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
Fiat Grande Punto
Gasoline
from Model Year 2006
For left-hand drive vehicles only
Ident. No.: 1310665B_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
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22
Fiat Grande Punto
Validity
Vehicle and engine types, equipment variants and national specifications not listed in these installation
instructionshavenotbeentested.However, installationaccordingtotheseinstallationinstructionsmay
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 Grande Punto 199 e3 * 2001/116 *0217*
Engine type Engine model Output in kW Displacement in cm³
350A1000 Gasoline 57 1368
199A6000 Gasoline 70 1368
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
Automatic air-conditioning fan controller 9
Remote Option (Telestart) 11
Preparing Bracket and Heater Unit 12
Installing Heater Unit 13
Coolant connection 14
Combustion air 18
Fuel Connection 19
Exhaust system 22
Final Work 24
Operating Instructions for End Customer 25
Template for Fuel Standpipe 26
Table of Contents

33
Fiat Grande Punto
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
The installation instructions apply to the Fiat Grande Punto vehicles with a Gasoline engine
- For the 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,thestipulations in 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
Quantity Description Order No.:
1 Retail accessories with desired heater control See price list
1 Installation kit for Fiat Grande Punto Gasoline 1310662A
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.
Fiat Grande Punto
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
Fiat Grande Punto
Heater unit installation location
1Heater unit
Installation
location
1
1
Preliminary Work
WARNING!
- 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 coolant reservoir cap.
- Remove the fuse and relay box.
- Open the fuel tank cap, ventilate the tank.
- Close the tank cap again.
- Fold over the rear seat surface.
- Open the right-hand fuel sender service lid.
- Remove the fuel-tank sending unit in accordance with the manufacturers specifications.

6
Fiat Grande Punto
Preparing electrical system
Cut out insulation mat along marked line.
Cuttingout
insulation
mat
Only with automatic air-conditioning
Wire section 1and 2will be required later for
connecting A/C control panel.
Cutting
wires to
length
Make connections as shown in the wiring
diagram with the tab receptacles provided.
Install wire section 2in protective sleeving
provided.
Pre-
mounting
K3 relay
2
rt 0,75mm²
1850
21
150
K3
87a8786
85 30
F4
br
br
rt
rt/
ws
1 2 rtrt
sw

7
Fiat Grande Punto
Electrical Connections
Fuse holder, relay K3
1Retaining plate of fuse holder, M5.5x9.5 bolt
2K3 relay, M5.5x9.5 bolt, washer
Wiring
harness
installation
diagram
Wiring harness pass through
1Protective rubber plug
Digital timer and summer/winter switch option
1Digital timer
2Summer/winter switch, drilled hole 12 mm dia.
3
12
br
bl
rt sw
Donot installthe meteringpump
cableharnessuntillatertogether
with fuel pipe along the original
vehicle fuel lines on the
underbody
i
4
1
5
1
2

8
Fiat Grande Punto
Fan controller for manual air
conditioning
Integration on connector of fuse and relay
box.
Make connections as shown in the wiring
diagram with the connectors provided.
1Connector
2Fuse and relay box
Con-
nectingfan
motor
Wiring
diagram
for manual
air con-
ditioning
Webasto components Fiat components Colors and symbols
Legend
HG Heater unit TT-C/E N085 Fan motor rt red
F3 Fuse GR Fan relay ws white
K3 Fan relay O030 Fan resistor sw black
H081 Fan switch br brown
F18 Fuse 40A gn green
bl blue
gr gray
or orange
vi violet
XCutting point
6
1
2
gn/
ws
sw
br
rt/ws
Webasto
31
30
15
Fiat
rt
4
HG
X1 F3
F18
M
+
-
N085
gn/
sw
gn/
sw
T5
K3
87a8786
85 30
H081
O030
i

9
Fiat Grande Punto
Automatic air-conditioning fan
controller
Integration on connector of fuse and relay
box.
Make connections as shown in the wiring
diagram with the connectors provided.
1Connector
2Fuse and relay box
Con-
nectingfan
motor
Integration on 40-pin connector, Pin 39 from
A/C control panel (wire colors may vary).
Remove connector half 2from Pin 21 to Pin
40 from connector housing.
Make connections as shown in wiring
diagram with connectors provided.
140-pin connector (2-piece)
Con-
necting air-
con-
ditioning
control
element
7
1
2
8
1
2

10
Fiat Grande Punto
Automatic
air-con-
ditioning
circuit
diagram
Webasto components Fiat components Colors and symbols
Legend
HG Heater unit TT-C/E N085 Fan motor rt red
F3 Heater unit fuse GR Fan relay ws white
K3 Fan relay M072 Fan controller sw black
F4 Fuse, 7.5 A M070
Air-conditioning control panel br brown
F24 Fuse, 7.5 A gn green
F18 Fuse 40A ro pink
or orange
*Wiring colors may vary
Insulate wire ends and
tie back
XCutting point
gn/
ws
sw
br
rt/ws
Webasto
31
30
15
Fiat
rt
4
HG
X1
F3
F18
M
+
-
N085
gn/
sw
gn/sw
K3
87a8786
85 30
M072
F4
F24
rt
gn/
or
1
2
!
M070
39
gn/or
T5
*
*
i

11
Fiat Grande Punto
Remote option (Telestart)
1Receiver
2Original vehicle bolt
3Telestart bracket
Installing
receiver
1Antenna
Installing
antenna
Only with Telestart HTM 100
1Temperature sensor with double-sided
adhesive installation strap
2Ventilation duct under instrument panel
Installing
tempera-
ture sensor
1
3
29
i
1
10
1
11
2

