Webasto | SUBARU Legacy | Subaru Legacy / Out- back 2.0 D Boxer Diesel Water Heater

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 D Boxer Diesel
Diesel
from Model Year 2008
Left-hand drive vehicle
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.: 1313691D_EN
Fee Euro 10.00
© Webasto AG
Subaru Legacy / Outback 2.0 D Boxer Diesel
Table of Contents
Validity
Heater/Installation Kit
Foreword
General Instructions
Special Tools
Explanatory Notes on the Document
Preliminary Work
Heater Installation Location
Electrical Connections
Fan controller
with Engine Start/Stop Push Button
Fan controller
without Engine Start/Stop Push Button
Remote Option (Telestart)
2
3
3
3
3
4
5
5
6
Preparing Installation Location
Preparing Heater
Installing Heater
Fuel Connection
Combustion Air
Water
Final Work
Template for Fuel Standpipe
Operating Instructions for End Customer
12
13
15
16
19
20
23
24
25
7
9
11
Validity
Manufacturer
SUBARU
SUBARU
Model
Legacy / Outback
Legacy / Outback
Type
BL / BP
BL / BPS
EG-BE No./ABE
e1 * 2001/116 * 0228 * ...
e1 * 2001/116 * 0256 * ...
Engine type
EE20
Engine model
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.
The installation location of a digital timer and summer/winter switch should be confirmed with the end
customer before installation.
1313691D_EN
2
Subaru Legacy / Outback 2.0 D Boxer Diesel
Heater/Installation Kit
Quantity
1
1
Description
Order No.:
Retail accessories with desired heater control
See price list
Installation kit Subaru Legacy / Outback / Forester / Impreza 1313756D
2.0 D Boxer Diesel
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 D Boxer Diesel - for validity, see page 2 - from model year 2008 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 the "installation instructions" and "operating and maintenance instructions"
for the Thermo Top C/P/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
1313691D_EN
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Subaru Legacy / Outback 2.0 D 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
Water
Fuel
Exhaust gas
Combustion air
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!
1313691D_EN
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Subaru Legacy / Outback 2.0 D 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 the rear bench seat.
Open the right-hand fuel sender service lid.
Remove the footwell trim on the driver's side.
Remove the lower instrument panel trim on the driver's side.
Remove the A-pillar trim in the footwell on the front passenger side.
Remove the lower B-pillar trim on the front passenger side.
Remove the door sill cover on the front passenger side.
Remove the right-hand fuel tank trim.
Please remove page 25 “Operating instructions for the end customer” and add this to the vehicle operating instructions.
Heater installation location
1
1 Heater
Installation location
1
1313691D_EN
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Subaru Legacy / Outback 2.0 D Boxer Diesel
Electrical Connections
Pass through of fuel line and wiring harness
of metering pump
Wiring harness pass through
1 Protective rubber plug
2 Original vehicle wiring harness
1 Protective rubber plug
1
1
2
2
3
Wiring harness installation
routing
bl
Do not install the metering-pump wiring harness
until later together with
the fuel line along the
original vehicle fuel lines
in the passenger com-
1
2
br
1
2
3
4
Fuse holder, K3 relay
Cut out insulation mat.
1 Fuse holder (replace F25A with 7.5 A)
2 Retaining plate of fuse holder, 4 mm dia. hole,
5.5x9.5 self-tapping screw
3 K3 relay, 4 mm dia. hole, 5.5x9.5 self-tapping
screw
1313691D_EN
5
Digital timer / Summer/winter switch option
1 Summer/winter switch, drilled hole 12 mm dia.
2 Digital timer
6
Subaru Legacy / Outback 2.0 D Boxer Diesel
Fan controller with engine
start/stop push button
1
1 Remove central electrical box, back
2 Socket of 10-pin connector
3 Socket of 24-pin connector
2
Disconnecting
connector
from central electrical box
6
3
1 10-pin connector, gray D (B152) disconnected
2 Yellow/red (ge/rt) wire from PIN 7
10-pin connector
1
2
7
1 24-pin connector white C (B52) disconnected
2 Green/orange (gn/or) from PIN 1
1
24-pin connector
8
2
Make connections as shown in the wiring diagram with the connectors provided.
1 24-pin connector white C (B52)
2 Diode group D1
3 10-pin connector, gray D (B152)
3
1
2
1313691D_EN
Connecting diode
group
9
7
Subaru Legacy / Outback 2.0 D Boxer Diesel
Webasto
Subaru
30
15
HG
F3
gn/ws
F28
F27
4
X1
Wiring Diagram with
Engine
Start/Stop
Push Button
F31
F22
D7
FB 29
C1
FB 46
rt/ws
rt
86
87 87a
F1
FB 8
!
