Thermo Top e PDF

Water Heater Unit
Feel the drive

e1
Thermo Top E Additional Heater 00 0003
e1
Thermo Top C Additional Heater 00 0002
e1
Thermo Top P Additional Heater 00 0104
Installation Instructions
Nissan Pathfinder and Navara

2.5 liter Diesel
from Model Year 2005
For left-hand drive vehicles only
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 equip-

ment 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 tech-
nical 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 warn-
ings.
Webasto does not accept any liability for defects and damage that are attributable to
installation by untrained staff.
Ident. No.: 1303637F_EN Fee Euro 10 © Webasto AG
Downloaded from www.Manualslib.com manuals search engine

Table of Contents
Validity 2 Preparing installation location 16
Heater Unit/Installation Kit 3 Premounting heater unit 17
Foreword 3 Installing Heater Unit 19
General Instructions 3 Coolant connection with manual transmission 20
Special Tools 3 Coolant connection for automatic transmission 24
Explanatory Notes on Document 4 Combustion air 28
Preliminary Work 5 Fuel Connection 29
Heater unit installation location 5 Exhaust system 31
Preparing electrical system 6 Final Work 34
Electrical Connections 7 Operating Instructions for End Customer 36
Remote option (Telestart) 8
Remote Option (Telestart) 8
Remote option (Thermo Call) 9
Fan controller for manual air conditioning 10
Automatic air-conditioning fan controller 12
Switch-off function of passenger compartment
monitoring 14
Validity
Manufacturer Model Type EG-BE No./ABE
Nissan Pathfinder R51 e9 * 2001/116 * 0051 * ...
Nissan Pathfinder R51 K492
Nissan Navara D40 L617
Engine type Engine model Output in kW Displacement in cm³

YD25 Diesel 128 2488
YD25 Diesel/DPF 126 2488
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.

Heater Unit/Installation Kit
Quantity Description Order No.:

1 Nissan-specific heater unit delivery scope See Nissan price list
1 Installation Kit for Nissan Pathfinder 2.5 liter Diesel 1303633C
1 Heater control See Nissan price list
Heater unit recommended for the respective vehicle class:
Vehicle Heater Unit

Compact car Thermo Top E
Mid-size car, station wagon Thermo Top C
Full-size car, van, offroader Thermo Top P
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
These installation instructions apply to Nissan Pathfinder and Navara vehicles with 2.5 liter Diesel
engines - for validity, see page 2 - from model year 2005 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 spec-
ified 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

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 work
Electrical system
Coolant connection
Fuel connection
Exhaust system
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 Webas-

i to 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.

Preliminary Work
WARNING!
- Copy the factory number from the original type label to the duplicate type label.
- Remove years that do not apply from duplicate label.
- Attach the duplicate label (type label) in the appropriate place.
- Open the fuel tank cap and vent the fuel tank.
- Close the tank cap again.
- Disconnect and remove the battery.
- Depressurize the cooling system!
- Remove the engine cover.
- Remove the intake hose between the intercooler and the engine.
- Detach the fuel filter.
- Remove the right front wheel.
- Remove the right-hand wheel well trim.
- Remove the underride protection.
- Remove the lower footwell trim on the front passenger side (not with automatic air-conditioning).
- Remove the A-pillar trim on the front passenger side (with passenger compartment monitoring)
- Remove front interior lighting and monitoring sensors (with passenger compartment monitoring)
- Expose the A/C control panel (only with automatic air-conditioning).
1 Heater unit installation location
1 Heater unit
Installa-
tion loca-
tion
1
5

Preparing electrical system
All equipment
1 2
sw Cutting
1mm²
wire to
100 2900 length
Produce connections as shown in wiring dia-

gram.
gn/ws Cut included protective sleeving to length of
rt
2,500 and push onto wire 2 .
5
86 87 87a Only with passenger compartment moni-

toring
K3 Connect-
85 30 Also connect 3,000 mm long red (rt) wire 5 ing fuse
to K3/86 and pull into protective sleeving. F4
F4
1 2
1 2 1 Cut off tab connector at Position 3 and crimp

on connector.
3
(2) Diode group
(1) Connector [2x]
(4) Insulate blue (bl) wire [2x] and tie back
Preparing
diode
4 4 group
Only with automatic air-conditioning
Wire sections 3 and 4 will be used later.
3 4
rt
2,5mm² Cutting
50 50 wire to
length

