Coolant heater. Thermo Top - Z/C additional heating system. Installation instructions. Volvo S60, Volvo V70, and Volvo S80 Beginning Model Year: 2000

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1 Coolant heater Thermo Top - Z/C additional heating system Approval code ~~~ S 9 Installation instructions Volvo S60, Volvo V70, and Volvo S80 Beginning Model Year: Volvo XC70 Beginning Model Year: 00 Left-hand drive gasoline models only All equipment versions Legend for Figure Thermo Top Z/C-B heater Blade-type fuse holder and voltage divider Digital timer Summer/winter switch (not applicable in N. America) Exhaust muffler 6 Combustion air intake line 7 Receiver T70, T80, TC (optional) 8 Dosing pump See page for validity details The vehicle types, engine types and equipment versions not listed in these installation instructions have not been tested. It may nevertheless be possible to install the system using these installation instructions. Compliance with the licensing regulations set out on page 6 is essential. Special tools Torque wrench for.0 0 Nm Hose clamping pliers Torx E nut Table of contents Volvo S60 Volvo V70 Volvo S80 Heater / Installation kit Validity Data acquisition Foreword 6 General information 7 Preparations 7 Installation site for the heater 7 Blade-type fuse holder and voltage divider 8 Blower control Digital timer To install the heater Integration into the fuel system 7 Fuel standpipe 0 Integration into the coolant system Combustion air intake line Concluding work To adjust the voltage divider Operating instructions for the end user (customer) 6 Rev. 0/0 DOC. P/N 0006A KIT P/N 00007B Edited for North American Applications Webasto Product North America, Inc.

2 Thermo Top Z/C (BlueHeat) S60, V70, S80, XC70 Improper installation or repair of Webasto heating and cooling systems can cause fire or the leakage of deadly carbon monoxide leading to serious injury or death. Installation and repair of Webasto heating and cooling systems requires special Webasto training, technical information, special tools and special equipment. NEVER attempt to install or repair a Webasto heating or cooling system unless you have successfully completed the factory training course and have the technical skills, technical information, tools and equipment required to properly complete the necessary procedures. ALWAYS carefully follow Webasto installation and repair instructions and heed all WARNINGS. Webasto rejects any liability for problems and damage caused by the system being installed by untrained personnel. Heater / Installation kit Quantity Description Order No. Coolant heater Thermo Top Z/C - gasoline with delivery 000A Also included: Volvo S60, V70, S80, XC70 gasoline installation kit 00007B Volvo hose set (as set out in the vehicle models table) 00008A

3 S60, V70, S80, XC70 Thermo Top Z/C (BlueHeat) Validity Manufacturer Type Trade name EC licence No. Volvo R S60 e9*98/*006*.. Volvo S V70 e*98/*000*.. Engine type Engine type Output in kw Displacement in cc B0T Gasoline 98 BT Gasoline 8 9 BS Gasoline 0 BS Gasoline BT Gasoline 7 Manufacturer Type Trade name EC licence No. Volvo T S80 e9*98/*008*.. Engine type Engine type Output in kw Displacement in cc B0T Gasoline 98 BS Gasoline 0 BS Gasoline BT Gasoline 7 B68T Gasoline B69S Gasoline 7 9 B60S Gasoline 0 9

4 Thermo Top Z/C (BlueHeat) S60, V70, S80, XC70 Data acquisition Data acquisition using VADIS: Version 00 B; June 00. Only the latest version is valid! Manufacturer Trade name Type EC licence No. Volvo S60 8 ( R ) e9*98/*006*00 Engine type Code Engine type Output in kw Displacement in cc Model year Gearbox Hose set B0T 9 Gasoline MT/AT BT Gasoline MT/AT BS 6 Gasoline 00 MT/AT BS 6 Gasoline 0 00 MT/AT BT 8 Gasoline 7 00 MT/AT Manufacturer Trade name Type EC licence No. Volvo V70 AWD 8 ( J ) e*98/*000*0 Volvo V70 Cross Country 9 ( Z ) e*98/*000*0 Engine type Code Engine type Output in kw Displacement in cc Model year Gearbox Hose set BT 8 Gasoline 7 000/00 MT/AT Manufacturer Trade name Type EC licence No. Volvo V70 8 ( S ) e*98/*000*0 Engine type Code Engine type Output in kw Displacement in cc Model year Gearbox Hose set B0T 9 Gasoline /00 MT/AT BT Gasoline /00 MT/AT BT 8 Gasoline 7 000/00 MT/AT BS 6 Gasoline 000/00 MT/AT BS 6 Gasoline 0 00 MT/AT

