Water heater unit thermo top c additional heater legend for figure 1 1 thermo top c -b heater unit 2 blade-type fuse holder 3 exhaust muffler 4 combustion-air intake pipe 5 telestart receiver, thermo call 6 metering pump 7 gateway control unit warning! Hazard warning: incorrect installation or repai...
Thermo top c xc 90 2 table of contents validity note: vehicle models, engine types, equipment variants as well as national specifications, which are not listed in these installation instructions, have not been tested. However, installation according to these installation instructions may be possible...
Xc 90 thermo top c 3 heater unit/installation kit depending on vehicle equipment, if not present: when using telestart and/or thermo call: foreword these installation instructions apply to the volvo xc 90gasoline passenger cars - for validity, see title page - from model year 2003 and later, assumin...
Thermo top c xc 90 4 preliminary work general preliminary work - remove years that do not apply from the duplicate label - attach duplicate label (type label) in an easily visible place - apply the filling station sticker in an easily visible location engine compartment warning: - open radiator cap,...
Xc 90 thermo top c 5 electrical connections preparing wiring harness for all vehicles - cut off brown (br) wire (4) to fan relay - insulate wire section to wiring harness and tie back - cut off green/white (gn/ws) wire (5) from fan relay - cut off red/white (rt/ws) wire (3) to blade fuse (2) - insul...
Thermo top c xc 90 6 routing wiring harness for gateway control unit - route wiring harness (1) behind battery to left-hand side to rem. - route white (ws) 0.5 mm 2 wiring harness (branch) to rem at rear left. - route wiring harness further under side trim to front, along original vehicle wiring har...
Xc 90 thermo top c 7 - connect green/white (gn/ws) wire end (4) to connector and green/white (gn/ws) wiring harness (3) from gateway with connector (crimp and shrink) - route green (gn) wire (8) from gateway through cable pass throughs (1,2) - connect green (gn) wire (8) and green/white (gn/ws) wire...
Thermo top c xc 90 8 - connect green/white (gn/ws) wire (1) from gateway wiring harness to green/white (gn/ws) wire (2) from connector c, pin 32 as shown in wiring diagram. - produce connection according to wiring diagram with included connector. Installing fuse holder for all vehicles - drill 18 mm...
Xc 90 thermo top c 9 - connect connector (2) to wiring harness of additional heater - connect connector (1) to telestart receiver (see telestart option) - connect positive wire (8 mm dia. Ring eye) (1) to positive support point (2) - connect ground wire (3) to ground support point (4) - route wiring...
Thermo top c xc 90 10 gateway wiring harness x3 gr 0,5mm² w s 0, 5mm² vi 0,5mm² sw/w s 0, 5mm² gn /ws 0,5mm² x5 b a x1 gn 0,5mm² ge 0,5mm² sw 0, 5mm² bl 0,5 mm² rt 0,75mm² rt 0,75mm² br 0,75m m² x2 x4 b a c a c b d a c b d an r e m (h inte n li nk s ) an ste c kplatz vom s tecker aem (h inte n rec h...
Xc 90 thermo top c 11 wiring diagram legend for wiring diagram: webasto components volvo components colors and symbols hg heater unit tt-c/e gw gateway ws white x1 connector on heater unit x3 connector on gateway gn green x4 connector on gateway bl blue x5 connector on gateway aem comfort electronic...
Thermo top c xc 90 12 remote option (telestart) note: the installation location of the telestart antenna (1) is on the windshield at the lower left! Produce connections according to general installation instructions and fasten lines with cable ties. - clean and degrease bonding surface on windshield...
Xc 90 thermo top c 13 - lay receiver (3) on trim as shown and copy hole pattern 1,2) - drill two 5.5 mm dia. Holes - fasten receiver and bracket with two m5x12 bolts, washers, spring lockwashers and nuts - connect antenna cable and telestart connector to receiver - reinstall trim note: to teach the ...
Thermo top c xc 90 14 29 1 2 3 4 30 1 2 3 31 1 2 installing heater unit preparing installation location - lay on included template (1) as shown - copy hole pattern (2,3,4) - drill three 7.0 mm dia. Holes - pry off central cover (1) on heater unit - cut off connector of circulating pump - remove circ...
Xc 90 thermo top c 15 - fasten 30 mm spacer nut (1) on stud bolt installing heater unit - drill 7 mm dia. Hole (1) as shown - connect wiring harness of heater unit - fasten premounted heater unit with four m6x20 bolts ( 1,2,4,5), a7.4 washers and flanged nuts - fasten strut to hole with m6x20 bolt (...