Electrical Connections
Fuse holder, relay K3 Fuse holder, relay K3
WARNING: (3) M6x12 bolt, angle bracket, flanged nut

Do not damage tank (4) Retaining plate, M5x12 bolt, large diameter
washer, flanged nut
(1) 6.5 mm dia. hole (5) Fuse holder mounted
(2) K3 relay, M5x12 bolt, large diameter washer,
flanged nut
(1) Positive wire on positive support point
(6) Ground wire on battery terminal
1 1 2 3 4 5
3 4
Wiring
harness
installa-
Do not install the metering pump tion dia-
cable harness until later togeth- gram
er with fuel pipe along the origi-
nal vehicle fuel lines on the
underbody
1 1 2
5 6
Wiring harness pass through Digital Timer and Summer/Winter Switch

(1) Protective rubber plug (1) Summer/winter switch, hole 12 mm dia.
(2) Digital timer with extension wiring harness,
drilling template
7

1 Remote option (Telestart)
(1) Receiver
2 (2) 4 mm dia. hole; 5.5x13 self-tapping screw
[2x]
2
Installing
receiver
1 Produce all connections in accordance with

general installation instructions provided and i
fasten wires with cable ties.
(1) Antenna
Installing
antenna

1 Remote option (Thermo Call)
(1) Receiver
(2) 4 mm dia. hole; 5.5x13 self-tapping screw
[4x]
Installing
receiver
2 2 9
1 (1) Antenna
Installing
antenna
10
1 Produce all connections in accordance with

general installation instructions provided and i
fasten wires with cable ties.
(1) Push button
Installing
push but-
ton
11

Fan controller for manual air conditioning
Webasto Nissan i
30
15
HG
F3 ge gr
X1 4 F8
bl
gn/ 1 6 3 F24 F27

ws GR
rt/ws
2 7 5
ws/sw
rt* 5
vi vi
pk
rt
ws
! sw
86 87 87a bl
K3 D
85 30 sw
bl
!
sw Wiring dia-
ws pk gram for
sw
manual air
sw M98 18 6 20 condition-
1 2 ing
F4 KB
ws
2
GM M
1 WG
3 2 4 1 M95
bl bl
BCM
ws
8 7 3 2 M59
3 2
4 1
0
GS
4
br
sw sw
31
Webasto components Nissan components Colors and symbols

HG Heater unit GM Fan motor rt red
X1 6-pin heater unit con- gr Fan relay ws white
nector
F3 25 A fuse WG Resistor group sw black
K3 Fan relay M95 4-pin connector WG br brown
F4 3 A fuse GS Fan switch gn green
D Diode group M59 8-pin connector GS bl blue Legend
F24 15 A fuse gr gray
* Red (rt) wire only on F27 15 A fuse vi violet
veh. with passenger F8 10 A fuse pk pink
compartment monitoring KB A/C control panel Insulate wire ends and
M98 26-pin connector KB tie back
X Cutting point
Wiring colors may vary.
10

1 Connection to 2-pin connector from blower

motor.
Cut off white (ws) wire approx. 50 mm before
connector. Produce connections as shown in
wiring diagram.
2 (3) 2-pin connector of fan motor, disconnected
3 (1) Red (rt) wire from K3/87a Connect-
(2) Black (sw) wire from K3/30 ing fan
motor
12
1 2 Connection of A/C control panel is carried out

on 26-pin connector M98 (6), Pin 6.
3 Produce connections as shown in wiring dia-
gram.
(1) Pink (pk) wire from fuse F8

