Webasto Thermo Top E Installation Instructions Manual

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Summary of Contents:

[Page 1] Webasto Thermo Top E

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...

[Page 2] Webasto Thermo Top E

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 pos...

[Page 3] Webasto Thermo Top E

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!...

[Page 4] Webasto Thermo Top E

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 viewi...

[Page 5] Webasto Thermo Top E

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...

[Page 6] Webasto Thermo Top E

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 ...

[Page 7] Webasto Thermo Top E

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...

[Page 8] Webasto Thermo Top E

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 Installi...

[Page 9] Webasto Thermo Top E

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 d...

[Page 10] Webasto Thermo Top E

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 comp...

[Page 11] Webasto Thermo Top E

11 Mitsubishi Grandis Preparing installation location (1) Bracket ( 2) Drill out existing hole to 8.5 mm dia. Preparing bracket 21 16 (1) Remove original vehicle bolt Preparing installa- tion loca- tion 1 17 (3) Install bracket and align ( 2) M8x3...

[Page 12] Webasto Thermo Top E

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 31 2 20 Preparing hea...

[Page 13] Webasto Thermo Top E

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! Insta...

[Page 14] Webasto Thermo Top E

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 installat...

[Page 15] Webasto Thermo Top E

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 locat...

[Page 16] Webasto Thermo Top E

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 sendi...

[Page 17] Webasto Thermo Top E

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 sendi...

[Page 18] Webasto Thermo Top E

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 r...

[Page 19] Webasto Thermo Top E

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 ba BA X X X Push braided protection hoses onto hose A and B Preparing coolant...

[Page 20] Webasto Thermo Top E

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. Ro...

[Page 21] Webasto Thermo Top E

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 s...

[Page 22] Webasto Thermo Top E

22 Mitsubishi Grandis a = 850 mm b = 760 mm Discard section 8 Cutting coolant hoses to length ba BA 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 C...

[Page 23] Webasto Thermo Top E

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 e...

[Page 24] Webasto Thermo Top E

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 En...

[Page 25] Webasto Thermo Top E

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 a...

[Page 26] Webasto Thermo Top E

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 21 3 51 Operating Instructions for End Customer (Please...

[Page 27] Webasto Thermo Top E

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 ...

[Page 28] Webasto Thermo Top E

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 s...

[Page 29] Webasto Thermo Top E

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 S...