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 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.
Water Heater Unit
Installation Instructions
Ident. No.:1311875A_EN Fee Euro 10.00 © Webasto AG
Opel Vivaro
Diesel
from Model Year 2007
Left-hand drive vehicle
Feel the drive
Thermo Top E Additional Heater e1
00 0003
Thermo Top C Additional Heater
e1
00 0002
Thermo Top P Additional Heater e1
00 0104

Opel Vivaro
1311875A_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.
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 Vivaro X83 e1 *98 / 14 * 0170 ...
Opel Vivaro F7 K830
Opel Vivaro E7 L048
Engine type Engine model Output in kW Displacement in cm³
M9R Diesel 66 1995
M9R Diesel 84 1995
G9U Diesel 107 2464
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 7
Remote option (Telestart) 9
Preparing heater unit 10
Installing heater unit 12
Coolant connection 14
2.0 l dCi 15
2.5 l dCi 16
Combustion air 18
Fuel Connection 19
Installing trim pieces 21
Final Work 22
Operating Instructions for End Customer 23

Opel Vivaro
1311875A_EN 3
Heater Unit/Installation Kit
Optional heater control either:
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 Vivaro Diesel vehicles - 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"operating and 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
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
- Torx E5 nut
Quantity Description Order No.:
1 Opel-specific heater unit delivery scope See Opel price list
1 Installation Kit for Opel Vivaro from 2001 TT/C Diesel 9002568H
Quantity Description Order No.:
1 Heater control See Opel 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

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 Vivaro
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.
1311875A_EN 4
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.

Opel Vivaro
1311875A_EN 5
Preliminary Work
WARNING!
- Open the fuel tank cap, ventilate the 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 entire air filter box together with the intake hose.
- Remove the front apron
- Remove the horn with the bracket
- Remove the left-hand headlight
- Detach and remove the right and left-hand wheel well trim
- Remove the bumper with trim pieces
- Remove the underride protection (2-piece)
- Remove the lower instrument panel trim on the front passenger side
- Take off the left-hand side trim of the instrument panel (only with HTM 100)
- Remove the A-pillar trim in the driver's side footwell (only with Telestart)
Remove page 23 "Operating Instructions for End Customer" and insert with vehicle operating
instructions.
Heater unit installation location
1Heater unit
Installation
location
11

Opel Vivaro
1311875A_EN 6
Electrical Connections
Digital timer and summer/winter switch
option
1Digital timer
2Summer/winter switch, drilled hole 12 mm dia.
Connection of positive wire
Connect red (rt) positive wire, 4mm², to positive
support point. Fasten retaining plate of fuse
holder with 3x9 self-tapping screw on battery
carrier. Mount fuse, F4 30 A 1.
Wiring
harness
installation
diagram
Fuse holder, relay K3
14 mm dia. hole, 5.5x13 self-tapping screw;
K3 relay
24 mm dia. hole, 5.5x13 self-tapping screw;
retaining plate, fuse holder
3Ground wire on ground support point
4Extend positive wire with connector and red
(rt) wire, 4mm² (crimp and shrink)
Wiring harness pass through
1Wiring harness of fan controller, wiring
harness of digital timer
2Route extended positive wire in protective
sleeving to battery box and connect to fuse F4
3Protective rubber plug
2
1
23
1
Do not install the metering
pump cable harness until
later together with fuel
pipe along the original
vehicle fuel lines on the
underbody
4
4
2
3
1
5
2
1
3

Opel Vivaro
1311875A_EN 7
Fan controller
Wiring
diagram
Webasto components Vehicle components Colors and symbols
Legend
HG Heater unit TT-C/E GM Fan motor rt red
X1 6-pin connector WG Resistor group X70 ws white
F3 Fuse, 25 A GS Fan switch S95 sw black
F4 Additional fuse, 30 A FC25 25 A fan fuse br brown
K3 Fan relay FC16 Fuse, 15 A gn green
K3.1 Isolating relay SH Switch for rear-window
heater, connector S70 ge yellow
Insulate wire end and tie
back
XCutting point
Wiring colors may vary.
Webasto
31
30
Opel
rt/ws
rt
gn/
ws
br
rt
sw
15
B4
B2
GS
S95
WG
X70
SH
S70
A1
5
ge
0,5mm²
ge
0,5mm²
ge
3 mm²
ge
3 mm²
br
2 mm²
br
2 mm²
ge 0,5mm²
br
86
85 30
87a87
K3
F3
HG
X1 4
85
86 30
87a87
K3.1
+
-
GM
M
!
FC25 FC16
ge
4 mm²
ge
1,5 mm²
F4
rt
rt