4 (2) Black (sw) wire to diode group Connec-
(3) Black (sw) wire 2 from F4 tion of A/C
(4) White/black (ws/sw) wire to diode group control
(5) Black (sw) wire from diode group panel
(7) Pink (pk) wire to connector M98, Pin 6
7 6 5 13
11

Automatic air-conditioning fan controller
Webasto Nissan i
30
15
HG F3 F27 F24 F8
X1 4
gr ro
gn/
ws rt/ws bl ge
rt/ws 3 6 1
rt* GRs
5
rt 5 7 2
pk
3 rt
86 87 87a ws/sw
85 30
K3 rt 4
! sw
bl
Automatic
sw
sw
D air-condi-
tioning cir-
vi ws bl sw cuit
1
F4
2
sw
! diagram
pk
ws
M60 6 20
2
M GM KB
1 38 32
M61
ws bl sw
br
vi
sw
M96 4 1 3 2
GRr
sw
31
Webasto components Nissan components Colors and symbols

HG Heater unit F24 15 A fuse rt red
X1 6-pin heater unit con- F27 15 A fuse ws white
nector
F3 25 A fuse F8 10 A fuse sw black
F4 3 A fuse GRs Fan relay, front br brown
K3 Fan relay GM Fan motor, front gn green
Legend
D Diode group KB A/C control panel, front bl blue
M60 26-pin connector KB ge yellow
* Red (rt) wire only on M61 40-pin connector KB pk pink
veh. with passenger GRr Fan controller, front vi violet
compartment monitoring M96 Connector GRr Insulate wire ends and
tie back
X Cutting point
Wiring colors may vary.
12

Fan motor is connected on original vehicle

fan relay for front in engine compartment.
(1) Fan relay, front

(2) Relay carrier
1 Fan relay
14
View of fan relay socket!

Seen from above!
Imprint on relay or socket may differ from
original vehicle wiring diagram, and is there-
fore irrelevant!
1 2
3 6 View of re-
lay
5 7 socket
3 1 Route wiring harness from K3 relay to relay

carrier and cut to length.
Premount wiring harness with included yellow
(ge) connector and wiring diagram.
Connect prepared red (rt) wires 3 and 4 .
2 (1) Red (rt) wire from K3/87a

(2) Black (sw) wire from K3/30 Preparing
wiring har-
ness
4 15
1 2 3 Expose relay carrier as shown.

Uncrimp original vehicle violet (vi) (2) and
white (ws) (3) wires from relay socket (5), Pin
5 and 7, and cut off tab receptacles.
4
Produce connections as shown in wiring dia-
gram.
(4) Relay carrier Connect-

(5) Relay socket ing fan mo-
5 (3) White (ws) wire to fan motor and fan con- tor
6 troller
(2) Violet (vi) wire to fan motor and fan con-
troller
(1) Black (sw) wire from K3/30
3 4 16 (6) Red (rt) wire from K3/87a
13

1 2 3 Connection of A/C control panel is carried out

on left-hand 26-pin connector M98 (4), Pin 6.
7 Produce connections as shown in wiring dia-
gram.
(1) Black (sw) wire to diode group

(2) Black (sw) wire 2 from F4
(3) Pink (pk) wire from fuse F8 Actuating
(5) Pink (pk) wire to connector M60, Pin 6 A/C con-
(6) Black (sw) wire from diode group trol panel
(7) White/black (ws/sw) wire to diode group
6 5 4 17
Switch-off function of passenger compartment monitoring

Webasto components:
K3.1 = Additional relay i
sw
rt* rt* = Red (rt) wire from K3/86
5
sw
Vehicle components:
86 87 87a
R6 = Ultrasound sensor
Wiring dia-
rt
K3.1 sw Legend: gram for
85 30 X = Cutting point passenger
rt = Red wire compart-
sw
sw = Black wire ment moni-
br R6 br = Brown wire toring
31
14

Connection is carried out on 2-pin connector

of ultrasound sensor R6 (1). Disconnect black
3 (sw) wire from 2-pin connector (1) and con-
nect to black (sw) wires (2) and (3) provided
(solder and insulate).
Discon-
necting
and ex-
tending
wire
2 1 18
1 2 (1) Brown (br) wire K3.1/85

