Webasto Thermo Top C Installation Instructions Manual

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Manual is about: Typ BW50 (Benzin/Petrol/Bensin) Typ DW50 (Diesel)

Summary of Thermo Top C

  • Page 1

    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 equ...

  • Page 2

    Fiat bravo 1312960a_en 2 table of contents validity vehicle and engine types, equipment variants and national specifications not listed in these installation instructions have not been tested. However, installation according to these installation instructions may be possible. The installation locati...

  • Page 3

    Fiat bravo 1312960a_en 3 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 these installation instructions apply...

  • Page 4: Mechanical System

    Fiat bravo 1312960a_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. Ref...

  • Page 5

    Fiat bravo 1312960a_en 5 preliminary work warning! - open fuel tank cap, ventilate tank. - close the tank cap again. - disconnect the battery "earth" or "ground" connection. - depressurize the cooling system. - copy the factory number from the original type label to the duplicate type label. - remov...

  • Page 6

    Fiat bravo 1312960a_en 6 preparing electrical system only with automatic air-conditioning cutting wires to length produce connections as shown in wiring diagram. Install wire section 2 in the protective sleeving provided. Preparing fuse f4 1750 1 250 2 sw o,75² f4 86 85 30 87a 87 k3 1 2.

  • Page 7

    Fiat bravo 1312960a_en 7 electrical system fuse holder, relay k3 1 fuse holder 2 angle bracket, drilled out to 8 mm dia. 3 original vehicle stud bolt, flanged nut 4 relay k3, m5x16 bolt, washer, flanged nut summer/winter switch option 1 summer/winter switch, drilled hole 12 mm dia. Wiring harness in...

  • Page 8: Webasto

    Fiat bravo 1312960a_en 8 fan controller for manual air conditioning wiring diagram webasto components vehicle components colors and symbols legend hg heater unit tt-e/c/p n085 fan motor rt red x1 6-pin heater unit connector grs fan relay t8 ws white f3 fuse h081 fan switch sw black k3 fan relay o030...

  • Page 9: Webasto

    Fiat bravo 1312960a_en 9 automatic air-conditioning fan controller wiring diagram webasto components vehicle components colors and symbols legend hg heater unit tt-e/c/p n085 fan unit rt red x1 6-pin heater unit connector grs fan relay t8 ws white f3 fuse m070 air-conditioning control panel sw black...

  • Page 10

    Fiat bravo 1312960a_en 10 connection on gray (gr) 3-pin connector b001b 1 of central electrical box. Produce connections as shown in wiring diagram. 2 red (rt) wire from k3/87a 3 gray/white (gr/ws) wire of fan motor 4 black (sw) wire from k3/30 5 gray/white (gr/ws) wire of connector connect- ing fan...

  • Page 11

    Fiat bravo 1312960a_en 11 remote option (telestart) 1 receiver 2 original vehicle stud bolt, original vehicle flanged nut 3 bracket, hole drilled out to 6.5 mm dia. Installing receiver 1 antenna installing antenna 1 2 9 3 1 10

  • Page 12

    1312960a_en 12 fiat bravo preparing heater unit washer on ejot stud 2! 1 heater unit premount- ing heater unit preparing installation location mount bracket 2 on original vehicle stud bolt 3 with flanged nut, align and copy hole pattern. 1 hole pattern, 9.1 mm dia. Hole 4 hole pattern, 6.5 mm dia. H...

  • Page 13

    1312960a_en 13 fiat bravo 1 100 mm edge protection section mounting edge protection section 1 50 mm edge protection section mounting edge protection section 1 50 mm edge protection section mounting edge protection section 1 14 15 1 16 1.

  • Page 14

    1312960a_en 14 fiat bravo installing bracket 1 m6x30 bolt, spring washer, 8 mm shim, m6 rivet nut 2 original vehicle stud bolt, 5 mm shim, flanged nut 3 m6x50 bolt [2x], 30 mm spacer [2x], 8 mm shim [2x], flanged nut [2x] 4 bracket installing bracket installing heater unit connect wiring harness of ...

  • Page 15

    Fiat bravo 1312960a_en 15 water 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...

  • Page 16

    Fiat bravo 1312960a_en 16 gasoline c = 1280 diesel c = 1220 discard section x cutting hose c to length all vehicles slide braided protection hose onto hose c and cut to length. Cut heat shrink plastic tubing to length. 1 25 mm long heat shrink plastic tubing [2x] braided protection hose c a = 970 b ...

