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 equip-
ment 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 tech-
nical skills, or if you do not have access tothe 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 warn-
ings.
Webasto does not accept any liability for defects and damage that are attributable to
installation by untrained staff.
Feel the drive
SUBARU Impreza 1.5R; 2.0R
Gasoline
Impreza 2.0R from Model Year 2006
Impreza 1.5R from Model Year 2007
For left-hand drive vehicles only
Ident. No.: 1311020B Fee Euro 10.00 © Webasto AG
Water Heater Unit
Thermo Top E Additional Heater
Thermo Top C Additional Heater
Installation Instructions
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22
SUBARU Impreza 1.5R; 2.0R
Validity
Vehicle and engine types, equipment variants and national specifications not listed in these installation
instructionshave notbeen tested.However, installationaccordingto theseinstallationinstructions may
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
SUBARU Impreza GD/GG e1*98/14*0145...
SUBARU Impreza GD/GGS e1*98/14*0163...
Engine type Engine model Output in kW Displacement in cm³
EL15 Gasoline 77 1498
EJ20 Gasoline 118 1994
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
Preparing electrical system 6
Electrical Connections 7
Automatic air-conditioning fan controller 8
Remote option (Telestart) 10
Remote option (Thermo Call) 11
Preparing heater unit 12
Preparing installation location 13
Preassembling heater unit 14
Installing heater unit 15
Coolant connection 17
Combustion air 21
Fuel Connection 22
Exhaust system 26
Final Work 28
Operating Instructions for End Customer 29
Template with Hole Pattern for Spring Strut Dome 30
Template for Bracket 31
Template for Perforated bracket A 32
Template for Perforated bracket B 32
Template for Fuel sender 33
Template for Fuel Standpipe 34
Table of Contents

33
SUBARU Impreza 1.5R; 2.0R
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
These installation instructions apply to SUBARU Impreza 1.5R; 2.0R vehicles with a Gasoline engine
- for validity, see page 2 - from model year 2006 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 inthe "installationinstructions" and"operatingand maintenanceinstructions"
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 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 with desired heater control See price list
1 Installation kit for SUBARU Impreza 1.5R; 2.0R 1310983A
Vehicle Heater unit
Compact car Thermo Top E
Mid-size car, station wagon Thermo Top C

44
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.
SUBARU Impreza 1.5R; 2.0R
Specific risk of injury or fatal accidents.
Specific risk of damage to components.
Specific risk of fire or explosion.
Referenceto generalinstallationinstructions of Webas-
tocomponentsortothemanufacturer'svehicle-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.

5
SUBARU Impreza 1.5R; 2.0R
Heater unit installation location
1Heater unit
Installa-
tion loca-
tion
1
1
Preliminary Work
WARNING!
- Disconnect the battery "earth" or "ground" connection.
- Depressurize the 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.
- Copy the vehicle data from the type label on the right-hand spring strut dome to the EC homolo-
gation for the heater unit.
- Remove the air filter together with the intake hose.
- Remove the coolant reservoir cap.
- Remove the A/C control panel.
- Remove the lower instrument panel trim on the driver's side.
- Remove the lower left-hand A-pillar trim and fold back the floor trim above the pedals.
- Remove the left-hand front and rear door sill cover.
- Remove the rear seat cushion.
- Remove the lower luggage compartment cover and take out the Styrofoam molded parts.
- Open the fuel tank cap, ventilate the tank.
- Close the tank cap again.
- Open the right-hand fuel sender service lid
Please remove page 29 of the “Operating instructions for the end customer” and add it to the vehicle
operating instructions.

6
SUBARU Impreza 1.5R; 2.0R
Preparing electrical system
Installwiresection2intheprotectivesleeving
provided.
Cutting
wires to
length
Make connections as shown in the wiringdia-
gram with the tab receptacles provided.
Preparing
fuse F4
sw 1²
1 2
70
F4 15A
sw
1sw 2
86
85 30
87a87
K3
rt/
ws
br rt
swbr

7
SUBARU Impreza 1.5R; 2.0R
Electrical Connections
Wiring harness pass through
1Protective rubber sleeve
Digital timer
1Digital timer (match installation location)
Wiring har-
ness in-
stallation
diagram
Fuse holder, K3 relay
See wiring diagram on page 9 !
1Fuse holder retaining plate, self-tapping screw
2Fan relay K3, self-tapping screw
Summer/winter switch option
(match installation location)
1Summer/winter switch, drilled hole 12 mm dia.
2
1
3
1
br bl
sw rt
sw
Do not install the
metering-pump wir-
ing harness until lat-
er together with the
fuel line along the
original vehicle fuel
lines in the passen-
ger compartment
i
4
21
5
1