(2) Black (sw) wire from ultrasound sensor R6
(3) Black (sw) wire from ultrasound sensor R6
(4) K3.1 relay
(5) Red (rt) wire 5 from K3/86
5
Preparing
K3.1 relay
4 3 19
1 (1) Original vehicle bolt

(2) K3.1 relay
Installing
K3.1 relay
2 20
1 (1) Original vehicle bolt

(2) Brown (br) wire K3.1/85
2 Ground
connec-
tion of
K3.1 relay
21
15

1 Preparing installation location

3
3
(1) Line from steering reservoir
(2) Line to automatic-transmission oil cooler
(3) Bolts from bracket of steering reservoir
[2x]
Original
state
2 22
1 (1) Bracket aligned as shown

(3) Bolts from bracket of steering reservoir
3 [2x]
3 (2) Copy hole pattern
Preparing
installa-
tion loca-
tion
23 Remove bracket again
(1) 15 mm dia. black (sw) rubber profile

3
(2) 6.5 mm dia. hole, M6x20 bolt, large diam-
3
eter washer (from inside), mm shim, pin
1 lock (from outside)
(3) Bolts replaced with M6x40 bolts, large di-
ameter washers (from inside) and large di-
Preparing
ameter washer (from outside)[2x]
installa-
tion loca-
tion
2
24
Route line to automatic-transmission oil cool-

er (2) before steering line (4)
1 (1) 20 mm dia. black (sw) rubber profile

(2) Line to transmission oil cooler
(4) Steering line
2 (3) 18/18 double clip Preparing
4
installa-
3 tion loca-
tion
25
16

Premounting heater unit
Spring clips [2x] will be reused!
Removing
circulat-
ing pump
x = 60 mm
Remaining sections will be used later

1
(1) Hose on heater unit outlet
Cutting
coolant
hose on
heater unit
output to
length
x
1 2 3 4 4 Ejot screws, tightening torque 10 Nm!
(2) Extension wiring harness for circulating

pump connected
(5) 27 mm dia. spring band clamp
(6) Hose on heater unit outlet
(3) Strut
(4) Ejot screws [2x] Premount-
(1) 100 mm edge protection ing heater
unit
6 5 26
1 1 2 3 Ejot stud, tightening torque 10 Nm.

Insert 2 washers between heater unit and
Ejot studs at Position (4) as height compen-
sation.
(1) Ejot stud [2x]

(4) Ejot stud, washer [2x]
(2) 20/20 connecting pipe Premount-
(3) 27 mm dia. spring band clamp ing heater
unit
4 27
17

1 2 (1) Exhaust pipe

a = 550 mm
(2) Exhaust end section
b = 350 mm
Discard section X
Cutting
exhaust
pipe to
length
a b
(1) M6x12 bolt (from below), pin lock (from

above) [2x]
1 Preassem-
bling
bracket
28
1 1 2 3 Shape exhaust pipe as shown

Only loosely mount all components.
(2) Bracket
(1) Flanged nut [3x]
(3) Exhaust pipe
(4) P-clamp, flanged nut [2x]
Preassem-
bling ex-
haust pipe
1 4 4 29
1 2 (3) Exhaust pipe

(1) Red (rt) rubber profile [3x]
(2) Hose clamp [2x]
Premount-
ing ex-
haust pipe
1
Remove bracket and exhaust pipe from heat-

2 3 1 30 er unit again.
18

Installing Heater Unit
Connect wiring harness on heater unit.
(1) Heater unit
Installing
heater unit
31
1 2 (3) Original vehicle bolt replaced with M6x20

bolt, washer
(2) Heater unit
(1) Strut loosely mounted on bolt (3) with
flanged nut
Installing
3
heater unit
32
19

Coolant connection with manual transmission
WARNING!
Tighten all hose clamps to 2.0 + 0.5 Nm.
Any cold water running off should be collected using an appropriate container!
Route coolant hoses kink-free! Unless specified otherwise, always fasten using cable ties.
Position hose and spring clips so that no other hose can be damaged!
The connection should be "inline" based on the following diagram:
Heat
exchanger
Coolant
diagram
for manual
transmis-
sion
E
A
Pipe
Motor
B
D
All clamps without a specific designation are 20-27 mm dia. hose clamps.
All connecting pipe not specified are 20 mm x 20 mm dia.!
20

Preparing coolant connection
Hose D is already mounted on heater unit!

