Water Heater

Water Heater

Water Heater

Water Heater Installation documentation Ident. No.: 1315902B_EN Fee Euro 10.00 © Webasto AG Opel Astra Diesel from Model Year 2010 Left-hand drive vehicle 6G manual gear Manual AC Not for automatic AC! Feel the drive 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. The initial startup is to be executed with the Webasto Thermo Test Diagnosis. Webasto does not accept any liability for defects and damage that are attributable to installation by untrained staff.

Thermo Top Evo Parking Heater e1 00 0258

Water Heater

Opel Astra 1315902B_EN 2 Table of Contents Validity Vehicle and engine types, equipment variants and national specifications not listed in this installation documentation have not been tested. However, installation according to this installation documentation may be possible. The installation location of the digital timer must be coordinated with the end-customer before the installation! Manufacturer Model Type EG-BE No./ABE Opel Astra P-J e1 * 2007 / 46 * 0141 . . Engine type Engine model Output in kW Displacement in cm³ A17DTR Diesel 92 1686 Validity 2 Heater / Installation Kit 3 Foreword 3 General Instructions 3 Special Tool 3 Explanatory Notes on Document 4 Preliminary Work 5 Heater installation location 5 Preparing electrical system 6 Electrical system 7 Fan controller 9 Digital timer 12 Remote option (Telestart) 12 Preparing installation location 13 Preparing heater 15 Installing heater 16 Fuel 17 Combustion air 20 Coolant circulation 21 Exhaust gas 25 Final Work 28 Template for bracket 29 Operating Instructions for End Customer 30

Water Heater

Opel Astra 1315902B_EN 3 Heater / Installation Kit Foreword This installation documentation is valid for Opel Astra Diesel vehicles with manual air-conditioning system - For the validity, see page 2 - from model year 2010 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 this installation documentation. However, where this is the case the stipulations in this "installation documentation" 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. 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 must be provided with rub protection (cut-open fuel hose)! Spray unfinished body areas, e.g. drilled holes, with anti-corrosion wax (Tectyl 100K, Order No. 111329). While installing an IPCU, the corresponding settings must be checked or adjusted before the installation!

Special Tool - Torque wrench for 2.0 - 10 Nm - Hose clamping pliers - Metric thread-setter kit Quantity Description Order No.: 1 Thermo Top Evo basic retail accessories See price list 1 Installation kit of Opel Astra 2010 Diesel manual air-conditioning 1315903B 1 Heater control See price list

Water Heater

Opel Astra 1315902B_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 5x13 heater bolts = 8Nm! Tightening torque of 5x15 bolt of water connection piece retaining plate = 7Nm! Mechanical system Electrical system Coolant circuit Fuel Exhaust gas Combustion air Software 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.

Water Heater

Opel Astra 1315902B_EN 5 Preliminary Work WARNING! - Open the fuel tank cap and vent the fuel tank. - Close the tank cap again. - 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. - Completely remove the battery - Remove the air filter box - Remove the coolant reservoir cap. - Remove the lubricant reservoir - Disconnect the coolant expansion tank and lay it aside. - Remove the front right underride protection - Remove the footwell trim on the driver's side.

Remove the lower instrument panel trim on the driver's side. - Remove the glove compartment.

Remove the A-pillar trim on the driver's side - Remove the control panel of the central console - Remove monitor screen - Remove radio / CD-changer - Remove the A/C control unit in accordance with the manufacturer's instructions. Remove page 30 "Operating Instructions for End Customer" and insert with vehicle operating instructions. Heater installation location 1 Heater Installation location 1 1

Water Heater

Opel Astra 1315902B_EN 6 Preparing electrical system 1 K1 relay 2 IPCU base 3 Wiring harness of fuse holder 4 Fuse holder 5 F3 1A fuse 6 K2 relay Preparing fuseholder of passenger compartment Remove green/black (gn/ws) wire 1 from slot 2 and insert it in the IPCU/86 base! Preparing IPCU IPCU view, from contact side! The pre-programmed settings must be checked during function control, and adjusted if necessary! Duty cycle: 70% Frequency: 100Hz Voltage: 11V Function: Low-side Preparing IPCU Fasten angle bracket 2 and brown (br) ground wire from K3.2 3 to original vehicle nut at original vehicle ground point! Produce connections as shown in wiring diagram.