12
Fiat Grande Punto
Preparing bracket and heater unit
Bend angle bracket 2 straight and shorten at
cutting line 3. Shape bracket as shown in
drawing.
1Included bracket
4Discard section
5Bracket reshaped Shaping
bracket
1Centered 7.0 mm dia. hole [2x]
27.0 mm dia. hole
Preparing
bracket
Shorten bracket at cutting line 2.
1Discard cut-off section [2x]
Preparing
bracket
Tighten EJOT screws to 10 Nm!
1Heater unit
2Included Ejot stud
Pre-
mounting
heater unit
12
1 2
4
3
35 mm
35 mm 5
13
1
2
25 mm
20 mm
25 mm
14 mm
14
2
1
15
1
2

13
Fiat Grande Punto
Tighten EJOT screws to 10 Nm!
1Prepared bracket
2Ejot screw [2x]
310 mm shim, M6x40 spacer nut
Installing
bracket on
heater unit
Installing heater unit
1M6x20 bolt, spring lockwasher, large
diameter washer,
2Existing hole
Installing
heater unit
1Copy hole pattern, drill 7.0 mm hole [2x]
Copying
hole
pattern
1M6x20 bolt [2x], large diameter washer
[4x], M6 flanged nut [2x]
Installing
heater unit
16
1 2
3
17
1
2
18
1 1
19
1 1

14
Fiat Grande Punto
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 clamps without a specific designation are 20-27 mm dia. hose clamps
Motor
Heat
exchanger
A
BC
Ø20x18
Ø20x20

15
Fiat Grande Punto
a = 810 mm
b = 870 mm
Discard section X
Cut braided protection hoses to length and
push onto hose Aand B.Cutting
coolant
hoses to
length
Push braided protection hoses onto hose A
and Band cut to length. Cut included heat
shrink plastic tubing in half, push on and
shrink.
1Heat shrink plastic tubing cut in half [4x]
Preparing
coolant
hoses
Pull hose 1on heat exchanger inlet off heat
exchanger after disconnecting.
On 70 kW engine, cut off vulcanized-on
connecting piece 3.
2Hose of engine outlet
Cutting
point
1Original vehicle connection piece on
heater exchanger inlet
2Discard hose section and clamp
Preparing
heat
exchanger
inlet
ab
A B
C
X
A
11
B
1 1
20
1
2
3
21
1
2

16
Fiat Grande Punto
Premount connection piece for heat
exchanger inlet and mount on heat
exchanger inlet.
Premount-
ing con-
nection
piece for
heat ex-
changer in-
let
1Included clip 1 with cable tie in existing
hole
Preparing
installa-
tion in en-
gine
compart-
ment
1Included clip 2 with cable tie in existing
hole
Preparing
installa-
tion in en-
gine
compart-
ment
Connec-
tion on
heat ex-
changer in-
let
22
A
23
1
24
1
25
B
C

17
Fiat Grande Punto
Connec-
tion to
heater unit
Before connecting, fill the coolant hoses with
coolant.
1Hose of engine outlet
Connec-
tion to en-
gine outlet
1Coolant hoses Aand Bin premounted
clip 1 with cable tie
2Included spacer bracket
Routing in
engine
compart-
ment
1Cable tie
2Coolant hoses Aand Bin premounted
clip 2 with cable tie
Routing in
engine
compart-
ment
26
B
A
27
A1
28
A
B
1 2
29
A
B
1 2

18
Fiat Grande Punto
Combustion air
1Combustion air pipe
a = 260 mm
Discard section XCutting
combus-
tion air
pipe to
length
1Retaining clip in hole of heater unit
Installing
retaining
clip
1Combustion-air intake muffler
227 mm dia. hose clamp
3Combustion-air intake pipe
Installing
muffler
a
1
X
30
1
31
1 2 3
i

19
Fiat Grande Punto
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.
1Mecanyl fuel line
2Hose section, 10 mm dia. hose clamp [2x]
Connec-
tion on
heater unit
1Mecanyl fuel line, wiring harness of
metering pump on original vehicle line
Installing
lines
Ensure proper installation position of
metering pump, see "Installation
Instructions“.
Installation location in front of vehicle fuel
tank!
1Anglebracket,originalvehiclehole,M6x20
bolt, large diameter washer, M6 flanged
nut
2Metering pump, rubber-coated p-clamp
3Silent block, flanged nut [2x]
Installing
metering
pump
32
1
6
33
1
34
1
2
3
i

20
Fiat Grande Punto
Fuel line from heater unit on pressure side of
metering pump [side with connector].
1Tab connector, connector housing
2Wiring harness of metering pump,
3Fuel line
4Hose section, 10 mm dia. hose clamps [2x] Installing
metering
pump
Remove fuel-tank sending unit in accordance
with manufacturer's instructions.
1Fuel-tank sending unit
2Large diameter washer, copy hole pattern,
6 mm dia. hole
Removing
fuel
Shape fuel standpipe according to template,
cut to length and install, see "installation
instructions".
1Fuel standpipe
Installing
fuel
standpipe
Install fuel-tank sending unit according to
manufacturer's specifications.
1Hose section, 10 mm dia. Caillau clamp
[2x]
2Mecanyl fuel line
Connect-
ing fuel
line
35
2
1
4
3
36
1
2
37
1
i
38
1
2