C A B E X D
a = 270 mm
b = 300 mm
c = 50 mm Cutting
e = 430 mm coolant
hoses to
Discard sections X length
X c a b e X
1 b 1 1 Push braided protection hose onto hose A, B,

C and E and cut to length.
Connect hose B and C.
C (1) Heat shrink plastic tubing [8x]

1
1
Premount-
ing cool-
1 ant hoses
1 E 1 33
1 Long hole spacing at Position (1)!
100°
Bending
perforat-
ed bracket
75
34
1 2 Observe direction of flow.
(1) Intake side

(2) 48 mm dia. rubber-coated p-clamp
(3) M6x20 bolt, flanged nut
(4) Perforated bracket
Premount-
ing circu-
lating
pump
4 3 35
21

Coolant connection
(1) Hose section on engine outlet

(2) Discard section
(3) Hose section on heat exchanger inlet
Cutting
3
point
2 1 36
(1) Hose section on engine outlet

Mounting
connec-
tion pipes
1 37
b 1 Align line (3) and rubber profile (2) as shown.
(1) 50 mm edge protection
C
3
2
Connec-
tion to
heater unit
inlet
38
1 (1) Unclip wiring harness
Installa-
tion loca-
tion of
circulat-
ing pump
b 39
22

a 1 2 b Observe direction of flow. Pressure side fac-

es toward heater unit!
Connect wiring harnesses to same colors
with red (rt) shrink connectors (crimp and
shrink).
(5) Circulating pump, premounted

(1) M6x12 bolt, large diameter washer, Installing
5 3 flanged nut circulat-
(2) Wiring harness of circulating pump ing pump
(3) Extension wiring harness from heater unit
(4) Wiring harness fastened with cable tie
4 40
Before connecting, fill the coolant hoses with

coolant.
1 (1) Hose section on engine outlet
Connec-
tion to en-
gine outlet
a 41
1 a E (1) Hose section on heat exchanger inlet

(2) 27x27 double clip
Connec-
tion to
heat ex-
changer
inlet
2 42
1 E D Before connecting, fill the coolant hoses with

coolant.
(1) 8x25 double clip on E and A/C line

(2) A/C line
Connec-
tion to
heater unit
outlet
Check positioning of coolant hoses A, B, C,

D, E and circulating pump and correct if nec-
2 43 essary.
23

Coolant connection for automatic transmission
WARNING!
Tighten all hose clamps to 2.0 + 0.5 Nm.
Any cold water running off should be collected using an appropriate container!
Route coolant hoses kink-free! Unless specified otherwise, always fasten using cable ties.
Position hose and spring clips so that no other hose can be damaged!
The connection should be "inline" based on the following diagram:
Heat
exchanger
Coolant
diagram
for auto-
matic
transmis-
D sion
Pipe
Motor
Original
clamp
A Original
hose
All clamps without a specific designation are 20-27 mm dia. hose clamps.
All connecting pipe not specified are 20 mm x 20 mm dia.!
24

Preparing coolant connection
Hose C is already mounted on heater unit!

