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.
Feel the drive
Renault Scenic / Grand Scenic / Megane
(international)
Diesel
from Model Year 2006
Electrical auxiliary heater
Manual transmission
Left-hand drive vehicle
Ident. No.: 1311308C_EN Fee Euro 10 © Webasto AG
Water Heater Unit
Thermo Top E Additional Heater
Thermo Top C Additional Heater
Thermo Top P Additional Heater
Installation Instructions
e1
00 0003
e1
00 0002
e1
00 0104

22
Renault Scenic / Grand Scenic / Megane
Validity
Vehicle and engine types, equipment variants as well as national specifications, which are not listed in
these installation instructions, have not been tested. However, installation according to these
installation instructions 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
Renault Scenic/Grand Scenic JM e2 * 2001/116 * 0274
Engine type Engine model Output in kW Displacement in cm³
F9Q Diesel 96 1870
Manufacturer Model Type EG-BE No./ABE
Renault Megane M e2 * 98/14 * 0272
Engine type Engine model Output in kW Displacement in cm³
K9K Diesel 76 1461
Validity 2
Delivery scope 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
Automatic air-conditioning fan controller 10
Remote option (Telestart) 11
Remote option (Thermo Call) 12
Preparing installation location 13
Preparing heater unit 15
Installing heater unit 16
Coolant connection 17
Fuel Connection 21
Combustion air 23
Exhaust system 24
Final Work 26
Operating Instructions for End Customer 27
Table of Contents

33
Renault Scenic / Grand Scenic / Megane
Delivery scope
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 Renault Scenic / Grand Scenic / Megane Diesel vehicles with
electric auxiliary heater - for validity, see page 2 - from model year 2006 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,thestipulationsin the "installationinstructions"and"operatingandmaintenanceinstructions"
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
- Torx E 5 3/8“ nut
- Flexible socket wrench, 7 mm and 10 mm
- Center bit, 36 mm dia
NOTE
Please ask customers to bring in the vehicle with as little fuel in the fuel tank as possible.
Quantity Description Order No.:
1 Retail accessories with desired heater control See Renault price list
1 International installation kit Renault Scenic / Grand Scenic /
Megane from 2003 Diesel 9008865C
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 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.
Renault Scenic / Grand Scenic / Megane
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.
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
Renault Scenic / Grand Scenic / Megane
Heater unit installation location
1Heater unit
Installation
location
1
1
Preliminary Work
WARNING!
- Depressurize the 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 battery complete with the carrier plate.
- Remove the air filter together with the intake hose.
- Open the fuel tank cap, ventilate the tank.
- Close the tank cap again.
- Detach the wheel well trim on the right and left.
- Remove the bumper.
- Remove the underride protection of the engine compartment.
- Note the radio security code.
- Remove the A/C control panel according to the manufacturer's specifications.
- Remove the side trim of the instrument panel on the driver's side (only with Telestart option).
- Remove the center console (only with Thermo-Call option).
- Please remove page 27 of the “Operating instructions for the end customer” and add this to the
vehicle operating instructions.

6
Renault Scenic / Grand Scenic / Megane
Preparing electrical system
For all vehicles
1Perforated bracket
Bending
perforated
bracket
Only with automatic air-conditioning
Cutting
additional
green/
white
(gn/ws)
wire to
length
Complete fuse F4 1 A as shown in wiring
diagram and install on fuse holder. Install
cable section 2in insulating hose provided.
Fuse F4
approx. 160°
90°
12
gn/ws
1 2
70
F4 1A
gn/ws
1gn/ws 2
86
85 30
87a87
K3
rt/
ws
br rt
swbr

7
Renault Scenic / Grand Scenic / Megane
Electrical Connections
Fuse holder, K3 relay with manual air
conditioning
16.5 mm hole, perforated bracket, M6x12 bolt,
flanged nut on battery trim
2Retaining plate of fuse holder, K3 relay,
M5x12 bolt, washers, M5 nut on perforated
bracket
Fuse holder, K3 relay with automatic air-
conditioning
16.5 mm hole, perforated bracket, M6x12 bolt,
flanged nut on battery trim
2Retaining plate of fuse holder, K3 relay,
M5x12 bolt, washers, M5 nut on perforated
bracket
3Fuse F4 1 A
Wiring
harness
installation
diagram
Wiring harness pass through
1Protective rubber plug
2Wiring harnesses of fan controller, digital
timer, additional green/white (gn/ws) wire with
automatic air-conditioning
Digital timer and summer/winter switch option
1Digital timer
2Summer/winter switch, drilled hole 12 mm dia.
3
1 2
4
21
3
Do not install themeteringpump
cableharnessuntillatertogether
with fuel pipe along the original
vehicle fuel lines on the
underbody
i
5
2
1
6
1 2

