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.:1313401A_EN Fee Euro 10.00 © Webasto AG
Fiat 500
Gasoline
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

Fiat 500
1313401A_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.
Note:
When the vehicle is delivered, the fuel tank should only be half filled; drain off fuel if necessary.
Manufacturer Model Type EG-BE No./ABE
Fiat 500 150 e3 * 2001/116 * 0261 * ...
Engine type Engine model Output in kW Displacement in cm³
169A4000 Gasoline 51 1242
169A3000 Gasoline 74 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 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 heater unit 13
Fuel 15
Coolant routing 18
Coolant on 1.2 liter 19
Coolant on 1.4 liter 21
Combustion air 24
Exhaust gas 25
1.2 liter engine 25
1.4 liter engine 26
Vehicle with underride protection 26
Final Work 27
Template for Perforated Bracket A 28
Template for Perforated Bracket B 28
Template for Perforated Bracket C 28
Template for Bracket 29
Operating Instructions for End Customer 30

Fiat 500
1313401A_EN 3
Heater Unit/Installation Kit
Optional heater control either:
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
TheseinstallationinstructionsapplytoFiat500Gasolinevehicles-forvalidity,seepage2-frommodel
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/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 500 Gasoline 1313387A
Quantity Description Order No.:
1 Telestart T80, T91, T100 HTM See price list
1 Thermo Call Comfort, Connect, Locate See price list
Vehicle Heater unit
Compact car Thermo Top E
Mid-size car, station wagon Thermo Top C

Fiat 500
1313401A_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 500
1313401A_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.
- Completely remove the battery together with the carrier.
- Remove the air intake hose (1.4 liter only).
- Detach and remove the right and left-hand wheel well trim.
- Remove the bumper.
- Remove the horn on the left.
- Detach the central electrical box in the engine compartment on the left.
- Remove the underride protection in the engine compartment (1.4 liter only).
- Remove the cover of the fuel line on the vehicle underbody.
- Detach the bracket of the fuel line/fuel tank ventilation on the right next to the fuel tank.
- Remove the storage compartment on the left next to the steering wheel.
- Remove the cover of the central electrical box in the footwell of the driver's side.
Remove page 30 "Operating Instructions for End Customer" and add to the vehicle operating
instructions.
Heater unit installation location
1Heater unit
Installation
location
11

Fiat 500
1313401A_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
1
250
2sw
O,75²
F4
86
85 30
87a87
K3
1 2

Fiat 500
1313401A_EN 7
Electrical system
Wiring harness pass through
1Protective rubber plug
Digital timer
1Digital timer
Wiring
harness
installation
diagram
Fuse holder, relay K3
Fuse F4 only with automatic air-conditioning
1Original vehicle stud bolt, plastic nut
2Angle bracket
3Retaining plate of fuse holder, M5x16 bolt,
washers, angle bracket, K3 relay, M5 nut
Summer/winter switch option
1Summer/winter switch, drilled hole 12 mm dia.
2
13
1
Do not install the metering
pump cable harness until
latertogetherwithfuelpipe
along the original vehicle
fuel lines on the underbody
4
31 2
5
1

Fiat 500
1313401A_EN 8
Fan controller for manual air conditioning
Wiring
diagram
Webasto components Vehicle components Colors and symbols
Legend
HG Heater unit TT-C/E M001 Body computer rt red
X1
6-pin heater unit connector B001 Central electrical box in
engine compartment ws white
F3 25 A fuse O030 Resistor group sw black
K3 Fan relay N085 Fan motor gr gray
T08 Fan relay
N086 Electr. thermostat
F51 Fuse, 7.5 A
F01 Fuse 60A
F06 Fuse 30A XCutting point
H080 Switch/A/C control panel Wiring colors may vary.
Connection on fan relay T08 of central
electrical box in engine compartment 4.
Produce connections as shown in wiring
diagram.
1Black (sw) wire from K3/30
2Gray/white (gr/ws) wire of fan motor N085,
Pin 1
3Gray/white (gr/ws) wire of connector B
from B001, Pin 63
5Red (rt) wire from K3/87a
Connec-
tion to fan
relay
Webasto
31
30
15
Fiat
F3
86
85 30
87a87
K3
HG X1
4M001
C24
F51
B001
T08
F01
B18 45 44 63
F06
1A 21
rt
4²
sw
4²
gr/ws
gr/ws
49 B
321
N086
N085
M
1 2
H080
234 5
AB
21
O030
1 2 3 4
T°
6
3
2
5
1
4