B X D C
b = 200 mm
d = 450 mm
Cutting
Discard sections X coolant
hoses to
length
X b d X
1 D 1 Push braided protection hose onto hose B

and D and cut to length!
(1) Heat shrink plastic tubing [4x]
Premount-
ing cool-
ant hoses
1 b 1 44
1 2 Do not damage radiator!
(1) Detach radiator trim

(2) 6.5 mm dia. hole
(3) M6x20 bolt, large diameter washer (from
inside), pin lock (from outside)
Installing
3 circulat-
ing pump
45
1 2 Observe direction of flow. Pressure side fac-

es toward heater unit!
Connect wiring harnesses to same colors
with red (rt) shrink connectors (crimp and
shrink).
(2) Circulating pump

(1) 48 mm dia. rubber-coated p-clamp, Installing
flanged nut circulat-
3 (3) Wiring harness of circulating pump ing pump
(4) Extension wiring harness from heater unit
4
46
25

a Coolant connection
Remove hose A. Hose A and clamp (1) will

be reused!
Removing
original
hose
1
47
1 (1) Discard section
Cutting
point
a 48
a Side of hose A cut to length is connected to

intake side of circulating pump
(1) Engine outlet

(2) 27x27 double clip
1 (3) Intake side of circulating pump Connect-
2 ing en-
gine outlet
and circu-
3 lating
pump
49
b (1) Pressure side of circulating pump
1
Connect-
ing pres-
sure side
of circulat-
ing pump
50
26

Align line (1) and rubber profile (2) as shown.
(1) 50 mm edge protection

(2) Line from steering reservoir
(3) Rubber profile (premounted)
1
2 Connec-
tion to
heater unit
3 inlet
B 51
1 D C (1) 8x25 double clip on D and A/C line
Connec-
tion to
heater unit
outlet
52
Pipe (1) remains without function!

(2) Discard hose section
(1) Pipe
3
Cutting
point
2 53
Before connecting, fill the coolant hoses with

coolant.

1
Connec-
tion to
heat ex-
changer
inlet
D
Check positioning of coolant hoses A, B, C, D

and circulating pump and correct if neces-
54 sary.
27

Combustion air
(1) Combustion-air intake pipe (slotted side

on heater unit)
(2) 27 mm dia. hose clamp
Installing
1 combus-
tion air
pipe
2 55
1 For improved overview, fuse holder is not

shown! i
Shape combustion-air intake pipe as shown
in picture.
(1) Combustion-air intake pipe

(2) Intake muffler
(3) Retaining clip engaged in existing hole
Installing
2 intake
muffler
3 56
28

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. Un-
less 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.
1 1 2 (1) Mecanyl line

(2) Hose section, 10 mm dia. hose clamp [2x]
Connec-
tion on
heater unit
Route Mecanyl line and wiring harness of me-

tering pump along vehicle wiring harness to
firewall.
57
2 1 Route Mecanyl line and wiring harness of me-

tering pump downward through cable duct (2).
1
(1) Mecanyl line, wiring harness of metering
pump
(2) Cable duct Routing
Mecanyl
line and
wiring har-
ness of
1
metering
pump
58
1 2 3 4 5 3 2 1 (5) Metering pump

(4) Rubber-coated p-clamp
(6) Silent block
(7) Flanged nut [2x]
(8) Angle bracket
(2) Hose section [2x]
(1) 10 mm dia. hose clamp [2x] loosely Premount-
mounted ing meter-
(3) 10 mm dia. hose clamp [2x] ing pump
6
7
8 59
29

1 2 Ensure proper installation position of meter-

ing pump, see "Installation Instructions“. i
Fuel line from heater unit on pressure side of
metering pump [side with connector].
Route Mecanyl line and wiring harness of me-
tering pump in included protective pipe (4).
5 3
(2) Premounted metering pump
(3) Original vehicle bolt, flanged nut Installing
4 (4) Protective pipe metering
4 (1) Wiring harness of metering pump, con- pump
nector housing completed
(5) Mecanyl line, 10 mm dia. hose clamp
tightened
60
1 2 3 Fuel is removed from return line!

