09163238 zafira b english

8/13/2019 09163238 Zafira B English

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part number: 09163238 0908


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WARNING!

Hazard warning:

Incorrect installation or repair of Webasto heating systems may cause a fire or resultin the emission o f carbon monoxide, which can be fatal. Serious or fatal injuries canbe caused as a result.

Specialist company training, technical documentation, specialized tools andequipment are required to install and repair Webasto heating and cooling systems.

NEVER attempt to ins tall or repair Webasto heating or cool ing sys tems if you have notsuccessfu lly completed the company training and thereby acquired the requiredtechnical skil ls, or if you do not have access to the required technical documentation,tools and equipment needed to carry out co rrect installation and repairs.

ALWAYS fo llow all Webasto installation and repair inst ruct ions and observe al lwarnings.

Webasto does not accept any liability for defects and damage that are attributable toinstallation by untrained staff.

Feel the driv e

Opel Zafira B

Gasoline and Diesel

from Model Year 2005

For left-hand drive vehicles only

Ident. No.: 1310309C_EN Fee Euro 10 Webasto AG

Water Heater Unit

Thermo Top EAdditional Heater

Thermo Top CAdditional Heater

Thermo Top PAdditional Heater

Installation Instructions

e1

00 0003

e1

00 0002

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00 0104

part number: 09163238


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Opel Zafira B

Validity

Vehicle and engine types and equipment variants not listed in these installation instructions have notbeen 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 endcustomer before installation.

Manufacturer Model Type EG-BE No./ABE

Opel Zafira B A-H/Monocab e1 * 2001/116 * 0325 *

Engine type Engine model Output in kW Displacement in cm

Z16XEP Gasoline 77 1598

Z18XER Gasoline 103 1796

Z20LEH Gasoline (OPC) 177 1998

Z20LER Gasoline 147 1998

Z22YH Gasoline 110 2198

Z17DTJ Diesel 81 1686

A17DTJ Diesel 81 1686

Z17DTR Diesel 92 1686A17DTR Diesel 92 1686

Z19DTL Diesel 74 1910

Z19DT Diesel 88 1910

Z19DTH Diesel 110 1910

Validity 2Heater Unit/Installation Kit 3Foreword 3General Instructions 3Special Tools 4

Explanatory Notes on Document 5Preliminary Work 5Heater unit installation location 5Preparing Electrical System 6Electrical Diagram 7Fan controller for manual air conditioning 9With passenger compartment monitoring 10Automatic Air-Conditioning Fan Controller 11With passenger compartment monitoring 12Remote option (Telestart) 13Remote option (Thermo Call) 14Combustion Air 15Preparing Installation Location 16

Preparing Heater Unit 18Installing Heater Unit 18

Coolant 201.6 liter gasoline 201.8 liter gasoline 212.0 liter gasoline 222.2 liter gasoline 23

1.9 liter diesel 241.7 liter diesel 25Cut hoses to length 26Braided protection 27Routing 27Fuel 34Exhaust Gas 38Final Work 40Template for Fuel Sender 41Template for Fuel Standpipe 42Operating Instructions for Customer 43

Table of Contents



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Opel Zafira B

Heater Unit/Installation Kit

Addi tionally required for 1.9 li ter diesel veh ic les

Optional heater cont rol either:

ForewordThe installation instructions apply to the Opel Zafira B vehicles with a Gasoline and Diesel engine- For the validity, see page 2 - from model year 2005 and later, assuming technical modifications to thevehicle do not affect installation, any liability claims excluded. Depending on the vehicle version andequipment, modifications may be necessary during installation with respect to these installationinstructions.

However, where this is the case the stipulations in the "installation instructions" and "operating andmaintenance instructions" for the Thermo Top Cshould be observed.The corresponding rules of technology and any information from the vehicle manufacturer should beobserved during the installation work.

General InstructionsInstallation should be carried out according to the general, standard rules of technology. Unlessspecified otherwise, fasten hoses, lines and wiring harnesses to original vehicle lines and wiringharnesses 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).