8
Renault Scenic / Grand Scenic / Megane
Fan controller for manual air
conditioning
Until 02/2006
Expose horizontally running, original vehicle
wiring harness behind A/C control panel.
Produce connections as shown in wiring
diagram.
1Yellow/brown (ge/br) wire from fuse
4Red (rt) wire to K3/87a
2Yellow/brown (ge/br) wire to resistor group
3Black (sw) wire from K3/30
Con-
nection to
resistor
group
From 02/2006
Connection to 6-pin connector 1in left-hand
footwell. Produce connections as shown in
wiring diagram.
2Yellow/brown (ge/br) wire to 6-pin
connector
3Black (sw) wire from K3/30
4Red (rt) wire to K3/87a
5Yellow/brown (ge/br) wire to original
vehicle fuse
Con-
nection to
resistor
group
7
1
4
2
3
8
1
5
2
4
3

9
Renault Scenic / Grand Scenic / Megane
Wiring
diagram
for manual
air con-
ditioning
Webasto components Renault components Colors and symbols
Legend
HG Heater unit TT-C/E GM Fan motor rt red
X1 6-pin connector F Fuse 30A ws white
F3 25 A fan fuse WG Resistor group sw black
K3 Fan relay GS Fan switch br brown
gn green
ge yellow
XCutting point
Wiring colors may vary.
Webasto
31
30
15
Renault
F3 F
GM
rt/ws
gn/
ws
br
rt
sw
ge/
br
ge/
br
WG
B1 A1 A2 A3 A4
p1 p2
+
-
M
GS
2 3 4 5 1
86
85 30
87a87
K3
HG
X1 4
i

10
Renault Scenic / Grand Scenic / Megane
Automatic air-conditioning fan
controller
Produce connections as shown in wiring
diagram. Watch direction of flow of diode.
1Yellow/brown (ge/br) wire from fuse F1
7Red (rt) wire to K3/87a
2Yellow/brown (ge/br) wire to fan controller
6Black (sw) wire from K3/30
3Yellow (ge) wire from fuse F2
4Yellow (ge) wire to connector A
5Green/white (gn/ws) wire from fuse F4
Con-
necting air-
con-
ditioning
control
element
Automatic
air-con-
ditioning
circuit
diagram
Webasto components Renault components Colors and symbols
Legend
HG Heater unit TT-C/E GM Fan motor rt red
X1 6-pin connector F1 Fuse 30A ws white
F3 25 A fan fuse F2 15 A fuse sw black
F4 1 A additional fuse KB Air-conditioning control
element br brown
K3 Fan relay GRr Fan controller gn green
D1 1 A diode St A 12-pin connector, blue ge yellow
XCutting point
Wiring colors may vary.
9
1
5
7
2
4
3
6
Webasto
31
30
15
Renault
F3 F1
rt/ws
gn/
ws
br
rt
sw
ge/
br
F4 KB
D1
F2
gn/wsgn/ws
GRr
GM
M
St A 10 26
5 2
143
ge/br
HG
X1 4
86
85 30
87a87
K3
ge
ge
i

11
Renault Scenic / Grand Scenic / Megane
Remote option (Telestart)
2Receiver
14.5 mm dia. hole, 5.5x13 self-tapping
screw; bracket
Installing
receiver
1Antenna
Installing
antenna
Temperature sensor for HTM100 only
Fasten temperature sensor with suitable
means (here double-sided Velcro strip).
Installing
tempera-
ture sensor
1
210
i
1
11
1
12

12
Renault Scenic / Grand Scenic / Megane
Remote option (Thermo Call)
Installation location of Thermo Call receiver 1
is dependent on equipment.
Installation location shown (here on
underside of center console 2) is a
recommendation. Fasten receiver 1with
suitable screws. Installing
receiver
1Antenna
Installing
antenna
1Pushbutton
Installing
push
button
1
13
i
1
14
1
15

13
Renault Scenic / Grand Scenic / Megane
Preparing installation location
Removecontrolunit forauxiliaryheater1 (will
be remounted offset later); flanged nuts will
be reused.
Disconnectelectricalconnectionsonauxiliary
heater [4x] and earthing strap.
2Removebracketofcontrol unit for auxiliary
heater
Removing
bracket
1Control unit for auxiliary heater
3Mount M6x20 bolt, original vehicleflanged
nut in existing hole
26.5 mm dia. hole, M6x20 bolt, original
vehicle flanged nut Installing
control
unit for
auxiliary
heater
Cut off bracket 2at markings.
1Discard section
Cutting off
bracket
Position electrical connections on auxiliary
heater 2[4x] as shown and tighten. Position
earthingstrap4asshown,tightenandsecure
with cable tie 3.
1Bracket of control unit for auxiliary heater
Re-
installing
bracket
16
1
2
17
1 2
3
18
2
1
19
3
1 2
4

