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.:1312732C_EN Fee Euro 10.00 © Webasto AG
Nissan Qashqai
2,0L 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

Nissan Qashqai
1312732C_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
Nissan Qashqai J10 e11 * 2001/116 * 0295 * ...
Engine type Engine model Output in kW Displacement in cm³
M9R Diesel 110 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
Fan controller for manual air conditioning 8
A
utomatic air-conditioning fan controller 9
Remote option (Telestart) 11
Preparing heater unit 12
Installing heater unit 13
Coolant connection 14
Fuel Connection 17
Combustion air 19
Exhaust system 20
Final Work 22
Operating Instructions for End Customer 23

Nissan Qashqai
1312732C_EN 3
Heater Unit/Installation Kit
Also required:
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 Qashqai 2.0 liter 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
Quantity Description Order No.:
1 Nissan-specific delivery scope See Nissan price list
1 Installation kit for Nissan Qashqai 2.0 liter Diesel 1312667A
Quantity Description Order No.:
1 Heater control according to Nissan price list 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

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.
Nissan Qashqai
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.
1312732C_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.

Nissan Qashqai
1312732C_EN 5
Preliminary Work
WARNING!
- Open fuel tank cap, ventilate 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.
- Completely remove the battery.
- Remove the air filter together with the intake hose.
- Remove the engine design cover.
- Detach the wheel well trim on the right and left.
- Remove the bumper.
- Remove the rear seat cushion.
- Open the tank-fitting service lid.
- Remove the lower cover of the instrument panel in the footwell on the left
- Remove the side cover of the instrument panel on the left
- Remove the lower cover of the instrument panel on the left
- Detach the fuse carrier on the left in the passenger compartment
- Remove the lower A-pillar trim in the footwell on the left (only with Telestart)
- Remove the A/C control panel (only with automatic air-conditioning).
Remove page 23 "Operating Instructions for End Customer" and insert with vehicle operating
instructions.
Heater unit installation location
1Heater unit
Installation
location
11

Nissan Qashqai
1312732C_EN 6
Preparing electrical system
Only with automatic air-conditioning
Cutting
wires to
length
Produce connections as shown in wiring
diagram. Install wire section 2in the
protective sleeving provided.
Preparing
fuse F4
sw 0,75mm²
1
250
2
F4
gn/ws rt
rt/
ws
br
86
85 30
87a87
K3
sw sw
1 2
sw

Nissan Qashqai
1312732C_EN 7
Electrical Connections
Wiring harness pass through
1Protective rubber plug
Summer/winter switch option
1Summer/winter switch, drilled hole 12 mm dia.
Wiring
harness
installation
diagram
Fuse holder, relay K3
7 mm dia. hole in plastic cover at position 2.
1Angle bracket
2M6x20 bolt, large diameter washer, flanged
nut
3Fan relay K3
4M5x12 bolt, washer, retaining plate for fuse
holder, washer, flanged nut on angle bracket
5Fuse holder
Digital timer
1Digital timer
2
1
3
1
Do not install the metering pump
cable harness until later together
with fuel pipe along the original
vehicle fuel lines on the underbody
in the corrugated tube
4
4
21
35 5
1

Nissan Qashqai
1312732C_EN 8
Fan controller for manual air conditioning
Wiring
diagram
Webasto components Vehicle components Colors and symbols
Legend
HG Heater unit TT-C/E GM Fan motor rt red
X1
6-pin heater unit connector GS Fan switch ws white
F3 25 A fuse M88 8-pin connector GS sw black
K3 Fan relay WG Resistor group gn green
M305 4-pin connector WG ge yellow
F15 15 A fuse
F16 15 A fuse XCutting point
Wiring colors may vary.
Connection on central electrical box 2on
driver's side.
Produce connections as shown in wiring
diagram.
1Yellow (ge) wire [2x] of fan motor
3Yellow (ge) wire [2x] for fuse F15 and F16
4Red (rt) wire from K3/87a
5Black (sw) wire from K3/30
Connect-
ing fan-mo-
tor
Webasto
31
30
15
Nissan
HG
X1 4
F3
86
85 30
87a87
K3
rt/ws
gn/
ws
br
+
-GM
M
F15 F16
sw
rt
ge
ge
ge
ge
1
WG
432 M305
5GS
1 2 3 4 M88
6
1
4
2
3
53

Nissan Qashqai
1312732C_EN 9
Automatic air-conditioning 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 heater unit connector KB Air-conditioning control panel ws white
F3 Fuse M53 40-pin connector KB sw black
K3 Fan relay GRr Fan controller br brown
D1 Diode group M311 4-pin connector, GRr gn green
F4 1 A fuse F4 Fuse bl blue
F15 Fuse ge yellow
F16 Fuse gr gray
F17 Fuse XCutting point
Wiring colors may vary.
Webasto
31
30
15
Nissan
HG
X1 4
F3
86
85 30
87a87
K3
rt/ws
gn/
ws
br
F4
sw
F15 F16
+
-GM
M
sw
rt ge ge
F17 F4
KB
M53 18 40
38 1
GRr
M311 1
3 2
ge gr
ge
gr
ws/
sw
bl
sw
bl
sw
D1
ge
1,5² ge 1,5²

Nissan Qashqai
1312732C_EN 10
Connection on central electrical box 2on
driver's side.
Produce connections as shown in wiring
diagram.
1Yellow (ge) wire [2x] of fan motor
3Yellow (ge) wire [2x] for fuse F15 and F16
4Red (rt) wire from K3/87a
5Black (sw) wire from K3/30
Connect-
ing fan mo-
tor
Connection to 40-pin connector M53 2from
A/C control panel.
Produce connections as shown in wiring
diagram.
Watch direction of flow of diode group D1 3.
1Black (sw) wire of F4
4White/black (ws/sw) of D1
Connect-
ing A/C
control
panel
Produce connections as shown in wiring
diagram.
1Gray (gr) wire of F4
2Yellow (ge) wire of F17
3Gray (gr) wire of connector M53/40 KB
4Yellow (ge) wire of connector M53/18 KB Connect-
ing A/C
control
panel
Connector imprint may differ from wiring
diagram!
1Connector M53 on line side
View of
connector
M53
7
1
4
2
3
53
8
2
3
1
9
1
4
2
3
21
140
20
10
1