ZE
gn/or
ge/rt
K3
85
br
30
sw
sw
sw
bl
D1
ws/sw
bl
gn/bl
gn/or
gn/or
gn/or
ge/rt
GRs
vi/ge
br
B87
gn/ws
2
M
GE
B86
2
3
11
5
12
32
2
21
B282
KB
bl/ge
sw
31
Webasto components
HG
Heater TT-C/E/P
X1
6-pin heater connector
F3
Replace 25 A fuse with
7.5 A fuse
K3
Fan relay
D1
Diode group
1313691D_EN
Vehicle components
F31
Fuse, 7.5 A
F22
Fuse, 15A
F27
Fuse, 15A
F28
Fuse, 15A
ZE
Central electrical box
C1
Connector C (B52) PIN 1
Connector D (B152) PIN 7
D7
KB
A/C control panel
B282 40-pin connector KB
GE
Fan unit
B87
2-pin connector of fan
motor
B86
5-pin connector of fan
controller
Colours and symbols
rt
red
ws
white
sw
black
br
brown
gn
green
bl
blue
ge
yellow
or
orange
vi
violet
Legends
Insulate wire end and tie
back
X
Cutting point
Wiring colours may vary.
8
Subaru Legacy / Outback 2.0 D Boxer Diesel
Fan controller without engine
start/stop push button
1
1 Remove central electrical box, back
2 Socket of 24-pin connector
Disconnecting
connector
from central electrical box
2
10
3
2
1 24-pin connector white C (B52) disconnected
2 Green/orange (gn/or) from PIN 1
1
24-pin connector
11
2
1
Make connections as shown in the wiring diagram with the connectors provided.
2
1 Black (sw) wire from K3/30
2 Diode group D1
3 24-pin connector white C (B52)
3
1313691D_EN
Connecting diode
group
12
9
Subaru Legacy / Outback 2.0 D Boxer Diesel
Webasto
Subaru
30
15
HG
F3
F27
4
X1
gn/ws
F28
F22
F1
C1
FB 46
Wiring Diagram without Engine
Start/Stop
Push Button
rt/ws
rt
86
87 87a
85
30
!
FB 8
K3
br
gn/bl
sw
ZE
gn/or
sw
D1
sw
ws/sw
gn/or
bl
gn/or
bl
gn/or
GRs
!
vi/ge
br
B87
gn/ws
2
M
GE
B86
2
3
5
11
12
32
21
B282
KB
bl/ge
sw
31
Webasto components
HG
Heater TT-C/E/P
X1
6-pin heater connector
F3
Replace 25 A fuse with
7.5 A fuse
K3
Fan relay
D1
Diode group
1313691D_EN
Vehicle components
Colours and symbols
F27
Fuse, 15A
rt
red
F28
Fuse, 15A
ws
white
F22
Fuse, 15A
sw
black
ZE
Central electrical box
br
brown
C1
Connector C (B52) PIN 1 gn
green
KB
A/C control panel
bl
blue
B282 40-pin connector KB
ge
yellow
GE
Fan unit
or
orange
B87
2-pin connector of fan mo- vi
violet
tor
B86
5-pin connector of fan
Insulate wire ends and
controller
tie back
X
Cutting point
Wiring colours may vary.
Legends
10
Subaru Legacy / Outback 2.0 D Boxer Diesel
Remote option (Telestart)
1
1 Receiver
2 Original vehicle bolt
3 Bracket, angle down 90°
Installing
receiver
3
2
13
1 Antenna
1
Installing
antenna
14
1313691D_EN
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Subaru Legacy / Outback 2.0 D Boxer Diesel
Preparing installation location
1
Cut insulation mat 2 at marking.
3
2
1 Discard section
3 Remove clip and discard
Cutting out
insulation
mat
15
1 7 mm dia. hole
65
Hole in
transmission
mounting
25
1
16
1 Drill out 9.1 mm dia. hole; install rivet nut
2 Rivet nut in existing hole
1
Installing
rivet nut
2
1313691D_EN
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Subaru Legacy / Outback 2.0 D Boxer Diesel
Preparing heater
Replace 193° cover of circulating pump with
axial cover.
Replacing
pump lid
1 Ejot stud
2 29 mm dia. clamp
3 Combustion air pipe
3
2
Preassembling heater
18
1
Insert three washers between heater and
bracket 1 at Position 2 and one washer at Position 4.
1
1
2
3
4
4
Bracket
Ejot screw, washer [3x]
M6x30 spacer nut
Ejot screw, washer
2
Preassembling
bracket on
heater
19
3
Shorten exhaust manifold 2 by 5 mm at marking.
1
1 Discard section
Shortening exhaust
manifold
5
2
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20
13
Subaru Legacy / Outback 2.0 D Boxer Diesel
1
1 Exhaust pipe
a = 240
2 Exhaust end section
b = 80
2
Discard section X
a
Preparing
exhaust
pipe
b
X
1
2
2
3
1
2
3
4
5
6
M6x16 bolt, spring lockwasher
Hose clamp [4x]
Exhaust manifold
Exhaust pipe
Exhaust muffler
Tail pipe
6
2
2
5
4
Preassembling exhaust
system
21
1 Hose section, 10 mm dia. clamp [2x]
2 Fuel line
2
Premounting fuel
hose on
heater
1
22
Twist perforated bracket 1 by approx. 45°.
1
Preparing
perforated
bracket
55
23
1313691D_EN
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Subaru Legacy / Outback 2.0 D Boxer Diesel
1
Installing heater
2
Insert 5 mm shim between bracket of heater
2 and body at Position 3.