8
SUBARU Impreza 1.5R; 2.0R
Automatic air-conditioning fan
controller
Connection to the 2-pin connector 3from the
fan motor.
Make connections as shown in the wiring dia-
gram with the wire connectors provided.
1Red (rt) wire from K3/87a
2Black (sw) wire from K3/30
32-pin connector of B87 fan motor
Connect-
ing fan mo-
tor
Connection to the 16-pin connector 1from
the A/C control panel.
Make connections as shown in the wiring dia-
gram with the tab connectors provided.
116-pin connector of B282, Pin 8
2Blocking diode
3Black (sw) wire from fuse F4
4Green/yellow (gn/ge) wire to connector
5Green/yellow (gn/ge) wire from fuse No.
17(IG) 15 A
Note:
Wire color green/yellow (gn/ge) is shown as
green/orange (gn/or) in workshop manual!
Connect-
ing air-con-
ditioning
control ele-
ment
6
1
2
3
7
1
4
3
2
5

9
SUBARU Impreza 1.5R; 2.0R
Automatic
air-condi-
tioning cir-
cuit
diagram
Webasto components Components of SUBARU
Impreza 1.5R; 2.0R Colors and symbols
Legend
HG Heater unit TT-C/E GM Fan motor rt red
X1 6-pin connector GV Fan amplifier ws white
F4 Fuse, 15 A GR Fan relay ge yellow
F3 Fuse, 25 A KB Air-conditioning control
element sw black
K3 Fan relay FB1 Fuse, 15 A br brown
D1 Diode 1 FB2 Fuse, 15 A gn green
FB17 Fuse, 15 A (IG)
XCutting point
Wiring colors may vary.
gn/
ws
sw
br
rt/ws
Webasto
31
30
15
SUBARU
rt sw/rt
86
85 30
87a87
K3
HG
4X1
F3
+
-GM
M
sw/rt
Webasto
2 4
GV
1
GR
B282 16 8
KB
11 B283
F4 sw
FB2
gn/ge
FB17
FB1
D1
i

10
SUBARU Impreza 1.5R; 2.0R
Remote option (Telestart)
1Receiver, Dual Lock, self-adhesive
Installing
receiver
1Antenna
Installing
antenna
Temperature sensor for HTM100 only
1Temperature sensor, cable tie
Installing
tempera-
ture sensor
1
8
i
1
9
i
1
10
i

11
SUBARU Impreza 1.5R; 2.0R
Remote option (Thermo Call)
1Receiver, Dual Lock, self-adhesive
Installing
receiver
1Antenna
Installing
antenna
1Pushbutton
Installing
push but-
ton
1
11
i
1
12
i
1
13
i

12
SUBARU Impreza 1.5R; 2.0R
Preparing heater unit
d = 360 mm
a = 450 mm
c = 90
Discard section XCutting
coolant
hoses to
length
Slide braided protection hose onto hose D
and cut to length.
Cut shrinkdown plastic tubing to length.
1Shrinkdown plastic tubing, 25 mm
2Rubber isolator, black
Preparing
coolant
hoses
Slide braided protection hose onto hose A
and cut to length.
Cut shrinkdown plastic tubing to length.
1Shrinkdown plastic tubing, 25 mm
Preparing
coolant
hoses
Included 180° molded hose 20 mm dia.
1Rubber isolator, black
Preparing
molded
hose
d
A
a c
XD C
14
D
2 21 1
A
15
11
16
B1

13
SUBARU Impreza 1.5R; 2.0R
Preparing installation location
Remove retaining clip for brake line, drill out
hole, 9.1 mm dia., install M6 rivet nut
1Retaining clip Preparing
installa-
tion loca-
tion
Bend perforated bracket as shown!
1Perforated bracket
Preparing
perforated
bracket
Cut open 8x12 fuel hose and slide onto brake
line 4, secure to rubber-coated pipe clamp 2
with cable ties.
1Perforated bracket
2Rubber-coated pipe clamp, 15 mm dia.
3M6x20 screw, spring lockwasher, rivet nut
4Brake line Installing
perforated
bracket
Cut open red rubber isolator with groove and
secure on wiring harness with cable tie as
shown!
1Red (rt) rubber isolator with groove
2Green (gn) cable tie, 3.5x290
Installing
rubber iso-
lator
17
1
18
1
65 mm
19
1 2 3
4
20
1 2