Fiat 500
1313401A_EN 9
Automatic air-conditioning fan controller
Wiring
diagram
Webasto components Vehicle components Colors and symbols
Legend
HG Heater unit TT-C/E M001 Body computer rt red
X1 6-pin heater unit
connector B001 Central electrical box in engine compartment ws white
K3 Fan relay M070 Air-conditioning control
panel sw black
F3 25 A fuse N085 Fan motor gr gray
F4 Fuse, 7.5 A T08 Fan relay gn green
F36 10 A fuse bl blue
F51 Fuse, 7.5 A
F01 Fuse 60A Insulate wire ends and
tie back
F06 Fuse 30A XCutting point
Wiring colors may vary.
Webasto
31
30
15
Fiat
F3
86
85 30
87a87
K3
HG X1
4
N085
M
1 2 4 3
M070
A2 1 8 7
!
bl/gn
bl/gn
F4
sw sw
1 2
M001
C2924
F36
F51
B001
T08
F01
B18 45 44 63
F06
1A 21
rt
4²
sw
4²
gr/ws
gr/ws

Fiat 500
1313401A_EN 10
Connection on fan relay T08 of central
electrical box in engine compartment 4.
Produce connections as shown in wiring
diagram.
1Black (sw) wire from K3/30
2Gray/white (gr/ws) wire of fan motor N085,
Pin 4
3Gray/white (gr/ws) wire of connector B
from B001, Pin 63
5Red (rt) wire from K3/87a
Connec-
tion to fan
relay
Connectionon 32-pinof black (sw) connector
C 3from body computer M001.
Produce connections as shown in wiring
diagram.
1Black (sw) wire from F4
2Insulate blue/green (bl/gn) wire of
connector C, Pin 24 and tie back
4Blue/green(bl/gn)wireofA/Ccontrolpanel
M070 connector A, Pin 2
Connect-
ing A/C
control
panel
7
3
2
5
1
4
8
1
3
2
4

Fiat 500
1313401A_EN 11
Remote option (Telestart)
Drill out bracket 1to 6.5 mm dia. at position 2.
2M6 flanged nut on original vehicle stud bolt
3Receiver Installing
receiver
1Antenna
Installing
antenna
1
3
2
9
1
10

1313401A_EN 12
Fiat 500
Preparing heater unit
Bend perforated bracket Caccording to
template. Precut thread at position 2.
1Ejot stud
3Ejot screw
4Perforated bracket C
Premount-
ing heater
unit
Preparing installation location
Remove horn 2with bracket. Original vehicle
bolt 1will be reused.
Removing
horn
1Existing hole; mount rivet nut (aluminum)
Installing
rivet nut
1Align horn
2Original vehicle bolt, spring lockwasher on
rivet nut
Installing
horn
11
1
3
4
2
12
1
2
13
1
14
2

1313401A_EN 13
Fiat 500
1Edge protection 100 [2x]
Installing
edge
protection
Cut out template 2and lay on cross member
(see marking).
17 mm dia. hole [3x]
Holes in
cross
member
Bend perforated bracket Aand Baccording
to template.
1Loosely mount M6x20 bolt, flanged nut [2x
each]
2Perforated bracket A
3Perforated bracket BLoosely
mounting
perforated
brackets
Installing heater unit
1Flanged nut on Ejot stud
2Ejot screw
Installing
heater unit
15
1
1
16
11
1
2
17
2
3
1
1
18
1
2

