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: Mitsubishi Grandis

    2 mitsubishi grandis 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 location of a digital timer ...

  • Page 3: Mitsubishi Grandis

    3 mitsubishi grandis 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 th...

  • Page 4: Mechanical Work

    4 special features are highlighted using the following symbols: mechanical work electrical connection coolant connection fuel connection exhaust system combustion air the arrow in the vehicle icon indicates the position on the vehicle and the viewing angle. Mitsubishi grandis specific risk of injury...

  • Page 5: Mitsubishi Grandis

    5 mitsubishi grandis preliminary work warning! - 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. - remove years that do not apply from the duplicate label. - attach the dupli...

  • Page 6: Mitsubishi Grandis

    6 mitsubishi grandis wiring harness pass through (1) protective rubber plug digital timer (1) digital timer (use wiring harness extension) opt. Summer/winter switch (1) summer/winter switch, hole 12 mm dia. 1 2 1 3 1 4 fuse holder, relay k3 (1) k3 relay, m5x12 bolt, washers, nut (3) fuse holder, m4x...

  • Page 7: Mitsubishi Grandis

    7 mitsubishi grandis remote option (telestart) (1) receiver (2) bracket, m5x12 bolt, washer, flanged nut installing receiver 1 8 2 i (1) antenna of telestart t100 htm installing antenna 1 9 (1) temperature sensor of telestart t100 htm (2) dual lock, self-adhesive (3) air distribution for passenger c...

  • Page 8: Mitsubishi Grandis

    8 mitsubishi grandis remote option (thermo call) cut out insulation mat. (1) thermo call receiver, m5x20 bolts, flanged nut, washers [4x] (2) lower footwell cover on front passenger side installing receiver 1 11 2 i (1) antenna tc 1.1 installing antenna 1 12 (1) push button installing push button 1 ...

  • Page 9: Mitsubishi Grandis

    9 mitsubishi grandis automatic air-conditioning fan controller connection to 2-pin connector from blower motor. Make connections as shown in the wiring diagram with the connectors provided. (1) connector, 2-pin fan controller 1 14 connection of diode group 8 on 26-pin connector 5 from a/c control pa...

  • Page 10: Mitsubishi Grandis

    10 mitsubishi grandis wiring diagram gn/ ws sw br rt/ws webasto 31 30 15 mitsubishi rt 4 hg x1 f3 f bl/rt k3 87a 87 86 85 30 f4 sw sw 8 kb st 1 m + - gm bl/rt rt/ws rt/ws gr ws/sw sw 0,5² 0,5² sw d1 bl bl ! I webasto components mitsubishi components colors and symbols legend hg heater unit tt-c/e gm...

  • Page 11: Mitsubishi Grandis

    11 mitsubishi grandis preparing installation location (1) bracket (2) drill out existing hole to 8.5 mm dia. Preparing bracket 2 1 16 (1) remove original vehicle bolt preparing installa- tion loca- tion 1 17 (3) install bracket and align (2) m8x30 bolt (1, 4, 5) copy hole pattern preparing installa-...

  • Page 12: Mitsubishi Grandis

    12 mitsubishi grandis (2) bracket (1) m6x35 bolt, spring lockwasher, 5 mm shim (3) m8x35 bolt, 5 mm shim, 8 mm dia. Washer (4) m6x35 bolt, 5 mm shim, flanged nut (5) m6x35 bolt, 5 mm shim, flanged nut installing bracket 4 5 3 1 2 20 preparing heater unit (1) exhaust pipe a = 250 mm (2) exhaust end s...

  • Page 13: Mitsubishi Grandis

    13 mitsubishi grandis tighten ejot screws to 10 nm! Insert two washers between heater unit and bracket at position 3. (2) heater unit (4) bracket (3) ejot screw (5) ejot screws [2x] (1) exhaust system, watch spacing to other components! Installing heater unit 3 4 2 5 23 1 installing heater unit tigh...

  • Page 14: Mitsubishi Grandis

    14 mitsubishi grandis (2) combustion-air intake pipe (3) combustion-air intake muffler (1) battery carrier, drill 7.0 mm dia. Hole (4) cable tie installing combus- tion-air in- take muffler 3 2 4 25 1 i combustion air ensure proper installation position of air intake muffler, see "installation instr...

  • Page 15: Mitsubishi Grandis

    15 mitsubishi grandis (3) heater unit (2) mecanyl fuel line (1) hose section, 10 mm dia. Hose clamp [2x] fuel on heater unit 3 2 26 1 ensure proper installation position of metering pump, see "installation instructions“. Installation location on left in front of vehicle fuel tank! Fuel line from hea...

