Subaru Legacy / Outback 2.0 Boxer Diesel

Water Heater
Feel the drive
e1
Thermo Top E Parking Heater
00 0003
e1
Thermo Top C Parking Heater
00 0002
Installation instructions
Subaru Legacy / Outback 2.0 Boxer Diesel
from Model Year 2010
Left-hand drive vehicle
Automatic air-conditioning
Gear box
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.
Webasto does not accept any liability for defects and damage that are attributable to installation by untrained staff.
Ident. No.: 1315486A_EN
Fee Euro 10.00
© Webasto AG
Subaru Legacy / Outback 2.0 Boxer Diesel
Table of Contents
Validity
Heater/Installation Kit
Foreword
General Instructions
Special Tools
Explanatory Notes on Document
Preliminary Work
Heater installation location
Preparing electrical system
Electrical system
Fan controller
Remote option (Telestart)
2
3
3
3
3
4
5
5
6
7
8
10
Preparing installation location
Preparing bracket
Preparing heater
Installing heater
Fuel
Combustion air
Coolant circuit
Exhaust gas
Final Work
Template for Fuel Standpipe
Operating Instructions for End Customer
11
12
12
12
14
17
18
21
22
23
24
Validity
Manufacturer
SUBARU
SUBARU
Model
Legacy / Outback
Legacy / Outback
Type
BM /BR
BM /BRS
EG-BE No./ABE
e1 * 2007 / 46 * 0079 * ...
e13 * 2007 / 46 * 1074 * ...
Engine type
EE20
Engine model
Boxer Diesel
Output in kW
110
Displacement in cm³
1998
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 possible.
Optional:
The installation location of a digital timer and summer/winter switch should be confirmed with the end
customer before installation.
1315486A_EN
2
Subaru Legacy / Outback 2.0 Boxer Diesel
Heater/Installation Kit
Quantity
1
1
1
Description
Retail accessories Thermo Top E / C
Installation kit for Subaru Legacy / Outback 2.0 Boxer Diesel
MY 2010
Heater control
Order No.:
See price list
1315487A
See price list
Heater recommended for the relevant vehicle class:
Vehicle
Compact car
Mid-size car, station wagon
Heater
Thermo Top E
Thermo Top C
The selection of the heater is based on the passenger compartment size of the vehicle and the level of
comfort required by the customer!
Foreword
These installation instructions apply to vehicles Subaru Legacy / Outback 2.0 Boxer Diesel - for 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 these installation instructions.
However, the stipulations in these "installation instructions" and "operating and maintenance instructions" 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
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Subaru Legacy / Outback 2.0 Boxer Diesel
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.
Mechanical system
Electrical system
Coolant circuit
Fuel
Exhaust gas
Combustion air
Software
Special features are highlighted using the following symbols:
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.
The arrow in the vehicle icon indicates the position on
the vehicle and the viewing angle.
All dimensions are in mm!
Tightening torque of hose clamps = 2.0 + 0.5 Nm!
Tightening torque of Ejot screws, Ejot studs = 10 Nm!
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Subaru Legacy / Outback 2.0 Boxer Diesel
Preliminary Work
WARNING!
-
Open fuel tank cap, ventilate tank.
Close the tank cap again.
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 years that do not apply from the duplicate label.
Attach the duplicate label (type label) in the appropriate place.
Remove intercooler on engine
Remove the engine cover
Remove underride protection at the left in front of the tank
Remove underride protection of gear
Remove left underbody trim
Remove rear bench seat
Open the tank-fitting service lid on the right and left.
Remove fuel-tank sending unit in accordance with manufacturer's instructions.
Remove the instrument panel trim on the driver's side.
Remove the instrument panel trim in the footwell on the front passenger side
Remove the lateral trim of the instrument panel on the front passenger side (for Telestart only)
Remove page 24 "Operating Instructions for End Customer" and add to the vehicle operating instructions.
Heater installation location
1 Heater
Installation location
1
1
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Subaru Legacy / Outback 2.0 Boxer Diesel
1
Preparing electrical system
2
Replace 25 A fuse F3 with 10A fuse.
