Vermes
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This article is to describe how to assemble Webasto Thermo top Z from Rover 75 in Ford Orion 1,8D 1992. Due to the fact that it is a really old car and sometimes it is difficult to start it in the winter, when you are an owner of such a vehicle – this text is for you.
Assembly:
First of all, you have to remove the original air filter and replace it with a conical air filter. Doing that, you make space for mounting the stove. The only disadvantage of this solution is that the motor works more noisy because of the conical air filter, but not too much.
Connection of the liquid:
The liquid should be connected in a way that at first it warms the motor and next the heater, because in this vehicle it is more important to warm up the motor.
Fuel:
It is recommended to purchase spring bands to provide better assembly. This car uses filtered fuel. You have to add a return filter in order to prevent fuel backtracking. Both the motor and Webasto work perfect and there is no problem with starting them.
Current:
The supply comes from the accumulator and is protected with 15A safety fuse. 8-wire twisted cable goes from the Webasto to the inside of the car. Why 8 wires? Ground and +12V (safety fuse 300mA) goes to the cabin, then output and return of the stove switching, KBUS signal from the stove so that when you sit inside the car you can easily read the errors of the stove or just it can be monitored.
Exhaust:
The exhaust was filed, cut, bent and then a corrugated aluminum tube was added.
Mounting the stove:
The mounting was carried out using original profile from Volkswagen and using flat bars and angles twisted on the bolts. Generally the stove is attached to the chassis but it is also stabilized by the side bars. Due to the vibration, everything is distanced by the rubber screws.
Control:
Control was carried out by processing a factory programmer - changing the 24V relay to 12V and adding 2 resistors. An old socket RJ45 was used as the output interface of the programmer. The programmer is equipped with its own battery, so that it can be disconnected and taken away. Main functions of the programmer are: setting the start and stop time (it has 20 modes). There is also Timer which is extremely useful when you want to start the stove for eg 15 minutes by one click.
Pictures:
Link to original thread - Webasto Thermo top Z w Ford Orion 1,8D 1992r.