  • Page 17

    Fiat bravo 1312960a_en 17 bend 48 mm dia. Rubber-coated p-clamp 1. Preparing p-clamp bend perforated bracket 1 by 90°. Preparing perforated bracket 1 perforated bracket, angled down 2 m6x20 bolt, flanged nut 3 48 mm dia. Rubber-coated p-clamp premount- ing p- clamp 1 perforated bracket 2 m6x20 bolt,...

  • Page 18

    Fiat bravo 1312960a_en 18 connec- tion to heater unit gasoline 1 engine-outlet hose section 2 hose section of heat exchanger inlet cutting point 1 48 mm dia. Rubber-coated p-clamp routing in engine compart- ment routing in engine compart- ment 24 c b 25 1 2 26 c 1 27 c.

  • Page 19

    Fiat bravo 1312960a_en 19 ensure sufficient distance to neighboring components. 1 hose on heat exchanger inlet connect- ing heat exchanger inlet 1 hose on engine outlet 2 spacer bracket connect- ing engine outlet 1 48 mm dia. Rubber-coated p-clamp routing in engine compart- ment 1 cable tie connect-...

  • Page 20

    Fiat bravo 1312960a_en 20 1 cable tie [5x] routing in engine compart- ment diesel 1 engine-outlet hose section 2 hose section of heat exchanger inlet 3 cutting point cutting point 1 48 mm dia. Rubber-coated p-clamp routing in engine compart- ment 2 hose section of heat exchanger inlet connect- ing h...

  • Page 21

    Fiat bravo 1312960a_en 21 1 engine-outlet hose section 2 spacer bracket connect- ing engine outlet 1 48 mm dia. Rubber-coated p-clamp routing in engine compart- ment connect- ing hose a and b 36 1 a 2 37 c a 1 38 b a.

  • Page 22

    Fiat bravo 1312960a_en 22 fuel caution! Open the vehicle's fuel tank lock, ventilate the fuel 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 spe...

  • Page 23

    Fiat bravo 1312960a_en 23 cut fuel standpipe 1 to length. Cutting fuel standpipe to length shape fuel standpipe 1. Shape fuel standpipe 1 cutting point 2 fuel-tank vent line removing fuel mount fuel standpipe 3 in fuel- tank vent line 1. Align removal pipe of fuel standpipe to fuel tank bottom. 2 ho...

  • Page 24

    Fiat bravo 1312960a_en 24 align fuel standpipe 1 so that freedom of movement of fuel gauge is ensured after mounting fuel-tank sending unit. 2 opening of fuel-tank sending unit removing fuel 1 fuel standpipe 2 8 mm dia. Clamp 3 hose section, 9 mm dia. Clamp 4 fuel line connect- ing fuel line 1 fuel ...

  • Page 25

    Fiat bravo 1312960a_en 25 combustion air 1 combustion air pipe a = 210 discard section x cutting combus- tion air pipe to length 1 combustion-air intake pipe 2 27 mm dia. Clamp installing intake pipe 1 intake muffler 2 cable tie, original vehicle hole 3 combustion-air intake pipe installing muffler ...

  • Page 26

    Fiat bravo 1312960a_en 26 exhaust gas 1 exhaust pipe a = 170 2 exhaust end section b = 230 discard section x preparing exhaust pipe bend perforated bracket 1 by 90°. Preparing perforated bracket all following photos show diesel vehicle. 1 m6x30 spacer nut, ejot stud 2 exhaust muffler 3 m6x12 bolt, s...

  • Page 27

    Fiat bravo 1312960a_en 27 1 hose clamp [2x] 2 exhaust pipe installing exhaust pipe secure wiring harness of pressure switch 3 in bracket of a/c line. Ensure sufficient spacing between exhaust end section 2 and charge-air tube 3. 1 hose clamp 5 perforated bracket 6 pipe clamp, m6x20 bolt, flanged nut...

  • Page 28

    Fiat bravo feel the drive webasto ag postfach 80 - 82132 stockdorf hotline 01805 / 932278 - hotfax 0395 / 5592-353 http://www.Webasto.De printed in germany 01/2008 printing: steffen 1312960a_en final work warning! Reassemble the disassembled components in reverse order. Check all hoses, clamps and a...

  • Page 29

    Fiat bravo 1312960a_en 29 operating instructions for end customer 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 reco...