4
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3
1 Angle bracket
2 M6x16 bolt, large diameter washer [2x] retaining plate for fuse holder, flanged nut
3 F1-3 fuses mounted
4 K3 relay
Pre-installing fuse
holder
6
Subaru Legacy / Outback 2.0 Boxer Diesel
Electrical system
Positive and ground connection
Digital timer and summer/winter switch option
1 Positive wire on positive battery terminal
2 Ground wire on ground support point
1 Digital timer
2 12 mm dia. hole, summer/winter switch
1
1
2
2
2
3
Do not install the metering pump
cable harness until later together
with fuel pipe along the original
vehicle fuel lines on the underbody
Wiring harness installation
routing
1
4
2
1
5
Fuse holder, K3 relay
Wiring harness pass through
1 M6x20 bolt, spring lockwasher, large diameter
washer in existing threaded hole
Detach original vehicle wiring harness 2 and put
it away.
1 Protective rubber plug
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Subaru Legacy / Outback 2.0 Boxer Diesel
Fan controller
Webasto
Subaru
30
15
F12
F31
F22
X1
A1
FB 24
A3
FB 38
F5
F4
HG
Wiring diagram
F3
4
A8
FB 31
rt
4²
F1
MB 4
ZE
ge/rt
gn/rt
0,5²
gn/or
0,5²
0,5²
86
87 87a
85
30
ge
K3
GRr
2
sw
sw
GRs
4²
sw/
ws
1
4
i183
GM
sw/rt
M
-
+
bl
3
sw/
ge
5
4
sw
5
1
0,75²
vi/ge
bl/ge
D1
sw
bl
gn/ws
ge/rt
0,5²
gn/rt
0,5²
i80
2
3
20
8
9
i181
A/C-V
31
Webasto components
HG
Heater TT-C/E
X1
6-pin heater connector
F3
Replace 25 A fuse with
10A fuse
K3
Fan relay
D1
Diode group
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Vehicle components
Colours and symbols
F31
Fuse, 7.5 A
rt
red
F22
Fuse, 15A
ws
white
F12
Fuse, 15A
sw
black
F4
Fan fuse
br
brown
F5
Fan fuse
gn
green
ZE
Central electrical box
bl
blue
A8
Connector A (i5) PIN 8 ZE ge
yellow
A1
Connector A (i5) PIN 1 ZE vi
violet
A3
Connector A (i5) PIN 3 ZE or
orange
GRs
Fan relay
GRr
Fan controller
i183
5-pin connector, GRr
GM
Fan motor
Insulate wire ends and
tie back
A/C-V A/C booster
i80
26-pin connector A/C-V X
Cutting point
i181
24-pin connector A/C-V
Wiring colours may vary.
Legends
8
Subaru Legacy / Outback 2.0 Boxer Diesel
Connection on 20-pin connector A (i5) 1 of
central electrical box.
Produce connections as shown in wiring diagram.
1
6
2
5
4
2 Green/orange (gn/or) wire of
connector A(i5), Pin 3
3 Additional black (sw) wire of A/C booster
4 Red (rt) wire from K3/87a
5 Black (sw) wire from K3/30
6 Green/orange (gn/or) wire of fan relay
Pin 2
Connection to central
electrical
box
6
3
Connector A (i5) contact side
1
1 Green/orange (gn/or) wire of Pin 3
1
2
3
4
10
11
12
13
14
15
5
6
7
8
9
16
17
18
19
20
Connector
A (i5)
7
Connection on 26-pin connector A (i80) 2
from A/C booster. Watch direction of flow of
diode group D1 6.
Produce connections as shown in wiring diagram.
1
2
3
6
5
4
1 Green/orange (gn/or) wire of connector
A(i80), Pin 2
3 Green/red (gn/rt) wire of connector A(i80),
Pin 3
4 Blue (bl) wire of diode group D1
5 Black (sw) wire of diode group D1
Connecting to A/C
booster
8
Produce connections as shown in wiring diagram.
1
6
5
4
2
3
1315486A_EN
1 Green/red (gn/rt) wire of fuse F12.
2 Black (sw) wire of diode group D1
3 White/black (ws/sw) wire of diode
group D1
4 Additional black (sw) wire from K3/30
5 Blue (bl) wire of diode group D1
6 Yellow/red (ge/rt) wire of fuse F31.
Connecting to A/C
booster
9
9
Subaru Legacy / Outback 2.0 Boxer Diesel
1
Connector A (i80) contact side
2
1 Green/red (gn/rt) wire of Pin 2
2 Yellow/red (ge/rt) wire of Pin 3
1
2
3
7
8
9
10
18
19
20
21
11
4
12
5
Connector
A (i80)
6
13
14
15
16
17
22
23
24
25
26
10
Remote option (Telestart)
1
Fasten receiver 1 with adhesive tape.
