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.:1312960A_EN Fee Euro 10.00 © Webasto AG
Fiat Bravo
Gasoline and 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

Fiat Bravo
1312960A_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
Fiat Bravo 198 e3 * 2001/116 * 0248 * ...
Engine type Engine model Output in kW Displacement in cm³
192B2000 Gasoline 66 1368
192A8000 Diesel 88 1910
192A5000 Diesel 110 1910
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 system 7
Fan controller for manual air conditioning 8
A
utomatic air-conditioning fan controller 9
Remote option (Telestart) 11
Preparing heater unit 12
Preparing installation location 12
Installing bracket 14
Installing heater unit 14
Water 15
All vehicles 16
Gasoline 18
Diesel 20
Fuel 22
Combustion air 25
Exhaust gas 26
Final Work 28
Operating Instructions for End Customer 29

Fiat Bravo
1312960A_EN 3
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 Fiat Bravo Gasoline and 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
- Metric thread-setter kit
Quantity Description Order No.:
1 Retail accessories with desired heater control See price list
1 Installation kit for Fiat Bravo Gasoline and Diesel 1312956A
Vehicle Heater unit
Compact car Thermo Top E
Mid-size car, station wagon Thermo Top C
Full-size car, van, offroader Thermo Top P

Fiat Bravo
1312960A_EN 4
Special features are highlighted using the following symbols:
The arrow in the vehicle icon indicates the position on
the vehicle and the viewing angle.
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.
All dimensions are in mm!
Tightening torque of hose clamps = 2.0 + 0.5 Nm!
Tightening torque of Ejot screws, Ejot studs = 10 Nm!
Mechanical system
Electrical system
Water
Fuel
Exhaust gas
Combustion air
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.

Fiat Bravo
1312960A_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.
- Detach the central electrical box in the engine compartment on the left.
- Remove the engine design cover; only on JTD
- Remove the wheel well trim on the right and left.
- Remove bumper
- Remove the underride protection; only on JTD.
- Remove the cover of the fuel lines on the underbody.
- Remove the cover on the right next to the fuel tank.
- Fold up the seat surface of the rear bench seat.
- Open the tank-fitting service lid.
- Remove the fuel-tank sending unit in accordance with the manufacturers specifications.
- Remove the cover of the central electrical box on the driver's side.
- Remove the A/C control panel; 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
11

Fiat Bravo
1312960A_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
1750
1
250
2sw
O,75²
F4
86
85 30
87a87
K3
1 2

Fiat Bravo
1312960A_EN 7
Electrical system
Fuse holder, relay K3
1Fuse holder
2Angle bracket, drilled out to 8 mm dia.
3Original vehicle stud bolt, flanged nut
4Relay K3, M5x16 bolt, washer, flanged nut
Summer/winter switch option
1Summer/winter switch, drilled hole 12 mm dia.
Wiring
harness
installation
diagram
Wiring harness pass through
1Protective rubber plug
Digital timer
1Digital timer
2
21
3
4
3
1
B001
Donot installthe meteringpump
cableharnessuntillatertogether
with fuel pipe along the original
vehicle fuel lines on the
underbody
4
1
5
1

Fiat Bravo
1312960A_EN 8
Fan controller for manual air conditioning
Wiring
diagram
Webasto components Vehicle components Colors and symbols
Legend
HG Heater unit TT-E/C/P N085 Fan motor rt red
X1
6-pin heater unit connector GRs Fan relay T8 ws white
F3 Fuse H081 Fan switch sw black
K3 Fan relay O030 Resistor group br brown
F8 Fuse gn green
B001B
Connector of central electrical box, gray gr gray
XCutting point
Wiring colors may vary.
Connection on gray (gr) 3-pin connector
B001B 1of central electrical box.
Produce connections as shown in wiring
diagram.
2Red (rt) wire from K3/87a
3Gray/white (gr/ws) wire of fan motor
4Black (sw) wire from K3/30
5Gray/white (gr/ws) wire of connector
Connect-
ing fan-mo-
tor
Webasto
31
30
15
Fiat
F3
86
85 30
87a87
K3
HG
X1 430
87
GRs 85
86
+
-
N085
M
H081
B C D E A
O030
4321
rt
sw
F8
gr/ws 4²
gr/ws 4²
C A B001B
T8
4
D008A
6
1
4
2
3
5

Fiat Bravo
1312960A_EN 9
Automatic air-conditioning fan controller
Wiring
diagram
Webasto components Vehicle components Colors and symbols
Legend
HG Heater unit TT-E/C/P N085 Fan unit rt red
X1
6-pin heater unit connector GRs Fan relay T8 ws white
F3 Fuse M070 Air-conditioning control panel sw black
K3 Fan relay St C Connector, blue, 12-pin br brown
F4 Fuse 5A B001B
Connector of central electrical box, gray gn green
F8 Fuse 30A ge yellow
F31 Fuse 5A gr gray
D008 Connector Insulate wire
ends and tie back
XCutting point
Wiring colors may vary.
Webasto
31
30
15
Fiat
F3
86
85 30
87a87
K3
HG
X1 430
87
GRs 85
86
F8
CB001B
F4
F31
St A 4 2
N085
M
1 3
!
sw 0,75²
rt
sw St A 4D008
gr/ws 4²
gr/ws 4²
ge/rt
ge/rt
rt
M070
St C 111 St A 8
St C 6
St B 6D008
T8