Opel Vivaro
1311875A_EN 8
1Isolating relay K3.1, M5x16 bolt, flanged
nut on existing hole
2Mount M8x16 bolt, flanged nut in existing
hole
3Brown (br) wire from K3.1/85, 8 mm dia.
cable lug Installing
isolating
relay
Connection to connector S95 4of fan switch.
Produce connections as shown in wiring
diagram.
1Yellow (ge) wire from original vehicle fuse
FC25
2Yellow (ge) wire from K3.1/87
3Yellow (ge) wire to connector S95 of fan
switch, Pin B4
Con-
nection to
fan switch
Connection to connector S70 3of switch for
rear-window heater.
Produce connections as shown in wiring
diagram.
1Yellow (ge) wire from K3.1/86
2Insulate free yellow (ge) wire and tie back
4Yellow(ge)wiretoconnectorS70ofswitch
for rear-window heater
5Yellow (ge) wire from original vehicle fuse
FC16
Con-
nection of
switch for
rear-
window
heater
Connection to connector S95 3of fan switch.
Produce connections as shown in wiring
diagram.
1Black (sw) wire from K3/30
2Red (rt) wire from K3/87a
4Brown (br) wire to connector S95 of fan
switch
5Brown (br) wire to resistor group
Con-
nection to
fan switch
6
3
2
1
7
1
3
2
4
8
1 2
5
4
3
9
1 2
45 3

Opel Vivaro
1311875A_EN 9
Remote option (Telestart)
Drill out bracket 3to 6.5 mm dia. at position 2.
1Receiver
2M6x20 bolt in existing hole Installing
receiver
1Antenna
Installing
antenna
Temperature sensor for HTM100 only
1Fasten temperature sensor with suitable
means
2Ventilation duct Installing
temper-
ature
sensor
1
2
3
10
1
11
1
12
2

1311875A_EN 10
Opel Vivaro
Preparing heater unit
2.0 l dCi
a = 580 mm
b = 50 mm
c = 470 mm
Discard section X.
Push braided protection hose onto hose A
and C.
Cutting
coolant
hoses to
length
2.5 l dCi
a = 755 mm
b = 50 mm
c = 655 mm
Discard section X.
Push braided protection hose onto hose A
and C.
Cutting
coolant
hoses to
length
All vehicles
127 mm dia. spring clip
227 mm dia. hose clamp
320x20 connecting pipe Preassem-
bling
hose B
Ejot stud, tightening torque 10 Nm.
1Short Ejot stud [2x], washer [2x each]
2Long Ejot stud, 5 mm shim, washer
3Hose section, 10 mm dia. hose clamp Preassem-
bling
heater unit
X
B
b c
C
Xa
A
X
X
B
b c
C
Xa
A
X
3
13
B 1
2
3 2
11
14

1311875A_EN 11
Opel Vivaro
Before installing, insert M8x20 bolt 1in
bracket 3.
2Flanged nut (3x)
Preassem-
bling
bracket on
heater unit
1Exhaust pipe
a = 330 mm
2Exhaust end section
b = 140 mm
Discard section XPreparing
exhaust
pipe
1Exhaust muffler
2M6x20 bolt, flanged nut
Preassem-
bling
exhaust
muffler
1Hose clamp [3x]
2Exhaust end section
3Exhaust pipe
4Red (rt) rubber isolator
Preassem-
bling
exhaust
system
15
1 2
2
32
a b
1 2
X
16
2
1
17
1
3
2
4
1
1

1311875A_EN 12
Opel Vivaro
1Strut
2Loosely premount Ejot screw [2x]
Preassem-
bling strut
on heater
unit
Installing heater unit
1Remove air ducting trim
Removing
trim
1Remove trim
Removing
trim
1M8x20 bolt, flanged nut [2x each] on
existing holes
Installing
heater unit
18
1 2 2
19
1
20
1
21
1 1