14
Renault Scenic / Grand Scenic / Megane
Cut out plastic molded part 1as shown (on
markings).
Installing
rivet nut
1Drill 9.1 mm dia. hole; install rivet nut
Installing
rivet nut
Loosely fasten retaining plate 2with M6 bolt
1on rivet nut and copy hole pattern to
position 3on frame side member.
Remove retaining plate.
Drill 9.1 mm hole in frame side member at
position 3and mount rivet nut.
2Bracket
1M6x40 bolt, spring lockwasher, 20 mm
shim on rivet nut
3M6x40 bolt, spring lockwasher, 20 mm
shim on rivet nut
Installing
bracket
2Original vehicle plastic molded part
16.2 mm dia. hole
Hole for
intake
muffler
20
1
10
24
21
1
22
1 2
3
23
1
2

15
Renault Scenic / Grand Scenic / Megane
Preparing heater unit
Saw off two long tabs on bracket 1as shown
(watch hole pattern).
Bend remaining short tabs upward by 90° as
shown.
Preparing
bracket
Ejot stud, tightening torque 10 Nm.
190° molded hose, 10 mm dia. hose clamp
2Ejot stud [3x]
Preparing
heater unit
Loosely mount bracket 3at position 2.
1Ejot screw [2x]
3Bracket
Installing
bracket
30
30
1
24
25
2
2
2
1
1
2
26
1
3

16
Renault Scenic / Grand Scenic / Megane
Installing heater unit
Mount heater unit with Ejot stud on retaining
plate.
Copy hole patterns to positions 1on bumper
mount.
Remove heater unit. Drill 9.1 mm hole in
bumper mount at position 1and mount rivet
nut. Installing
heater unit
1Flanged nut [3x] on stud bolt
2Retaining plate
Installing
heater unit
1Mount M6x20 bolt, spring lockwasher
[2x each] on prepared rivet nuts
2Bracket
WARNING!
On vehicles with front fog lights, position
bumper and check for freedom of movement
relative to bracket. If bracket makes contact,
cut off at marking and discard lower section.
Installing
heater unit
27
1 1
28
1
1
1
2
29
1 1
2

17
Renault Scenic / Grand Scenic / Megane
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:
Coolant
routing
diagram
All connecting pipes = 20x20 dia.. All hose clamps = 20-27 mm dia.!
1= Black (sw) rubber isolator . 2= Original vehicle spring clip
1
2B
A

18
Renault Scenic / Grand Scenic / Megane
Scenic/Grand Scenic 1.9 dCi
a = 460 mm
Discard section X
Megane 1.5 dCi
a = 540 mm
Discard section X
Cutting
coolant
hoses to
length
Slide braided protection hoses onto hose A
and cut to length.
1Push on black (sw) rubber isolator
Preparing
coolant
hoses
Scenic/Grand Scenic 1.9 dCi
2Detach spacer bracket
1Original vehicle hose from heat exchanger
outlet
3Original vehicle hose to auxiliary heater
inlet
Cutting
point
Megane 1.5 dCi
1Original vehicle hose from heat exchanger
outlet
2Cutting point
3Original vehicle hose to auxiliary heater
inlet Cutting
point
a
BA X
1
A
30
3
1
2
31
3
1
2

19
Renault Scenic / Grand Scenic / Megane
All vehicles
Remove hose section 1on electric auxiliary
heater; spring clip will be reused.
Con-
nection on
heater unit
Cut off hose section 2at marking.
1Discard cut-off sections
Cutting
hose to
length
1Original vehicle spring clip
2Prepared hose section
Con-
nection to
heater unit
outlet
Scenic/Grand Scenic 1.9 dCi
Route hose Athrough original vehicle pass
through to heater unit.
1Original vehicle hose from heater
exchanger outlet
2Reinstall spacer brackets Con-
nection on
heat
exchanger
outlet
32
1
33
1
1
2
34
1
B
2
35
1
A
2

20
Renault Scenic / Grand Scenic / Megane
Megane 1.5 dCi
Route hose Athrough original vehicle pass
through to heater unit.
1Original vehicle hose from heater
exchanger outlet Con-
nection on
heat
exchanger
outlet
All vehicles
Before connecting, fill the coolant hoses with
coolant.
Con-
nection to
heater unit
inlet
1Position black (sw) rubber isolator
2Cable tie on original vehicle hole
3Insert spacer bracket
Securing
rubber
isolator
36
1A
37
A
38
1
3 2