1 M6x20 bolt, spring lockwasher, large diameter washer
3 M6x25 bolt, spring lockwasher, large diameter washer, 5 mm shim
3
Installing
heater
24
1 Edge protection 100
2 Mount wiring harness of heater
1
Installing
heater
25
2
1 Perforated bracket
2 M6x20 bolt, large diameter washer, flanged nut
3 Ejot screw
1
Installing
heater
3
2
26
1313691D_EN
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Subaru Legacy / Outback 2.0 D Boxer Diesel
Fuel Connection
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 fuel line along original vehicle lines in
passenger compartment to rear.
1
1 Wiring harness pass through
2 Fuel line
3 Metering pump wiring harness
2
Routing
lines in
passenger
compartment
3
27
Route fuel line under door sill cover to rear.
1
1 Metering pump wiring harness
2 Fuel line
Routing
lines in
passenger
compartment
2
28
1
1 Protective rubber plug
2 Metering pump wiring harness
3 Fuel line
2
Installing
lines to underbody
3
1313691D_EN
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16
Subaru Legacy / Outback 2.0 D Boxer Diesel
1
2
1 Metering pump
2 Fuel line
3 Metering pump wiring harness
3
Installation location of
metering
pump
30
1 Existing hole
1
Mounting
metering
pump
31
1
1 Metering pump
2 Rubber-coated pipe clamp
3 Silent block, flanged nut [2x]
2
Installing
metering
pump
32
3
1 Hose section, 10 mm dia. hose clamp [2x]
2 Wiring harness of metering pump, connector mounted
Connecting metering pump
1
2
1313691D_EN
33
17
Subaru Legacy / Outback 2.0 D Boxer Diesel
Remove and dismantle fuel-tank sending
unit 1 according to manufacturer's instructions.
1
2 Flanged nut
3 Copy hole pattern, 6 mm dia. hole
Removing
fuel
3
34
2
1
Shape fuel standpipe 1 according to template, cut to length and install.
1
Installing
fuel standpipe
1
35
1
Install fuel-tank sending unit 3 in accordance
with manufacturer's instructions.
2
1 Fuel line, hose section, 10 mm dia.
clamp [2x]
2 Fuel standpipe
3
Connecting fuel
line
36
Check the position of the components; adjust
if necessary. Check that they have free clearance.
2
1 Hose section, 10 mm dia. hose clamps [2x]
2 Fuel line
1
Connecting to metering
pump
37
1313691D_EN
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Subaru Legacy / Outback 2.0 D Boxer Diesel
Combustion air
1 Angle bracket
2 Existing stud bolt, original vehicle nut
Installing
angle
bracket
1
38
2
1 Cable tie [2x]
2 Muffler
3 Combustion air pipe
1
Installing
muffler
3
2
1
1313691D_EN
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19
Subaru Legacy / Outback 2.0 D Boxer Diesel
Water
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 coolant hose, the heater must be filled with coolant.
The connection should be "inline" based on the following diagram:
Coolant
routing diagram
B
1
A
All connecting pipes
= 15x20 dia. All hose clamps
1 = Black (sw) rubber isolator
.
1313691D_EN
= 20-27 mm dia.!
20
Subaru Legacy / Outback 2.0 D Boxer Diesel
a = 430
b = 490
Discard section X
A
B
X
Cutting
coolant
hoses to
length
X
X
Cut off hose on engine outlet/heat exchanger
inlet at markings.
1
1 Hose section of heat exchanger inlet
2 Engine outlet hose section
3 Discard hose section
3
40
2
1
Drill out angle bracket 2 to 8.5 mm dia. at position 1.
2
3
4
Cutting
point
1 Original vehicle bolt
3 M6x20 bolt, large diameter washer, flanged nut
4 29 mm dia. rubber-coated p-clamp
Installing
angle
bracket
41
Route hose B through rubber-coated pclamp 2.
1
1 Hose on heat exchanger inlet
Connecting heat
exchanger
inlet
2
1313691D_EN
B
42
21
Subaru Legacy / Outback 2.0 D Boxer Diesel
B
Connecting heater
outlet
43
Slide black (sw) rubber isolator 1 onto
hose A.
Connecting heater
inlet
1
44
A
1 Hose of engine outlet
1
Connecting engine
outlet
45
A
1 20x20 mm spacer bracket
2 Original vehicle spacer bracket
3 Lockable spacer bracket [2x]
1
Installing
spacer
bracket
3
3
1313691D_EN
2
46
22
Subaru Legacy / Outback 2.0 D 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.
Set the digital timer.
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
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
1313691D_EN
Printed in Germany
09/2010
Printing: Steffen
23
Subaru Legacy / Outback 2.0 D Boxer Diesel
Template for Fuel Standpipe
A
A
100 mm
Section A-A
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
1313691D_EN
24
Subaru Legacy / Outback 2.0 D 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
1 Air outlet to windshield
2 Set temperature on both sides to "max."
(29°C.)
3 Set fan to level "1", or possibly "2"
2
Two-zone
automatic
air-conditioning
3
1313691D_EN
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25
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