Water Heater
Feel the drive
e1
Thermo Top E Parking Heater
00 0003
e1
Thermo Top C Parking Heater
00 0002
Thermo Top P Parking Heater
00 0104
e1
Installation instructions
Nissan Pixo
1.0 Gasoline
from Model Year 2009
Left-hand drive vehicle
Manual air-conditioning system
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.
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.: 1315218A_EN
Fee Euro 10.00
© Webasto AG
Nissan Pixo
Table of Contents
Validity
Heater/Installation Kit
Foreword
General Instructions
Special Tools
Explanatory Notes on Document
Preliminary Work
Heater installation location
Electrical system
Fan controller
Digital timer, summer/winter switch option
Remote option (Telestart)
2
3
3
3
3
4
5
5
6
7
8
8
Preparing installation location
Installing heater
Coolant circuit
Fuel
Exhaust gas
Combustion air
Final Work
Template for Fuel Standpipe
Operating Instructions for End Customer
9
10
11
15
19
21
22
23
24
Validity
Manufacturer
Nissan
Model
Pixo
Type
HF
EG-BE No./ABE
e6 * 2001 / 116 * 0124 * ...
Engine type
K10B
Engine model
Gasoline
Output in kW
50
Displacement in cm³
996
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.
1315218A_EN
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Nissan Pixo
Heater/Installation Kit
Quantity
1
1
1
Description
Nissan-specific delivery scope Thermo Top E Gasoline
Installation kit for Nissan Pixo 2009 1.0 Gasoline
Heater control
Order No.:
See Nissan Price list
1315151A
See Nissan Price list
Heater recommended for the respective vehicle class:
Vehicle
Compact car
Mid-size car, station wagon
Full-size car, van, offroader
Heater
Thermo Top E
Thermo Top C
Thermo Top P
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 Nissan Pixo 1.0 Gasoline - for validity, see page 2 from model year 2009 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 E/C/P 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).
Special Tools
- Torque wrench for 2.0 - 10 Nm
- Hose clamping pliers
- Metric thread-setter kit
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Nissan Pixo
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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Nissan Pixo
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 battery
Remove the air filter together with the intake hose
Detach the wheel well trim on the right and left.
Remove bumper trim
Remove fuel-tank in accordance with manufacturer's instructions.
Remove the fuel-tank sending unit in accordance with the manufacturers specifications.
Remove footwell trim on the driver side
Remove page 24 "Operating Instructions for End Customer" and add to the vehicle operating instructions.
Heater installation location
1 Heater
Installation location
1
1315218A_EN
1
5
Nissan Pixo
Electrical system
Plus wire
Wiring harness pass through
1 Positive wire to positive battery terminal
1 Protective rubber plug
1
1
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
1
Wiring harness installation
diagram
2
3
5
4
4
1
5
Fuse holder, K3 relay
Ground wire
1 Mount M6x20 bolt, spring lockwasher, flanged
nut, existing hole
2 Angle bracket
3 M5x16 bolt, washers, fuse holder retaining
plate, flanged nut
4 K3 relay
5 F1-3 fuses mounted
1 Groundwire to original vehicle ground support
point
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Nissan Pixo
Fan controller
Webasto
Nissan
30
15
F3
HG
X1
Wiring diagram
F2
4
GR
rt
86
87
85
30
4²
sw/
ge
sw
sw/
ge
87a
K3
4²
KB
+
M
GM
-
31
Webasto components
HG
Heater TT-E/C/P
X1
6-pin heater connector
K3
Fan relay
F3
25A fuse
Vehicle components
GM
Fan motor
GR
Fan relay
KB
A/C control panel
F2
30A fuse
Colours and symbols
rt
red
ge
yellow
sw
black
Legend
X
Cutting point
Wiring colours may vary.
1
Connection to 2-pin connector 5 from fan motor.
Produce connections as shown in wiring diagram.
2
3
5
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4
1
2
3
4
Black / yellow (se/ge) wire to fan relay
Black (sw) wire from K3/30
Red (rt) wire from K3/87a
Black / yellow (se/ge) wire to connector
Connecting fan-motor
6
7
Nissan Pixo
Digital timer, summer/winter
switch option
1 12 mm dia. hole, summer/winter switch
2 Digital timer
Installing
digital timer
2
7
1
Remote option (Telestart)
1
Fasten receiver 1 with adhesive tape.