5 S60, V70, S80, XC70 Thermo Top Z/C (BlueHeat) Manufacturer Trade name Type EC licence No. Volvo S80 8 ( T ) e9*98/*008*06 Engine type Code Engine type Output in kw Displacement in cc Model year Gearbox Hose set B0T Gasoline MT/AT B0T 8 Gasoline MT/AT BS 6 Gasoline 999 MT/AT BS 6 Gasoline MT/AT B68T 90 Gasoline AT 9 8 B60S 97 Gasoline AT 9 8 B60S 97 Gasoline MT 9 8 B0T Gasoline MT/AT B0T 8 Gasoline MT/AT B0T 9 Gasoline /00 MT/AT BS 6 Gasoline 000/00 MT/AT BS 6 Gasoline 0 000/00 MT/AT B68T 90 Gasoline /00 AT 9 8 B69S 9 Gasoline /00 AT 9 8 B69S 9 Gasoline /00 MT 9 8

6 Thermo Top Z/C (BlueHeat) S60, V70, S80, XC70 Foreword These non-binding installation instructions apply to the Volvo S60, S70 and S80 gasoline versions (see tables for validity) model year as listed in the tables and later, unless technical modifications on the car influence the installation, excluding all liability claims. Depending on the version and equipment in the car, changes may be required to the installation work set out in these installation instructions. In any event, however, the directives in the installation manual and operating manual Thermo Top Z/C; E must be followed. The appropriate engineering conventions must be observed for the installation work. IMPORTANT! The licensing regulations must be observed. Retrofitting the Thermo Top Z/C (BlueHeat) additional heating systems using these installation instructions must be approved since the general operating licence does not feature a special supplement. The system must be installed as set out in the installation manual. It must be tested by an officially approved expert or tester for the motor trade, a motor vehicle expert or employees. 6

7 S60, V70, S80, XC70 Thermo Top Z/C (BlueHeat) General information - Bare body parts, for example around drilled holes, must be treated with anti-corrosive coating. - Secure hoses, cables and wiring harnesses with cable ties and fit protective hoses around them at chafing points. - Fit edge protectors (opened fuel hose) to sharp edges. Preparations - Remove the inapplicable year number from the duplicate plate. - Fit the duplicate plate (model plate) in a suitable position. Engine compartment IMPORTANT! Disconnect the battery negative (ground). - Release the pressure from the cooling system Exterior - Open the tank cover, vent the tank and close the tank cover. - Remove the windshield wipers, wiper motor area cover and wiper linkage. - Remove the bumper. - Remove the trim for the fuel lines from the underbody. Interior - Remove the rear seat backrests following the manufacturer s instructions. - Remove the service cover from the right-hand tank fittings. - Remove the bottom dashboard trim on the driver side. - Remove the bottom dashboard trim on the passenger side. Installation site for the heater - The heater (/) is to be installed at the front left between the wheel arch and the bumper. It is installed horizontally and longitudinally along the vehicle s length. 7

