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
Nissan Pathfinder and Navara
2.5 liter Diesel
from Model Year 2005
For left-hand drive vehicles only
Ident. No.: 1303637F_EN Fee Euro 10 © Webasto AG
Feel the drive
Water Heater Unit
Thermo Top E Additional Heater
Thermo Top C Additional Heater
Thermo Top P Additional Heater
Installation Instructions
e1
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22
Nissan Pathfinder and Navara
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
Nissan Pathfinder R51 e9 * 2001/116 * 0051 * ...
Nissan Pathfinder R51 K492
Nissan Navara D40 L617
Engine type Engine model Output in kW Displacement in cm³
YD25 Diesel 128 2488
YD25 Diesel/DPF 126 2488
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
Remote option (Telestart) 8
Remote Option (Telestart) 8
Remote option (Thermo Call) 9
Fan controller for manual air conditioning 10
Automatic air-conditioning fan controller 12
Switch-off function of passenger compartment
monitoring 14
Preparing installation location 16
Premounting heater unit 17
Installing Heater Unit 19
Coolant connection with manual transmission 20
Coolant connection for automatic transmission 24
Combustion air 28
Fuel Connection 29
Exhaust system 31
Final Work 34
Operating Instructions for End Customer 36
Table of Contents

33
Nissan Pathfinder and Navara
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 Nissan Pathfinder and Navara vehicles with 2.5 liter Diesel
engines - for validity, see page 2 - from model year 2005 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,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 must be provided with rub protection (cut-open fuel 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 Nissan-specific heater unit delivery scope See Nissan price list
1 Installation Kit for Nissan Pathfinder 2.5 liter Diesel 1303633C
1 Heater control See Nissan price list
Vehicle Heater Unit
Compact car Thermo Top E
Mid-size car, station wagon Thermo Top C
Full-size car, van, offroader Thermo Top P

44
Special features are highlighted using the following symbols:
Mechanical work
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.
Nissan Pathfinder and Navara
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
Nissan Pathfinder and Navara
Preliminary Work
WARNING!
- Copy the factory number from the original type label to the duplicate type label.
- Remove years that do not apply from duplicate label.
- Attach the duplicate label (type label) in the appropriate place.
- Open the fuel tank cap and vent the fuel tank.
- Close the tank cap again.
- Disconnect and remove the battery.
-Depressurizethe cooling system!
- Remove the engine cover.
- Remove the intake hose between the intercooler and the engine.
- Detach the fuel filter.
- Remove the right front wheel.
- Remove the right-hand wheel well trim.
- Remove the underride protection.
- Remove the lower footwell trim on the front passenger side (not with automatic air-conditioning).
- Remove the A-pillar trim on the front passenger side (with passenger compartment monitoring)
- Remove front interior lighting and monitoring sensors (with passenger compartment monitoring)
- Expose the A/C control panel (only with automatic air-conditioning).
Heater unit installation location
1Heater unit
Installa-
tion loca-
tion
1
1

6
Nissan Pathfinder and Navara
Preparing electrical system
All equipment
Cutting
wire to
length
Produce connections as shown in wiring dia-
gram.
Cut included protective sleeving to length of
2,500 and push onto wire .
Only with passenger compartment moni-
toring
Also connect 3,000 mm long red (rt) wire
to K3/86 and pull into protective sleeving.
Connect-
ing fuse
F4
Cut off tab connector at Position 3and crimp
on connector.
(2) Diode group
(1) Connector [2x]
(4) Insulate blue (bl) wire [2x] and tie back
Preparing
diode
group
Only with automatic air-conditioning
Wire sections and will be used later.
Cutting
wire to
length
2900
1
100
2sw
1mm²
F4
86
85 30
87a87
K3
1 2
gn/ws
rt 52
5
2
2
4
3
4
11
3
50
4
50
2,5mm²
rt
3 4

