Webasto Thermo Top E Installation Instructions Manual

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 Opel Antara 3.2 Gasoline from Model Year 2007 Left-hand drive vehicle Automatic transmission Ident. No.: 1311938A_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 part number: 93199670

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 Opel Antara L-A e4 * 2001 / 116 * 0118 Engine type Engine model Output in kW Displacement in cm³ 10HM Gasoline 167 3195 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 Electrical Connections 6 Fan controller for manual air conditioning 7 Automatic air-conditioning fan controller 9 Remote option (Telestart) 12 Remote option (Thermo Call) 13 Preparing heater unit 14 Preparing installation location 16 Installing heater unit 18 Coolant connection 19 Fuel Connection 22 Combustion air 24 Exhaust system 25 Final Work 28 Operating Instructions for End Customer 29 Table of Contents part number: 93199670

Optional heater control: Also required with automatic air-conditioning: 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 Opel Antara vehicles with a 3.2 Gasoline engine and a manual transmission - for validity, see page 2 - from model 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, the stipulations in the "installation instructions" and "operating and maintenance instructions" 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 Opel-specific heater unit delivery scope See Opel price list 1 Installation kit for Opel Antara (basic kit) 1311919A 1 Additional kit for Opel Antara 3.2 liter Gasoline 1311922A Quantity Description Order No.: 1 Heater control See Opel price list Quantity Description Order No.: 1 Kit for Opel Antara with Automatic Air-Conditioning 1311923A Vehicle Heater unit Compact car Thermo Top E Mid-size car, station wagon Thermo Top C Full-size car, van, offroader Thermo Top P part number: 93199670

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. Opel Antara 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. part number: 93199670

- 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. - Completely remove the battery - Remove the fuse and relay box - Remove the engine cover - Remove the engine control unit - Disconnect the power-steering fluid reservoir - Disconnect the expansion tank - Remove the charge-air tube between the air filter and the turbocharger - Disconnect the air hose from the charge-air tube to the engine at the engine - Remove the filler neck of the window washer system - Remove the vent line at the top to the coolant expansion tank - Open the fuel tank cap, ventilate the tank. - Close the tank cap again. - Remove the underride protection - Open the left tank mounting service lid - Remove the A/C control panel according to the manufacturer's instructions (only with manual air- conditioning) - Remove the glove compartment (only with automatic air-conditioning) Remove page 29 "Operating Instructions for End Customer" and add to the vehicle operating instructions. Heater unit installation location 1 Heater unit Installation location 1 1 part number: 93199670

1 Protective rubber plug Digital timer 1 Digital timer Wiring harness installation diagram Fuse holder, relay K3 1 Move original vehicle clip 2 Angle bracket 3 Drill out hole to 9 mm dia., mount M6 rivet nut, M6x20 bolt, spring lockwasher 4 Fuse holder 5 K3 relay 6 Align M5x16 bolt, large diameter washer, M5 flanged nut to right in oblong hole Summer/winter switch option 1 Summer/winter switch, drilled hole 12 mm dia. 2 1 3 1 rt sw br bl Do not install the metering pump cable harness until later together with fuel pipe along the original vehicle fuel lines on the underbody i 4 6 5 1 3 4 2 5 1 part number: 93199670

Wiring diagram for manual air con- ditioning Webasto components Components of Opel Antara Colors and symbols Legend HG Heater unit TT-C/E GM Fan motor rt red X1 6-pin connector GS Fan switch ws white F3 Fuse, 25 A EF3 40 A fan fuse sw black K3 Fan relay WG Resistor group br brown K3.1 Additional relay GR Fan relay gn green bl blue or orange X Cutting point Wiring colors may vary. Webasto 31 30 15 Opel HG X1 4 F3 86 85 30 87a 87 K3 rt/ws gn/ ws br br br EF3 86 85 30 87a 87 K3.1 sw rt GM M 2 1 86 85 30 87 GR F22 3 4 1 2 WG bl/sw bl/sw bl/gn ws or sw sw sw sw bl/sw bl/gn 1 2 3 4 5 A6 GS 1 2 3 4 0 A4 A1 A2 A3 br 0,75² rt 2,5² br 4² sw 4² rt 2,5² i part number: 93199670