1313401A_EN 14
Fiat 500
1Loosely mount M6x20 bolt, flanged nut
2Perforated bracket C
Installing
heater unit
Check position of all components and adjust
if necessary. Check that they have free
clearance.
Align heater unit and tighten all bolts.
Connect wiring harness of heater unit 1.Installing
heater unit
19
1
2
20
1

Fiat 500
1313401A_EN 15
Fuel
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.
1Fuel line
2Hose section, 10 mm dia. clamp [2x]
Connect-
ing heater
unit
Route fuel line and wiring harness of
metering pump behind cover 1along original
vehicle fuel lines to installation location of
metering pump.
Installing
lines
Cut open fuel hose 1lengthwise, slide onto
fuelline and wiringharness ofmetering pump
2and secure on strut with cable tie 3.
Installing
lines
21
1
6
2
22
1
23
21
3

Fiat 500
1313401A_EN 16
Short standpipe 1by 210 mm and shape as
shown. Bend connection piece 2by 90°.
Removing
fuel
Remove fuel-tank vent line 1from bracket
and cut off approx. 200 mm before fuel tank
connection piece. Remove section on
connection piece.
Cutting
point
116-24 mm dia. clamp
2Fuel-tank vent line
3Fuel standpipe
4Dia. 3.5 x 4.5 mm hose section; 8 mm dia.
Caillau clamp Premount-
ing fuel
standpipe
When installing, align standpipe of fuel
standpipe 2to fuel tank bottom.
116-24 mm dia. clamp [2x]
2Fuel standpipe
310 mm dia. Caillau clamp
4Fuel line Installing
fuel
standpipe
24
1
2
210
430
170
25
1
200
26
2
4
13
27
3
11
4 2

Fiat 500
1313401A_EN 17
Insert fuel-tank vent line in bracket again.
Route fuel line 1to metering pump.
Aligning
fuel-tank
vent line
1Silentblock, flanged nut
2Angle bracket
3Original vehicle bolt
Installation
location of
metering
pump
Check the position of the components; adjust
if necessary. Check that they have free
clearance.
1Wiring harness of metering pump,
connector mounted
2Rubber-coated p-clamp, flanged nut on
silent block
3Metering pump
4Hose section, 10 mm dia. clamp [2x]
5Fuel line from fuel standpipe
6Hose section, 10 mm dia. clamp [2x]
7Fuel line from heater unit
Connect-
ing meter-
ing pump
28
1
29
2
1
3
30
3
7
5
2 4
6
1

Fiat 500
1313401A_EN 18
Coolant routing
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 hose clamps = 20-27 mm dia.! All connecting pipes without a specific designation = dia. 20x20.
1 = Black (sw) rubber isolator (with 1.2 liter engine).
1and 2= Black (sw) rubber isolator (with 1.4 liter engine).
A
B
C
1
2
Ø 20x17

Fiat 500
1313401A_EN 19
Coolant on 1.2 liter
b = 655
c = 720
Hose A= 17x20 180° molded hose
Discard section XCutting
coolant
hoses to
length
Push braided protection hoses onto hose B
and C and cut to length.
Cut heat shrink plastic tubing to length.
125 mm long heat shrink plastic tubing [4x] Preparing
coolant
hoses
Connect-
ing heater
unit inlet
Connect-
ing heater
unit outlet
BC
X
X
A
B
C
1
1 1
1
31
B
32
C

Fiat 500
1313401A_EN 20
1Cable tie
Routing in
engine
compart-
ment
Disconnect hose to engine outlet/heat
exchanger inlet 2at connection piece of
engine outlet. Discard clamp 1
Cutting
point
Fasten hose Awith small diameter on
connection piece on engine outlet.
Connect-
ing engine
outlet
Ensure sufficient distance to neighboring
components.
1Black (sw) rubber isolator
2Hose on heat exchanger inlet
3Spacer bracket Connect-
ing heat
exchanger
inlet
33
1
C
B
34
1 2
35
A
B
36
1
C 2
3