1 M5x16 bolt, large diameter washer Installing angle bracket 86 85 A E 15 IPCU A 15 86 85 E sw br 1 gn/ws 2 1 3 2

Water Heater

Opel Astra 1315902B_EN 7 Electrical system Ground wire 1 Ground wire at original vehicle ground support point Positive wire 1 Positive wire Wiring harness installation diagram Engine compartment fuse holder Fasten wiring harness of fuse holder 2 with cable tie. Ensure adequate distance from Fuses F1 and F2 1, because the battery carrier is installed later. For routing, see next page! Passenger compartment fuse holder 1 Large diameter washer, M5 flanged nut 2 Fuse holder 3 1 4 1 Do not install the metering pump cable harness until later together with fuel pipe along the original vehicle fuel lines on the underbody 5 1 2 approx.150 6 1 2

Water Heater

Opel Astra 1315902B_EN 8 4. Routing wiring harness of heater 1 Wiring harness of heater unit to A/C line 3. Routing wiring harness of heater 1 Wiring harness of heater unit to brake lines Wiring harness installation diagram 1. Routing wiring harness of fuse holder 1 Wiring harness of heater unit to original vehicle wiring harness of electrical steering 2 Wiring harness of engine compartment fuse holder 2. Wiring harness pass through 1 Protective rubber plug 2 Wiring harness of heater control 3 Wiring harness of passenger compartment fuse holder Do not install the metering pump cable harness until later together with fuel pipe along the original vehicle fuel lines on the underbody 9 1 2 2 10 1 2 3

Water Heater

Opel Astra 1315902B_EN 9 Fan controller Wiring diagram for manual air conditioning Webasto components Vehicle components Colours and symbols Legends HG TT-Evo heater GE Fan unit rt red X1 6-pin heater connector KS A/C control unit ws white X2 2-pin heater connector J2 20-pin connector brown (br) sw black X10 4-pin connector Heater control F Fuses br brown gn green K1 Fan relay bl blue K2 Additional relay vi violet F1 Fuse 20A bl blue F2 Fuse 30A or orange F3 Fuse 1A IPCU settings: Duty cycle: 70% Frequency: 100Hz Voltage: 11V X Cutting point Function: Low-side Wiring colours may vary. Webasto 31 30 15 Opel HG X2 1 2 X1 5 2 F2 F1 br gn/ws 0,75² ge 0,5² rt/sw 0,5² rt 4² br 0,5² X10 gn/ws 0,75² br 0,5² rt 4² rt/sw 0,5² F3 86 85 30 87a 87 K1 86 85 30 87a 87 K2 sw sw br bl bl 3 GE M KS J2 15 9 bl/ ws bl/ ws rt vi/ gn vi/ gn 1 or/ gn F 1 F or/ gn 85 A E 86 IPCU br 0,5²

Water Heater

Opel Astra 1315902B_EN 10 Install battery carrier 3. 1 Mount M5x16 bolt, large diameter washer [2x], retaining plate of fuse holder, flanged nut, existing hole 2 F1, F2 fuses mounted Fastening fuse holder Connection add-on wiring harness 2 with wiring harness of fuse holder 1 according to circuit diagram, such that same-colour wires are connected! Connecting heater unit wiring harness Connection to 20-pin, brown (br) J2 connector 5 from the air conditioning control panel. Produce connections as shown in wiring diagram.

1 Orange/green wire (or/gn) of Terminal 30 2 Blue (bl) wire K2/87 3 Blue (bl) wire K2/30 4 Orange/green (or/gn) wire of 20-pin brown (br) connector Pin 1 Connecting K2 relay Connection to 20-pin, brown (br) J2 connector 4 from the air conditioning control panel.

Detach connector of black (sw) wire 2. Produce connections as shown in wiring diagram. 1 Blue/white wire of 6-pin connector GE Pin 3 2 Black (sw) wire of K1/30 3 Blue/white wire of 20-pin brown (br) connector Pin 15 Connecting K1 relay 11 3 1 2 12 2 1 13 14 4 2 1 3

Opel Astra 1315902B_EN 11 Connection to 20-pin, brown (br) J2 connector 2 from the air conditioning control panel. Produce connections as shown in wiring diagram. 1 Violet/green wire (vi/gn) wire of Terminal 15 3 Violet/green (vi/gn) wire of 20-pin brown (br) connector Pin 9 4 Red (rt) wire from K1/86 Connecting K1 relay 15 1 2 3 4

Opel Astra 1315902B_EN 12 Digital timer 1 Digital timer Installing digital timer Remote option (Telestart) Fasten receiver 1 with adhesive tape. Installing receiver 1 Antenna Installing antenna Installing T100 HTM temperature sensor Fasten temperature sensor 1 with adhesive tape.

Installing temperature sensor 16 1 1 17 1 18 1 19

Opel Astra 1315902B_EN 13 Preparing installation location Pull out connector 1 from fan controller. Press tab 2 downwards, and turn fan motor 3 to the right. Removing fan motor Cut out insulation 1 and discard! Cutting out insulation Cut out insulation in the area of the holes and discard. 1 7 mm dia. hole [2x] Holes in firewall Cut out insulation in the area of the holes 1. Provide holes with corrosion protection. Cutting out insulation of engine compartment 20 1 2 3 21 1 50 50 50 22 1 1 30 40 30 23 1 1 40 40 40 40

1315902B_EN 14 Opel Astra Angle down tab 1 by 90° on the strut mounting.