7
Nissan Pathfinder and Navara
Electrical Connections
Fuse holder, relay K3
WARNING:
Do not damage tank
(1) 6.5 mm dia. hole
Fuse holder, relay K3
(3) M6x12 bolt, angle bracket, flanged nut
(4) Retaining plate, M5x12 bolt, large diameter
washer, flanged nut
(5) Fuse holder mounted
(2) K3 relay, M5x12 bolt, large diameter washer,
flanged nut
(1) Positive wire on positive support point
(6) Ground wire on battery terminal
Wiring
harness
installa-
tion dia-
gram
Wiring harness pass through
(1) Protective rubber plug Digital Timer and Summer/Winter Switch (1) Summer/winter switch, hole 12 mm dia.
(2) Digital timer with extension wiring harness,
drilling template
1
3
41 2 3 5
6
4
Donotinstallthemeteringpump
cable harness until later togeth-
er with fuel pipe along the origi-
nal vehicle fuel lines on the
underbody
i
1
5
1 2
6

8
Nissan Pathfinder and Navara
Remote option (Telestart)
(1) Receiver
(2)4 mm dia.hole; 5.5x13 self-tappingscrew
[2x]
Installing
receiver
Produce all connections in accordance with
general installation instructions provided and
fasten wires with cable ties.
(1) Antenna
Installing
antenna
1
2
7
2
1
8
i

9
Nissan Pathfinder and Navara
Remote option (Thermo Call)
(1) Receiver
(2)4 mm dia.hole; 5.5x13 self-tappingscrew
[4x]
Installing
receiver
(1) Antenna
Installing
antenna
Produce all connections in accordance with
general installation instructions provided and
fasten wires with cable ties.
(1) Push button
Installing
push but-
ton
1
29 2
1
10
1
11
i

10
Nissan Pathfinder and Navara
Fan controller for manual air conditioning
Wiring dia-
gram for
manual air
condition-
ing
Webasto components Nissan components Colors and symbols
Legend
HG Heater unit GM Fan motor rt red
X1 6-pin heater unit con-
nector gr Fan relay ws white
F3 25 A fuse WG Resistor group sw black
K3 Fan relay M95 4-pin connector WG br brown
F4 3 A fuse GS Fan switch gn green
D Diode group M59 8-pin connector GS bl blue
F24 15 A fuse gr gray
*Red (rt) wire only on
veh. with passenger
compartment monitoring
F27 15 A fuse vi violet
F8 10 A fuse pk pink
KB A/C control panel Insulate wire ends and
tie back
M98 26-pin connector KB XCutting point
Wiring colors may vary.
gn/
ws
sw
br
rt/ws
30
15
rt
ws
ws
Webasto Nissan
gr
bl
vi vi
bl
sw
1
HG
X1 4F3
86
85 30
87a87
K3
F4 2
1
GM M
5
3GR
1
2 7
6
WG
3 2 4 1
4
GS
1
2
3
4
0
2378
F24 F27
F8
pk
sw
ws/sw
sw
bl
bl
31
D
!
!
M95
M59
ws
bl
pk
2
sw
sw
ge
sw
KB
M98 18 6 20
BCM
ws
rt*5
i

11
Nissan Pathfinder and Navara
Connection to 2-pin connector from blower
motor.
Cut off white (ws) wire approx. 50 mm before
connector. Produce connections as shown in
wiring diagram.
( 3 ) 2-pin connector of fan motor, disconnected
(1) Red (rt) wire from K3/87a
(2) Black (sw) wire from K3/30 Connect-
ing fan
motor
Connection of A/C control panel is carried out
on 26-pin connector M98 (6), Pin 6.
Produce connections as shown in wiring dia-
gram.
(1) Pink (pk) wire from fuse F8
(2) Black (sw) wire to diode group
(3) Black (sw) wire from F4
(4) White/black (ws/sw) wire to diode group
(5) Black (sw) wire from diode group
(7) Pink (pk) wire to connector M98, Pin 6
Connec-
tion of A/C
control
panel
2
12
3
1
13
5
21
7 6
4
3
2