Disconnect return line at coupling.
(1) Supply line

(2) Return line from fuel cooler
(3) Return line to fuel tank
Discon-
necting re-
turn line
61
1 Cut off return line as shown.
(5) Return line

5 (1) Metal 6x5x6 T-piece
(6) 8 mm dia. hose clamp [2x]
6 (3) Hose section
6 (4) Remaining section of Mecanyl fuel line
2
3 (2) 10 mm dia. hose clamp [2x] Fuel re-
5
moval
2
4
Reconnect return line and route Mecanyl line
along original vehicle fuel lines to metering
62 pump
1 Fuel line from T-piece on intake side of meter-

ing pump [side without connector].
Check position of components; adjust if nec-
essary. Check that they have free clearance.
2 (2) Mecanyl line from T-piece Connec-

(1) Hose section, 10 mm dia. hose clamp tion to me-
tightened tering
pump
Align Mecanyl line and wiring harness of me-

tering pump over entire length and fasten with
63 cable ties
30

Exhaust system
Bend perforated bracket as shown!
Bending
20° perforat-
ed bracket
50
64
1 (1) 6.5 mm dia. hole
Hole in un-
derride
protection
65
1 First guide preshaped exhaust pipe to heater

unit, then insert bracket.
(1) Heater unit

(2) Hose clamp
(3) Exhaust pipe (premounted) Installing
(4) Line to transmission oil cooler exhaust
(5) Red (rt) rubber profile pipe
5 2
4
3
Position rubber profile (5) in area of line (4)
66
1 Ejot stud, tightening torque 10 Nm.

2 Position exhaust pipe as shown
2
(1) Bracket
(2) Flanged nut on premounted bolt [3x]
5 (4) Flanged nut on Ejot stud bolt [3x]
(3) Exhaust pipe Installing
(5) 30 mm edge protection bracket
4
4 2
Cut included 4.5 mm dia. fuel hose to length
and connect to Ejot stud (4) as rub protection
[3x].
4 3 67
31

1 2 1 3 4 Fasten long hole spacing of perforated brack-

et (4) on muffler.
(2) Exhaust pipe

(1) P-clamp [2x]
(8) Flanged nut on premounted bolt [2x] Installing
3 (5) Hose clamp exhaust
(7) Muffler pipe and
8 5 (4) Perforated bracket (preshaped) muffler
8 (6) M6x20 bolt, large diameter washer,
flanged nut [2x each]
6
Position rubber profiles (3) as shown [2x].
7
6 68
1 1 2 Shape exhaust end section as shown.
(1) Red (rt) rubber profile [2x]

(2) Hose clamp loosely mounted
Premount-
ing ex-
haust end
section
69
1 2 3 4 4 (3) Exhaust end section

5 (5) Muffler
(6) Hose clamp
6 (2) P-clamp
(1) M6x20 bolt, 10 mm shim, flanged nut Installing
exhaust
end sec-
tion
Position rubber profiles (4) as shown [2x].
70
Check positioning of exhaust pipe and t-pipe

end section over entire length and position of
muffler and rubber profiles [5x] and correct if
necessary.
In particular, ensure sufficient distance of ex-
haust pipe, t-pipe end section and muffler
from original vehicle lines and plastic parts.
Position-
ing ex-
haust
system
71
32

1 Installing wheel well trim
Cut out wheel well trim as shown.
(1) Discard section
Cutting
out wheel
well trim
72
Rework cut-out if necessary.
Installing
wheel well
trim
73
1 Ensure sufficient distance of wheel well trim

from exhaust system.
If necessary, cut out wheel well trim accord-
ingly.
(1) Exhaust pipe

2 (2) Wheel well trim
(3) Exhaust end section
Installing
wheel well
trim
3
74
33

1 2 3 Final Work
Position rubber profiles and lines as shown.
(1) Black (sw) rubber profile positioned on

hose of heater unit inlet (2)
(4) Red (rt) rubber profile positioned on line (3)
5 (3) Line to automatic-transmission oil cooler Position-
(5) Line from steering reservoir ing rubber
profiles
and lines
4 75
1 2 3 4 Position rubber profile, lines and spacer

bracket as shown.
(1) Heater unit

(2) Black (sw) rubber profile positioned be-
tween heater unit and radiator trim (6)
(3) Spacer bracket
(4) Steering line Position-
(5) Line to transmission oil cooler ing rubber
5 (6) Radiator trim profiles
and lines
6
76
a Only with automatic transmission

