation Kit
Optional heater control:
Also required with automatic air-conditioning:
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 apply to Opel Antara vehicles with a 3.2 Gasoline engine and a manual
transmission
- for validity, see page 2 - from model year 2007 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
- Metric Thread-Setter Kit
Quantity Description Order No.:
1 Opel-specific heater unit delivery scope See Opel price list
1 Installation kit for Opel Antara (basic kit) 1311919A
1 Additional kit for Opel Antara 3.2 liter Gasoline 1311922A
Quantity Description Order No.:
1 Heater control See Opel price list
Quantity Description Order No.:
1 Kit for Opel Antara with Automatic Air-Conditioning 1311923A
Vehicle Heater unit
Compact car Thermo Top E
Mid-size car, station wagon Thermo Top C
Full-size car, van, offroader Thermo Top P
part number: 93199670

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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.
Opel Antara
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.
i
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.
part number: 93199670

5
Opel Antara
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.
- Completely remove the battery
- Remove the fuse and relay box
- Remove the engine cover
- Remove the engine control unit
- Disconnect the power-steering fluid reservoir
- Disconnect the expansion tank
- Remove the charge-air tube between the air filter and the turbocharger
- Disconnect the air hose from the charge-air tube to the engine at the engine
- Remove the filler neck of the window washer system
- Remove the vent line at the top to the coolant expansion tank
- Open the fuel tank cap, ventilate the tank.
- Close the tank cap again.
- Remove the underride protection
- Open the left tank mounting service lid
- Remove the A/C control panel according to the manufacturer's instructions (only with manual air-
conditioning)
- Remove the glove compartment (only with automatic air-conditioning)
Remove page 29 "Operating Instructions for End Customer" and add to the vehicle operating
instructions.
Heater unit installation location
1Heater unit
Installation
location
1
1
part number: 93199670

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Opel Antara
Electrical Connections
Wiring harness pass through
1Protective rubber plug
Digital timer
1Digital timer
Wiring
harness
installation
diagram
Fuse holder, relay K3
1Move original vehicle clip
2Angle bracket
3Drill out hole to 9 mm dia., mount M6 rivet nut,
M6x20 bolt, spring lockwasher
4Fuse holder
5K3 relay
6Align M5x16 bolt, large diameter washer, M5
flanged nut to right in oblong hole
Summer/winter switch option
1Summer/winter switch, drilled hole 12 mm dia.
2
1
3
1
rt
sw
br
bl
Do not install the metering pump
cableharnessuntillatertogether
with fuel pipe along the original
vehicle fuel lines on the
underbody
i
4
6
5
1 3
4
2
5
1
part number: 93199670

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Opel Antara
Fan controller for manual air conditioning
Wiring
diagram
for manual
air con-
ditioning
Webasto components Components of Opel Antara Colors and symbols
Legend
HG Heater unit TT-C/E GM Fan motor rt red
X1 6-pin connector GS Fan switch ws white
F3 Fuse, 25 A EF3 40 A fan fuse sw black
K3 Fan relay WG Resistor group br brown
K3.1 Additional relay GR Fan relay gn green
bl blue
or orange
XCutting point
Wiring colors may vary.
Webasto
31
30
15
Opel
HG
X1
4
F3
86
85
30
87a
87
K3
rt/ws
gn/
ws
br
br
br
EF3
86
85
30
87a
87
K3.1
sw
rt
GM
M
2
1
86
85
30
87
GR
F22
3
4
1
2
WG
bl/sw
bl/sw
bl/gn
ws
or
sw
sw
sw
sw
bl/sw
bl/gn
1
2
3
4
5
A6
GS
1234
0
A4
A1
A2
A3
br
0,75²
rt
2,5²
br
4²
sw
4²
rt
2,5²
i
part number: 93199670