12
Nissan Pathfinder and Navara
Automatic air-conditioning fan controller
Automatic
air-condi-
tioning cir-
cuit
diagram
Webasto components Nissan components Colors and symbols
Legend
HG Heater unit F24 15 A fuse rt red
X1 6-pin heater unit con-
nector F27 15 A fuse ws white
F3 25 A fuse F8 10 A fuse sw black
F4 3 A fuse GRs Fan relay, front br brown
K3 Fan relay GM Fan motor, front gn green
D Diode group KB A/C control panel, front bl blue
M60 26-pin connector KB ge yellow
*Red (rt) wire only on
veh. with passenger
compartment monitoring
M61 40-pin connector KB pk pink
GRr Fan controller, front vi violet
M96 Connector GRr Insulate wire ends and
tie back
XCutting point
Wiring colors may vary.
KB
M60 620
M61 38 32
br
rt/ws
gn/
ws
Webasto
31
30
15
Nissan
sw
ge
sw
sw
pk
bl
vi
bl
ro
rt
rt
vi ws
ws
ws
pk
sw
sw
gr
D
ws/sw
sw
bl
bl
!
!
5
3GRs
1
27
6
HG
X1 4
rt/ws
F3
86
85 30
87a87
K3
sw
rt
1F4 2
sw
3
4
F8
F24
F27
2
1GM
M
GRr
M96 4 1 3 2
rt*5
i

13
Nissan Pathfinder and Navara
Fan motor is connected on original vehicle
fan relay for front in engine compartment.
(1) Fan relay, front
(2) Relay carrier
Fan relay
View of fan relay socket!
Seen from above!
Imprint on relay or socket may differ from
original vehicle wiring diagram, and is there-
fore irrelevant!
View of re-
lay
socket
Route wiring harness from K3 relay to relay
carrier and cut to length.
Premountwiringharnesswithincludedyellow
(ge) connector and wiring diagram.
Connect prepared red (rt) wires and .
(1) Red (rt) wire from K3/87a
(2) Black (sw) wire from K3/30 Preparing
wiring har-
ness
Expose relay carrier as shown.
Uncrimp original vehicle violet (vi) (2) and
white (ws) (3) wires from relay socket (5), Pin
5 and 7, and cut off tab receptacles.
Produce connections as shown in wiring dia-
gram.
(4) Relay carrier
(5) Relay socket
(3) White (ws) wire to fan motor and fan con-
troller
(2) Violet (vi) wire to fan motor and fan con-
troller
(1) Black (sw) wire from K3/30
(6) Red (rt) wire from K3/87a
Connect-
ing fan mo-
tor
1
14
2
3
1 2
7
6
5
1
2
15
3
4
3 4
16
1 2 3
6
34
5
4

14
Nissan Pathfinder and Navara
Switch-off function of passenger compartment monitoring
Connection of A/C control panel is carried out
on left-hand 26-pin connector M98 (4), Pin 6.
Produce connections as shown in wiring dia-
gram.
(1) Black (sw) wire to diode group
(2) Black (sw) wire from F4
(3) Pink (pk) wire from fuse F8
(5) Pink (pk) wire to connector M60, Pin 6
(6) Black (sw) wire from diode group
(7) White/black (ws/sw) wire to diode group
Actuating
A/C con-
trol panel
Webasto components:
K3.1 = Additional relay
rt*= Red (rt) wire from K3/86
Vehicle components:
R6 = Ultrasound sensor
Legend:
X = Cutting point
rt = Red wire
sw = Black wire
br = Brown wire
Wiring dia-
gram for
passenger
compart-
ment moni-
toring
17
7
54
3
2
6
1
2
86
85 30
87a87
K3.1
31
br
rt*5
R6
sw
sw
sw
sw
rt
i

15
Nissan Pathfinder and Navara
Connection is carried out on 2-pin connector
ofultrasoundsensorR6(1).Disconnectblack
(sw) wire from 2-pin connector (1) and con-
nect to black (sw) wires (2) and (3) provided
(solder and insulate).
Discon-
necting
and ex-
tending
wire
(1) Brown (br) wire K3.1/85
(2) Black (sw) wire from ultrasound sensor R6
(3) Black (sw) wire from ultrasound sensor R6
(4) K3.1 relay
(5) Red (rt) wire from K3/86
Preparing
K3.1 relay
(1) Original vehicle bolt
(2) K3.1 relay
Installing
K3.1 relay
(1) Original vehicle bolt
(2) Brown (br) wire K3.1/85
Ground
connec-
tion of
K3.1 relay
18
3
12
19
5
4
2
3
1
5
20
2
1
21
2
1