8 Thermo Top Z/C (BlueHeat) S60, V70, S80, XC70 Blade-type fuse holder and voltage divider To prepare the wiring harness The blower relay K (/) is to be replaced with the supplied voltage divider (/); fuse F (/; /) will not be used. All brown wires of the harness are ground (Negative) wires. - Disconnect the blower relay (/) from the plastic relay housing (/). - Release all the cables from the plastic housing (/8) and discard housing. - Remove the red cable (/) from the blower relay K/87 to the fuse F ( amp.) (/) at the fuse output. - Take fuse F ( amp.) out of the fuse holder (/). - Connect the supplied voltage divider (/) to the supplied plug housing with mounting tab (/9) on the wiring harness as shown in the circuit diagram in figure 6. - Connect the green/white cable (/; /8) from the heater control module (previously on terminal 86 of the blower relay K) to the voltage divider terminal Connect the brown cable (/7; /7) from the ground post (previously on terminal 8 of the blower relay K) to the voltage divider terminal 87a. - Connect the red cable (/6; /) from the blower wiring harness (previously on terminal 87a of the blower relay K) to the voltage divider terminal E. - Connect the black cable (/; /6) from the blower wiring harness (previously on terminal 0 of the blower relay K) to the voltage divider terminal A. - Cut a section of cable, approx. 00 mm (8 in.) long, from the supplied black cable. - Connect the 00 mm (8 in.) black cable (/) to the voltage divider terminal 8. - Cut all ground cables (brown) from the ground post (/) Connect the supplied brown cable.0 mm (/) together with the five cut ground cables using yellow wire nut (/). Use heat gun to shrink wire nut insulation. 8

9 S60, V70, S80, XC70 Thermo Top Z/C (BlueHeat) or or * green/white * green/white * Note: Wire color changed in To install the wiring harness The fuse holder and voltage divider are to be installed in the fuse/relay box (7/) located in the engine compartment as shown. IMPORTANT! Remember that there may be components, cables and lines behind drill points! - Mark the holes for the retaining plate for the fuse holder (8/) and for the socket for the voltage dividers (8/) on the casing for the fuse/relay box as shown in figure 8. - Drill a. mm hole (8/) for the fuse holder mm ( in.) from top. - Drill a. mm hole (8/) for the voltage divider 8 mm (. in.) from top. - Secure the retaining plate for the fuse holder using a countersunk screw Mx0, washer and nut. - Secure the socket for the voltage divider using a screw Mx6, washer and nut. - Mount the fuse holder on the retaining plate and the voltage divider on the socket as shown in figure

10 Thermo Top Z/C (BlueHeat) S60, V70, S80, XC70 The red/white wire from the -pin plug was changed to a green/white wire in Cut the vehicle red/white cable (9/,) from Pin (0/) of the -pin plug /0 (9/) (from generator D+ 6) approx. 0 mm ( in.) from the plug /0. - Connect both ends of the cut red/white cable (9/,) together with the black cable (9/) to the voltage divider terminal 8 using a yellow connector (part # 9070) (9/) as shown in the circuit diagram in figure Route the entire wiring harness to the left under the fuse/relay holder as shown in figure. - Enlarge the existing passage hole (/) appropriately and route the wiring harness into the engine compartment. - Secure the fuse/relay holder again. - Route the standard wiring harness (/) so that there is no strain on the plug /0 (/). - Route the red positive cable to the positive post (/), cut it to length and connect it with an 8 mm terminal lug. - Route the brown ground cable to the ground post (/), cut it to length and connect it with a 6 mm terminal lug. 0 - Route the heater wiring harness on the wheel well forwards to the installation site for the heater. - Drill a 0.0 mm (/6 in.) hole (/) in the passage to the windshield wiper motor area. - Thread the blower wiring harness and the digital timer wiring harness through the hole (/) into the windshield wiper motor area. as shown in figure. - Remove the cover from the wiring harness passage (/). - Drill an 8.0 mm (/6 in.) hole (/) in the wiring harness passage casing as shown in figure. - Insert the supplied grommet into the hole. - Thread the blower wiring harness and the digital timer wiring harness through the cable grommet (/) into the interior. - Secure the wiring harnesses with cable ties. 0

