ALWAYS follow all Webasto installation and repair instructions and observe all warnings.

Transcription

1 Water Heater Feel the drive Thermo Top E Parking Heater Thermo Top C Parking Heater e e Installation instructions Subaru Legacy / Outback.0 and.5 Gasoline from Model Year 00 Left-hand drive vehicle Automatic air-conditioning Gear box / Lineartronic 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, specialised tools and equipment are required to install and repair Webasto heating and cooling systems. Only original Webasto parts must be used. For this, also see the catalog of air and water heater accessories from Webasto. 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. Ident. No.: 585A_EN Fee Euro 0.00 Webasto AG

2 Table of Contents Validity Heater/Installation Kit Foreword General Instructions Special Tools Explanatory Notes on Document Preliminary Work 5 Heater installation location 5 Preparing electrical system 6 Electrical system 7 Fan controller 8 Digital timer and summer/winter switch option Remote option (Telestart) Preparing installation location Preparing bracket Preparing heater heater 5 Fuel 6 Coolant circuit 9 Combustion air Exhaust gas Final Work 6 Template for Fuel Standpipe 7 Template for Fuel sender 7 Operating Instructions for End Customer 8 Validity Manufacturer Model Type EG-BE No./ABE Subaru Legacy / Outback BM /BR e * 007 / 6 * 0079 *... Subaru Legacy / Outback BM /BRS e * 007 / 6 * 07 *... Engine type Engine model Output in kw Displacement in cm³ EJ0 Gasoline 0 99 EJ5 Gasoline 57 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. Optional: The installation location of a digital timer and summer/winter switch should be confirmed with the end customer before installation. 585A_EN

3 Heater/Installation Kit Quantity Description Order No.: Retail accessories Thermo Top E / C See price list Installation Kit for Subaru Legacy / Outback.0 and.5 58A Gasoline MY 00 Heater control See price list Heater recommended for the relevant vehicle class: Vehicle Compact car Mid-size car, station wagon Heater Thermo Top E Thermo Top C The selection of the heater 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 the vehicles Subaru Legacy / Outback.0 and.5 Gasoline - for validity, see page - from model year 00 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 these "installation instructions" and "operating and maintenance instructions" for the Thermo Top C/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 00K, Order No. 9). Special Tools - Torque wrench for.0-0 Nm - Hose clamping pliers - Metric thread-setter kit 585A_EN

4 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. Mechanical system Electrical system Coolant circuit Fuel Exhaust gas Combustion air Software Special features are highlighted using the following symbols: 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. The arrow in the vehicle icon indicates the position on the vehicle and the viewing angle. All dimensions are in mm! Tightening torque of hose clamps = Nm! Tightening torque of Ejot screws, Ejot studs = 0 Nm! 585A_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. - Remove years that do not apply from the duplicate label. - Attach the duplicate label (type label) in the appropriate place. - Remove the air filter together with the intake hose. - Remove the engine cover - Remove underride trim at the left in front of the tank - Open the tank-fitting service lid on the right and left. - Remove fuel-tank sending unit in accordance with manufacturer's instructions. - Remove the instrument panel trim on the driver's side. - Remove the instrument panel trim in the footwell on the front passenger side - Remove the lateral trim of the instrument panel on the front passenger side (for Telestart only) Heater installation location Heater Remove page 8 "Operating Instructions for End Customer" and add to the vehicle operating instructions. Installation location 585A_EN 5

6 Preparing electrical system Replace 5 A fuse F with 0A fuse. Angle bracket M5x6 bolt, large diameter washer [x] retaining plate for fuse holder, flanged nut F- fuses mounted K relay Pre-installing fuse holder 585A_EN 6

7 Electrical system Positive and ground connection Positive wire on positive battery terminal Ground wire on ground support point Wiring harness pass through of lineartronic Protective rubber plug Do not install the metering pump cable harness until later together with fuel pipe along the original vehicle fuel lines on the underbody Wiring harness installation routing Fuse holder, K relay M6x0 bolt, spring lockwasher, large diameter washer in existing threaded hole Angle bracket Wiring harness pass through of gear box Detach original vehicle wiring harness and put it away. Protective rubber plug 5 585A_EN 7

8 Fan controller Webasto Subaru 0 5 HG X F F F F F F5 Wiring diagram a rt ² A8 FB gn/rt 0,5² A FB ge/rt 0,5² A FB 8 MB gn/or 0,5² ZE F ge 85 0 K GRr sw ² sw 0,75² 5 GRs 5 sw/ ge i8 sw sw/ ws bl sw/rt + GM M - D sw gn/rt 0,5² bl ge/rt 0,5² vi/ge i bl/ge i8 gn/ws A/C-V Webasto components Vehicle components Colours and symbols HG Heater TT-C/E F Fuse, 7.5 A rt red X 6-pin heater connector F Fuse, 5A ws white F Replace 5 A fuse with F Fuse, 5A sw black 0A fuse F Fan fuse br brown K Fan relay F5 Fan fuse gn green D Diode group ZE Central electrical box bl blue A8 Connector A (i5) PIN 8 ZE ge yellow A Connector A (i5) PIN ZE vi violet A Connector A (i5) PIN ZE or orange GRs Fan relay GRr Fan controller i8 5-pin connector, GRr GM Fan motor Insulate wire ends and A/C-V A/C booster tie back i80 6-pin connector A/C-V X Cutting point i8 -pin connector A/C-V Wiring colours may vary. Legends 585A_EN 8