Quantity Description Order No.:

1 Delivery scope of Thermo Top C GasolineOpel Catalog No.:

83343C1734010

1 Delivery scope of Thermo Top C DieselOpel Catalog No.:

83344C1734011

1 Installation kit for Opel Zafira B Gasoline and DieselOpel Catalog No.:

1303047F1734115

Quantity Description Opel Part No.:

1 Bracket of vacuum valveOpel Catalog No.:

92689281734144

Quantity Description Order No.:1 Heater control See Opel price list



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Special features are highlighted using the following symbols:

Mechanical work

Electrical system

Coolant connection

Fuel connection

Exhaust system

Combustion air

The arrow in the vehicle icon indicates the position onthe vehicle and the viewingangle.

Opel Zafira B

Specific risk of injury or fatal accidents.

Specific risk of damage to components.

Specific risk of fire or explosion.

Reference to general installation instructions ofWebasto components or to the manufacturer's vehicle-specific documents.

Reference to a special technical feature.

i

Special Tools- Torque wrench for 2.0 - 10 Nm- Hose clamping pliers- Metric thread-setter kit



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5

Opel Zafira B

Heater unit installation location

1 Heater unit

Installationlocation

1

1

Explanatory Notes on Document

To provide you with a quick overview of the individual working steps, you will find an identification markon the outside top right corner of the page in question.

Preliminary Work

WARNING!

- Disconnect the battery "earth" or "ground" connection.- Depressurizethe 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.- Completelz remove the battery (only on 1.9 liter diesel).- Remove the air filter together with the intake hose.- Remove the right/hand windshield wiper.- Remove the coolant reservoir cap.- Remove the fuel filter.

- Open fuel tank cap, ventilate tank.- Close the tank cap again.- Remove fuel tank according to manufacturer's specifications.- Remove the bumper.- Remove the front section of the wheel well trim on the right.- Remove the underride protection (depending on vehicle equipment).- Remove the horns.- Remove the vacuum valve (only on 1.9 liter diesel).- Remove the lower instrument panel trim on the driver's side.- Remove the glove compartment.- Remove the fuel-tank sending unit in accordance with the manufacturers specifications.- Remove the glove compartment.- Remove the A/C control panel (only with automatic air-conditioning).

- Remove the A-pillar trim in the footwell on the front passenger side.- Remove the left-hand door sill cover completely (only on vehicles with alarm system).- Open the cable duct under the door sill cover (only with alarm system).



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Opel Zafira B

Preparing electrical system

Au tomat ic air -condit ioning (ECC andSAC)

Wire section 1 will be required later for

connection on A/C control panel.Cuttingwires tolength

Vehicles with passenger compartmentmonitoring

Wire sections 2, 3, 4 and 5will be requiredlater for switching off passengercompartment monitoring.

Cuttingwires tolength

Premount-ing wiringharness

sw 0,75mm1

100

sw 0,75mm2

70 200200

3 4 5

F3

K3

87a8786

85 30

K3.1

87a8786

85 30

31

30

rt/ws

4

HG

X1

gn/ws

rt

swsw

4

5

br

3sw sw

2



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Opel Zafira B

Electrical system

Wiring harness pass through

1 Protective rubber plug

Digital timer, summer/winter switch option

1 Summer/winter switch, drilled hole 12 mm dia.2 Digital timer, drilling template

Wiringharnessinstallationdiagram

Fuse holder, relay K3

2 5.5 mm dia. hole1 M5x12 bolt, large diameter washer [2x], K3

relay, angle bracket, M5 flanged nut

3 Ground support point, M6 flanged nut onexisting stud bolt4 Fuse holder retaining plate, M4x10 bolt,

washer, M4 nut5 Fuse holder

Addi tional K3.1 relay wi th passengercompartment monitoring

2 K3.1 relay1 4 mm dia. hole, 5.5x13 self-tapping screw

2

1

3

1

2

sw

rt

sw

sw

bl

br

Do not install the metering pumpcable harness until later togetherwith fuel pipe along the originalvehicle fuel lines on theunderbody

i

4

4

2

3

1

5

5

1

2



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Opel Zafira B

Only for vehicles with passengercompartment monitoring

Slide protective sleeving provided ontoadditional line (5) up to cable grommet inpassenger compartment.

Route additional line along left-hand A-pillarin cable duct to rear

1 Wire section 5

Installingadditionalline

Passenger compartment monitoring isswitched off on rear zone module behind left-hand luggage compartment trim!