Nissan Qashqai
1312732C_EN 11
Remote option (Telestart)
Fastenreceiver1withdouble-sidedadhesive
tape.
Installing
receiver
1Antenna
Installing
antenna
Temperature sensor for HTM100 only
1Fasten temperature sensor with double-
sided adhesive tape
2Air duct on driver's side Installing
tempera-
ture sensor
1
11
1
12
1
13
2

1312732C_EN 12
Nissan Qashqai
Preparing heater unit
Angle down perforated bracket 1.
Bending
perforated
bracket
Ejot screw bolt, tightening torque 10 Nm!
1Ejot screw
2Perforated bracket, mount loosely
Premount-
ing perfo-
rated
bracket
Ejot screw bolt, tightening torque 10 Nm!
1Ejot screw, large diameter washer
[2x each]
2Angle bracket [2x] Premount-
ing angle
bracket
approx. 150°
approx. 120°
35 mm
22 mm
1
14
15
1 2
16
1
2
1
2

1312732C_EN 13
Nissan Qashqai
Installing heater unit
Before installing, push on wiring harness of
heater unit.
1M6x20 bolt, spring lockwasher in existing
threaded hole Loosely
mounting
heater unit
Align heater unit. 6.5 mm dia. hole [2x] at
position 1!
Drilling
hole in
cross
member
1M6x20 bolt, flanged nut [2x each]
Installing
heater unit
1Tighten M6x20 bolt
Installing
heater unit
17
1
1
18
1
1
19
1
1
20
1
1

Nissan Qashqai
1312732C_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:
The coolant connection which differs from the standard for routing-related reasons!
Coolant
routing
diagram
All connecting pipes = 20x20 dia..
All hose clamps = 20-27 mm dia.
1= Original vehicle spring clips .
AB
C
1
1
D

Nissan Qashqai
1312732C_EN 15
a = 680 mm
c = 110 mm
d = 520 mm
Hose B=90° elbow
Discard section XCutting
coolant
hoses to
length
Cut braided protection hose in middle and,
push onto hose Aand D and cut to length.
Cut heat shrink plastic tubing to size and
shrink.
125 mm heat shrink plastic tubing [4x] Slide on
braided
protection
Premount-
ing hoses
Remove original vehicle hose on heat
exchanger outlet/engine inlet 1and discard.
Spring clip will be reused!
Cutting
point
X
D
B
XA C
D
A
1
1 1
1
21
A B
D
C
22
1

Nissan Qashqai
1312732C_EN 16
Connec-
tion to
heater unit
Routing in
engine
compart-
ment
1Original vehicle spring clip
Connec-
tion on en-
gine inlet
Before connecting, fill the coolant hoses with
coolant.
1Original vehicle spring clip
Connec-
tion on
heat ex-
changer
outlet
23
B
C
A
24
A
D
25
1
D
26
A
1

Nissan Qashqai
1312732C_EN 17
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.
1Fuel line
2Retaining clip
3Hose section, 10 mm dia. hose clamp [2x]
Connec-
tion to
heater unit
Route fuel line from heater unit and wiring
harness of metering pump in corrugated
tube 1as shown and secure with cable ties.
Installing
lines
Check the position of the components; adjust
if necessary. Check that they have free
clearance.
1Original vehicle bolt for fastening fuel tank,
angle bracket on short leg drilled out
to 10.5 mm dia.
2Rubber-coated p-clamp, silent block,
flanged nut [2x]
3Metering pump
Installation
location of
metering
pump
27
2
1
3
28
1
29
1 2 1
3

Nissan Qashqai
1312732C_EN 18
Fuel line 3from heater unit on pressure side
of metering pump 1.
Check the position of the components; adjust
if necessary. Check that they have free
clearance.
2Hose section, 10 mm dia. hose clamps [2x]
4Wiring harness of metering pump,
connector mounted
Connect-
ing to me-
tering
pump
Separate fuel return line 4approx. 50 mm
before coupling.
1Fuel line
2Hose section, 10 mm dia. hose clamp [2x]
36x5x6 fuel standpipe, 8 mm dia. hose
clamp [2x] Removing
fuel
Fuel line 1from fuel standpipe on intake side
of metering pump 3.
Check the position of the components; adjust
if necessary. Check that they have free
clearance.
2Hose section, 10 mm dia. hose clamp [2x] Connect-
ing to me-
tering
pump
30
2 13
4
31
2
1
4
3
32
1
3 2

Nissan Qashqai
1312732C_EN 19
Combustion air
1Combustion-air intake pipe
227 mm dia. hose clamp
Installing
combus-
tion air
pipe
1Combustion-air intake muffler
2Cable tie [2x]
Installing
muffler
1
233
1
2
34
2

Nissan Qashqai
1312732C_EN 20
Exhaust system
1Exhaust pipe
a = 290 mm
2Exhaust end section
b = 280 mm
Discard section X
Preparing
exhaust
pipe
Ejot stud 1, tightening torque 10 Nm.
Installing
stud bolt
130 mm spacer nut on Ejot stud
Installing
spacer nut
1Exhaust muffler
2M6x12 bolt, spring lockwasher on spacer
nut
Installing
muffler
a B
1 2
X
35
1
36
1
1
2
37