Installing
receiver
11
1 Antenna
1
Installing
antenna
12
Temperature sensor HTM100
1
Fasten temperature sensor 1 with adhesive
tape.
Installing
temperature sensor
13
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Subaru Legacy / Outback 2.0 Boxer Diesel
Preparing installation location
1
Cut out insulation mat 1, remove and discard
with clip.
Preparing
installation location
14
Drill out existing hole at position 1 to 9.1 mm
dia. and mount rivet nut.
2 Rivet nut, existing hole
Installing
rivet nut
1
15
2
Remove original vehicle bolt at position 1 and
discard.
Removing
bolt
16
1
Install retaining plate 3 loosely. Place bolts at
position 1, 2 and 5. Copy hole pattern to position 4, dismantle retaining plate 3, drill 9.1mm
dia. hole and install rivet nut.
1
5
2
1 M6x30 bolt
2 M6x20 bolt
5 M6x40 bolt, existing threaded hole
Installing
rivet nut
3
4
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Subaru Legacy / Outback 2.0 Boxer Diesel
1
2
Preparing bracket
1
1 M6x12 bolt, flanged nut [4x each]
2 Bracket
3 Retaining plate
Preparing
bracket
1
1
18
3
Insert 5 mm shim at position 1 and 20 mm
shim at position 4 between retaining plate 3
and large diameter washer.
1
2
4
3
1
1 M6x30 bolt, spring lockwasher, large diameter washer, 5 mm shim
2 M6x20 bolt, spring lockwasher
3 M6x20 bolt, spring lockwasher, large diameter washer
4 M6x40 bolt, spring lockwasher, large diameter washer, 20 mm shim, existing threaded hole
19
Preparing heater
2
1
2
3
4
5
5
4
4
Combustion air pipe
27 mm dia. clamp
Hose section, 10 mm dia. clamp [2x]
Fabric fuel hose [2x]
Fuel line
Preassembling heater
20
3
1
Installing
bracket
Installing heater
2
Mount the wiring harness on the heater before installation.
1 Ejot screw, washer [2x]
2 Ejot screw [2x]
2
1315486A_EN
Installing
heater
21
12
Subaru Legacy / Outback 2.0 Boxer Diesel
1 Ejot screw
Installing
heater
1
22
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Subaru Legacy / Outback 2.0 Boxer Diesel
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.
Route wiring harness of heater and fuel
pipe 1 to original vehicle wiring harness on
the left side of vehicle.
1
Installing
lines
23
1
Divide corrugated tube at the centre. Route
fuel line and wiring harness of metering pump
in corrugated tube 1 of underbody
1
Installing
lines
24
1
1
1
1
1
Route fuel line and wiring harness of metering pump to the installation location of metering pump
1
1 Pasting socket, cable tie [5x each]
Installing
lines
25
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Subaru Legacy / Outback 2.0 Boxer Diesel
1
Drill out perforated bracket 1 at position 5 to
8.5 mm dia. and install loosely
2
2 Silent block, flanged nut [2x]
3 Rubber-coated pipe clamp
4 Metering pump
5
3
Pre-installing metering pump
4
26
Align metering pump, tighten nut at
position 2.
1
1 M8x20 bolt, spring lockwasher, existing
threaded hole
3 Perforated bracket
2
Installing
metering
pump
27
3
1
2
1 Hose section, 10 mm dia. clamp [2x]
2 Fuel line
3 Wiring harness of metering pump, connector mounted
Connecting metering pump
3
28
Remove fuel-tank sending unit 1 in accordance with manufacturer's specifications. Lay
out large diameter washer da = 14.6 mm 2.
3 Copy hole pattern, 6 mm dia. hole
1
Removing
fuel
2
3
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15
Subaru Legacy / Outback 2.0 Boxer Diesel
Shape fuel standpipe 1 according to template, cut to length and install.
Installing
fuel standpipe
1
1
1
30
Install fuel-tank sending unit 1 in accordance
with manufacturer's instructions. Slide corrugated tube 5 onto fuel line 4 and route to the
left vehicle side.
