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
Honda Civic
Gasoline
from Model Year 2006
For left-hand drive vehicles only
Ident. No.: 1311074C_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
Honda Civic
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
Honda Civic FK e11 * 2001/116 * 0256
Engine type Engine model Output in kW Displacement in cm³
R18A Gasoline 103 1798
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 8
Remote option (Telestart) 10
Preparing heater unit 11
Preparing Installation Location 11
Installing heater unit 12
Coolant connection 13
Combustion air 17
Fuel Connection 18
Exhaust system 21
Final Work 22
Operating Instructions for End Customer 23
Table of Contents

33
Honda Civic
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 Honda Civic 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 Honda Civic Gasoline 1311070B
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.
Honda Civic
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
Honda Civic
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 air filter together with the intake hose.
- Open the fuel tank cap, ventilate the tank.
- Close the tank cap again.
- Remove the entire underride protection
- Remove the center console trim and the center tunnel
- Open the center fuel sender service lid.
- Remove the fuel-tank sending unit in accordance with the manufacturers specifications.
- Remove the glove compartment (only with Telestart).
- Remove the trim below the steering column
- Remove the A/C control panel.
- Please remove page 23 of the “Operating instructions for the end customer” and add this to the
vehicle operating instructions.

6
Honda Civic
Preparing electrical system
Cut included black (sw) wire to a length of
3,000 mm as shown.
All wire are required for connection of IPCU
and fan controller!
Cutting
wires to
length
Pull wire section 3into protective sleeving
provided [2x] and route into passenger
compartment together with clock and fan
wiring harness.
Pre-
mounting
4th fuse
Connect wires to IPCU.
FollowingadjustmentvaluesofIPCUmustbe
checked and set if necessary prior to
installation:
Duty cycle: 100 %
Frequency: 14000 Hz
Voltage: 2.8 V
Function: high-side active Preassem-
bling IPCU
sw 0,5²
1 2
100 200
3
4rt 0,5²
5br 0,5²
F4 10A
sw
1sw 3
86
85 30
87a87
K3
rt/
ws
br rt
swbr
86 85
E
A
15
IPCU 2
4
5
A
15
86 85
E

7
Honda Civic
Electrical Connections
Wiring harness pass through
1Protective rubber plug
Digital timer
1Digital timer
Wiring
harness
installation
diagram
Fuse holder, relay K3
1Fuse holder with retaining plate, M5x16 bolt,
washer, angle bracket 2, K3 relay 3, M5
flanged nut
4Original vehicle bolt
Summer/winter switch option
1Summer/winter switch, drilled hole 12 mm dia.
2
1
3
1
br
bl
rt
sw
Donot installthe meteringpump
cableharnessuntillatertogether
with fuel pipe along the original
vehicle fuel lines on the
underbody
i
4
4
2
3
1
5
1

8
Honda Civic
Fan controller
Connection on 2-pin connector 1from wiring
harness of fan relay to fan motor.
Make connections as shown in the wiring
diagram with the connectors provided.
2White (ws) wire from fan relay
3Red (rt) wire to K3/87a
4Black (sw) wire from K3/30
5White (ws) wire to fan motor
Con-
nectingfan
motor
Connection to 4-pin connector 6from fan
controller.
1Yellow (ge) wire from A/C control panel
2Red (rt) wire from IPCU/E
33wire from F4 to IPCU/86
4Black (sw) wire from IPCU/A
5Yellow (ge) wire to fan controller Con-
nection of
IPCU on
fan
controller
Connect brown (br) wire 2from IPCU/85 and
black (sw) wire 3from cigarette lighter.
1Connector of cigarette lighter
Con-
necting
ground
wire
6
1
5
3
4
2
7
1
5
4
6
2
3
8
1
2
3

9
Honda Civic
Automatic
air-con-
ditioning
circuit
diagram
Webasto components Components of Honda Civic Colors and symbols
Legend
HG Heater unit TT-C/E GM Fan motor rt red
X1 6-pin connector GR Fan relay ws white
F3 Fuse KB Air-conditioning control
panel sw black
K3 Fan relay F19 Fuse 40A br brown
F4 1 A fuse ST 1 32-pin connector ge yellow
IPCU Pulse width modulator ST 2 4-pin connector bl blue
XCutting point
Wiring colors may vary.
Webasto
31
30
15
Honda
sw
sw
86
85 30
87a87
K3
rt/ws
gn/
ws
rt
sw
br
HG
4
X1 F3 F19
ws
ws
1
3
F4
86 85
E
A
IPCU
+
-GM
M
br
St 1
KB
St 2
GR
ge
0,5²
ge
0,5² bl
bl/sw
GRs
4²
4²
sw 0,5²
rt 0,5²
5
2
4
15
i

10
Honda Civic
Remote option (Telestart)
3Receiver
1Original vehicle bolt
2Telestart bracket, drill out hole to 7 mm dia.
Installing
receiver
1Antenna
Installing
antenna
Temperature sensor for HTM100 only
1Fasten temperature sensor with
installation tape
2Original vehicle air duct
Installing
tempera-
ture sensor
1
3
2
9
i
1
10
1
11
2

11
Honda Civic
Preparing heater unit
Coolant hose 1 = 20 mm dia.
b = 90 mm
c = 30 mm
Discard section XCutting
coolant
hose 1 to
length
1Heater unit
2Hose clamp
318x20 connecting pipe
4Combustion-air intake pipe
Preassem-
bling
heater unit
Preparing installation location
Copy hole pattern as shown in to center of
fold and drill 7 mm dia. hole 1.
2Weld seam
Copying
hole
pattern
1Radiator carrier
2Screw M6x20 bolt into existing thread
Preparing
installation
location
cb
C B X
X
C1
4
2
3
12
13
45 mm
1
2
14
1
2

