Webasto Thermo Top E Manual de usuario

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

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.

Water Heater Unit

Installation Instructions

Ident. No.:1313401A_EN Fee Euro 10.00 © Webasto AG

Fiat 500

Gasoline

from Model Year 2007

Left-hand drive vehicle

Feel the drive

Thermo Top E Additional Heater e1

00 0003

Thermo Top C

Additional Heater

00 0002

Fiat 500

1313401A_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.

Note:

When the vehicle is delivered, the fuel tank should only be half filled; drain off fuel if necessary.

Manufacturer Model Type EG-BE No./ABE

Fiat 500 150 e3 * 2001/116 * 0261 * ...

Engine type Engine model Output in kW Displacement in cm³

169A4000 Gasoline 51 1242

169A3000 Gasoline 74 1368

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 system 7

Fan controller for manual air conditioning 8

utomatic air-conditioning fan controller 9

Remote option (Telestart) 11

Preparing heater unit 12

Preparing installation location 12

Installing heater unit 13

Fuel 15

Coolant routing 18

Coolant on 1.2 liter 19

Coolant on 1.4 liter 21

Combustion air 24

Exhaust gas 25

1.2 liter engine 25

1.4 liter engine 26

Vehicle with underride protection 26

Final Work 27

Template for Perforated Bracket A 28

Template for Perforated Bracket B 28

Template for Perforated Bracket C 28

Template for Bracket 29

Operating Instructions for End Customer 30

Fiat 500

1313401A_EN 3

Heater Unit/Installation Kit

Optional heater control either:

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!

Foreword

TheseinstallationinstructionsapplytoFiat500Gasolinevehicles-forvalidity,seepage2-frommodel

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

necessary during installation with respect to these installation instructions.

However,thestipulations in the "installationinstructions"and"operating and maintenanceinstructions"

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 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

1 Installation kit for Fiat 500 Gasoline 1313387A

Quantity Description Order No.:

1 Telestart T80, T91, T100 HTM See price list

1 Thermo Call Comfort, Connect, Locate See price list

Vehicle Heater unit

Compact car Thermo Top E

Mid-size car, station wagon Thermo Top C

Fiat 500

1313401A_EN 4

Special features are highlighted using the following symbols:

The arrow in the vehicle icon indicates the position on

the vehicle and the viewing angle.

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.

All dimensions are in mm!

Tightening torque of hose clamps = 2.0 + 0.5 Nm!

Tightening torque of Ejot screws, Ejot studs = 10 Nm!

Mechanical system

Electrical system

Water

Fuel

Exhaust gas

Combustion air

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.

Fiat 500

1313401A_EN 5

Preliminary Work

WARNING!

- Open fuel tank cap, ventilate 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 together with the carrier.

- Remove the air intake hose (1.4 liter only).

- Detach and remove the right and left-hand wheel well trim.

- Remove the bumper.

- Remove the horn on the left.

- Detach the central electrical box in the engine compartment on the left.

- Remove the underride protection in the engine compartment (1.4 liter only).

- Remove the cover of the fuel line on the vehicle underbody.

- Detach the bracket of the fuel line/fuel tank ventilation on the right next to the fuel tank.

- Remove the storage compartment on the left next to the steering wheel.

- Remove the cover of the central electrical box in the footwell of the driver's side.

Remove page 30 "Operating Instructions for End Customer" and add to the vehicle operating

instructions.

Heater unit installation location

1Heater unit

Installation

location

Fiat 500

1313401A_EN 6

Preparing electrical system

Only with automatic air-conditioning

Cutting

wires to

length

Produce connections as shown in wiring

diagram. Install wire section 2in the

protective sleeving provided.

Preparing

fuse F4

250

2sw

O,75²

85 30

87a87

1 2

Fiat 500

1313401A_EN 7

Electrical system

Wiring harness pass through

1Protective rubber plug

Digital timer

1Digital timer

Wiring

harness

installation

diagram

Fuse holder, relay K3

Fuse F4 only with automatic air-conditioning

1Original vehicle stud bolt, plastic nut

2Angle bracket

3Retaining plate of fuse holder, M5x16 bolt,

washers, angle bracket, K3 relay, M5 nut

Summer/winter switch option

1Summer/winter switch, drilled hole 12 mm dia.

Do not install the metering

pump cable harness until

latertogetherwithfuelpipe

along the original vehicle

fuel lines on the underbody

31 2

Fiat 500

1313401A_EN 8

Fan controller for manual air conditioning

Wiring

diagram

Webasto components Vehicle components Colors and symbols

Legend

HG Heater unit TT-C/E M001 Body computer rt red

6-pin heater unit connector

B001 Central electrical box in

engine compartment ws white

F3 25 A fuse O030 Resistor group sw black

K3 Fan relay N085 Fan motor gr gray

T08 Fan relay

N086 Electr. thermostat

F51 Fuse, 7.5 A

F01 Fuse 60A

F06 Fuse 30A XCutting point

H080 Switch/A/C control panel Wiring colors may vary.

Connection on fan relay T08 of central

electrical box in engine compartment 4.

Produce connections as shown in wiring

diagram.

1Black (sw) wire from K3/30

2Gray/white (gr/ws) wire of fan motor N085,

Pin 1

3Gray/white (gr/ws) wire of connector B

from B001, Pin 63

5Red (rt) wire from K3/87a

Connec-

tion to fan

relay

Webasto

Fiat

85 30

87a87

HG X1

4M001

C24

F51

B001

T08

F01

B18 45 44 63

F06

4²

gr/ws

49 B

321

N086

N085

1 2

H080

234 5

O030

1 2 3 4

T°

Fiat 500

1313401A_EN 9

Automatic air-conditioning fan controller

Wiring

diagram

Webasto components Vehicle components Colors and symbols

Legend

HG Heater unit TT-C/E M001 Body computer rt red

X1 6-pin heater unit

connector B001 Central electrical box in

engine compartment ws white

K3 Fan relay M070 Air-conditioning control

panel sw black

F3 25 A fuse N085 Fan motor gr gray

F4 Fuse, 7.5 A T08 Fan relay gn green

F36 10 A fuse bl blue

F51 Fuse, 7.5 A

F01 Fuse 60A Insulate wire ends and

tie back

F06 Fuse 30A XCutting point

Wiring colors may vary.

Webasto

Fiat

85 30

87a87

HG X1

N085

1 2 4 3

M070

A2 1 8 7

bl/gn

sw sw

1 2

M001

C2924

F36

F51

B001

T08

F01

B18 45 44 63

F06

4²

gr/ws

Fiat 500

1313401A_EN 10

Connection on fan relay T08 of central

electrical box in engine compartment 4.

Produce connections as shown in wiring

diagram.

1Black (sw) wire from K3/30

2Gray/white (gr/ws) wire of fan motor N085,

Pin 4

3Gray/white (gr/ws) wire of connector B

from B001, Pin 63

5Red (rt) wire from K3/87a

Connec-

tion to fan

relay

Connectionon 32-pinof black (sw) connector

C 3from body computer M001.

Produce connections as shown in wiring

diagram.

1Black (sw) wire from F4

2Insulate blue/green (bl/gn) wire of

connector C, Pin 24 and tie back

4Blue/green(bl/gn)wireofA/Ccontrolpanel

M070 connector A, Pin 2

Connect-

ing A/C

control

panel

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