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 suc-
cessfully 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 installa-
tion by untrained staff.
Water Heater Unit
Installation Instructions
Ident. No.:1311770A_EN Fee Euro 10.00 © Webasto AG
Opel Corsa
Diesel
from Model Year 2007
Left-hand drive vehicle
Manual transmission
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 Corsa
1311770A_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 Corsa S-D e1 * 2001 / 116 * 0379 * ...
Engine type Engine model Output in kW Displacement in cm³
Z13DTJ Diesel 55 1248
Z13DTJ Diesel 66 1248
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
Preparing installation location 12
Installing heater unit 14
Combustion air 15
Exhaust system 16
Coolant connection 17
Fuel Connection 20
Final Work 23
Operating Instructions for End Customer 24
Template for Fuel Standpipe 25

Opel Corsa
1311770A_EN 3
Heater Unit/Installation Kit
Foreword
These installation instructions apply to Opel Corsa Diesel vehicles - for validity, see page 2 - from mod-
el 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 nec-
essary 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 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
For installation parts, see Webasto calculation program

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 Corsa
Specific risk of injury or fatal accidents.
Specific risk of damage to components.
Specific risk of fire or explosion.
ReferencetogeneralinstallationinstructionsofWebas-
tocomponentsortothemanufacturer'svehicle-specific
documents.
Reference to a special technical feature.
1311770A_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 Corsa
1311770A_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.
- Completely remove the battery
- Remove the wiper arms
- Remove the coolant reservoir cap.
- Expose the fuse and relay box in the engine compartment
- Remove the rear bench seat
- Open the right-hand fuel sender service lid
- Remove the fuel-tank sending unit in accordance with the manufacturers specifications
- Remove the footwell trim on the driver's side
Remove page 24 "Operating Instructions for End Customer" and insert with vehicle operating instruc-
tions.
Heater unit installation location
1Heater unit
Installa-
tion loca-
tion
1
1

Opel Corsa
1311770A_EN 6
Preparing electrical system
Only with automatic air-conditioning
Produce connection as shown in wiring dia-
gram with tab receptacle. Pull line section 1
(2,000 mm long, 0.75 mm²) into protective
sleeving and install in passenger compart-
ment together with wiring harness for digital
timer and fan controller. This will be required
later for connection of the A/C control panel.
Cutting
wires to
length
gn/ws
rt
rt/
ws
br
86
85 30
87a87
K3
sw
1
gn/ws

Opel Corsa
1311770A_EN 7
Electrical Connections
Fuse holder, K3 relay with manual air condi-
tioning
17 mm dia. hole, M6x20 bolt, large diameter
washer, flanged nut
2Angle bracket
3Retaining plate for fuse holder, M5x16 bolt,
large diameter washer, K3 relay, flanged nut
on angle bracket
Digital timer
1Digital timer
Wiring har-
ness in-
stallation
diagram
Wiring harness pass through
1Protective rubber plug
Summer/winter switch option
1Summer/winter switch, drilled hole 12 mm dia.
2
1 2
3
3
1
Do not install the metering pump
cableharnessuntillatertogether
with fuel pipe along the original
vehicle fuel lines on the under-
body
4
1
5
1

Opel Corsa
1311770A_EN 8
Fan controller for manual air conditioning
Wiring dia-
gram
Webasto components Vehicle components Colors and symbols
Legend
HG Heater unit TT-C/E M1 A60 Fan motor rt red
X1 6-pin connector FU5 Fuse 40A ws white
F3 Fuse, 25 A R1 A60 Resistor group sw black
K3 Fan relay S1 A60 Fan switch br brown
gn green
XCutting point
Wiring colors may vary.
Connection to connector 1of fuse and relay
box 2.
Produce connections as shown in wiring dia-
gram.
3Brown (br) wire to fan motor
4Black (sw) wire from K3/30
5Red (rt) wire to K3/87a
6Brown (br) wire from fuse FU5
Connect-
ing fan-mo-
tor
Webasto
31
30
15
Opel
HG
X1 4
F3
86
85 30
87a87
K3
rt/ws
gn/
ws
br
sw
rt
FU5
+
-
M1
A60
M
S1 A60
br
br
R1 A60
6
1
5
2
6
3
4

Opel Corsa
1311770A_EN 9
Automatic air-conditioning fan controller
Wiring dia-
gram
Webasto components Vehicle components Colors and symbols
Legend
HG Heater unit TT-C/E M1 A13 Fan motor rt red
X1
6-pin heater unit connector FU5 Fuse 40A ws white
F3 Fuse, 25 A Y1 A13 Fan controller sw black
K3 Fan relay A14 Air-cond. control element br brown
XC...... Connector designations gn green
X...... Connector designations hbl light blue
or orange
Insulate wire ends and
tie back
XCutting point
Wiring colors may vary.
Webasto
31
30
15
Opel
HG
X1 4
F3
86
85 30
87a87
K3
rt/ws
gn/
ws
br
sw
rt
!
ws/
gn
ws/
gn
1gn/ws
FU5
br
br
X42 1
A14
XC42
1
XC42 3 8
+
-
M1 A13
M
swrt
or
sw
hbl
hbl
Y1 A13
XC33 1 2
XC32
2
XC32 1
XC31
1 2

Opel Corsa
1311770A_EN 10
Connection to connector 1of fuse and relay
box 2.
Produce connections as shown in wiring dia-
gram.
3Brown (br) wire to fan controller Y1 A13
4Black (sw) wire from K3/30
5Red (rt) wire to K3/87a
6Brown (br) wire from fuse FU5
Connect-
ing fan-mo-
tor
Connection to gray 32-pin connector 2from
the air conditioning control.
Disconnect white/green (ws/gn) wire 1and
produce connection as shown in wiring dia-
gram with connector.
WARNING!
If no white/green (ws/gn) wire is connected to
Pin 1, the green/white (gn/ws) wire from
K3/86 is connected there with a suitable plug-
in contact.
Connect-
ing A/C
control
panel
7
1
5
2
6
3
4
8
1
2