2 Wire section 53 Connector X51 Socket of connector X5

Discon-nectingconnector

Dismantle connector X5 according tomanufacturer's instructions.Cut off front cable ties. Press both unlockinglugs toward rear with small screwdriver andpull off connector housing.

1 Connector X5

Unlockingconnector

Connection on blue (bl) connector X5 fromrear zone module.Produce connections according to wiringdiagram on Page 10 or 12, depending onequipment.

1 Connector X5, Pin 122 Wire section 5

Connect-ing line

61

1

73

1

2

81

92

1



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Opel Zafira B

Fan controller for manual airconditioning

Integration on 6-pin connector ZF 5-12 fromfan motor.

Produce connections as shown in wiringdiagram with blade connectors provided.

1 6-pin connector from resistor group

WARNING!Wiring colors may vary.Fan speed 2 must be controlled!

Connect-ing fan mo-tor

Wiring dia-

gram formanual aircondition-ing

Webasto components Opel components Colors and symbols

Legend

HG Heater unit TT-C/E M5 Fan motor rt red

X1 6-pin heater unit connector K15 Fan relay ws white

F3 Fuse R1 Fan resistor sw black

K3 Fan relay A1 Air-conditioning control panel br brown

FE Fuse gn green

bl blue

ge yellow

or orange

vi violet

X Cutting point

Wiring colors may vary.

101

sw

br

rt/ws

Webasto

31

30

15

Opel

rt

4

HG

X1

F3

25A

M

+

-

M5_A60

K3

87a8786

85 30

4

5

A1_A60

13 2

XC41

XC41

K15_X125

87 85

8630

FE4

30A

A1_X125

rt

or vi bl gn

R1_A60

4 1 2 5

1P

rt

sw

gn/ws

3

1P

sw

i



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10

Opel Zafira B

Only for manual air conditioning withpassenger compartment monitoring

Produce connection as shown in wiringdiagram with blade connectors provided.


Wiring dia-gram formanual aircondition-ing withpassengercompart-ment moni-toring


Legend

HG Heater unit TT-C/E M5 Fan motor rt red

X1 6-pin heater unitconnector

K15 Fan relay ws white

F3 Fuse R1 Fan resistor sw black

K3 Fan relay A1 Air-conditioning controlpanel

br brown

K3.1 Additional relay FE Fuse gn green

RZM Rear Zone module bl blue

or orangevi violet

X Cutting point


sw

sw

rt/ws

Webasto

31

30

15

Opel

rt

4

HG

X1F3

25A

M

+

-

M5_A60

K3

87a8786

85 30

4

5

A1_A60

13 2

XC41

XC41

K15_X125

87 85

8630

FE4

30A

A1_X125

rt

or vi bl gn

R1_A60

4 1 2 5

1P

rt

sw

gn/ws

K3.1

87a8786

85 30

12 X5

RZM

br

sw

sw

sw 24

3

5sw

3

1P

i



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Opel Zafira B

Fan controller of automatic air-conditioning (ECC and SAC)

Integration on 32-pin connector ZF 32 - 1from A/C control panel.

Produce connections as shown in wiringdiagram with blade connectors and micro-timer.

1 Wire section 12 32-pin connector

Connect-ing air-con-ditioningcontrol ele-ment

Wiring dia-gram of au-

tomatic air-condition-ing (ECCand SAC)


Legend

HG Heater unit TT-C/E KB Air-conditioning controlpanel

rt red

X1 6-pin heater unit connector ws white

F3 Fuse sw black

K3 Fan relay br brown

gn green

Insulate wire ends andtie back


112

1

gn/ws

sw

br

rt/ws

Webasto

31

30

15

Opel

rt

4

HG

X1

F3

1A

sw

K3

87a8786

85 30

!

1 ZF32-1

KB

1

i



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Opel Zafira B

Onlz for automatic air-conditioning withpassenger compartment moni toring (ECCand SAC)

Produce connection as shown in wiringdiagram with blade connectors provided.