Installing
receiver
8
1 Antenna
Installing
antenna
1
9
Temperature sensor HTM100
1
Fasten temperature sensor 1 with adhesive
tape.
Installing
temperature sensor
10
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Nissan Pixo
Preparing installation location
1
Angle down perforated bracket 1 2x by 90°.
32
Angling
down perforated
bracket
53
11
1 Bracket
2 Perforated bracket, mount loosely
3 M6x12 bolt, flanged nut
Preassembling
bracket
1
3
2
12
Drill out existing hole to 9.1mm dia and tighten rivet nut!
Installing
rivet nut
1
13
1
Align bracket 2, mount loosely and copy hole
pattern to Position 1 [3x]!
2
3 M6x20 bolt
30
3
1
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1
Copying
hole pattern
14
9
Nissan Pixo
Remove bracket!
1
1 9.1 mm dia. hole; rivet nut [3x each]
2 Drill out hole to 9.1 mm dia, river nut
1
Installing
rivet nut
1
2
15
Insert one 15mm spacer nut each between
bracket and side member at Position 1 and 3,
and a large diameter washer at Position 3!
1
2
1
3
1 M6x35 bolt, spring lockwasher, 15mm
shim [2x each]
2 M6x20 bolt, spring lockwasher
3 M6x35 bolt, spring lockwasher, 15mm
spacer nut, large diameter washer
Installing
bracket
16
Installing heater
1
Connect wiring harness 1 on heater before installation.
2 Ejot screw [2x]
Installing
heater
2
2
17
1 48 mm dia. p-clamp
2 Ejot screw, mount loosely
1
Installing
heater
2
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10
Nissan Pixo
Coolant circuit
WARNING!
Any coolant running off should be collected using an appropriate container! Install hoses so that they
are kink-free. 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
circuit diagram
Ø 20x18
A
Ø 20x18
3
1
D
B
2
All connecting pipes without a specific designation
All hose clamps without a specific designation
25.5 mm
3 = Black (sw) rubber isolator
dia = 22mm
1315218A_EN
2
C
= dia. 20x20 mm. 1 = Original vehicle spring clip
.
dia =
= 20-27 mm dia 2 = Black (sw) rubber isolator
11
Nissan Pixo
Discard section X
Hose A = 180°, 18x18mm moulded hose
D
C
B = 635
C = 450
D = 100
B
X
Cutting
coolant
hoses to
length
X
X
A
Push braided protection hose onto hose B
and cut to length!
Cut heat shrink plastic tubing to length.
1
1 50 mm long heat shrink plastic tubing [2x]
A
Preparing
hoses A
and B
1
19
B
1
2
2
Push braided protection hose onto hose D
and cut to length!
Cut heat shrink plastic tubing to length.
1
1 50 mm long heat shrink plastic tubing [2x]
2 = Black (sw) rubber isolator [2x]
C
Preparing
hoses C
and D
20
D
Detach engine outlet/heat exchanger inlet
hose 1 on neck of engine outlet. Spring clip 2
will be reused.
Cutting
point
2
1
1315218A_EN
21
12
Nissan Pixo
A
Connecting engine
outlet
22
B
Routing in
engine
compartment
23
B
B
D
Connecting heater
C
24
D
Routing in
engine
compartment
D
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25
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Nissan Pixo
Slide black (sw) rubber isolator dia = 22 1
onto hose of heat exchanger inlet 3 and align
with air filter box.
2 Original vehicle spring clip
3
Connecting heat
exchanger
inlet
1
2
D
26
Ensure sufficient distance from neighbouring
components. Align black (sw) rubber
isolator 1 [2x] on expansion tank!
Aligning
rubber isolator
1
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1
D
27
14
Nissan Pixo
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 protective hose 1 onto fuel line 2
1
3 Hose section, 10 mm dia. clamp [2x]
Connecting heater
2
28
3
Detach corrugated tube 1. Route fuel line and
wiring harness of metering pump in corrugated tube 1 to firewall!
1
Installing
lines
29
Route fuel line and wiring harness of metering pump in corrugated tube 1 to original vehicle lines at the installation location of the
metering pump!