Angling down tab 1 M6x55 bolt, large diameter washer [2x each] Inserting bolt 1 40mm ship, pin lock [2x each] Sliding shim on Prepare holder according to template. Mount bracket 4 on bolt and place on upper edge 2. Make markings 3 on the insulation at the left and right of the bracket! 1 Copy hole pattern [2x] Copying hole pattern 24 1 25 1 1 26 1 1 27 3

1315902B_EN 15 Opel Astra Cut out insulation in the area of the holes 1 up to the markings at the left and right. Provide holes with corrosion protection. 1 7 mm dia. hole [2x] Holes in the coolant reservoir Preparing heater 1 Coolant connecting piece, sealing ring [2x each] 2 5x15 self-tapping bolt, retaining plate of coolant connecting pieces Installing coolant connecting pieces 1 90° moulded hose, 10 mm dia. clamp [2x] 2 Fuel line 3 Mount wiring harness of circulating pump 4 Combustion air pipe, 25 mm dia. spring clip Preparing heater unit 1 5x13 self-tapping bolt [3x] 2 Bracket Installing bracket 28 1 1 10 29 1 1 2 4 30 1 2 3 2 31 1 1 1

1315902B_EN 16 Opel Astra Installing heater Connect wiring harness on heater. 1 Flanged nut [2x] Installing heater 1 M6x12 bolt, flanged nut [2x each] Installing heater 32 1 1 33 1 1

Opel Astra 1315902B_EN 17 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.

Slide corrugated tube 1 over the fuel line and wiring harness of the metering pump and route together to the original vehicle lines on the underbody. Installing lines Route wiring harness of metering pump and fuel line in corrugated tube 1 along original vehicle lines to installation location of metering pump. Installing lines Angle down perforated bracket 1 and drill at position 2 to 8.5mm dia.! Preparing perforated bracket 34 1 1 35 1 1 36 1 2 47 100°

Opel Astra 1315902B_EN 18 1 Perforated bracket 2 Cable tie 3 Mounting of metering pump 4 Metering pump 5 M6x25 bolt, flanged nut Premounting metering pump Figure depicts vehicle with electric hand brake! 1 M8x20 bolt, spring lockwasher, existing threaded hole (in vehicles without electrical handbrakes, use the original vehicle bolt, bracket of the hand brake rope!) 2 Perforated bracket Installing metering pump Cut out the fuel return line 2 along the marking! 1 Cutting point Removing fuel Diameter of the fuel return line depends on the equipment.

Variant 1 da = 8mm 1 9mm dia. Caillau clamp [2x] 2 6x5x6 fuel standpipe Variant 2 da = 10mm 1 10 mm dia. Caillau clamp [2x] 2 8x5x8 fuel standpipe Mounting fuel standpipe 37 38 1 2 39 1 2 40 2 1 1

Opel Astra 1315902B_EN 19 180° moulded hose 3 shortened by 15mm at short leg! 1 10 mm Caillau clamp [2x] 2 Fuel line Connecting fuel line Check the position of the components; adjust if necessary. Check that they have free clearance. 1 Fuel line fuel standpipe 2 Wiring harness of metering pump, connector mounted 3 180° moulded hose, 10 mm dia. Caillau clamp [2x] 4 Hose section, 10 mm dia.

Caillau clamp [2x] 5 Fuel line of heater Connecting metering pump 41 1 2 1 3 42 2 3 4 5 1

Opel Astra 1315902B_EN 20 Combustion air 1 Combustion air pipe 2 5x13 self-tapping bolt 3 51 mm dia. clamp 4 Muffler Installing muffler 43 2 3 1 4

Opel Astra 1315902B_EN 21 Coolant circulation WARNING! Any coolant running off should be collected using an appropriate container! Route 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 installation diagram All spring clips without a specific designation = 25 mm dia.

Hose clamp = 20-27 mm dia.! 1= Circulating pump All connecting pipes without a specific designation and = dia. 18x18! 18x20 Ø 27 1

Opel Astra 1315902B_EN 22 Remove hose section of heat exchanger inlet 1. . 2 Engine outlet hose section Cutting point Remove hose section. Cut out ring 2 carefully. Do not damage the coupling, it will be reused. Discard ring 2 and 90° elbow 3. 1 Coupling of heat exchanger inlet Preparing connection of heat exchanger inlet Discard section X. Hose A-F = 18mm dia. moulded hose Hose B = 90° elbow. Hose G = 180°, 20mm dia. moulded hose A = 60 C = 290 D = 90 E = 100 F = 300 Cutting hoses to length Premounting hoses 44 2 1 45 B

Opel Astra 1315902B_EN 23 1 Coupling of heat exchanger inlet Connecting heat exchanger inlet Connecting heater outlet Angle down perforated bracket 1 and drill at position 2 to 8.5mm dia.