Wiring dia-gram of au-tomatic air-condition-ing withpassengercompart-ment moni-toring

(ECC andSAC)


Legend

HG Heater unit TT-C/E KB Air-conditioning controlpanel

rt red

X1 6-pin heater unitconnector

RZM Rear Zone module ws white

F3 Fuse sw black

K3 Fan relay br brown

K3.1 Additional relay gn green

Insulate wire ends andtie back


sw

sw

rt/ws

Webasto

31

30

15

Opel

4

HG

X1F3

1A

K3

87a8786

85 30

rt

gn/ws

K3.1

87a8786

85 30

12 X5

RZM

br

sw

sw

sw 24

3

5

1 ZF32-1

KB

1sw

!

i



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Opel Zafira B

Remote opt ion (Telestart)

1 Receiver2 5.5 mm dia.hole, M5x12 bolt, flanged nut

[2x]3 Bracket

Installingreceiver

1 Antenna

Installingantenna

Only with T100HTM

1 Temperature sensor T100HTM

Installingtempera-ture sensor

2

3

3

12

1i

1

13

1

14



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Opel Zafira B

Remote option (Thermo Call)

1 Receiver2 4 mm dia. hole, 5.5x9.5 self-tapping screw

[4x]

Installingreceiver

1 Antenna

Installingantenna

1 Pushbutton

Installingpushbutton

1

2

15

i

1

16

1

17



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Opel Zafira B

Combustion air

1 Combustion air pipe a = 150 mm

Discard section X Cuttingcombus-tion airpipe tolength

Ensure proper installation position of airintake muffler, see "Installation Instructions.

1 Remove retaining clip and fasten wiringharness above wheel well with cable tie

Preassem-bling in-takemuffler

1 Combustion-air intake hose shortened2 Intake muffler3 Included clip with cable tie in existing hole

Preassem-bling in-takemuffler

a

1

X

18

1i

19

1 2 3



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Opel Zafira B

Preparing installation location

Cut included 200 mm long edge protection incenter.

1 Wiring harness of heater unit2 100 mm long edge protection

Installingedgeprotection

1 Cross member of bumper2 100 mm long edge protection

Installingedgeprotection

Remove the horns. Flanged nut will bereused.With 2 horns, mount bracket as shown

1 Original vehicle bolt

Preparinghorns

1 Original vehicle stud bolt, flanged nut2 Horn bracket

Installinghorns

20

1 2

21

2

1

22

1

23

2

1



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Opel Zafira B

With 1 horn, mount bracket as shown.Ensure freedom of movement to adjacentcomponents.

1 Original vehicle stud bolt, flanged nut2 Horn bracket

Installinghorns

Only for 1.9 liter diesel vehicles

2 Screw out silent block

1 Discard original vehicle bracket of vacuumvalve

Removingbracket ofvacuumvalve

1 Bracket of vacuum valve (Opel Number:9268928)

2 Screw in silent block [2x]

Completebracket ofvacuumvalve

3 Bracket of vacuum valve4 Original vehicle stud bolt, flanged nut of

horn bracket2 Vacuum valve1 Original vehicle flanged nuts

Installingvacuumvalve

24

2

1

25

1 2 2

26

1

2 2

273

1

4

2

1



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Opel Zafira B

Dimensions in mm!

1 7 mm dia. hole [2x]

Preparinginstallationlocation

Completely remove embossed grid on wheelwell trim.

1 Wheel well trim

Mountingrubberisolator

Preparing heater unit

Tighten EJOT screws to 10 Nm!

1 Heater unit2 Bracket3 Ejot screw [2x]

Preparingheater unit

Installing heater unit

Install 30 mm long spacer sleeve betweenbracket and body

1 Premounted bracket2 M6x50 bolt, large diameter washer, outside

22 mm, 30 mm long spacer sleeve, largediameter washer, outside 17.6 mm, M6flanged nut

3 M6x50 bolt, 30 mm long spacer sleeve,M6 flanged nut


28

20

11

23

27

1

1

29

1

30

1 2

3

31

1 2 3



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Opel Zafira B

1 Loosely mount bracket2 Heater unit3 Ejot screw [2x]4 Copy hole pattern, drill 9 mm hole [2x]


Install bracket 1 on heater unit again.Tighten EJOT screws to 10 Nm!

