Webasto Air Top 3500 ST D Installation Instructions
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
equipment are required to install and repair Webasto heating and cooling systems.
NEVER attempt to install or repair Webasto heating or cooling systems if you have not
successfully completed the company training and thereby acquired the required
technical skills, or if you do not have access to the required technical document ation,
tools and equipment needed to carry out correct installation and repairs.
ALWAYS follow all Webasto installation and repair instructions and observe all
warnings.
Webasto does not accept any liability for defects and damage that are attributable to
installation by untrained staff.
Feel the drive
Renault Master/Nissan Interstar
Diesel
from Model Year 2004
Left-hand drive vehicle
Vehicles without partition wall
ID No.:1312624C_EN Fee Euro 10 © Webasto AG
Air Heater Unit
Air Top 3500 ST D Additional Heater
Installation Instructions
e1
00 0015
22
Renault Master/Nissan Interstar
Validity 2
Heater Unit/Delivery Scope 3
Foreword 3
General Instructions 3
Special Tools 3
Explanatory Notes on Document 4
Preliminary Work 5
Heater unit installation location 5
Preparing installation location 6
Preparing heater unit 7
Installing heater unit 7
Preparing hot air ducting 8
Preassembling hot air ducting 9
Installing hot air ducting 9
Installing hot air distribution 10
Recirculating air intake 12
Exhaust system 14
Combustion air 15
Fuel Connection 16
Electrical Connections 19
Connection Diagram for Combination Timer and
Telestart 20
Heater control option 21
Remote option (Telestart) 22
Installing trim parts 23
Final Work 24
Template for Heater Unit 25
Table of Contents
Validity
Manufacturer Model Type EG-BE No./ABE
Nissan Interstar J3 e2 * 2001 / 116 * 273
F3 L223
U3 L414
E3 N004
N3 L226
Manufacturer Model Type EG-BE No./ABE
Renault Master JD e2 * 98 / 14 * 0129
ED H914
FD H912
GD K150
HD K149
UD H913
ND K309
PD K535
RD K535
Engine type Engine model Output in kW Displacement in cm³
F9Q Diesel 60 1870
G9T Diesel 66 2188
G9T Diesel 84 2188
G9U Diesel 73 2463
G9U Diesel 74 2463
G9U Diesel 88 2463
G9U Diesel 107 2463
ZD3 Diesel 100 2953
33
Renault Master/Nissan Interstar
Heater Unit/Delivery Scope
Optional heater control either:
Foreword
These installation instructions apply to Renault Master/Nissan In terst ar vehicles with a Diesel engine
- for validity, see page 2 - from model year 2004 and later, assuming technical modifications to the
vehicle do not affect installation, any liability claims excluded. Depending on the version and the
equipment variants of the vehicle, changes may be necessary relative to these "installation
instructions" during installation and must be adjusted accordingly.
However, where this is the case the stipulations in the "installation instructions" and "operating and
maintenance instructions" for the Air Top 3500 ST should be observed.
The corresponding rules of technology and any information from the vehicle manufacturer should be
observed during the installation work.
The installation location of heater controls and the ro uting of the air ducting part s must be coor dinated
with the final customer prior to installation!
WARNING!
Original load-bearing components of the vehicle and/or component used for crash safety may not be
modified for the hot air and recirculating air ducting!
General Instructions
Installation should be carried out according to the general, standard rules of technology. Unless
specified otherwise, fasten hoses, lines and wiring harnesses to original vehicle lines and wiring
harnesses using cable ties.
Sharp edges 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).
Special Tools
- Metric thread-setter kit
- Hole circle bit 83 mm dia.
- Hole circle bit 92 mm dia.
Quantity Description Order No.:
1 Delivery scope of AT 3500 ST D 12V with heater control 9008944A
1 Installation kit Renault Master / Nissan Interstar Diesel
AT3500ST
1312622B
Quantity Description Order No.:
1 Digital timer (combination 12 V) 9010385A
1 Mounting plate for digital timer (frame) 474630
1 Telestart (only in conjunction with combination timer) See price list
1 Y-cable for combination timer - Telestart 1311194A
44
Special features are highlighted us ing the following symbols:
Mechanical work
Electrical system
Hot air system
Fuel connection
Exhaust system
Combustion air
The arrow in the vehicle icon indicates the position on
the vehicle and the
viewing angle.
Renault Master/Nissan Interstar
Specific risk of injury or fatal accidents.
Specific risk of damage to components.
Specific risk of fire or explosion.
Reference to general installation instructions of
Webasto components or to the manufacturer's vehiclespecific documents.
Reference to a special technical feature.
i
Explanatory Notes on Document
T o 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.
5
Renault Master/Nissan Interstar
Heater unit installation location
1 Heater unit
Installation
location
1
1
Preliminary Work
WARNING!
- Disconnect the battery "earth" or "ground" connection.
- 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.
- If installed, remove the rear seat row behind the driver's seat
- If installed, remove the floor covering behind the driver's seat
- Remove the trim of the A-pillar on the driver's side
- Remove the sun vizor on the driver's side
- Remove the front left side trim in the cargo space (only with cargo space trim)
6
Renault Master/Nissan Interstar
Preparing installation location
Lay on drilling template 2 provided exactly;
remove underbody protection in corners as
shown (arrows) if necessary. Holes may not
be located in area of beads.
1 Copy hole pattern, drill 7 mm hole [4x] in
floor panel
Copying
hole
pattern
Reapply underbody protection.
1 83 mm dia.hole in floor panel
Hole in
floor panel
Drill opening so that only horizontal bar is left
in place.
1 92 mm dia. hole in floor panel
Hole in
floor panel
Ensure sufficient corrosion protection for all
holes.
1 92 mm dia. hole in floor panel, install edge
protection
Hole in
floor panel
2
1
1 2
6
1
1
85 mm
535 mm
3
1
46 mm
70 mm
4
1
60 mm
65 mm
5
1
7
Renault Master/Nissan Interstar
Preparing heater unit
1 Push on wiring harness
Connecting wiring
harness
1 Mount cover offset by 180°
Installing
cover
2 Bracket of heater unit
1 Washer, self-locking nut [4x each]
3 Loosely lay on bracket for splash
protection
Installing
bracket
Installing heater unit
Fasten preassembled heater unit 1 to
underbody with 4 self-locking M6 nuts and 4
large diameter washer.
Remove red (rt) wire in wiring harness to fuse
holder on blade-type fuse holder.
Route wiring harness of fuse and
digital/combination timer 2 in frame side
member along frame side member to battery
box.
Insert red (rt) wire again on fuse holder.
Fasten wiring harness with cable ties.
Installing
heater unit
6
1
7
1
8
1
1 2
1
1
3
9
1
2
8
Renault Master/Nissan Interstar
Preparing hot air ducting
2 Insert pass through into existing opening
1 Copy hole pattern, drill 4.5 mm hole [4x]
Preparing
pass
through
2 Insert pass through in existing opening and
seal off with sealing compound
1 M4x12 bolt [4x], washers [8x], M4 flanged
nut [4x]
Installing
pass
through
1 Position kick guard
2 Copy hole pattern for 9.1 mm hole [4x]
Lay on kick
guard
1 Drill out hole to 9.1 mm dia., mount rivet nut
[4x each]
Installing
rivet nut
10
1 1
1
2
1
1 1
1
2
1
11
12
2
1
2
2
2
1 1
1
1
13
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