Thermo top c xc 90 16 - angle down perforated bracket (4) by 45° at center - fasten water pump (1) on existing hole on engine support with m6x85 bolt, rubber-coated p-clamp (4), 15 mm spacer nut (5), perforated bracket (4), a7.4 washer and flanged nut - drill out hole to 7 mm dia. If necessary - con...
Xc 90 thermo top c 17 exhaust system warning: ensure sufficient spacing to hoses and lines when installing exhaust system. - cut exhaust pipe (1) and exhaust-pipe end section (2) to length as shown - mount 370 mm long exhaust pipe (1,4) on exhaust muffler (2) and secure with hose clamp - shape exhau...
Thermo top c xc 90 18 integration in water circuit note: tighten all hose clamps to 2.0 + 0.5 nm. Any coolant running off should be collected with an appropriate container! Install hoses so that they are kink-free. The connection of the heater unit "in series" (inline) in the vehicle coolant circuit...
Xc 90 thermo top c 19 - cut off original vehicle coolant hose (1,2) as shown - connect cut-off 90° elbow (1) to engine outlet, turn toward front in driving direction and fasten with hose clamp - connect coolant hose, 900 mm long (1) to heater- unit coolant outlet with 180° elbow, align and fasten wi...
Thermo top c xc 90 20 - connect 500 mm long coolant hose (1) with 90° elbow to water-pump coolant inlet, route to cutting point and fasten with hose clamp as shown - connect 500 mm long coolant hose (1) from water- pump coolant inlet and original vehicle 90° elbow (2) with 18/20 connecting pipe and ...
Xc 90 thermo top c 21 coolant connection for 3.2 liter engine cut off hose sections from included coolant hoses as shown in figure 55 and 56: 1 x 1,070 mm long + 90° elbow (1) (from engine outlet to water-pump coolant inlet - push included braided protection hose onto 1070 mm long coolant hose (1) u...
Thermo top c xc 90 22 - cut off original vehicle coolant hose as shown. Discard hose elbow. Loosen coupling (1) and pull off. - connect shortened hose (2) to coupling (1) with 18/20 connecting pipe (4) and hose clamp (3). - mount coupling (1) and engage. Connect original vehicle hose from engine out...
Xc 90 thermo top c 23 - mount coolant hose, 1,070 mm long (1) on water- pump coolant inlet with 90° elbow and fasten with hose clamp (2) - route 1,070 long coolant hose (1) below frame side member to firewall. - fasten to original vehicle stud bolt at position (2) with 29 mm dia. Rubber-coated p-cla...
Thermo top c xc 90 24 - fasten premounted angle bracket (1) on original vehicle threaded hole with m8x20 (5) bolt and spring lockwasher as shown. - fasten angle bracket (3) on original vehicle threaded hole with m8x20 (4) bolt and spring lockwasher as shown. - clip cable tie clip (2) into hole of sh...
Xc 90 thermo top c 25 fuel connection warning: open the vehicle's fuel tank cap, ventilate the tank and then re-close the fuel tank cap. Catch any fuel running off with an appropriate container. Route fuel line so that it is protected against stone impact. Mount the fuel line and wiring harness with...
Thermo top c xc 90 26 - push included heat protection hose (1) onto mecanyl fuel line and wiring harness of metering pump - route mecanyl fuel line and wiring harness of metering pump along original vehicle fuel lines on firewall to underbody - position heat protection hose as shown - route mecanyl ...
Xc 90 thermo top c 27 - fasten perforated bracket (2) with metering pump (1) and fuel filter (4) with original vehicle bolt (3; 64/5) as shown in figure 63 and figure 64 - route mecanyl fuel line (6; 64/2) and wiring harness of metering pump (5; 64/4) along original vehicle lines to metering pump (1...
Thermo top c xc 90 28 - push molded hose (1) as far as possible onto standpipe and connection piece at end with inside 8.0 mm dia. - fasten molded hose (1) on connection piece with 12 mm hose clamp (4) - insert remaining mecanyl fuel line (3) into molded hose (1) and fasten with 10 mm hose clamp (2)...
Xc 90 thermo top c 29 installing software - depending on date of manufacture and equipment of vehicle, the corresponding volvo software must be installed on the vehicle teaching telestart option note: - to teach the telestart, the connector must be pulled off at the telestart receiver! - teach teles...
Thermo top c xc 90 30 template for bracket Ø 7mm Ø 7mm Ø 7mm original vehicle hole 0 100 mm 100 mm scale 1:1 compare the size of the printed version with dimension lines. Permitted tolerance a maximum of 2%. Set the printer settings to “no margin” or “minimize margins” and 100% of the normal size..
Xc 90 thermo top c 31 operating instructions for end customer please remove page and add to the vehicle operating instructions. Additional heater can be switched with following heater controls: - steering column lever over original vehicle display in instrument panel (clock/direct start), - "telesta...