Preparing perforated bracket 1 Mounting of circulating pump 2 Circulating pump 3 Perforated bracket 4 M6x25 bolt, flanged nut Premounting circulating pump 46 G 1 F 47 F E 90° 90° 40 22 2 1 48 3 2 1 4

Opel Astra 1315902B_EN 24 1 Perforated bracket 2 Original vehicle stud bolt, M8 flanged nut Installing circulating pump 1 Hose of engine outlet Connecting circulating pump Connecting heater inlet Slide wiring harness of the circulating pump 2 on the circulating pump. Align hoses. Ensure sufficient distance from adjacent components; correct if necessary. 1 Cable tie Routing wiring harness of circulating pump 49 2 1 2 1 50 A 1 B C 51 D C 52 2 1

Opel Astra 1315902B_EN 25 Exhaust gas Discard section X. 1 Exhaust pipe a = 450 2 Exhaust end section b = 280 Preparing exhaust pipe 1 Rivet nut, existing hole Installing rivet nut 1 Rivet nut, existing hole Installing rivet nut Cut away insulation at the marking, if available! 1 Remove and discard section Cutting out insulation 53 1 54 1 1 55

Opel Astra 1315902B_EN 26 Angle down perforated bracket 1 by 90° Preparing perforated bracket 1 Muffler 2 Perforated bracket 3 M6x12 bolt, flanged nut Preassembling muffler Insert two plain washers between perforated bracket 2 and frame side member. 1 M6x20 bolt, spring lockwasher, plain washer [2x] Installing muffler 1 Hose clamp 2 Exhaust pipe Installing exhaust pipe 32 44 1 1 2 3 56 2 57 1 1 2 58

Opel Astra 1315902B_EN 27 1 M6x20 bolt, spring lockwasher, large diameter washer 2 Angle bracket 3 Exhaust pipe 4 M6x20 bolt, p-clamp, flanged nut Installing exhaust pipe 1 Hose clamp 2 Exhaust pipe Installing exhaust pipe Remove retaining clip from original vehicle wiring harness 3 at position 2 and install at position 5 in the existing hole! 1 Perforated bracket 2 M6x12 bolt, flanged nut 4 M6x20 bolt, p-clamp, flanged nut 6 Exhaust end section Installing exhaust end section 60 mm dia.

hole in underride protection 1 at position 2. Cut out insulation (if available) in the area of the hole.

Ensure sufficient distance from adjacent components; correct if necessary! 1 Underride protection installed 2 Exhaust end section Aligning exhaust end section 59 3 1 2 4 60 61 5 3 1 2 62

Opel Astra Printed in Germany 02/2011 Printing: Steffen 28 1315902B_EN Feel the drive Webasto AG Postfach 80 D-82132 Stockdorf / Germany National Hotline: 01805 93 22 78 (14 Cent aus dem deutschen Festnetz) Hotfax: 0395 5592 353 Hotmail: hotline@webasto.de http://www.webasto.de Final Work WARNING! Mount removed parts in reverse order. Check all hoses, clamps and all electrical connections for firm seating.

Insulate and tie back all loose wires. Only use manufacturer-approved coolant. Spray heater components with anti-corrosion wax (Tectyl 100K, Order No. 111329).

Connect the battery. - Fill and bleed the coolant circuit according to the vehicle manufacturer’s specifications. - Set the digital timer, try out Telestart transmitter - Make settings on A/C control panel according to the "Operating Instructions for End Customer". - Place the "Switch off parking heater before refuelling" signboard in the area of the filler neck - For initial start-up and function check, see installation instructions

Opel Astra 1315902B_EN 29 Template for bracket 0 100mm 100mm 55 Ø 6,5 Ø 6,5 5 15 15 Scale 1:1 Compare the size of the printed version with dimension lines.

Permitted tolerance a maximum of 2%. Set the printer settings to “no margin” or “minimise margins” and 100% of the normal size.

Opel Astra 1315902B_EN 30 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. 20 min. (in one direction), we recommend not exceeding a switch-on time of 20 min. In vehicles with passenger compartment monitoring it must be deactivated in addition to the vehicle settings for the heating operation . For information on deactivation, please see the vehicle owner's manual. Before parking the vehicle, make the following settings: 1 Air outlet upward 2 Set temperature to "max." Manual air conditioning 63 2 1