11 S60, V70, S80, XC70 Thermo Top Z/C (BlueHeat) Blower control - The blower control is at Pin (/) of the -pin plug A (/) of the blower controller in the foot-well on the passenger side. - Extend the blower wiring harness (red and black cables) in the interior using the supplied material. - Extend the red cable (/) from the voltage divider terminal E of the blower wiring harness using the supplied red cable. mm and the blue shrink butt connector (crimp and shrink) - Extend the black cable (/) from the voltage divider terminal A of the blower wiring harness using the supplied black cable. mm and the blue shrink butt connector (crimp and shrink) - Push a 000 mm (9 in.) insulation hose onto both extended cables. - Route the extended blower wiring harness (/,) to the plug (/) on the blower controller. - Cut the blue cable (/,) from Pin (/) of the -pin plug (/) approx. 0 mm ( in.) from plug A - Cut the red cable (/) and the black cable (/) and make the connections shown in the circuit diagram in figure 6 using the supplied blade terminals. - Connect the blue cable (/) from the standard air conditioning control module to the red cable (/) from the voltage divider, terminal E. - Connect the blue cable (/) going to the standard blower controller to the black cable (/) from the voltage divider, terminal A. - Secure the wiring harness with cable ties.

12 Thermo Top Z/C (BlueHeat) S60, V70, S80, XC70 Digital timer IMPORTANT! Do not press on the LCD display as you install the digital timer. The installation site for the digital timer (6/) shown in figure 6 is only a recommendation. Before installation, please confirm the installation site with your customer. - Affix the drilling template for the digital timer (6/) in the required position. - Drill two holes using the template as a guide. - Remove the template. - Install the mounting sleeve using a self-tapping screw. - Thread the digital timer wiring harness through the hole and connect the plug to the digital timer. - Connect the digital timer. 6

13 S60, V70, S80, XC70 Thermo Top Z/C (BlueHeat) To install the heater To prepare the installation site - Remove the standard screw from position (0/) and replace it with the screw M0x0 and a washer. - Do not tighten the screw (0/) as shown in figure 0. - Remove the screw (0/) in the trim. To prepare the heater - Cut the exhaust pipe and exhaust pipe end piece as shown in figure. Exhaust pipe 0 Heater muffler Cut off End piece 00 0 The strut (/) is secured to the hole (/) in the holder (/) on model S60 cars. The strut (/) is secured to the hole (/) in the holder (/) on model V70 and S80 cars. - Loosely attach the strut (/) to the holder in the oval hole using the screw M6x0 (/), body washer and flanged nut. Only use the special screws and special EJOT PT stud bolt supplied to secure the holder to the heater (tightening torque 0 Nm). Insert two washers between the holder and the heater in position (/6). Figure shows models V70 and S80. - Secure the heater (/7) to the holder using three Ejot screws (/,,6) (tightening torque 0 Nm). - Insert two washers between the holder and the heater in position (/6). 7 6

14 Thermo Top Z/C (BlueHeat) S60, V70, S80, XC70 - Fit the 00 mm (.7 in.)exhaust pipe (/) to the heater and secure it with a pipe clamp. - Shape the 00 mm (.7 in.) exhaust pipe (/) as shown in figure and figure. - Screw the Ejot stud bolt into the heater in position (/) (tightening torque 0 Nm). - Screw a spacer nut M6x0 (/) on to the Ejot stud bolt. - Secure the exhaust muffler (/; /) and 00 mm (.7 in.) exhaust pipe to the spacer nut using the screw M6x6 (/), split-lock washer and pipe clip (/) as shown in Figure and Figure. - Connect the 00 mm (.7 in.) exhaust pipe (/; /) to the exhaust muffler and secure it with a pipe clamp. - Connect the exhaust pipe end piece (/; /) to the exhaust muffler and secure it with a pipe clamp. To install the heater - Place the heater (6/) at the installation position as shown in figure 6 and connect the wiring harness. - Insert the mounting bracket with the heater as shown in figure 6 to figure Ensure that exhaust does not make contact with fender. Drill a /6 in. hole in the low point of exhaust tube to allow drainage of collected condensation. 6 Place the mounting bracket (7/) with the oval hole (7/,,) on the existing screw (8/) depending on the model (S60, V70, S80). - For model S60 place the mounting bracket (7/) with the oval hole (7/) on the existing screw (8/) - For model V70 place the mounting bracket (7/) with the oval hole (7/) on the existing screw (8/) 7