16
Nissan Pathfinder and Navara
Preparing installation location
(1) Line from steering reservoir
(2) Line to automatic-transmission oil cooler
(3)Bolts from bracket of steering reservoir
[2x] Original
state
(1) Bracket aligned as shown
(3) Bolts from bracket of steering reservoir
[2x]
(2) Copy hole pattern
Remove bracket again
Preparing
installa-
tion loca-
tion
(1) 15 mm dia. black (sw) rubber profile
(2) 6.5 mm dia. hole, M6x20 bolt, large diam-
eter washer (from inside), mm shim, pin
lock (from outside)
(3) Bolts replaced with M6x40 bolts, large di-
ameter washers (from inside) and large di-
ameter washer (from outside)[2x] Preparing
installa-
tion loca-
tion
Route line to automatic-transmission oil cool-
er (2) before steering line (4)
(1) 20 mm dia. black (sw) rubber profile
(2) Line to transmission oil cooler
(4) Steering line
(3) 18/18 double clip Preparing
installa-
tion loca-
tion
1
2
3
3
22
23
1
2
3
3
24
1
2
3
3
25
1
2
3
4

17
Nissan Pathfinder and Navara
Premounting heater unit
Spring clips [2x] will be reused!
Removing
circulat-
ing pump
x = 60 mm
Remaining sections will be used later
(1) Hose on heater unit outlet Cutting
coolant
hose on
heaterunit
output to
length
Ejot screws, tightening torque 10 Nm!
(2) Extension wiring harness for circulating
pump connected
(5) 27 mm dia. spring band clamp
(6) Hose on heater unit outlet
(3) Strut
(4) Ejot screws [2x]
(1) 100 mm edge protection Premount-
ing heater
unit
Ejot stud, tightening torque 10 Nm.
Insert 2 washers between heater unit and
Ejot studs at Position (4) as height compen-
sation.
(1) Ejot stud [2x]
(4) Ejot stud, washer [2x]
(2) 20/20 connecting pipe
(3) 27 mm dia. spring band clamp Premount-
ing heater
unit
1
x
26
3
65
4 41 2
27
11 32
4

18
Nissan Pathfinder and Navara
(1) Exhaust pipe
a = 550 mm
(2) Exhaust end section
b = 350 mm
Discard section XCutting
exhaust
pipe to
length
(1) M6x12 bolt (from below), pin lock (from
above) [2x]
Preassem-
bling
bracket
Shape exhaust pipe as shown
Only loosely mount all components.
(2) Bracket
(1) Flanged nut [3x]
(3) Exhaust pipe
(4) P-clamp, flanged nut [2x] Preassem-
bling ex-
haust pipe
(3) Exhaust pipe
(1) Red (rt) rubber profile [3x]
(2) Hose clamp [2x]
Remove bracket and exhaust pipe from heat-
er unit again.
Premount-
ing ex-
haust pipe
ab
1 2
X
28
1
1
29
44
1
1
1
2 3
30
31
21
1
2

19
Nissan Pathfinder and Navara
Installing Heater Unit
Connect wiring harness on heater unit.
(1) Heater unit
Installing
heater unit
(3) Original vehicle bolt replaced with M6x20
bolt, washer
(2) Heater unit
(1) Strut loosely mounted on bolt (3) with
flanged nut
Installing
heater unit
31
1
32
2
3
1

20
Nissan Pathfinder and Navara
Coolant connection with manual transmission
WARNING!
Tighten all hose clamps to 2.0 + 0.5 Nm.
Any cold water running off should be collected using an appropriate container!
Route coolant hoses kink-free! Unless specified otherwise, always fasten using cable ties.
Position hose and spring clips so that no other hose can be damaged!
The connection should be "inline" based on the following diagram:
Coolant
diagram
formanual
transmis-
sion
All clamps without a specific designation are 20-27 mm dia. hose clamps.
All connecting pipe not specified are 20 mm x 20 mm dia.!
Heat
exchanger
Motor
A
B
C
Pipe
D
E