Preparing electrical system Produce connections as shown in wiring diagram. Cut 500 mm off included protective sleeving and push onto lines 2, 3 and 4. Push remaining end of protective sleeving onto line 1. Preparing additional relay K3.1 Fan controller Produce connections as shown in wiring diagram. 1 Mount M5x16 bolt, flanged nut in existing hole 2 Original vehicle ground support point 3 Brown (br) wire 5 0,75² from K3.1/85 4 Additional relay K3.1 Con- necting additional relay Connection to 2-pin connector 1 from fan motor. Produce connections as shown in wiring diagram (crimp and shrink). 2 Brown (br) wire to connector 3 Brown (br) wire from fuse EF3 4 Red (rt) wire 1 2.5² from K3.1/86 5 Red (rt) wire to K3/87a 6 Black (sw) wire from K3/30 Con- necting fan motor Connection to 6-pin connector 6 from fan switch. Produce connections as shown in wiring diagram (crimp and shrink). 1 Brown (br) wire 4 4² from K3.1/30 2 Black (sw) wire to original vehicle ground point 3 Red (rt) wire 3, 2.5² from K3.1/87a 4 Blue/green (bl/gn) wire to resistor group 5 Blue/green (bl/gn) wire from connector A1 7 Black (sw) wire from connector A6 8 Black (sw) wire 2, 4² from K3.1/87 Con- nection to fan switch 86 85 30 87a 87 K3.1 1 2 3 4 5 rt 2,5² 1000mm br 0,75² 500mm sw 4² 500mm br 4² 500mm rt 2,5² 500mm 6 7 2 3 4 1 8 1 5 3 2 4 6 9 1 3 7 6 5 4 2 8 part number: 93199670

Automatic air-con- ditioning circuit diagram Webasto components Components of Opel Antara Colors and symbols Legend HG Heater unit TT-C/E GM Fan motor rt red X1 6-pin heater unit connector GR Fan controller ws white F3 Fuse, 25 A KB Air-conditioning control element sw black K3 Fan relay F22 Fuse 10A br brown K3.1 Additional relay EF3 Fuse 40A gn green R1 0.9 ohm resistor A Connector for A/C control panel bl blue B Connector for A/C control panel GR gray vi violet X Cutting point Wiring colors may vary. gn/ ws sw br rt/ws Webasto 31 30 15 Opel rt 86 85 30 87a 87 K3 HG 4 X1 F3 86 85 30 87a 87 K3.1 R1 2 3 4 5 6 1 sw F22 br br A A5 A1 KB B B1 gr/sw 2 3 GR 4 sw br + - GM M vi EF3 vi br 0,75² rt 2,5² br 4² sw 4² br 4² br 4² i part number: 93199670

Produce connections as shown in wiring diagram. Crimp cable lug onto brown (br) wire 3 0.75² provided and onto brown (br) wire section 6 4². Cutting brown (br) wire to length Produce connections as shown in wiring diagram. Pull wires 1, 2 and 4 in protective sleeving provided. Preparing additional relay K3.1 Fan controller Resistor 1 becomes hot! Ensure sufficient spacing (at least 20 mm) to neighboring components. 3 M5x30 cap screw, large diameter washer, nut [2x] 2 Angle bracket 1 M6x20 bolt, spring lockwasher, brown (br) ground wires 3 0.75² and 6 br 4² on existing threaded hole 5 Mount edge protection Installing resistor and additional relay Produce connections as shown in wiring diagram. 1 Brown (br) wire 5 4² from K3/87a to resistor 2 Additional relay K3.1 3 M5x16 bolt, flanged nut on existing hole Con- necting resistor and additional relay 5 200 6 br 4² 200 rt 2,5² 1000mm 86 85 30 87a 87 K3.1 1 2 5 4 3 br 0,75² 500mm sw 4² 500mm br 4² 500mm br 4² 200mm 10 11 4 2 3 1 5 12 1 2 3 part number: 93199670

motor. Produce connections as shown in wiring diagram (crimp and shrink). 2 Violet (vi) wire from connector 3 Violet (vi) wire to fan controller 4 Black (sw) wire 4, 4² from K3.1/30 5 Brown (br) wire 2 4² from K3.1/87 6 Brown (br) wire from fuse EF3 7 Red (rt) wire 1 2.5² from K3.1/86 8 Red (rt) wire to K3/87a 9 Black (sw) wire from K3/30 10Brown (br) wire to connector Con- necting fan motor Cut away insulation of glove compartment at marking. Cutting away insulation 13 1 8 9 2 7 5 4 3 10 6 14 part number: 93199670