2 M6x20 bolt, spring lockwasher, largediameter washer, M6 rivet nut

3 Ejot screw [2x]4 M6x20 screw, spring lock washer, M6 rivet

nutInstallingheater unit

1 Flexible tube2 27 mm dia. clamp3 Heater unit

Installingcombus-tion-air in-take pipe

32

1

3

2

3

4

33

1 2

4

3

34

2

1

3



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Opel Zafira B

Water

WARNING!Tighten all hose clamps to 2.0 + 0.5 Nm.Any cold water 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 hose clamps and spring band clamps so that no other hose can be damaged.The connection should be "inline" based on the following diagram:

1.6 liter gasoline

Coolantroutingdiagram

All clamps without a specific designation = 27 mm dia. spring clips!

Engine

15x20

20x15

22

22

Heat

exchanger

20x20

B

A



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Opel Zafira B

WARNING!Tighten all hose clamps to 2.0 + 0.5 Nm.Any cold water 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 hose clamps and spring band clamps so that no other hose can be damaged.The connection should be "inline" based on the following diagram:

1.8 liter gasoline



Heat

exchanger

20x15

20x15

22

22

Engine

B

C

20x20

A



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Opel Zafira B


2.0 liter gasoline



Heat

exchanger

Engine

20x15

20x15

22

22

A

B



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Opel Zafira B


2.2 liter gasoline



Heat

exchanger

22

Engine

20x15

A

B C

20x20



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Opel Zafira B


1.9 liter diesel



Heat

exchanger

Engine

20x18

20x18

25

25

A

B



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25

Opel Zafira B


1.7 liter diesel



Heat

exchanger

22

Engine

20x15

C

A

B

20x15

20x20

22



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Opel Zafira B

Cut hoses to length

1.6 liter gasoline

a = 1,500 mmb = 1,250 mmc = 100 mm

Discard section X

Cuttingcoolanthoses tolength

1.8 liter gasoline

b = 1,500 mm

c = 1,150 mm

Discard section X


2.2 liter gasoline

Shorten hose sectionAaccording to diagramb = 1,570 mmc = 1,350 mm

Discard section XCuttingcoolanthoses tolength

2.0 liter gasoline

a = 1,500 mmb = 1,250 mm

Discard section X


a

A XX

b c

CB X

Ab

B XX

c

C X

b

B XX

XAc

C X

a

A XX

b

B X



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Opel Zafira B

1.9 liter diesel

a = 1,750 mmb = 1,350 mm

Discard section X


1.7 liter diesel

a = 1,530 mm

b = 1,250 mm

Discard section X


Braided protection

Al l vehicles

Cut one of the included braided protectionhoses and 2 pieces of heat shrink plastictubing in half. Mount braided protection hosesas shown and shrink.

1 Heat shrink plastic tubing cut in half2 Heat shrink plastic tubing completely at

cutting point

Mountingbraidedprotectionhose

Routing

Al l vehicles

1 27 mm dia. hose clamp [2x]

Connec-tion onheater unit

a

A XX

b

B X

C

a

A XX

b

B X

2A (B)1 1

21

1B (C)

35

B

A

1

1



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Opel Zafira B

1 40 mm spacer nut, rubber-coated p-clamp[2x], M6x20 bolt, spring lockwasher

2 M6x50 bolt, spring lockwasher, largediameter washer

Fasteningon enginesupport

1 Perforated bracket3 M6x20 bolt (from inside to outside), large

diameter washer, flanged nut

2 M6x20 bolt (from outside to inside), rubber-coated p-clamp, flanged nut [2x]

Fasteningon enginesupport

1.6 liter ; 1.8 liter; 2.0 liter gasoline and 1.9liter d iesel

1 Original vehicle nut2 Angle bracket

Routing inenginecompart-ment

1 Rubber-coated pipe clamp4 M6x20 bolt, flanged nut2 Cable tie3 Black (sw) rubber profile [2x]


36

B

A

2

1

37

B

A

1 2

2

3

38

1 2

39

B

A

3

4

1 2



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Opel Zafira B

Position rubber profile as shown in picture.