15 S60, V70, S80, XC70 Thermo Top Z/C (BlueHeat) - For model S80 place the mounting bracket (7/) with the oval hole (7/) on the existing screw (8/). 8 - Secure the mounting bracket to the existing screw (8/) using a flanged nut M8 (9/). 9 - Tighten the screw (0/) and secure the mounting bracket using a nut M0 (0/) and split-lock washer. 0 Use the existing hole (/) to secure the strut

16 Thermo Top Z/C (BlueHeat) S60, V70, S80, XC70 - Secure the strut (/; /) and the trim (/; /) to the existing hole (/) using the screw Mx6 (/), nut, washer and split-lock washer. - Tighten the nut (/). - Align the exhaust pipe (/), exhaust pipe end piece (/) and the exhaust muffler (/) as shown in figure, ensuring that they move freely in position (/ & ). Ensure that exhaust does not make contact with fender. Drill a /6 in. hole in the low point of exhaust tube to allow drainage of collected condensation. 6

17 S60, V70, S80, XC70 Thermo Top Z/C (BlueHeat) Integration into the fuel system IMPORTANT! Open the car s fuel filler cap, vent the tank and close the fuel filler cap again. Catch any escaping fuel using a suitable container. Route the fuel lines so that they are protected from stones. Fit a chafing guard on the fuel lines and wiring harness to protect from sharp edges. Connect the supplied 6000 mm (9.6 ft.) Mecanyl fuel line to the heater. - Connect the supplied Mecanyl fuel line (/) to the heater using the hose section (/) and 0 mm hose clamps. - Fit the supplied edge protector (/) as shown in figure. - Lay the Mecanyl fuel line (/) along the heater wiring harness to the fuse / relay box. - Drill a 0.0 mm (/6 in.) hole (6/) in the passage to the windshield wiper motor area. - Thread the Mecanyl fuel line (6/) and the dosing pump wiring harness (6/) through the hole (6/) into the windshield wiper motor area as shown. 6 - Drill another 0.0 mm (/6 in.) hole (7/) in the passage to the windshield wiper motor area. - Thread the Mecanyl fuel line (7/) and the dosing pump wiring harness (7/) from the hole (6/) in the windshield wiper motor area to the right and through the hole (7/) back into the engine compartment as shown in figure 7 and figure

18 Thermo Top Z/C (BlueHeat) S60, V70, S80, XC70 - Push the supplied heat protection hose (8/) on to the Mecanyl fuel line and the dosing pump wiring harness - Route the Mecanyl fuel line and the dosing pump wiring harness along the standard fuel lines on the bulkhead to the underbody. - Position the heat protection hose as shown in figure Route the Mecanyl fuel line (9/) and the dosing pump wiring harness (9/) along the standard fuel lines to the tank as shown in figure 9. Dosing pump Check the installation site of the dosing pump, see installation manual 9 - Enlarge the perforated strip (0/) at one end (0/) to a diameter of 8. mm (/ in.). - Secure the anti-vibration mount (0/) to the perforated strip using a flanged nut as shown in figure 0. - Secure the dosing pump (0/) to the anti-vibration mount (0/) using a rubberized pipe clip (0/) and a flanged nut as shown in figure Connect the hose sections (/,) to the dosing pump and secure them with 0 mm (/6 in.) hose clamp (/,). - Push 0 mm (/6 in.) hose clamps (/,6) loosely on the hose sections as shown in figure. 6 8

19 S60, V70, S80, XC70 Thermo Top Z/C (BlueHeat) - Secure the perforated strip (/) with the dosing pump (/) and fuel filter (/) using the standard screw (/; /) as shown in figure and figure. 6 - Route the Mecanyl fuel line (/; /6) and the dosing pump wiring harness (/; /) along the standard fuel lines to the dosing pump (/) as shown in figure and figure. - Push the supplied fabric hose section (/) on to the Mecanyl fuel line (/). - Cut the Mecanyl fuel line (/) at the dosing pump and connect it to the outfeed side of the dosing pump (side with the electrical plug) using the hose section and 0 mm (/6 in.) hose clamps. - Cut the wiring harness at the dosing pump, push on a rubber grommet, crimp on a blade terminal, complete the plug casing and connect the wiring harness to the dosing pump. - Position the fabric hose section (/) as shown in figure. - Secure the Mecanyl fuel line and dosing pump wiring harness using cable ties. 9