1
Installing
lines
1
30
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Nissan Pixo
1
Remove fuel-tank in accordance with manufacturer's instructions. Remove fuel-tank
sending unit 1 according to manufacturer's
specifications. Remove fuel pump, level indicator and charcoal filter connecting pieces.
Drill 6mm dia hole 2 at the centre of the circular elevation.
Pay attention to the components at the rear
when drilling!
2
Removing
fuel
31
Shape fuel standpipe 1 according to template, cut to length and install according to the
following figures.
1
Installing
fuel standpipe
1
32
1 Fuel standpipe
1
Installing
fuel standpipe
1
33
Complete the fuel tank sending unit. Check
the position of the components; adjust if necessary. Check that they have free clearance.
1
1 Fuel standpipe
Installing
fuel standpipe
1
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34
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Nissan Pixo
Ensure sufficient distance between fuel tank
standpipe 1 and connector 2.
2
Installing
fuel standpipe
1
35
1
Install fuel-tank sending unit 2 in accordance
with manufacturer's specifications.
2
1 Fuel standpipe
3 Hose section, 10 mm dia. clamp [2x]
4 Fuel line
4
3
36
4
1
1
2
3
4
2
Silent block, flanged nut
Metering pump
Hose section, 10 mm dia. clamp [2x]
Rubber-coated pipe clamp
Premounting metering pump
3
3
4
Connecting fuel
line
37
Remove fuel-tank in accordance with manufacturer's instructions.
1
1 Angle bracket
2 Original vehicle bolt, flanged nut
Installing
metering
pump
2
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17
Nissan Pixo
1 Flanged nut
1
Installing
metering
pump
39
1
Route fuel line from fuel tank standpipe 3 to
metering pump. Check the position of the
components; adjust if necessary. Check that
they have free clearance.
2
1 Wiring harness of metering pump, connector mounted
2 Fuel line of heater, 10mm dia clamp
4 10 mm dia. clamp
4
3
1315218A_EN
Connecting metering pump
40
18
Nissan Pixo
1
Exhaust gas
2
Discard section X
1 Exhaust pipe
a = 145
2 Exhaust end section
b = 145
a
Preparing
exhaust
pipe
b
X
1
1 42 mm dia. hole
2 Wheel well inner panel
2
Cutting out
wheel well
inner panel
41
Angle down perforated bracket1 by 90°.
80
Angling
down perforated
bracket
42
1
1
1 Exhaust muffler
2 M6x35 bolt, spring lockwasher, 20 mm
shim, flanged nut
3 Perforated bracket
4 M6x55 bolt, spring lockwasher, 40 mm
shim
2
Installing
muffler
3
4
1315218A_EN
43
19
Nissan Pixo
1
1 Hose clamp [3x]
2 Exhaust manifold
3 Exhaust pipe
2
1
Installing
exhaust
pipe
3
1
1
44
Slide red (rt) rubber isolator 1 and red (rt) rubber isolator with groove 3 on to exhaust end
section 4. Position red (rt) rubber isolator 1
along side member.
2
2 Hose clamp
Installing
exhaust
end section
4
3
1
45
Ensure sufficient distance to neighbouring
components.
Align exhaust end section 3 flush on red rubber isolator 1.
2
2 Wheel well inner panel
3
1315218A_EN
Mounting
rubber isolator
46
20
Nissan Pixo
Combustion air
1
Discard section X
1 Combustion air pipe
a = 220
Cutting
combustion air
pipe to
length
a
X
1
2
3
4
5
1
2
5
1315218A_EN
4
3
Combustion air pipe
27 mm dia. clamp
Muffler
Tighten Ejot screw
48 mm dia. p-clamp
Installing
muffler
47
21
Nissan Pixo
Final Work
WARNING!
Mount removed parts 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 the 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.
- Apply the sticker "Switch off parking heater before refilling" 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:
[email protected]
http://www.webasto.de
1315218A_EN
Printed in Germany
07/2010
Printing: Steffen
Nissan Pixo
Template for Fuel Standpipe
100mm
Top view
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.
100mm
0
1315218A_EN
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Nissan Pixo
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.
The passenger compartment monitoring is to be deactivated in vehicles equipped with anti-theft alarm
system.
Deactivation instructions can be taken from the operating instructions of the vehicle!
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:
1 Air outlet to windshield
2 Set temperature to "max."
3 Set fan to level "1“ or max. "2"
3
Manual air
conditioning
2
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48
24