2.2 liter gasoline

2 M6x20 bolt, rubber-coated p-clamp, angle

bracket, flanged nut1 Original vehicle bolt


1 Servopump


1.6 liter gasoline

1 Hose of engine outlet2 Cutting point3 Hose section of heat exchanger inlet

Cuttingpoint

40

B

A

412

1 B

A

42

B

A

1

43

1 2 3



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30

Opel Zafira B

1 Hose of engine outlet

Connec-tion to en-gine outlet

1 Hose section of heat exchanger inlet

Connec-tion onheat ex-changer in -let

1.8 liter gasoline

1 Hose of engine outlet2 Cutting point3 Hose section of heat exchanger inlet

Cuttingpoint

1 Hose of engine outlet


44A

1

45B

1

46

1 2 3

47A1

B



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Opel Zafira B


Connec-

tion onheat ex-changer in -let

2.0 liter gasoline

Hose has been disconnected from heat

exchanger inlet!

1 Hose section of heat exchanger inlet2 Hose of engine outlet3 Cutting point [2x]

Cuttingpoint

1 Hose section of heat exchanger inlet2 Hose of engine outlet

Connec-tion on en-gine outletand heatexchangerinlet

2.2 liter gasoline

1 Cutting point2 Hose section of heat exchanger inlet3 Discard hose on engine outlet, original

vehicle clamp will be reused

Cuttingpoint

48

C 1

49

3

2

1

50

B

A 2

1

513

21



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32

Opel Zafira B




1.9 liter diesel

Remove hose 1 from engine outlet/heatexchanger inlet.

3 Cutting point [2x]1 Discard hose section2 Hose section of heat exchanger inlet4 Hose of engine outlet

Cuttingpoint

Routing onfirewall

52B A

53C

1

5434

21

55

B

A



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Opel Zafira B

1 Hose of engine outlet2 Spacer bracket




1.7 liter diesel

Cut off hose on engine outlet/heat exchangerinlet 1at markings.

1 Engine-outlet hose section2 Discard hose section3 Remove hose section on heat exchanger

inletCuttingpoint

Reinstall hose on heat exchanger inlet.


Premount-ing hose C

56A

1

2

57

B

1

582 1

3

59

C

1



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34

Opel Zafira B

Slide on 48 mm dia. rubber-coated p-clamp 3over hoseAand Band fasten on originalvehicle stud bolt with plastic nut 1.

2 Black (sw) rubber isolator [2x]

Routing onfirewall


1 Hose of engine outlet2 Black (sw) rubber isolator


1 Spacer bracket

Installingspacerbracket

60

B

A

21

3

2

61

B

C

621

A

2

63

1A

B



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Opel Zafira B

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 harnessrouting diagram.

1 Mecanyl fuel line2 Hose section, 10 mm dia. hose clamp [2x]

Connec-tion onheater unit

1 Mecanyl fuel line and wiring harness of

metering pump, original vehicle lines

Installinglines

Fuel line from fuel standpipe on intake side ofmetering pump [side without connector].Check the position of the components; adjustif necessary. Check that they have freeclearance.

3 Mecanyl fuel line4 Hose section, 10 mm dia. hose clamp [2x]2 Metering pump wiring harness1 Plug-in contacts, single wire seal,

connector housing

Connec-tion to me-teringpump

64

2

1

65

1

66

2

1

4

3



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36

Opel Zafira B

Al l vehicles except 1.7 l iter diesel

Remove and dismantle fuel tank and fuel-tank sending unit 1according tomanufacturer's instructions.

2 Cut out template and lay on3 Copy hole pattern, 6 mm dia. hole

Removingfuel

1 Fuel standpipe2 Hose section, 10 mm dia. Caillau clamp

[2x]

3 Fuel line

Mountingfuelstandpipe

1.7 liter diesel

Remove and dismantle fuel tank and fuel-tank sending unit 1according tomanufacturer's instructions.

2 Cut out template and lay on3 Copy hole pattern, 6 mm dia. hole

Removingfuel

1 Fuel standpipe2 Fuel line3 Hose section, 10 mm dia. Caillau clamp

[2x]

Mountingfuelstandpipe

67

1

23

68

31 2

69

1

3

2

70

1

1

2

3



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Opel Zafira B

1 Cable tie [2x]2 Fuel line

Mountingfuel-tanksendingunit

Al l vehicles

Route fuel line along original vehicle fuel lines

to installation location of metering pump. Fuelline from fuel standpipe on intake side ofmetering pump [side without connector].Check the position of the components;adjust if necessary. Check that they have freeclearance.