Opel Corsa
1311770A_EN 11
Remote option (Telestart)
Fasten receiver 1with suitable means (dou-
ble-sided adhesive tape).
Installing
receiver
1Antenna
Installing
antenna
Temperature sensor for HTM100 only
Fasten temperature sensor 1with suitable
means (double-sided adhesive tape).
Installing
tempera-
ture sensor
19
1
10
11
1

1311770A_EN 12
Opel Corsa
Preparing heater unit
b1 = 250 mm
b2 = 20 mm
c = 80 mm
d = 330 mm
Discard section X
Cutting
coolant
hoses to
length
120x20 connecting pipe
227 mm dia. hose clamp [2x]
Preassem-
bling hose
Conheater
unit
Preparing installation location
1Drill 9.1 mm dia. hole; install rivet nut
Installing
rivet nut
1M6x12 bolt, flanged nut [2x each]
2Angle bracket [2x]
3Bracket
Preassem-
bling
bracket
b1
B D
d
X C
X
c
A
b2
X
2
C
12
2
1
13
1
35 mm
30 mm
14
1
3
1
22

1311770A_EN 13
Opel Corsa
1Loosely screw M6x30 bolt into rivet nut
2Copy hole pattern
3Bracket
Copying
hole pat-
tern
1Copy hole pattern [2x], remove bracket
Copying
hole pat-
tern
1Drill 9.1 mm hole; install rivet nut [3x each]
Installing
rivet nut
Insert one 5 mm shim each between bracket
2and frame side member at position 1.
1Mount M6x30 bolt, spring lockwasher, 5
mm shim on rivet nut [2x each]
3Wiring harness of heater unit, cable tie on
angle bracket Installing
bracket
15
1 2
3
16
1 1
17
1
1 1
18
1 1
2
3

1311770A_EN 14
Opel Corsa
1Mount M6x20 bolt, spring lockwasher on
rivet nut [2x each]
Installing
bracket
Installing heater unit
Ejot screw bolt, tightening torque 10 Nm!
1Ejot screw [2x] Installing
heater unit
Ejot screw bolt, tightening torque 10 Nm!
1Ejot screw
Installing
heater unit
1Wiring harness of heater unit
Connect-
ing wiring
harness
19
1 1
20
1
1
21
1
22
1

Opel Corsa
1311770A_EN 15
Combustion air
1Combustion air pipe
a = 250 mm
Discard section XCutting
combus-
tion air
pipe to
length
Route combustion-air intake pipe 1under
battery carrier
2Combustion-air intake muffler
327 mm dia. hose clamp Installing
intake pipe
and muffler
1Combustion-air intake pipe
2P-clamp
3Mount M6x20 bolt, flanged nut in existing
hole
Fastening
intake pipe
a
1
X
23
1
1
3
2
24
21
3

Opel Corsa
1311770A_EN 16
Exhaust system
1Exhaust pipe
a = 280 mm
2Exhaust end section
b = 80 mm
Discard section X
Preparing
exhaust
pipe
1Muffler
2M6x20 bolt, flanged nut
3Perforated bracket
4Mount M6x20 bolt, large diameter washer,
flanged nut in existing hole Installing
muffler
1Hose clamp [2x]
2Exhaust pipe
Installing
exhaust
pipe
1Hose clamp
2Exhaust end section
Installing
end sec-
tion
a b
1 2
X
25
1
4 3 2
2
1
126
1
227

Opel Corsa
1311770A_EN 17
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 connecting pipes = dia. 20x20. 1= Original vehicle spring clip .
All hose clamps without a specific designation = 20-27 mm dia 2= Black (sw) rubber isolator
B
A
C
D
1
2
2

Opel Corsa
1311770A_EN 18
Disconnect hose to heat exchanger inlet 1on
connection piece of engine outlet. Discard
spring clip 2.
Cutting
point
Slideblack(sw)rubberisolator1ontooriginal
vehicle hose to heat exchanger inlet 2and
position.
3Slide black (sw) rubber isolator onto hose
Dand position Connect-
ing heat
exchanger
inlet
Disconnect connection between line 2and
line 3; catch clutch fluid running out. Position
black (sw) rubber isolator 1. Refill clutch fluid
and bleed.
Connect-
ing heater
unit outlet
Connect hose Bwith 180° elbow to circulat-
ing pump.
1Spacer bracket
Connect-
ing heater
unit inlet
28
2
1
29
1
D3 2
30
DC 1 2
3
31
1
B

Opel Corsa
1311770A_EN 19
Connect hose Aand B.
Connect-
ing engine
outlet
32
AB
A

Opel Corsa
1311770A_EN 20
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. Un-
less 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
2Hose section, 10 mm dia. hose clamp [2x]
Connect-
ing heater
unit
1Connect fuel line, wiring harness of meter-
ing pump to original vehicle lines
Installing
lines
Ensure proper installation position of meter-
ing pump 2, see "Installation Instructions“.
Installation location in front of vehicle fuel
tank!
1Mount M6x20 bolt, angle bracket, large di-
ameter washer, flanged nut in original vehi-
cle hole
3Rubber-coated pipe clamp
4Silent block, flanged nut [2x]
Installa-
tion loca-
tion of
metering
pump
33
2
1
1
34
1
35
1 2
4 3