1
Ensure freedom of movement of intake hose.
If necessary, correct position of circulating
pump and of hose A and B.
b (1) Circulating pump

(2) Intake hose
Installing
intake
hose
2
77
34

WARNING!
Mount removed parts in reverse order.
Check all hoses, hose, spring and Caillau clamps, as well as all electrical connections for firm seating.
Secure all loose cables using cable ties.
Spray heater unit components with anti-corrosion wax (Tectyl 100K, Order No. 111329).
- Connect the battery.

- Bleed and fill the coolant circuit according to the vehicle manufacturer’s specifications.
- Set the digital timer.
- Adjust the vehicle heater with automatic air-conditioning or without automatic air-conditioning ac-
cording to "Operating Instructions for End Customer".
- Check the proper operation of the additional heater, see the operating instructions/installation in-
structions. i
- Attach the "Switch off additional heater before refueling" sticker to the left-hand B-pillar.
Feel the drive

Webasto AG
Postfach 80 - 82132 Stockdorf, Germany - Hotline +49-
(0)1805-932278
Hotfax +49-(0)395-5592-353 - http://www.webasto.de
Printed in Germany 04/09Printed by: Steffen

Operating Instructions for End Customer

Please remove page and add to the vehicle operating instructions.
On vehicles with passenger compartment monitoring, the ultrasound passenger compartment moni-
toring is deactivated simultaneously with the control of the passenger compartment fan to prevent an
alarm from being triggered.
Before parking the vehicle, make the following settings:
1 2 (2) Direct air outlet toward windshield

(1) Set fan to level "1", or possibly "2"
(3) Set temperature to "max."
Manual air
condition-
ing
3 78
1 2 1 (1) Set temperature to "HI." [2x]

(2) Direct air outlet toward windshield
(3) Set fan speed to level 2 (possibly to 3)
Automatic
air-condi-
tioning
3 79
36

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Water Heater Unit

Feel the drive

Nissan Pathfinder and Navara

Specialist company training, technical documentation, specialized tools and equip-

Ident. No.: 1303637F_EN Fee Euro 10 © Webasto AG

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Engine type Engine model Output in kW Displacement in cm³

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Heater Unit/Installation Kit

Quantity Description Order No.:

Heater unit recommended for the respective vehicle class:

Vehicle Heater Unit

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Explanatory Notes on Document

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 Webas-

Reference to a special technical feature.

The arrow in the vehicle icon indicates the position on

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1 Heater unit installation location

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Preparing electrical system

Produce connections as shown in wiring dia-

86 87 87a Only with passenger compartment moni-

1 2 1 Cut off tab connector at Position 3 and crimp

Only with automatic air-conditioning

Wire sections 3 and 4 will be used later.

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WARNING: (3) M6x12 bolt, angle bracket, flanged nut

Wiring harness pass through Digital Timer and Summer/Winter Switch

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1 Remote option (Telestart)

1 Produce all connections in accordance with

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1 Remote option (Thermo Call)

1 Produce all connections in accordance with

(1) Push button

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Fan controller for manual air conditioning

gn/ 1 6 3 F24 F27

Webasto components Nissan components Colors and symbols

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1 Connection to 2-pin connector from blower

1 2 Connection of A/C control panel is carried out

(1) Pink (pk) wire from fuse F8

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Automatic air-conditioning fan controller

Webasto components Nissan components Colors and symbols

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Fan motor is connected on original vehicle

(1) Fan relay, front

View of fan relay socket!

3 1 Route wiring harness from K3 relay to relay

2 (1) Red (rt) wire from K3/87a

1 2 3 Expose relay carrier as shown.

(4) Relay carrier Connect-

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1 2 3 Connection of A/C control panel is carried out

(1) Black (sw) wire to diode group

Switch-off function of passenger compartment monitoring