1 Existing hole, M5x16 bolt, washer, flanged nut 2 Receiver 3 Telestart bracket Installing receiver 1 Antenna Installing antenna Temperature sensor for HTM100 only 1 Fasten temperature sensor with suitable means (here double-sided adhesive tape) Installing tempera- ture sensor 1 2 3 15 i 1 16 1 17 part number: 93199670

1 Fasten receiver with suitable means (here double-sided adhesive tape) Installing receiver 1 Antenna Installing antenna 1 Pushbutton Installing push button 1 18 i 1 19 1 20 part number: 93199670

b = 240 mm c = 335 mm Discard section X Cutting coolant hoses to length Remove water pump 2 from heater unit. Hose section 1 and spring clip will be reused. Discard retaining clip 3 and bolt. Removing water pump Replace 193° lid 1. Replacing pump lid Ejot screw 2 [3x], tightening torque 10 Nm! 1 Bracket part 1 Preassem- bling bracket 1 on heater unit X X C B b c 3 1 2 1 21 1 2 2 part number: 93199670

2 Water pump 3 Rubber-coated pipe clamp, 48 mm dia. 4 M6x20 bolt, M6 flanged nut Preassem- bling water pump Ejot screw 1 [3x], tightening torque 10 Nm! Connect adapter line of water pump 2, cut to length and connect identical colors to wiring harness of water pump using connectors (crimp and shrink). 3 Existing spring clip [2x] 4 Existing hose section Preassem- bling heater unit 22 3 1 4 2 23 1 4 3 3 1 1 2 part number: 93199670

1 Cross member for battery carrier 2 Drill out thread to 10 mm dia. [2x] Drilling out thread Remove bracket 3 of hydraulic line 5 and mount as shown (depending on equipment). Original vehicle bolt 1 will be reused 2 Perforated bracket 3 M6x16 bolt, M6 flanged nut Reposi- tioning hydraulic line Remove original vehicle hose 1. Spring clip 2 will be reused. Removing hose Shorten original vehicle hose 1 by 25 mm. Dispose of hose section 2. Separating hose 24 1 2 25 1 3 4 5 2 26 1 2 27 2 1 25 mm part number: 93199670

2 Original vehicle spring clip Re- mounting hose Completely remove control unit 1 with bracket 2. Discard bracket 2. Removing control unit 1 Self-tapping Torx screw [2x] 2 Additional bracket 3 Control unit Preassem- bling control unit 1 M6x20 bolt, spring lockwasher [2x each] on existing threaded holes 2 Additional bracket with control unit Installing control unit 28 1 2 29 1 2 30 1 2 1 3 31 1 2 1 part number: 93199670

1 Loosely mount M8x30 bolt [2x] 2 Preassembled heater unit Installing heater unit Remove original vehicle screw 1 and discard. Removing screw 1 Bracket part 2 2 M6 flanged nut [3x] 3 M8x40 bolt, spring lockwasher, large diameter washer Installing bracket Ensure sufficient spacing to neighboring components, especially to A/C line 1; correct if necessary. Aligning heater unit 32 1 2 1 33 1 34 1 3 2 35 1 part number: 93199670

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 spring clips = 27 mm dia.! All connecting pipes = Ø 18x20. All hose clamps = 20-27 mm dia.! 1 = hose section between circulating pump and heater unit. A = 18 mm dia. 180° molded hose. 1 C A B part number: 93199670

exchanger inlet 2 at connection piece of engine outlet. Discard spring clip 1. Cutting point When installing the coolant hose, ensure sufficient spacing to the vehicle gear shift mechanism. Con- nection to heater unit inlet Hose A = 180° elbow provided. 1 Connection piece for engine outlet Con- nection to engine outlet 1 Edge protection Con- nection to heater unit outlet 36 2 1 37 B 38 B A 1 39 C 1 part number: 93199670

coolant. 1 Hose section of heat exchanger inlet Con- nection to heat exchanger inlet 1 Spacer bracket Installing spacer bracket 40 1 C 41 C 1 part number: 93199670