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Opel Antara
Preparing electrical system
Preparing electrical system
Produce connections as shown in wiring
diagram.
Cut 500 mm off included protective sleeving
and push onto lines 2, 3and 4. Push
remaining end of protective sleeving onto
line 1.
Preparing
additional
relay K3.1
Fan controller
Produce connections as shown in wiring
diagram.
1Mount M5x16 bolt, flanged nut in existing
hole
2Original vehicle ground support point
3Brown (br) wire 50,75² from K3.1/85
4Additional relay K3.1
Con-
necting
additional
relay
Connection to 2-pin connector 1from fan
motor.
Produce connections as shown in wiring
diagram (crimp and shrink).
2Brown (br) wire to connector
3Brown (br) wire from fuse EF3
4Red (rt) wire 12.5² from K3.1/86
5Red (rt) wire to K3/87a
6Black (sw) wire from K3/30
Con-
nectingfan
motor
Connection to 6-pin connector 6from fan
switch.
Produce connections as shown in wiring
diagram (crimp and shrink).
1Brown (br) wire 44² from K3.1/30
2Black (sw) wire to original vehicle ground
point
3Red (rt) wire 3, 2.5² from K3.1/87a
4Blue/green (bl/gn) wire to resistor group
5Blue/green (bl/gn) wire from connector A1
7Black (sw) wire from connector A6
8Black (sw) wire 2, 4² from K3.1/87
Con-
nection to
fan switch
86
85 30
87a
87
K3.1
1
2
3
4
5
rt 2,5²
1000mm
br 0,75²
500mm
sw 4²
500mm
br 4²
500mm
rt 2,5²
500mm
6
7
2
3
4
1
8
1
5
3
2
4
6
9
1 3
7 6 5
42
8
part number: 93199670

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Opel Antara
Automatic air-conditioning fan controller
Automatic
air-con-
ditioning
circuit
diagram
Webasto components Components of Opel Antara Colors and symbols
Legend
HG Heater unit TT-C/E GM Fan motor rt red
X1 6-pin heater unit
connector GR Fan controller ws white
F3 Fuse, 25 A KB Air-conditioning control
element sw black
K3 Fan relay F22 Fuse 10A br brown
K3.1 Additional relay EF3 Fuse 40A gn green
R1 0.9 ohm resistor A Connector for A/C
control panel bl blue
B Connector for A/C
control panel GR gray
vi violet
XCutting point
Wiring colors may vary.
gn/
ws
sw
br
rt/ws
Webasto
31
30
15
Opel
rt
86
85 30
87a
87
K3
HG
4
X1 F3
86
85 30
87a
87
K3.1
R1
2
34
5
6
1
sw
F22
br
br
A
A5
A1
KB
BB1
gr/sw
2
3
GR
4
sw
br
+
-GM
M
vi
EF3
vi
br
0,75²
rt
2,5²
br
4²
sw
4²
br
4²
br
4²
i
part number: 93199670

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Opel Antara
Preparing electrical system
Produce connections as shown in wiring
diagram.
Crimp cable lug onto brown (br) wire 30.75²
provided and onto brown (br) wire
section 64². Cutting
brown (br)
wire to
length
Produce connections as shown in wiring
diagram.
Pull wires 1,2and 4inprotective sleeving
provided.
Preparing
additional
relay K3.1
Fan controller
Resistor 1becomes hot!
Ensure sufficient spacing (at least 20 mm) to
neighboring components.
3M5x30 cap screw, large diameter washer,
nut [2x]
2Angle bracket
1M6x20 bolt, spring lockwasher, brown (br)
ground wires 30.75² and 6br 4² on
existing threaded hole
5Mount edge protection
Installing
resistor
and
additional
relay
Produce connections as shown in wiring
diagram.
1Brown (br) wire 54² from K3/87a to
resistor
2Additional relay K3.1
3M5x16 bolt, flanged nut on existing hole Con-
necting
resistor
and
additional
relay
5
200
6br 4²
200
rt 2,5²
1000mm
86
85 30
87a87
K3.1
1
2
5
43
br 0,75²
500mm sw 4² 500mm
br 4²
500mm
br 4²
200mm
10
11
4 23
1
5
12
1
2
3
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Opel Antara
Connection to 2-pin connector 1from fan
motor.
Produce connections as shown in wiring
diagram (crimp and shrink).
2Violet (vi) wire from connector
3Violet (vi) wire to fan controller
4Black (sw) wire 4, 4² from K3.1/30
5Brown (br) wire 24² from K3.1/87
6Brown (br) wire from fuse EF3
7Red (rt) wire 12.5² from K3.1/86
8Red (rt) wire to K3/87a
9Black (sw) wire from K3/30
10Brown (br) wire to connector
Con-
nectingfan
motor
Cutawayinsulationofglovecompartment at
marking.
Cutting
away
insulation
13
1
8
9
2
75
4
3
10
6
14
part number: 93199670