20 Thermo Top Z/C (BlueHeat) S60, V70, S80, XC70 Fuel standpipe IMPORTANT! Open the car s filler cap, vent the tank and close the filler cap again. 0 mm Catch any escaping fuel using a suitable container. The fuel is extracted through a riser pipe (/) in the tank fittings. 00 mm IMPORTANT! Drill the port (/) exactly in the centre of the tank fitting as shown in figure. - Enlarge the existing port (/) on the tank fitting with a. mm (/6 in.) drill bit as shown in figure. - Cut the supplied riser pipe (/,) at the end without the bead (/) to a length of 00 mm (.8 in.) (cut at any angle) as shown in figure. - Dispose of the remainder (/). - Cut 0 mm (/ in.) off the supplied shaped hose (/) at the end with an internal diameter of 8.0 mm (/6 in.) as shown in figure. - Insert the riser pipe (/) as far as possible into the enlarged port (/). - Push the end of the shaped hose (6/; /) with an internal diameter of 8.0 mm (/6 in.) as far as possible on to the riser pipe and port (/) - Secure the shaped hose (6/) to the port using a mm (/ in.) hose clamp (6/). Connect the supplied 000 mm (6. ft.) Mecanyl fuel line to the tank fitting. - Insert the 000 mm Mecanyl fuel line (6/) into the shaped hose (6/) and secure it with a 0 mm (/6 in.) hose clamp (6/) as shown in figure Route the Mecanyl fuel line (7/; 6/) along the standard fuel lines to the intake side of the dosing pump (7/) and cut it to length. - Push the supplied fabric hose section (7/) on to the Mecanyl fuel line. - Connect the Mecanyl fuel line to the intake side of the dosing pump (side without the electrical plug) using the hose section (7/) and hose clamps. - Position the fabric hose section (7/) as shown in figure 7. - Secure the Mecanyl fuel line with cable ties. 7 0

21 S60, V70, S80, XC70 Thermo Top Z/C (BlueHeat) Integration into the coolant system Tighten all hose clamps with a torque of Nm. Catch escaping coolant using a suitable container. Install the coolant hoses with no kinks. The following describes how to integrate the heater into the car s coolant system in an inline version (Figure 8). Legend for Figure 8 Expansion tank Radiator thermostat Car engine Circulating pump (heater) Heater 6 Heating system heat exchanger (car) 7 Radiator ϑ 8 Cut two lengths off the coolant hose supplied in the kit as shown in figure 9: x 90 mm + 90 bend (9/) (from the coolant hose (9/) to the hose package as shown in the tables on pages and to the heat exchanger). x 90 bend (9/) (from the heater coolant outlet to the coolant hose (9/)) In addition to the coolant hose supplied with the kit, a genuine Volvo hose group (60/,) must be used. This genuine Volvo hose group must be ordered direct from Volvo using the tables on page and page. Position all the hose clamps so that they cannot damage the other hoses. 60

22 Thermo Top Z/C (BlueHeat) S60, V70, S80, XC70 - Remove the standard coolant hose (6/; 6/) from the engine outlet to the heat exchanger coolant inlet and dispose of it Route the genuine Volvo hose group (6/,) into the engine compartment and to the heater as shown in figure 9 to figure Connect the coolant hose (6/; 6/) to the engine outlet and secure it with a hose clamp. - Connect the coolant hose (6/; 6/) to the heat exchanger coolant inlet connector using a hose coupling. 6 6

