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.:1312754A_EN Fee Euro 10.00 © Webasto AG
Nissan X-Trail
Diesel
from Model Year 2008
Left-hand drive vehicle
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

Nissan X-Trail
1312754A_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
Nissan X-Trail T31 e1 * 2001/116 * 0432 * ...
Engine type Engine model Output in kW Displacement in cm³
M9R Diesel 110 1995
M9R Diesel 127 1995
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
A
utomatic air-conditioning fan controller 8
Remote option (Telestart) 10
Remote option (Thermo Call) 11
Preparing heater unit 12
Preparing installation location 12
Installing heater unit 13
Coolant for diesel engine 15
Combustion air 19
Fuel 20
Exhaust gas 22
Operating Instructions for End Customer 24

Nissan X-Trail
1312754A_EN 3
Heater Unit/Installation Kit
Also required:
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 Nissan X-Trail Diesel vehicles - for validity, see page 2 - from
model year 2008 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/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 Nissan-specific delivery scope See Nissan price list
1 Installation kit for Nissan X-Trail Diesel xxxxxxA
Quantity Description Order No.:
1 Heater control according to Nissan price list See Nissan price list
Vehicle Heater unit
Compact car Thermo Top E
Mid-size car, station wagon Thermo Top C
Full-size car, van, offroader Thermo Top P

Nissan X-Trail
1312754A_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.

Nissan X-Trail
1312754A_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 air filter together with the intake hose.
- Remove the trim in the right footwell
- Remove the fuse and relay box
- Remove the A/C control panel.
- Remove the bumper.
- Remove the underride protection
- Open the right-hand fuel sender service lid.
Remove page 24 "Operating Instructions for End Customer" and add to the vehicle operating
instructions.
Heater unit installation location
1Heater unit
Installation
location
1
1

Nissan X-Trail
1312754A_EN 6
Preparing electrical system
Only with automatic air-conditioning
Wire section 1 and 2 will be required later for
connecting fuse F4. Cutting
wires to
length
Produce connections as shown in wiring
diagram. Install wire section 2in the
protective sleeving provided.
Preparing
fuse F4
1900
1
100
2sw
0,75²
F4
86
85 30
87a87
K3
1 2

Nissan X-Trail
1312754A_EN 7
Electrical system
Digital timer / summer/winter switch option
1Digital timer
2Summer/winter switch, drilled hole 12 mm dia.
Wiring
harness
installation
diagram
Fuse holder, relay K3
1Fuse holder
2Retaining plate of fuse holder, M5x12 bolt,
washer, angle bracket 3, K3 relay 5, M5
flanged nut
4M6x20 bolt, large diameter washer, existing
hole, M6 flanged nut
Wiring harness pass through
1Protective rubber plug
2
1
2
Donot installthe meteringpump
cableharnessuntillatertogether
with fuel pipe along the original
vehicle fuel lines on the
underbody
3
32
5
1 4
4
1

Nissan X-Trail
1312754A_EN 8
Automatic air-conditioning fan controller
Wiring
diagram
Webasto components Vehicle components Colors and symbols
Legend
HG Heater unit TT-C/E GM Fan motor rt red
X1
6-pin heater unit connector KB Air-conditioning control panel ws white
F3 25 A fuse M53 40-pin connector KB sw black
K3 Fan relay GRr Fan controller br brown
F4 10 A fuse M311 4-pin connector, GRr gn green
F1 10 A fuse bl blue
F8 10 A fuse ge yellow
F15 15 A fuse Insulate wire ends and
tie back
F16 15 A fuse XCutting point
Wiring colors may vary.
Webasto
31
30
15
Nissan
HG
X1 4
F3
86
85 30
87a87
K3
rt/ws
gn/
ws
br
F4
sw
F15 F16
+
-GM
M
sw
rt
bl ge
bl ge
F8 F1
KB
M53 22 21
8 7
GRr
M311 1
3 2
ws/gr
ge
sw
!
ws/gr
0,75²
0,75²
0,75²
2,0² 2,0²
2,0² 2,0²
4,0²
4,0²

Nissan X-Trail
1312754A_EN 9
Connection on fuse carrier 6 behind fuses
F15andF16.Produceconnections as shown
in wiring diagram.
1Yellow and blue (ge/bl) wire of fan motor
2Black (sw) wire from K3/30
3Red (rt) wire from K3/87a
4Yellow (ge) wire from fuse 16
5Blue (bl) wire of fuse 15
Con-
necting
fan-motor
Connection to 40-pin connector 3from A/C
control element.
Produce connections as shown in wiring
diagram.
1Black (sw) wire from F4
2Insulate and tie back white/green (ws/gr)
wire
4White/green (ws/gr) wire, Pin 21
Con-
necting
A/Ccontrol
panel
1Connector M53 on contact side
View of
connector
M53
5
1
3
6
2
5 4
6
1
4
3
2
21
140
20
7
1