1
2
2 Fuel standpipe
3 Hose section, 10 mm dia. clamp [2x]
3
5
4
Connecting fuel
line
31
Route fuel line in corrugated tube 1 to metering pump.
1
Installing
fuel line
32
Check the position of the components; adjust
if necessary. Check that they have free clearance.
1
1 Hose section, 10 mm dia. clamp [2x]
2 Fuel line
Connecting metering pump
2
33
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Subaru Legacy / Outback 2.0 Boxer Diesel
Combustion air
1
1 Combustion air pipe
Installing
combustion air
pipe
34
1
2
1
2
3
4
5
3
Original vehicle nut
Angle bracket
M6x20 bolt, flanged nut
Muffler
P-clamp
Installing
muffler
5
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4
35
17
Subaru Legacy / Outback 2.0 Boxer Diesel
Coolant circuit
WARNING!
Any coolant running off should be collected using an appropriate container. Install 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-routing diagram
B
1
A
1
All hose clamps
= 20-27 mm dia.!
1 = Black (sw) rubber isolator
.
All connecting pipes
= 15x20 dia..
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Subaru Legacy / Outback 2.0 Boxer Diesel
Discard section X
A =
B =
B
A
360
550
X
Cutting
coolant
hoses to
length
X
Remove hose section of heat exchanger
inlet 1. Spring clip will be reused. If necessary, adjust original vehicle spacer bracket 2
as shown.
1
3 Engine outlet hose section
4 Discard hose section
Cutting
point
2
4
36
3
Hose A with 90° elbow on heater outlet!
B
Connecting heater
A
37
1
1 Push on black (sw) rubber isolator
2 Hose of engine outlet
2
Connecting engine
outlet
A
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38
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Subaru Legacy / Outback 2.0 Boxer Diesel
Fasten black (sw) rubber isolator 1 with cable
tie 2 on bracket of brake line.
1
Routing in
engine
compartment
2
39
1
Slide black (sw) rubber isolator 1 onto hose B
and position on A/C line. Install hose of heat
exchanger inlet 3 with longer side on connecting piece of heat exchanger inlet. Ensure
sufficient distance to neighbouring components.
2
2 Original vehicle spring clip
Connecting heat
exchanger
inlet
3
B
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40
20
Subaru Legacy / Outback 2.0 Boxer Diesel
Exhaust gas
1
Angle down perforated bracket 1 and twist
mildly as shown
Preparing
perforated
bracket
15
1
25
41
1
2
Insert 30 mm shim between silencer 2 and
perforated bracket 4.
3
1
2
3
5
5
Hose clamp
Muffler
M6x40 bolt, 30 mm shim, flanged nut
Exhaust end section
Pre-installing silencer
4
42
1
1 Original vehicle nut
2 Perforated bracket
2
Installing
muffler
43
1 Combustion air pipe
2 Hose clamp
1
2
Installing
exhaust
pipe
2
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21
Subaru Legacy / Outback 2.0 Boxer Diesel
Final Work
WARNING!
Reassemble the disassembled components in reverse order.
Check all hoses, clamps and all electrical connections for firm seating.
Secure all loose cables using cable ties.
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.
Adjust digital timer / remote control
Make settings on A/C control panel according to the "Operating Instructions for End Customer".
Check the proper operation of the parking heater, see the operating instructions/installation instructions.
- Place the instruction plate "Switch off parking heater before refuelling" in the area of the filling neck
1 Transmission cover
2 Insert edge protection
1
Preparing
transmission cover
2
45
Install transmission cover 1. Ensure sufficient
distance to adjacent components (especially
to exhaust pipe); correct if necessary.
1
Installing
transmission cover
46
Feel the drive
Webasto AG
Postfach 80
D-82131 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
1315486A_EN
Printed in Germany
09/2010
Printing: Steffen
22
Subaru Legacy / Outback 2.0 Boxer Diesel
Template for Fuel Standpipe
100 mm
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.
100 mm
0
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Subaru Legacy / Outback 2.0 Boxer Diesel
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.
If the summer/winter switch option has been installed, this must be switched in accordance with the
time of year. The heater will then only switch on the vehicle fan to ventilate the vehicle interior in the
position Winter
heat and in the position Summer .
Before parking the vehicle, make the following settings:
2
1 Air outlet to windshield
2 Set temperature on both sides to "HI"
2
Automatic
air-conditioning
1
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