14
SUBARU Impreza 1.5R; 2.0R
Position drilling template as shown and copy
hole pattern
1Drilling template
2Copy hole pattern, 7 mm dia. drilled hole
3Threaded insert on vehicle
4Threaded insert on vehicle Copying
hole pat-
tern
Preassembling heater unit
Discard retaining clip 2and molded hose 1
Removing
circulating
pump
Machine bracket 2and perforated bracket A
and Bin accordance with template.
1M6x12 bolt, flanged nut M6
Preassem-
bling
bracket
Assemble perforated brackets as shown.
1Perforated bracket B
2Perforated bracket A
3Bracket
Preassem-
bling
bracket
21
1
4
32
22
1
2
23
B
1 1
2
A
24
1 2
3

15
SUBARU Impreza 1.5R; 2.0R
Tighten EJOT screws to 10 Nm!
Connect circulating pump harness and en-
sure freedom of movement.
1Ejot bolt, spacer nut, M6x30
4Circulating pump
3Rubber-coated pipe clamp, 48 mm dia.
2M6x12 bolt, spring lockwasher
5Hose clamp
6Black (sw) rubber isolator
7Heater unit
Preassem-
bling heat-
er unit
1Heater unit
2Hose clamp
Preassem-
bling heat-
er unit
Tighten EJOT screws to 10 Nm!
2Bracket
37 mm dia. hole
1Ejot screw [3x]
Installing
bracket
Installing heater unit
Loosely mount heater unit with bracket on
stud of strut tower with flanged nut already on
vehicle.
1Stud bolt, flanged nut already on vehicle
2Heater unit
25
4
1 2
6
3
5
7
C
26
C
1
2
27
1
1
1
2
3
28
1 2

16
SUBARU Impreza 1.5R; 2.0R
1Bracket
27 mm dia. hole, M6x20 bolt, 5 mm shim,
M6 flanged nut
3M6x20bolt,springlockwasher,5mmshim,
M6 threaded insert already on vehicle
Installing
heater unit
1M6x20 bolt, large diameter washer
Installing
heater unit
Tighten all loose mounting hardware. Be sure
to apply specified torque at Position 1.
1Stud bolt, flanged nut already on vehicle
2M6x12 bolt, flanged nut
3M6x12 bolt, flanged nut
Installing
heater unit
Tighten all loose mounting hardware.
17 mm dia. hole, M6x20 bolt, 5 mm shim,
M6 flanged nut
2M6x20bolt,springlockwasher,5mmshim,
M6 threaded insert already on vehicle
Installing
heater unit
29
1
2
3
30
1
31
2
3
1
32
1
2

17
SUBARU Impreza 1.5R; 2.0R
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. Po-
sition 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 di-
agram
All clamps without a specific designation = 20-27 mm dia. hose clamps!
All connecting pipes without a specific designation = dia. 20x20!
Wärme-
tauscher
Motor
Ø 20x15
Ø 20x15
A
B
C
D
Heat
exchanger

18
SUBARU Impreza 1.5R; 2.0R
For all vehicles
Remove existing spacer from coolant hose
and retain for later use..
1Turn hose section of engine outlet to right-
hand side of vehicle Cutting
point
Only for 1.5R
Shorten hose section of engine outlet 2on
connection piece for heat exchanger inlet by
40 mm and remount.
1Discard hose section Cutting
point
For all vehicles
Connec-
tion to cir-
culating
pump
1Engine-outlet hose section
Connec-
tion to en-
gine outlet
1
1 2
40 mm
B
C
33
A
D
34
1AB

19
SUBARU Impreza 1.5R; 2.0R
Before connecting, fill the coolant hoses with
coolant.
1Hose section on heat exchanger inlet
Connec-
tiontoheat
exchanger
inlet
1Cable tie
Routing of
coolant
hoses
1Black (sw) rubber isolator [3x]
Aligning
rubber iso-
lator
Only for 2.0R
1Black (sw) rubber isolator [2x]
Aligning
rubber iso-
lator
35
1
D
36
A
D
1 1BC
37
11 1
38
1 1

20
SUBARU Impreza 1.5R; 2.0R
1Hose on heat exchanger inlet
2Spacer bracket
3Spacer bracket already on vehicle
Installing
spacer
bracket
Only for 1.5R
Ensure sufficient distance for clutch actua-
tion!
2Black (sw) rubber isolator
1Cable tie Aligning
rubber iso-
lator
1Spacer bracket already on vehicle
2Spacer bracket
Installing
spacer
bracket
39
A1 2 3
40
2
1D
41
1 2