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. 1 Included hose section as scuff guard [2x] 2 Mecanyl fuel line 3 Hose section, 10 mm dia. hose clamp [2x] Con- nection on heater unit 1 Mecanyl fuel pipe and metering pump cable harness Installing lines Ensure proper installation position of metering pump 3, see "Installation Instructions“. Installation location in front of vehicle fuel tank! 1 5 mm shim 2 Angle bracket 4 Rubber-coated pipe clamp 5 Silent block, flanged nut [2x] 6 Original vehicle nut Installation location of metering pump 42 2 1 1 3 43 1 1 44 1 4 3 6 2 5 i part number: 93199670

pressure side of metering pump [side with connector]. 1 Wiring harness of metering pump, connector mounted 3 Hose section, 10 mm dia. hose clamps [2x]. Installing metering pump 1 Separate 90° molded hose at marking 2 Discard section Preparing fuel standpipe Cut closure off existing removal connection piece and push on short end of 90° molded hose 3. 1 Fuel line 2 10 mm dia. hose clamp [2x] 4 Fuel sender 5 Cable tie Removing fuel Fuel line 2 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. 1 180° molded hose, 10 mm dia. hose clamp [2x] Con- nection to metering pump 45 1 3 2 46 1 2 5 mm 47 2 1 2 4 3 5 48 1 2 part number: 93199670

2 Hose clamp Installing com- bustion air pipe 1 Combustion air pipe 2 48 mm dia. p-clamp; rubber coating removed 3 Combustion-air intake muffler 4 Existing hole, M6 rivet nut, M6x20 bolt, spring lock washer Installing muffler 1 2 49 50 2 1 3 4 part number: 93199670

a = 460 mm 2 Exhaust end section b = 230 mm Discard section X Preparing exhaust pipe Shape exhaust pipe 1. 2 Red (rt) rubber isolator Preparing exhaust pipe Remove clip 2 from original vehicle wiring harness 1. Dis- connecting original vehicle wiring harness 1 Drill 9.1 mm dia. hole; install rivet nut Installing rivet nut a b 1 2 X 51 1 2 52 1 2 1 53 part number: 93199670

75° at bending line. Bending perforated bracket Check the position of the components; adjust if necessary. Check that they have free clearance. 1 Perforated bracket 2 Exhaust muffler 3 M6x20 bolt, flanged nut 4 M6x20 screw, spring lockwasher on rivet nut Installing exhaust muffler 1 Hose clamp 2 Position red (rt) rubber isolator 3 Exhaust pipe Installing exhaust pipe 1 Exhaust pipe 2 Hose clamp Installing exhaust pipe 60mm Biegelinie 50mm 54 Bending line 2 55 3 4 1 1 56 3 2 57 1 2 part number: 93199670

components (wiring harness to exhaust system). 1 Cable tie 2 Exhaust end section 3 Hose clamp 4 Original vehicle wiring harness Installing exhaust end section 1 Red (rt) rubber isolator 2 Red (rt) rubber isolator with groove Pushing on rubber isolator 1 Underride protection 2 42 mm dia. hole Cutting out underride protection Align red (rt) rubber isolator 2 with groove flush on exhaust end section 3 and on underride protection 1. Mounting rubber isolator 58 4 1 3 2 59 2 1 60 1 2 61 2 1 3 part number: 93199670

(0)1805-932278 Hotfax +49-(0)395-5592-353 - http://www.webasto.de Feel the drive Final Work WARNING! Reassemble the disassembled components in reverse order. Check all hoses, hose, spring and Caillau clamps, as well as all electrical connections for firm seating. Secure all loose cables using cable ties. Only use manufacturer-approved coolant. Spray the heater unit components with anti-corrosion wax (Tectyl 100K, Order No. 111329). 1 M8x30 bolt, spring lockwasher, flanged nut [2x each] Installing battery carrier - Connect the battery - Bleed and fill the coolant circuit according to the vehicle manufacturer’s specifications. - Set the digital timer. - Set the manual air conditioning or automatic air conditioning according to the "operating instructions for the end customer". - Check the proper operation of the additional heater, see the operating instructions/installation instructions. - Attach the "Switch off additional heater before refueling" sticker to the left-hand B-pillar. 62 1 1 i Printed in Germany 02/07Printed by: Steffen part number: 93199670

Please remove page and add to the vehicle operating instructions. Note: We recommend matching the heating time to the driving time. Heating time = driving time Example: For a driving time of approx. 20 min. (in one direction), we recommend not exceeding a switch-on time of 20 min. If the summer/winter switch option has been installed, this must be switched in accordance with the time of year. The heater unit will then only switch on the vehicle fan to ventilate the vehicle interior in the position Winter heat and in the position Summer . Before parking the vehicle, make the following settings: 1 Set temperature to "max." 2 Set fan to level "1", or possibly "2" 3 Direct air outlet toward windshield Manual air con- ditioning 1 Set temperature to "max." 2 Air outlet to windshield Automatic air-con- ditioning 63 1 2 3 64 1 2 part number: 93199670