Webasto Thermo Top C Manual de usuario
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 repair of Webasto heating and cooling 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
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.
Installation Instructions
Volvo XC 90
Gasoline
From model year 03
For left-hand drive vehicles only
See Page 2 for validity
Note:
Only in conjunction with Webasto Gateway!
Only in conjunction with the corresponding
Volvo vehicle software!
For combination with Telestart and/or Thermo
Call, the Volvo AEM must also be used with the
corresponding software!
1
63 14 2 5
4
7
Ident. No. 9010409D_EN Fee Euro 10 © Webasto AG
e1
00 0002
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.
Manufacturer Typ
eModel EG-BE No.
Volvo T6 XC90 e9*2001/116*0046*..
Engine type Engine
model Output in kW Displacement in
cm3
B5254T2 Gasoline 154 2521
B6294T Gasoline 200 2922
B6324S Gasoline 175 3192
Volvo XC 90 1
Validity 2
Heater Unit/Installation Kit 3
Foreword 3
Special Tools 3
General Instructions 3
Preliminary Work 4
Heater Unit Installation Location 5
Electrical Connections 5
Gateway Wiring Harness up to 2004 Model 7
Gateway Wiring Harness from to 2005 Model 8
Gateway Wiring Harness 10
Wiring Diagram 11
Remote Option (Telestart) 12
Thermo Call option 13
Installing Heater Unit 14
Combustion-Air Intake Pipe 16
Exhaust System 17
Coolant Connection for 2.5 and 3.0 Liter Engine 18
Coolant Connection for 3.2 Liter Engine 21
Fuel Connection 25
Removing Fuel 27
Installing Software 29
Final Work 29
Template for Bracket 30
Operating Instructions for End Customer 31
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, 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, where this is the case the stipulations in the "installation instructions" and "operating and
maintenance instructions" for the Thermo Top C should be observed.
The corresponding rules of technology and any information from the vehicle manufacturer should be
observed during the installation work.
Special Tools
Hose clamping pliers
Torque wrench for 2.0 - 10 Nm
General Instructions
- Provide bare areas on body, e.g. on holes, with corrosion protection
- Secure hoses, lines and wiring harnesses with cable ties and provide them with a protective hose in rubbing
areas
- Provide sharp edges with edge protection (cut-open fuel hose)
Quantity Description Volvo Order No.:
1Thermo Top C -B water heater unit with vehicle-specific delivery scope 12000093
Quantity Description Volvo Order No.:
1Volvo heater software in accordance with equipment Various
1Volvo AEM (if not present in vehicle equipment) up to Model Year ’04 8666691
1Volvo AEM (if not present in vehicle equipment) from Model Year ’05 30660541
1Volvo Y-Adapter Telestart-ThermoCall 12001637
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, release pressure and close
radiator cap again.
- Remove the wiper arms.
- Remove the coolant reservoir cap.
- Remove the wiper unit.
- Remove the air filter housing and the intake hose.
Outside of vehicle
- Open fuel tank cap, release pressure from fuel tank
system and close fuel tank cap again
- Remove left front wheel
- Remove the underride protection
- Remove left front wheel well trim
- Remove left bumper trim
- Remove the left-hand headlight.
Vehicle interior
- Remove left/right lower instrument panel cover (on
right only with installation of Thermo Call 1.1)
- Remove rear corner trim at left/right in cargo space
- Remove left rear and front door sill trim
- Remove floor cover in cargo space
- Remove bracket and battery cover
- Disconnect battery
- Remove cover of fuel-tank sending unit behind
second seat row at right
Heater unit installation location
- The heater unit (1) is installed at the front left
between the wheel well and the bumper. The
installation position is horizontal, lengthwise in the
driving direction.
2
1
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)
- Insulate wire section to wiring harness and tie back
- Cut open cable tie and discard entire fan relay (1)
together with blade fuse (2)
- Connect included purple (li) wire (3) to purple (li)
wire from wiring harness of digital timer (1) with
connector.
- Connect violet (li) wire (3) to connector of digital
timer (2).
Installing gateway control unit
- Connect wiring harness (2) to gateway control unit
(1) and route to left-hand side of vehicle.
- Glue wiring harness (2) onto control unit (1) with
socket (3).
- Fasten gateway control unit (1) with cable tie.
Only with Telestart
- If no AEM is installed, route AEMwiring harness and
connect in accordance with separate installation
instructions.
- Connect blue (bl) wire (2) from gateway wiring
harness with microtimer to Pin 3 of 50-pin connector
of AEM (1).