9 Connection on 0-pin connector A (i5) of central electrical box. Produce connections as shown in wiring diagram. 6 5 Green/orange (gn/or) wire of connector A(i5), Pin Black (sw) wire of diode group D Red (rt) wire from K/87a 5 Black (sw) wire from K/0 6 Green/orange (gn/or) wire of fan relay Pin Connection to central electrical box 6 Connector A (i5) contact side Green/orange (gn/or) wire of Pin Connector A (i5) Green/orange (gn/or) wire of connector A(i80), Pin Green/red (gn/rt) wire of connector A(i80), Pin Blue (bl) wire of diode group D 5 Black (sw) wire of diode group D Connection on 6-pin connector A (i80) from A/C booster. Watch direction of flow of diode group D 6. Produce connections as shown in wiring diagram. Connecting to A/C booster Green/red (gn/rt) wire of fuse F. Black (sw) wire of diode group D White/black (ws/sw) wire of diode group D Additional black (sw) wire from K/0 5 Blue (bl) wire of diode group D 6 Yellow/red (ge/rt) wire of fuse F. Produce connections as shown in wiring diagram. Connecting to A/C booster 9 585A_EN 9

10 Connector A (i80) contact side Green/red (gn/rt) wire of Pin Yellow/red (ge/rt) wire of Pin 5 6 Connector A (i80) A_EN 0

11 Digital timer and summer/winter switch option Digital timer mm dia. hole, summer/winter switch digital timer Remote option (Telestart) Fasten receiver with adhesive tape. receiver Antenna antenna Temperature sensor T00 HTM Fasten temperature sensor with adhesive tape. temperature sensor 585A_EN

12 Preparing installation location Manual transmission Removing plug. Drill out existing hole to 9. mm dia. and mount rivet nut rivet nut 5 Lineartronic Remove clip at position drill hole up to 9.mm dia and tighten rivet nut. Insulation mat is retained. rivet nut 6 All vehicles Fasten original vehicle wiring harnesses, with cable tie. Preparing installation location 7 Removing brake line bracket Removing bracket 8 585A_EN

13 Cut and discard tab at position. Remount brake line bracket. Preparing bracket 9 Drill 9. mm dia. hole; install rivet nut rivet nut 0 Detach radiator tank, lift and insert suitable material in between Detaching radiator tank Preparing bracket Only for bracket version 09C! Drill out hole at position to 8.5 mm dia. 0 5 Bracket Discard section 7 mm dia. hole Preparing bracket 6 585A_EN

14 Preparing heater Perforated bracket 80 Angling down perforated bracket 90 M6x bolt, spring lockwasher Perforated bracket Ejot screw Hose section, 0 mm dia. clamp [x] 5 Fuel line Preassembling heater 5 Discard section X Manual transmission Exhaust pipe a = 0 Exhaust end section b = 500 Lineartronic Preparing exhaust pipe a b Exhaust pipe a = 0 Exhaust end section b = 0 X Ejot screw [x] Exhaust pipe Hose clamp, install loosely Hose clamp Preassembling heater 5 585A_EN

15 heater Large diameter washer, flanged nut on existing hole heater 6 Slide one 0mm shim [x] on each ejot screw. heater 7 Ensure free movement between bracket of heater and brake lines at position 5 Flanged nut [x] M6x0 bolt, spring lockwasher 5 Large diameter washer, original vehicle bolt heater 8 Mount wiring harness of heater and close radiator tank again. Check the position of the components; adjust if necessary. Check that they have free clearance. Mounting wiring harness 9 585A_EN 5

16 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. Route wiring harness of heater and fuel pipe to original vehicle wiring harness on the left side of vehicle. lines 0 Divide corrugated tube at the centre. Route fuel line and wiring harness of metering pump in corrugated tube of underbody lines Route fuel line and wiring harness of metering pump to the installation location of metering pump Pasting socket, cable tie [5x each] lines 585A_EN 6

17 Drill out perforated bracket at position to 8.5 mm dia. and install loosely Silent block, flanged nut [x] Rubber-coated pipe clamp 5 Metering pump Pre-installing metering pump 5 Align metering pump, tighten nut at position. M8x0 bolt, spring lockwasher, existing threaded hole Perforated bracket metering pump Hose section, 0 mm dia. clamp [x] Fuel line Wiring harness of metering pump, connector mounted Connecting metering pump 5 Remove fuel-tank sending unit in accordance with manufacturer's specifications. Cut out template and lay on. Copy hole pattern, 6 mm dia. hole Removing fuel 6 585A_EN 7