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Opel Antara
Remote option (Telestart)
1Existing hole, M5x16 bolt, washer, flanged
nut
2Receiver
3Telestart bracket
Installing
receiver
1Antenna
Installing
antenna
Temperature sensor for HTM100 only
1Fasten temperature sensor with suitable
means (here double-sided adhesive tape)
Installing
tempera-
ture sensor
1 2
3
15
i
116
1
17
part number: 93199670

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Opel Antara
Remote option (Thermo Call)
1Fasten receiver with suitable means (here
double-sided adhesive tape)
Installing
receiver
1Antenna
Installing
antenna
1Pushbutton
Installing
push
button
1
18
i
119
1
20
part number: 93199670

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Opel Antara
Preparing heater unit
b = 240 mm
c = 335 mm
Discard section XCutting
coolant
hoses to
length
Removewaterpump 2from heaterunit.Hose
section 1and spring clip will be reused.
Discard retaining clip 3and bolt.
Removing
water
pump
Replace 193° lid 1.
Replacing
pump lid
Ejot screw 2[3x], tightening torque 10 Nm!
1Bracket part 1
Preassem-
bling
bracket 1
on heater
unit
X
X
CB
b c
3
1
2
1
21
1 2
2
part number: 93199670

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Opel Antara
1M6x12 bolt, angle bracket, M6 flanged nut
2Water pump
3Rubber-coated pipe clamp, 48 mm dia.
4M6x20 bolt, M6 flanged nut
Preassem-
bling water
pump
Ejot screw 1[3x], tightening torque 10 Nm!
Connect adapter line of water pump 2, cut to
length and connect identical colors to wiring
harness of water pump using connectors
(crimp and shrink).
3Existing spring clip [2x]
4Existing hose section Preassem-
bling
heater unit
22
3
1
4 2
23
1
4 33
11
2
part number: 93199670

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Opel Antara
Preparing installation location
1Cross member for battery carrier
2Drill out thread to 10 mm dia. [2x]
Drilling out
thread
Remove bracket 3of hydraulic line 5and
mount as shown (depending on equipment).
Original vehicle bolt 1will be reused
2Perforated bracket
3M6x16 bolt, M6 flanged nut Reposi-
tioning
hydraulic
line
Remove original vehicle hose 1. Spring clip 2
will be reused.
Removing
hose
Shorten original vehicle hose 1by 25 mm.
Dispose of hose section 2.
Separating
hose
24
1 2
25
1
3
4
5
2
26
1
2
27
2
1
25 mm
part number: 93199670

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Opel Antara
1Original vehicle hose
2Original vehicle spring clip
Re-
mounting
hose
Completelyremovecontrolunit1withbracket
2. Discard bracket 2.
Removing
control
unit
1Self-tapping Torx screw [2x]
2Additional bracket
3Control unit
Preassem-
bling
control
unit
1M6x20 bolt, spring lockwasher [2x each]
on existing threaded holes
2Additional bracket with control unit
Installing
control
unit
28
1
2
29
1
2
30
1
2
1
3
31
1
2
1
part number: 93199670

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Opel Antara
Installing heater unit
1Loosely mount M8x30 bolt [2x]
2Preassembled heater unit
Installing
heater unit
Remove original vehicle screw 1and discard.
Removing
screw
1Bracket part 2
2M6 flanged nut [3x]
3M8x40 bolt, spring lockwasher, large
diameter washer
Installing
bracket
Ensure sufficient spacing to neighboring
components, especially to A/C line 1; correct
if necessary.
Aligning
heater unit
32
1
2
1
33
1
34
1
3
2
35
1
part number: 93199670

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Opel Antara
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 spring clips = 27 mm dia.! All connecting pipes = Ø 18x20.
All hose clamps = 20-27 mm dia.! 1= hose section between circulating pump and heater unit.
A= 18 mm dia. 180° molded hose.
1
C
A
B
part number: 93199670