Webasto Thermo Top E Manuale utente
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 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 suc-
cessfully 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 installa-
tion by untrained staff.
Water Heater Unit
Installation Instructions
Ident. No.:1311770A_EN Fee Euro 10.00 © Webasto AG
Opel Corsa
Diesel
from Model Year 2007
Left-hand drive vehicle
Manual transmission
Feel the drive
Thermo Top E Additional Heater e1
00 0003
Thermo Top C
Additional Heater
e1
00 0002
Thermo Top P Additional Heater e1
00 0104
Opel Corsa
1311770A_EN 2
Table of Contents
Validity
Vehicle and engine types, equipment variants and national specifications not listed in these installation
instructionshavenotbeentested.However,installation according to these installationinstructions 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 Corsa S-D e1 * 2001 / 116 * 0379 * ...
Engine type Engine model Output in kW Displacement in cm³
Z13DTJ Diesel 55 1248
Z13DTJ Diesel 66 1248
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
Preparing electrical system 6
Electrical Connections 7
Fan controller for manual air conditioning 8
A
utomatic air-conditioning fan controller 9
Remote option (Telestart) 11
Preparing heater unit 12
Preparing installation location 12
Installing heater unit 14
Combustion air 15
Exhaust system 16
Coolant connection 17
Fuel Connection 20
Final Work 23
Operating Instructions for End Customer 24
Template for Fuel Standpipe 25
Opel Corsa
1311770A_EN 3
Heater Unit/Installation Kit
Foreword
These installation instructions apply to Opel Corsa Diesel vehicles - for validity, see page 2 - from mod-
el 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 nec-
essary during installation with respect to these installation instructions.
However,thestipulations in the "installationinstructions"and"operating and maintenanceinstructions"
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 spec-
ified 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 Retail accessories with desired heater control See price list
For installation parts, see Webasto calculation program
Special features are highlighted using the following symbols:
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 Corsa
Specific risk of injury or fatal accidents.
Specific risk of damage to components.
Specific risk of fire or explosion.
ReferencetogeneralinstallationinstructionsofWebas-
tocomponentsortothemanufacturer'svehicle-specific
documents.
Reference to a special technical feature.
1311770A_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.
Opel Corsa
1311770A_EN 5
Preliminary Work
WARNING!
- Open the fuel tank cap, ventilate the tank.
- Close the tank cap again.
- Disconnect the battery "earth" or "ground" connection.
-Depressurizethe 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 wiper arms
- Remove the coolant reservoir cap.
- Expose the fuse and relay box in the engine compartment
- Remove the rear bench seat
- Open the right-hand fuel sender service lid
- Remove the fuel-tank sending unit in accordance with the manufacturers specifications
- Remove the footwell trim on the driver's side
Remove page 24 "Operating Instructions for End Customer" and insert with vehicle operating instruc-
tions.
Heater unit installation location
1Heater unit
Installa-
tion loca-
tion
1
1
Opel Corsa
1311770A_EN 6
Preparing electrical system
Only with automatic air-conditioning
Produce connection as shown in wiring dia-
gram with tab receptacle. Pull line section 1
(2,000 mm long, 0.75 mm²) into protective
sleeving and install in passenger compart-
ment together with wiring harness for digital
timer and fan controller. This will be required
later for connection of the A/C control panel.
Cutting
wires to
length
gn/ws
rt
rt/
ws
br
86
85 30
87a87
K3
sw
1
gn/ws
Opel Corsa
1311770A_EN 7
Electrical Connections
Fuse holder, K3 relay with manual air condi-
tioning
17 mm dia. hole, M6x20 bolt, large diameter
washer, flanged nut
2Angle bracket
3Retaining plate for fuse holder, M5x16 bolt,
large diameter washer, K3 relay, flanged nut
on angle bracket
Digital timer
1Digital timer
Wiring har-
ness in-
stallation
diagram
Wiring harness pass through
1Protective rubber plug
Summer/winter switch option
1Summer/winter switch, drilled hole 12 mm dia.
2
1 2
3
3
1
Do not install the metering pump
cableharnessuntillatertogether
with fuel pipe along the original
vehicle fuel lines on the under-
body
4
1
5
1
Opel Corsa
1311770A_EN 8
Fan controller for manual air conditioning
Wiring dia-
gram
Webasto components Vehicle components Colors and symbols
Legend
HG Heater unit TT-C/E M1 A60 Fan motor rt red
X1 6-pin connector FU5 Fuse 40A ws white
F3 Fuse, 25 A R1 A60 Resistor group sw black
K3 Fan relay S1 A60 Fan switch br brown
gn green
XCutting point
Wiring colors may vary.
Connection to connector 1of fuse and relay
box 2.
Produce connections as shown in wiring dia-
gram.
3Brown (br) wire to fan motor
4Black (sw) wire from K3/30
5Red (rt) wire to K3/87a
6Brown (br) wire from fuse FU5
Connect-
ing fan-mo-
tor
Webasto
31
30
15
Opel
HG
X1 4
F3
86
85 30
87a87
K3
rt/ws
gn/
ws
br
sw
rt
FU5
+
-
M1
A60
M
S1 A60
br
br
R1 A60
6
1
5
2
6
3
4
Opel Corsa
1311770A_EN 9
Automatic air-conditioning fan controller
Wiring dia-
gram
Webasto components Vehicle components Colors and symbols
Legend
HG Heater unit TT-C/E M1 A13 Fan motor rt red
X1
6-pin heater unit connector
FU5 Fuse 40A ws white
F3 Fuse, 25 A Y1 A13 Fan controller sw black
K3 Fan relay A14 Air-cond. control element br brown
XC...... Connector designations gn green
X...... Connector designations hbl light blue
or orange
Insulate wire ends and
tie back
XCutting point
Wiring colors may vary.
Webasto
31
30
15
Opel
HG
X1 4
F3
86
85 30
87a87
K3
rt/ws
gn/
ws
br
sw
rt
!
ws/
gn
ws/
gn
1gn/ws
FU5
br
br
X42 1
A14
XC42
1
XC42 3 8
+
-
M1 A13
M
swrt
or
sw
hbl
hbl
Y1 A13
XC33 1 2
XC32
2
XC32 1
XC31
1 2
Opel Corsa
1311770A_EN 10
Connection to connector 1of fuse and relay
box 2.
Produce connections as shown in wiring dia-
gram.
3Brown (br) wire to fan controller Y1 A13
4Black (sw) wire from K3/30
5Red (rt) wire to K3/87a
6Brown (br) wire from fuse FU5
Connect-
ing fan-mo-
tor
Connection to gray 32-pin connector 2from
the air conditioning control.
Disconnect white/green (ws/gn) wire 1and
produce connection as shown in wiring dia-
gram with connector.
WARNING!
If no white/green (ws/gn) wire is connected to
Pin 1, the green/white (gn/ws) wire from
K3/86 is connected there with a suitable plug-
in contact.
Connect-
ing A/C
control
panel
7
1
5
2
6
3
4
8
1
2
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2
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