Nissan X-Trail
1312754A_EN 10
Remote option (Telestart)
1Fasten receiver with double-sided
adhesive tape
Installing
receiver
1Antenna
Installing
antenna
Temperature sensor for HTM100 only
1Fasten temperature sensor with double-
sided adhesive tape
Installing
temper-
ature
sensor
18
1
9
1
10

Nissan X-Trail
1312754A_EN 11
Remote option (Thermo Call)
1Fasten receiver with double-sided
adhesive tape
Installing
receiver
1Antenna
Installing
antenna
1Pushbutton
Installing
push
button
1
11
1
12
1
13

1312754A_EN 12
Nissan X-Trail
Preparing heater unit
1Perforated bracket
Bending
perforated
bracket
Loosely mount perforated bracket with 90°
angle bracket on heater unit.
1Ejot screw
Installing
perforated
bracket
1Ejot screw, large diameter washer
[2x each]
2Angle bracket [2x]
Installing
angle
bracket
Preparing installation location
1Resistor
2Discard bracket
3Discard original vehicle bolt
4Original vehicle bolt will be reused Moving
resistor
1
approx. 115°
approx. 95°
15
15
1
14
21 1
15
3
1 2
4

1312754A_EN 13
Nissan X-Trail
1Original vehicle bolt on existing threaded
hole
Moving
resistor
1Disconnect ground wire, bolt will be reused
2Disconnect ground wire
3Disconnect ground wire
4Wiring harness of heater unit
5Remove clip of wiring harness Moving
ground
wires
1Ground wire
2Ground wire
3Ground wire
Moving
ground
wires
Installing heater unit
1Original vehicle bolt on existing threaded
hole
2Tighten Ejot screw Installing
heater unit
16
1
17
3
1
4
2
5
18
1 2 3
19
1
2

1312754A_EN 14
Nissan X-Trail
1M6x20 bolt, M6 flanged nut
2Copy hole pattern, drill 6.5 mm dia. hole in
cross member
Installing
heater unit
1M6x20 bolt, M6 flanged nut
Installing
heater unit
20
1
2
21
1

Nissan X-Trail
1312754A_EN 15
Coolant for diesel engine
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 connecting pipes = 20x20 dia..
All hose clamps = 20-27 mm dia.!
1= Original vehicle spring clips .
AB
C
D
1

Nissan X-Trail
1312754A_EN 16
a = 700
c = 110
d = 600
Discard section XCutting
coolant
hoses to
length
Push braided protection hoses onto hose A
and Dand cut to length.
Cut heat shrink plastic tubing to size and
shrink.
125 mm long heat shrink plastic tubing [4x] Preparing
coolant
hoses
Pre-
mounting
hoses
1Discard hose section; original vehicle
clamp will be reused
Cutting
point
X
A
B
X D C
A
D
1
1 1
1
22
A B
D
C
23
1

Nissan X-Trail
1312754A_EN 17
Con-
nection to
heater unit
Con-
nection to
heater unit
1Cable tie
Routing in
engine
compart-
ment
1Original vehicle clamp
Con-
nection on
engine
outlet
24
C
25
BA
26
D
A1
27
1
A

Nissan X-Trail
1312754A_EN 18
1Original vehicle clamp
Con-
nection on
heat
exchanger
inlet
28
1
D

Nissan X-Trail
1312754A_EN 19
Combustion air
1Combustion air pipe
a = 280
Discard section XCutting
com-
bustion air
pipe to
length
127 mm dia. clamp
2Combustion-air intake pipe
Installing
intake pipe
1Intake muffler
2Cable ties [2x] through guide slit
3Cable ties [2x] through guide slit
Installing
muffler
a
1
X
29
1 2
30
3
1
2

Nissan X-Trail
1312754A_EN 20
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 bracket between fuel line and hose D
3Hose section, 10 mm dia. clamp [2x]
Con-
nection to
heater unit
Route fuel line to right-hand side of vehicle,
slide into 2x corrugated tube together with
wiring harness of metering pump and route
along original vehicle fuel line to installation
location of metering pump.
1Corrugated tube with fuel line and wiring
harness for metering pump
Installing
lines
1Angle bracket, hole drilled out to 10.5 mm
dia.
2Original vehicle bolt
Installation
location of
metering
pump
31
3
1
2
32
1
33
1 2