Fiat Bravo
1312960A_EN 10
Connection on gray (gr) 3-pin connector
B001B 1of central electrical box.
Produce connections as shown in wiring
diagram.
2Red (rt) wire from K3/87a
3Gray/white (gr/ws) wire of fan motor
4Black (sw) wire from K3/30
5Gray/white (gr/ws) wire of connector
Connect-
ing fan-mo-
tor
Connection on 12-pin connector 2from A/C
control panel 3.
Produce connections as shown in wiring
diagram.
1Black (sw) wire of K3/30, fuse F4
4Yellow/red (ge/rt) connector
5Yellow/red (ge/rt) wire of fuse F31
Connect-
ing A/C
control
panel
7
1
4
2
3
5
8
4
2
3
1
5

Fiat Bravo
1312960A_EN 11
Remote option (Telestart)
1Receiver
2Original vehicle stud bolt, original vehicle
flanged nut
3Bracket, hole drilled out to 6.5 mm dia. Installing
receiver
1Antenna
Installing
antenna
1
29 3
1
10

1312960A_EN 12
Fiat Bravo
Preparing heater unit
Washer on Ejot stud 2!
1Heater unit Premount-
ing heater
unit
Preparing installation location
Mount bracket 2on original vehicle stud bolt
3with flanged nut, align and copy hole
pattern.
1Hole pattern, 9.1 mm dia. hole
4Hole pattern, 6.5 mm dia. hole [2x]
Copying
hole
pattern
1M6 rivet nut, 9.1 mm dia. hole
Installing
rivet nut
1Edge protection section
Cutting
edge
protection
section to
length
1
211
12
1 2
4
3
4
13
1
100 50 50
1

1312960A_EN 13
Fiat Bravo
1100 mm edge protection section
Mounting
edge
protection
section
150 mm edge protection section
Mounting
edge
protection
section
150 mm edge protection section
Mounting
edge
protection
section
1
14
15
1
16
1

1312960A_EN 14
Fiat Bravo
Installing bracket
1M6x30bolt, springwasher, 8 mm shim,M6
rivet nut
2Original vehicle stud bolt, 5 mm shim,
flanged nut
3M6x50 bolt [2x], 30 mm spacer [2x], 8 mm
shim [2x], flanged nut [2x]
4Bracket
Installing
bracket
Installing heater unit
Connect wiring harness of heater unit before
installing heater unit 1.
2Ejot screw [2x] Installing
heater unit
1Ejot screw
Installing
heater unit
17
1
4
2
3
3
18
2
1
2
19
1

Fiat Bravo
1312960A_EN 15
Water
WARNING!
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 clamps so that no
other hose can be damaged! When installing the coolant hose, the heater unit must be filled with
coolant.
The connection should be "inline" based on the following diagram:
Coolant
routing
diagram
All connecting pipes without a specific designation = dia. 18x20.
All hose clamps = 20-27 mm dia.!
A
B
C
Ø 20x20

Fiat Bravo
1312960A_EN 16
Gasoline
c = 1280
Diesel
c = 1220
Discard section X
Cutting
hose C to
length
All vehicles
Slide braided protection hose onto hose C
and cut to length.
Cut heat shrink plastic tubing to length.
125 mm long heat shrink plastic tubing [2x] Braided
protection
hose C
a = 970
b = 410
Discard section X
Cutting
hose
A and B to
length
Push braided protection hoses onto hose A
and Band cut to length.
Cut heat shrink plastic tubing to length.
125 mm long heat shrink plastic tubing [4x] Braided
protection
hoses A
and B
C
XX
C
1
1
AB
X
X
X
10
B
A
1
1 11

Fiat Bravo
1312960A_EN 17
Bend 48 mm dia. rubber-coated p-clamp 1.
Preparing
p-clamp
Bend perforated bracket 1by 90°.
Preparing
perforated
bracket
1Perforated bracket, angled down
2M6x20 bolt, flanged nut
348 mm dia. rubber-coated p-clamp
Premount-
ing p-
clamp
1Perforated bracket
2M6x20 bolt, original vehicle hole, flanged
nut
Installing
p-clamp
20
1
21
1
60
22
1
2
3
23
1
2

Fiat Bravo
1312960A_EN 18
Connec-
tion to
heater unit
Gasoline
1Engine-outlet hose section
2Hose section of heat exchanger inlet
Cutting
point
148 mm dia. rubber-coated p-clamp
Routing in
engine
compart-
ment
Routing in
engine
compart-
ment
24
C
B
25
1 2
26
C 1
27
C

Fiat Bravo
1312960A_EN 19
Ensure sufficient distance to neighboring
components.
1Hose on heat exchanger inlet
Connect-
ing heat
exchanger
inlet
1Hose on engine outlet
2Spacer bracket
Connect-
ing engine
outlet
148 mm dia. rubber-coated p-clamp
Routing in
engine
compart-
ment
1Cable tie
Connect-
ing hose A
and B
28
C 1
29
A1 2
30
1
A
C
31
1
A
B

Fiat Bravo
1312960A_EN 20
1Cable tie [5x]
Routing in
engine
compart-
ment
Diesel
1Engine-outlet hose section
2Hose section of heat exchanger inlet
3Cutting point Cutting
point
148 mm dia. rubber-coated p-clamp
Routing in
engine
compart-
ment
2Hose section of heat exchanger inlet
Connect-
ing heat
exchanger
inlet
32
11 A
111
C
33
1 2
3
34
C
1
35
C 1