  • Page 16: Mitsubishi Grandis

    16 mitsubishi grandis shape fuel standpipe according to template, cut to length and install, see "installation instructions". (1) fuel-tank sending unit (2) fuel standpipe installing fuel standpipe 1 2 30 i install fuel-tank sending unit according to manufacturer's specifications. Shorten molded hos...

  • Page 17: Mitsubishi Grandis

    17 mitsubishi grandis shape fuel standpipe according to template, cut to length and install, see "installation instructions". (1) fuel-tank sending unit (2) fuel standpipe installing fuel standpipe 1 2 33 i install fuel-tank sending unit according to manufacturer's specifications. Shorten molded hos...

  • Page 18: Mitsubishi Grandis

    18 mitsubishi grandis coolant diagram motor heat- exchanger Ø 17x20 a b Ø 17x20 all clamps without a specific designation are 20-27 mm dia. Hose clamps. Coolant for gasoline engine warning! Tighten all hose clamps to 2.0 + 0.5 nm. Any cold water running off should be collected using an appropriate c...

  • Page 19: Mitsubishi Grandis

    19 mitsubishi grandis (1) hose section on engine outlet connec- tion on engine outlet 37 a 1 a = 950 mm b = 860 mm discard section 8 cutting coolant hoses to length b a b a x x x push braided protection hoses onto hose a and b preparing coolant a b 35 (2) hose on heat exchanger inlet (1) hose on eng...

  • Page 20: Mitsubishi Grandis

    20 mitsubishi grandis fill heater unit with coolant before installing coolant hoses. Connec- tion on heater unit b a 41 (1) hose section on heat exchanger inlet connec- tion on heat exchang- er inlet b 38 1 secure coolant hoses with cable ties. Routing in engine compart- ment a b 39 secure coolant h...

  • Page 21: Mitsubishi Grandis

    21 mitsubishi grandis coolant diagram motor heat exchanger Ø 20x20 a b all clamps without a specific designation are 20-27 mm dia. Hose clamps. Coolant for diesel engine warning! Tighten all hose clamps to 2.0 + 0.5 nm. Any cold water running off should be collected using an appropriate container! I...

  • Page 22: Mitsubishi Grandis

    22 mitsubishi grandis a = 850 mm b = 760 mm discard section 8 cutting coolant hoses to length b a b a x x x push braided protection hoses onto hose a and b preparing coolant a b 42 disconnect hose from engine outlet. (1) hose on engine outlet cutting point 1 44 disconnect wiring harness. (1) wiring ...

  • Page 23: Mitsubishi Grandis

    23 mitsubishi grandis fill heater unit with coolant before installing coolant hoses. Connec- tion on heater unit b a 48 secure hoses with cable ties. Connec- tion on heat exchang- er inlet b 46 a secure coolant hoses with cable ties. Routing in engine compart- ment a b 47 (1) connection piece on eng...

  • Page 24: Mitsubishi Grandis

    24 mitsubishi grandis (1) lower wheel well trim, expand existing cut-out to 42 mm dia. (2) exhaust tailpipe (3) red (rt) rubber isolator with groove cutting out under- ride pro- tection and posi- tioning rubber isolator 3 2 50 1 exhaust gas ensure sufficient distance to neighboring components. (2) 1...

  • Page 25: Mitsubishi Grandis

    Mitsubishi grandis printed in germany 03/07 printed by: steffen webasto ag postfach 80 - 82132 stockdorf, germany - hotline +49- (0)1805-932278 i final work warning! Reassemble the disassembled components in reverse order. Check all hoses, hose and caillau clamps, as well as all electrical connectio...

  • Page 26: Mitsubishi Grandis

    26 mitsubishi grandis (1) direct air outlet toward windshield (2) set fan to level "2", or possibly "3" (3) set temperature to "max." automatic air-condi- tioning 2 1 3 51 operating instructions for end customer (please remove page and add to the vehicle operating instructions.) before parking the v...

  • Page 27: Mitsubishi Grandis

    27 mitsubishi grandis 0 100 mm 100 mm scale 1:1 compare the size of the printed version with dimension lines. Permitted tolerance a maximum of 2%. Correct major differences in the printer settings or request an original printout. 6 mm dia. Template for fuel-tank sending unit on gasoline vehicles.

  • Page 28: Mitsubishi Grandis

    28 mitsubishi grandis 0 100 mm 100 mm scale 1:1 compare the size of the printed version with dimension lines. Permitted tolerance a maximum of 2%. Correct major differences in the printer settings or request an original printout. Template for fuel standpipe on gasoline vehicles.

  • Page 29: Mitsubishi Grandis

    29 mitsubishi grandis 0 100 mm 100 mm scale 1:1 compare the size of the printed version with dimension lines. Permitted tolerance a maximum of 2%. Correct major differences in the printer settings or request an original printout. Template for fuel standpipe on diesel vehicles.