- Fasten AEM control unit with included bracket or
suitable means.
3
5
3
4
1 2
3
2
1
4
1
2
3
5
1
2
6
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 mm2wiring harness (branch)
to REM at rear left.
- Route wiring harness further under side trim to front,
along original vehicle wiring harness in left-hand
door sill into footwell on driver's side.
Gateway wiring harness up to 2004
model
- Unclip fuse box and fold forward
- Unlock secondary lock of fuse box
- Connect white (ws) wire with microtimer (2) to free
socket of fuse 16 (1) on back of fuse box
- Lock secondary lock of fuse box again and clip in
fuse box
- Fasten all wiring harnesses with cable ties
- Insert 5 ampere fuse in fuse slot 16
- Route green (gn) and green/white (gn/ws) wiring
harnesses (branch) through existing opening into
coolant reservoir
- Pull connector trim (2) off connector (3)
- Seal off cable pass through (grommet) (1) with butyl
tape, e.g. with following part numbers: 1161780,
1161783, 1161784.
- Cut off green/white (gn/ws) wire, Pin F13 (1) approx.
50 mm before connector
- Insulate green/white (gn/ws) wire end to wiring
harness and tie back
1
7
8
2
1
9
3
2
1
1
10
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 (7) from wiring harness of heater unit with
connector (crimp and shrink)
- Complete connector (6) with trim (5) and reconnect
Gateway wiring harness from to 2005
model
- Connect white (ws) wire (1) from gateway with
microtimer to Pin F from connector E of REM (lower
right socket, terminal 15).
- If Pin F is occupied (e.g. when a trailer towing device
is installed), then connect white (ws) wire (1) from
gateway to white (ws) 2.5 mm² wire from Pin F.
- Route green (gn) and green/white (gn/ws) wire from
gateway wiring harness through existing opening
from passenger compartment into coolant reservoir.
- Green (gn) wire will be routed to K3 relay later.
- Remove connector C (gray) (1) from CEM
- Pull compact housing (blue) (4) out of cover with
locking device (light blue)
- 36-pin connector C (gray) (3)
- Green/white (gn/ws) wire (2)
- Green (gn) wire (1)
11
6
54321
7
8
1
12
113
3
2
4
1
14
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 dia. hole in plastic trim and insert
protective rubber plug (3).
- Detach protective rubber plug (1).
- 10 mm dia. hole at Position (2). When drilling, watch
components located behind!
- Fasten fuse holder (2) with original vehicle stud bolt
and plastic nut (1).
- Fasten prepared K3 relay (7) on fuse holder (2) with
M5x16 bolt and flanged nut (3).
- Fasten retaining plate of fuse holder (5) on fuse
holder (2) with washer and flanged nut (4).
- Mount fuses F1 and F2 (6).
- Route wiring harness of digital timer (1) through
prepared protective rubber plugs into passenger
compartment.
- route green (gn) wire from gateway wiring harness
(2) along wiring harness of digital timer through
prepared protective rubber plugs to K3 relay and
connect to green /white (gn/ws) wire from heater
unit (3).
1
22 15
1
2
16
3
1
3
5
4
2
6
7
17
11
2
2
3
18
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)
- Routewiring harness of heater unit(1) alongoriginal
vehicle lines to left-hand headlight and further to
installation location of heater unit.
- Fasten wiring harness with cable ties.
1
2
19
1
2
20
4
3
1
21
Thermo Top C XC 90
10
Gateway wiring harness
X3
gr 0,5mm²
ws 0,5mm²
vi 0,5mm²
sw/ws 0,5mm²
gn/ws 0,5mm²
X5
B
A
X1
gn 0,5mm²
ge 0,5mm²
sw 0,5mm²
bl 0,5mm²
rt 0,75mm²
rt 0,75mm²
br 0,75mm²
X2
X4
B
A
C
A
C
B
D
A
C
B
D
an REM
(hinten links)
an Steckplatz vom Stecker AEM
(hinten rechts)
A
B
E
C
D
H
F
G
1
6
4
5
3
rt 0,5mm²
br 0,5mm²
vi 0,5mm²
rt 0,5mm²
gr 0,5mm²
br 0,5mm²
3
1
4
2
vi 0,5mm²
auf Leitung gn/ws vom
Stecker C Pin 32 aufschleifen
sw 0,5mm²
mit Leitung gn/ws vom Heizgerät
Stecker X1 Pin 4 verbinden
Stecker Thermo Call
(Option)
sw/ws 0,5mm²
12 4185
R 1kΩ
Stecker
Telestart Stecker
Vorwahluhr
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10
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