23 S60, V70, S80, XC70 Thermo Top Z/C (BlueHeat) - Fit the black chafing guard (6/) on to the coolant hose (6/) from the engine outlet. - Connect the coolant hose (6/; 6/) from the engine outlet to the heater, align it as shown in figure 6 and secure it with a hose clamp. 6 - Cut the coolant hose (66/,) to the heat exchanger coolant inlet as shown in figure Dispose of the hose section (66/). - Connect the 90 bend (67/; 9/) to the heater coolant outlet, align it as shown in figure 67 and secure it with a hose clamp. - Insert a 0 x 0 mm (/ x / in.) connection pipe (67/) into the 90 bend (67/) and secure it with a hose clamp. - Connect the short end of the 90 mm coolant hose (67/; 9/) to the 0 x 0 mm (/ x / in.) connection pipe (67/), align it as shown in figure 67 and secure it with hose clamps Connect the 90 mm coolant hose (68/) and coolant hose (68/) to the heat exchanger coolant inlet using the 8 x 0 mm (/8 x / in.) connection pipe and hose clamps as shown in figure Align all the coolant hoses shown in figure 6 to figure 68 and secure them with cable ties

24 Thermo Top Z/C (BlueHeat) S60, V70, S80, XC70 Combustion air intake line Check the installation site of the air intake silencer, see installation manual. - Connect the combustion air intake line (69/) with the slotted side on the heater combustion air port and secure it with a hose clamp. - Route the combustion air intake line (69/) behind the headlight to the installation site of the air intake silencer as shown in figure 69 and figure Screw the air intake silencer (70/) as far as possible into the combustion air intake line (70/). - Secure the air intake silencer (70/) with a cable tie as shown in figure 70. Concluding work - Push the red rubber section (7/) on to the exhaust pipe end piece (7/) as shown in figure 7. - Shape the exhaust pipe end piece as shown in figure 7. - Position the red rubber section (7/) and chafing guard (7/) on the contact points with the bumper as you install the bumper. - As you install the bumper ensure that the exhaust pipe, exhaust pipe end piece and exhaust muffler can more freely Before installing headlight wiper arms, ensure wiper system is in the Park position by turning on the headlight wipers and then turning them off (after connecting battery). - Install all the parts you have removed in reverse order apart from the cover for the fuse / relay box in the engine compartment. - Check that all hose lines, hose and pipe clamps and all electrical connections are secure. - Secure all loose lines and cables with cable ties. - Spray the heater components with anti-corrosive wax (Tectyl ML, order No. 9). - Connect the battery. - Bleed the cooling system following the instructions supplied by the car manufacturer. - Start the engine, bleed the coolant system as described in the vehicle manufacturer s instructions, and top up the coolant. - Set the heating system to warm and the blower to level. - Switch on the Webasto heating system, see operating manual/installation manual. 70 7

25 S60, V70, S80, XC70 Thermo Top Z/C (BlueHeat) To adjust the voltage divider If the coolant temperature is higher than 0 C (86 F) and the engine has been switched off, the heater control module will switch on the voltage divider. - Switch on the heater as described in the Operating instructions for the end user (customer). - Switch off the engine. - Allow the heater to operate until the coolant temperature exceeds 0 C and the heater is operating at maximum. - Remove the cover cap (7/) from the voltage divider. IMPORTANT! The total current consumption of the heater (at maximum) and the blower must be less than 0 A. The voltage at terminal A of the voltage divider is then approx..0 V. - Set the blower speed as required by turning the adjusting screw. - Check that the total current consumption of the heater (at maximum) and the blower is less than 0 A. - Fit the cover cap (7/) back on to the voltage divider. - Fit the cover on the fuse / relay box. 7 Operating instructions for the end user (customer) Cut out the Operating instructions for the end user (customer) on page 6 and place them into the owner s handbook supplied with the car.

26 Thermo Top Z/C (BlueHeat) S60, V70, S80, XC70 Operating instructions for the end user (customer) Settings to be made before you operate the heating system: Figure 7 shows a car without an automatic air conditioning system. Make the following settings before you shut down the car: - Set the temperature (7/,) to max/warm - Air vent (7/) to the windshield. Figure 7 shows a car with an automatic air conditioning system. Make the following settings before you shut down the car: - Set the temperature (7/,) to max/warm. - Air vent (7/) to the windshield Webasto Product North America, Inc. Technical Assistance Hotline USA: (800) -8 Canada: (800) /

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