18 Shape fuel standpipe according to template, cut to length and install. At position insert five plane washers d a = mm as height compensation. fuel standpipe 7 Install fuel-tank sending unit in accordance with manufacturer's instructions. Slide protective hose onto fuel line 5 and route to the left vehicle side. Fuel standpipe Hose section, 0 mm dia. clamp [x] Connecting fuel line 5 8 Route fuel line in corrugated tube to metering pump. fuel line 5 9 Check the position of the components; adjust if necessary. Check that they have free clearance. Hose section, 0 mm dia. clamp [x] Fuel line Connecting metering pump 0 585A_EN 8

19 Coolant circuit WARNING! Any coolant running off should be collected using an appropriate container. Install coolant hoses kinkfree. Unless specified otherwise, always fasten using cable ties. Position clamps so that no other hose can be damaged! When installing the hoses, the heater must be filled with coolant. The connection should be "inline" based on the following diagram: Hose-routing diagram B A All hose clamps = 0-7 mm dia.! = Black (sw) rubber isolator. = Original vehicle spring clip. All connecting pipes = 5x0 dia.. 585A_EN 9

20 Discard section X A B X A = 80 B = 60 Cutting coolant hoses to length X A Push braided protection hoses onto hose A and B and cut to length. Cut heat shrink plastic tubing to length. 5 mm long heat shrink plastic tubing [x] Preparing coolant hoses B Remove hose section of heat exchanger inlet. Spring clip will be reused. Adjust original vehicle spacer bracket as shown Engine outlet hose section Discard hose section Cutting point Connecting heater inlet A 585A_EN 0

21 A Cable tie Black (sw) rubber isolator A Hose of engine outlet Routing in engine compartment Connecting engine outlet Connecting heater outlet B 5 Install hose of heat exchanger inlet with cut side on connecting piece of heat exchanger inlet. Ensure sufficient distance to neighbouring components. Original vehicle spring clip Connecting heat exchanger inlet B 6 585A_EN

22 Combustion air a Discard section X Combustion air pipe a = 00 Cutting combustion air pipe to length X Pierce through perforation at centre of heater cover at position and insert retaining clip. Inserting retaining clip 7 Muffler Retaining clip in hole Combustion air pipe 7 mm dia. clamp muffler 8 585A_EN

23 Exhaust gas Insert 0 mm ship between silencer and rivet nut. For Lineartronic, insert an additional large diameter washer between shim and insulation mat. Tighten hose clamp Muffler M6x50 bolt, spring lockwasher, 0 mm shim, large diameter washer (Lineartronic only) muffler 9 Manual transmission Original vehicle stud bolt, flanged nut Angle bracket angle bracket 50 Exhaust end section Hose clamp exhaust end section 5 M6x0 bolt, flanged nut P-clamp Fastening end section 5 585A_EN

24 Aligning exhaust end section Ensure sufficient distance to neighbouring components. M6x0 bolt, flanged nut P-clamp M6x0 bolt, large diameter washer, flanged nut, existing hole Perforated bracket Fastening end section 5 Lineartronic Original vehicle stud bolt, flanged nut Angle bracket angle bracket 5 Exhaust end section Hose clamp exhaust end section 55 M6x0 bolt, flanged nut P-clamp Fastening end section A_EN

25 Exhaust end section M6x0 bolt, large diameter washer, flanged nut, existing hole Perforated bracket M6x0 bolt, pipe clamp, flanged nut Fastening end section 57 Aligning exhaust end section Ensure sufficient distance to neighbouring components. Aligning end section A_EN 5

26 Final Work WARNING! Reassemble the disassembled components in reverse order. Check all hoses, clamps and all electrical connections for firm seating. Secure all loose cables using cable ties. Only use manufacturer-approved coolant. Spray heater components with anti-corrosion wax (Tectyl 00K, Order No. 9). - Connect the battery. - Fill and bleed the coolant circuit according to the vehicle manufacturer s specifications. - Adjust digital timer / remote control - Make settings on A/C control panel according to the "Operating Instructions for End Customer". - Check the proper operation of the parking heater, see the operating instructions/installation instructions. - Place the instruction plate "Switch off parking heater before refuelling" in the area of the filling neck Feel the drive Webasto AG Postfach 80 D-8 Stockdorf / Germany National Hotline: ( Cent aus dem deutschen Festnetz) Hotfax: Hotmail: hotline@webasto.de 585A_EN Printed in Germany 09/00 Printing: Steffen 6

27 Template for Fuel Standpipe Template for Fuel sender Ø 6mm 00 mm Scale : Compare the size of the printed version with dimension lines. Permitted tolerance a maximum of %. Set the printer settings to no margin or minimise margins and 00% of the normal size. 00 mm 0 585A_EN 7

28 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. 0 min. (in one direction), we recommend not exceeding a switch-on time of 0 min. If the summer/winter switch option has been installed, this must be switched in accordance with the time of year. The heater 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: Air outlet to windshield Set temperature on both sides to "HI" Set fan to level "", or "" Automatic air-conditioning A_EN 8