1311875A_EN 13
Opel Vivaro
Tighten Ejot screws on heater unit, tightening
torque 10 Nm.
Connect wiring harness on heater unit.
1Premounted strut
2M10x16 bolt, spring lockwasher in existing
threaded hole Installing
bracket
Ensure sufficient distance to neighboring
components.
1M8x12 bolt in existing threaded hole
2Horn with bracket Installing
horn
22
1
2
23
1
2

Opel Vivaro
1311875A_EN 14
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:
(Second heat exchanger is dependent on equipment!)
Coolant
routing
diagram
Spring clip = 27 mm dia. All hose clamps = 20-27 mm dia.!
Allconnectingpipes=dia.20x20.Pos.
1 =black(sw)rubberisolator .Pos. 2 =solenoidvalve .
B
A
C
1
1
2

Opel Vivaro
1311875A_EN 15
2.0 l dCi
Connect hose Band C.
Con-
nection to
heater unit
Slide rubber isolator 1onto hose C. Slide
rubber isolator onto hose A(hidden in photo).
2Spacer bracket
Routing in
engine
compart-
ment
1Original vehicle hose of engine outlet/heat
exchanger inlet
Removing
original
vehicle
hose
Remount both hose sections after cutting to
length.
1Hose section of heat exchanger inlet
2Discard hose section
3Engine outlet hose section Cutting
original
vehicle
hose to
length
24
A
C
B
25
A
C
2
B
1
26
1
1
27
1
2
3

Opel Vivaro
1311875A_EN 16
1Engine-outlet hose section
Con-
nection on
engine
outlet
Before connecting, fill the coolant hoses with
coolant.
Position rubber isolator on hose Aand Con
original vehicle wiring harness.
1Hose section of heat exchanger inlet Con-
nection on
heat
exchanger
inlet
2.5 l dCi
Connect hose Band C.
1Spacer bracket Con-
nection to
heater unit
Slide rubber isolator 1[2x] onto hose Aand
C.
1Spacer bracket
2Cable tie Routing in
engine
compart-
ment
28
1
A
29
C
1
30
A
BC
1
31
1
AC
1
2

Opel Vivaro
1311875A_EN 17
Pulloriginal vehicle hose 3ofheatexchanger
inlet off bleeder valve 2. Spring clip 1will be
reused.
Pulling off
original
vehicle
hose
Turn bleeder valve 2toward front.
1Hose section of heat exchanger inlet
Turning
valve
1Hose section of heat exchanger inlet
2Original vehicle spring clip
Con-
nection on
heat
exchanger
inlet
Before connecting, fill the coolant hoses with
coolant.
1Bleeder valve
2Spacer bracket Con-
nection on
engine
outlet
32
1
3
2
33
2
1
34
1 C2
35
1
A
2

Opel Vivaro
1311875A_EN 18
Combustion air
1Combustion air pipe
a = 300 mm
Discard section XCutting
com-
bustion air
pipe to
length
1Retaining clip in hole of strut
227 mm dia. hose clamp
3Combustion-air intake pipe
4Combustion-air intake muffler
Installing
intake pipe
a
1
X
36
2
1
34

Opel Vivaro
1311875A_EN 19
Fuel Connection
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.
Unless 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.
Slide protective hose 1onto fuel line 2
3Hose section, 10 mm dia. hose clamp [2x]
Con-
nection to
heater unit
Remove original vehicle bolt at position 1and
discard.
1Silentblock
Installing
silent
block
Route fuel line 1and wiring harness of
metering pump 2along original vehicle fuel
lines on underbody to installation location of
metering pump.
Installing
lines
37
2
3
1
38
1
39
1
2

Opel Vivaro
1311875A_EN 20
Ensure proper installation position of
metering pump 4, see "Installation
Instructions“.
Connect fuel line from heater unit 1to
pressure side of metering pump [end with
connector].
2Wiring harness of metering pump, single-
wire seal, tab connector, connector
housing
3Flanged nut
5Rubber-coated pipe clamp
6Hose section, 10 mm dia. hose clamp [2x]
Installing
metering
pump
Disconnect fuel supply line at position 4.
Fuel line 2on intake side of metering pump
[side without connector].
Check the position of the components; adjust
if necessary. Check that they have free
clearance.
1Hose section, 10 mm dia. hose clamp [2x]
3Hose section, 10 mm dia. hose clamp [2x]
48x5x8 fuel standpipe, 10 mm dia. hose
clamp [2x]
Removing
fuel
40
3
5
41
6
2
41
1 2
4 3