1 Fuel line2 Hose section, 10 mm dia. hose clamp [2x]

Connec-tion to me-teringpump

71

1

12

1

72

1 2



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Opel Zafira B

Exhaust gas

1 Exhaust pipe a = 200 mm2 Exhaust end section b = 150 mm

Discard section X

Preparingexhaustpipe

1 Bracket2 M6x16 bolt, flanged nut3 Muffler

Installingmuffler

4 Exhaust elbow2 Exhaust pipe3 Red (rt) rubber isolator1 Hose clamp [3x]

Installingexhaustpipe

4 Exhaust muffler3 Exhaust end section1 Hose clamp2 Position red (rt) rubber isolator [2x]

Installingexhaustpipe andendsection

a B

1 2

X

73

1

23

1

1

2

3

4

741

1 2

3

4

75



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39

Opel Zafira B

Gasoline

Design of underride protection/wheel welltrim is dependent on vehicle equipment

Cut out underride protection/wheel well trim

on marking. Dimensions in mm!

1 42 mm dia. holeCutting outunderrideprotection

Diesel

1 42 mm dia. hole

Cutting outunderrideprotection

Al l vehicles

First position red (rt) rubber isolator 2onexhaust end section 3from below, then insertwith groove in underride protection 1. Alignend cap of exhaust end section 3flush on red(rt) rubber isolator 2as shown.

1 Underride protection/wheel well trim2 Red (rt) rubber isolator with groove3 Exhaust end section

Mountingrubberisolator

1 Wheel well trim2 Premounted bolt from fastener of coolant

hoses, M6 flanged nut

Mountingwheel welltrim

76

1

90

50

77

1

50

90

78

1

3

2

79

1

2



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Opel Zafira B

Webasto AGPostfach 80 - 82132 Stockdorf, Germany - Hotline +49-(0)1805-932278Hotfax +49-(0)395-5592-353 - http://www.webasto.de

Feel the dr ive

Final Work

WARNING!Reassemble the disassembled components 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 the heater unit components with anti-corrosion wax (Tectyl 100K, Order No. 111329).

- Connect the battery- Start the engine, bleed the coolant circuit according to the instructions of the vehicle manufacturer

and add coolant- Set the digital timer.- Adjust the vehicle heater with automatic air-conditioning or without automatic air-conditioning

according to "Operating Instructions for End Customer".- Check the proper operation of the additional heater, see the operating instructions/installation

instructions.- Attach the "Switch off additional heater before refueling" sticker to the left-hand B-pillar.

i

Printed in Germany 03/08Printed by: Steffen



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Opel Zafira B

6 mm dia.

Template for Fuel Sender

All vehicles except 1.7 liter diesel

1.7 liter diesel

6 mm dia.

0

100 mm

100 mm

Scale 1:1

Compare the size of the printed version with dimension lines.Permitted tolerance a maximum of 2%.

Correct major differences in the printer settings or request anoriginal printout.



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42

Opel Zafira B

Template for Fuel StandpipeAl l vehicles except 1.7 l iter diesel

1.7 liter diesel

0

100 mm

100 mm

Scale 1:1

Compare the size of the printed version with dimension lines.Permitted tolerance a maximum of 2%.

Correct major differences in the printer settings or request anoriginal printout.



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Opel Zafira B

Operating Instructions for End CustomerPlease remove page and add to the vehicle operating instructions.

On vehicles with passenger compartment moni toring, this is deactivated when operating theadditional heater!Before parking the vehicle, make the following settings:

1 Air outlet at windshield for "Defrost"2 Set temperature to "max."

For vehi-cles with-outautomaticair-condi-tioning

1.Air outlet at windshield for "Defrost"2 Set temperature to "max."

Vehicleswith "Auto-matic aircondition-ing" (SAC)

1 Set temperature to "max."2 Air distribution upward

For vehi-cles withautomaticair-condi-tioning

(ECC)

Forvehicleswithautomatic

i

80

1

2

812

1

82

1

2


09163238 zafira b english

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