12
Honda Civic
1Bracket
2Copy hole pattern, 7 mm dia. drilled hole
3Copy hole pattern, drill 9 mm dia. hole and
mount M6 rivet nut
4Original vehicle bolt
Copying
hole
pattern
1M6x20 bolt, M6 flanged nut
2Premounted M6x20 bolt, M6 flanged nut
3M6x12 bolt, flanged nut M6
4Strut
Installing
bracket
1M6x20 bolt, large diameter washer, M6
flanged nut
2M6x20 screw, spring lock washer, M6 rivet
nut
Installing
bracket
Installing heater unit
Tighten EJOT screws to 10 Nm!
Insert two washers between heater unit and
bracket at position 2.
1Heater unit
2Ejot screw
3Ejot screw [2x] Installing
heater unit
15
1 2
4
3
16
1
2
3
4
17
1
2
18
2
3
1
3

13
Honda Civic
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 = 20-27 mm dia. hose clamps!
All connecting pipes = 18x20 dia..
Wärme-
tauscher
Motor
B
A
D
C
Heat
exchanger

14
Honda Civic
Coolant hose 2 = 18 mm dia.
a = 580 mm
d = 870 mm
Discard section X
Cutting
coolant
hose 2 to
length
Cut braided protection hose in half and push
onto hose Aand D.
Cut heat shrink plastic tubing into 4 pieces.
125 mm heat shrink plastic tubing [4x]
a = 90 mm
d = 170 mm Preparing
coolant
hoses
1Discard hose of engine outlet - heat
exchanger inlet with clamps
Cutting
point
1Drill out angle bracket to 9 mm dia.
2Original vehicle bolt
Preparing
routing
ad
A D
X
X
1
D
1
d
1
A
1
a
19
1
20
1 2

15
Honda Civic
Con-
nection on
heater unit
1M6x20 bolt, M6 flanged nut
2Rubber-coated pipe clamp
Routing in
engine
compart-
ment
Routing in
engine
compart-
ment
Install hose Dwith 90° elbow on heat
exchanger inlet.
Con-
nection on
heat
exchanger
inlet
21
D
C
22
D
1
2
23
D
24
D

16
Honda Civic
Con-
nection on
heater unit
Before connecting, fill the coolant hoses with
coolant. Install hose Awith 180° elbow on
engine outlet 1.
Con-
nection to
engine
outlet
1Rubber-coated pipe clamp
2M6x16 bolt, spring lockwasher, existing
thread
Routing in
engine
compart-
ment
25
A
B
26
1
A
27
2
1

17
Honda Civic
Combustion air
1Combustion-air intake pipe
Installing
intake pipe
1Combustion-air intake muffler
2Cable tie
3Combustion-air intake pipe
Installing
muffler
28
1
i
29
3
1 2

18
Honda Civic
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.
2Mecanyl fuel line
3Hose section, 10 mm dia. hose clamp [2x]
1Cable tie
Con-
nection on
heater unit
RouteMecanylfuel line and wiringharnessof
metering pump together along original
vehicle fuel lines to installation location of
metering pump. Pull both into corrugated
tube on underbody at position 2.
1Metering pump Installing
lines
Ensure proper installation position of metering
pump, see "Installation Instructions“.
Installation locationon left behind vehicle fuel
tank!
Fuel line from heater unit on pressure side of
metering pump [side with connector].
1Noise isolation mounts, flanged nut M6 [2x]
2Rubber-coated pipe clamp
3Hose section, 10 mm dia. hose clamp [2x]
4Corrugated tube
5Wiring harness with connector
6Original vehicle bolt, large diameter
washer between perforated bracket 7and
vehicle
Installation
location of
metering
pump
30
1 2
3
31
2
1
32
4
1 2
7 6
3
5
i

19
Honda Civic
Removeanddismantlefuel-tanksending unit
according to manufacturer's instructions.
1Fuel-tank sending unit
2Washer
3Copy hole pattern, 6 mm dia. hole
Removing
fuel
Insert fuel standpipe, see "Installation
Instructions“. Install 5 washers between
cover of fuel-tank sending unit and nut of fuel
standpipe at position 2
1Fuel standpipe
Installing
fuel
standpipe
Aligning
fuel
standpipe
Determine fuel tank height 1 of vehicle and
cut Mecanyl fuel line 3to length.
2Cutting point of Mecanyl fuel line
410 mm dia. Caillau clamp
5Molded hose, dia. 3.5 mm x 4.5 mm
69 mm dia. Caillau clamp Con-
necting
fuel line
33
1
6
2
34
1
2
i
35
36
5 3
6
4
1
2

20
Honda Civic
Install fuel-tank sending unit according to
manufacturer's specifications.
19 mm dia. Caillau clamp
2Molded hose, dia. 3.5 mm x 4.5 mm
310 mm dia. Caillau clamp
4Remaining end of Mecanyl fuel line Con-
necting
fuel line
Fuel line from fuel standpipe on intake side of
metering pump [side without connector].
Check the position of the components; adjust
if necessary. Check that they have free
clearance.
1Remaining end of Mecanyl fuel line
2Hose section, 10 mm dia. hose clamp [2x] Con-
nection to
metering
pump
37
1 2
4
3
38
1 2
7