Webasto Thermo Top E Manuale dell'operatore

Water Heater

Installation documentation

Ident. No.: 1314421C_EN Fee Euro 10.00 © Webasto AG

VW Golf VI, Golf Plus, Golf Variant

1.2 and 1.4 TSI

from Model Year 2008

Left-hand drive vehicle

Feel the drive

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, specialised tools and equipment are

required to install and repair Webasto heating and cooling systems.

Only original Webasto parts must be used. For this, also see the catalog of air and water heat-

er accessories from Webasto.

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 warnings.

Webasto does not accept any liability for defects and damage that are attributable to installa-

tion by untrained staff.

Thermo Top E Parking Heater

00 0003

Thermo Top C Parking Heater

00 0002

Thermo Top P Parking Heater

00 0104

VW Golf VI, Golf Plus, Golf Variant

1314421C_EN 2

Table of Contents

Validity

Vehicle and engine types, equipment variants and national specifications not listed in this installation

documentationhavenot beentested. However,installationaccordingtothis installationdocumentation

may be possible.

The installation location of a digital timer and summer/winter switch should be confirmed with the end

customer before installation.

Manufacturer Model Type EG-BE No./ABE

VW Golf VI 1K e1 * 2001/116 * 0242 * ...

VW Golf Plus 1KP e1 * 2001/116 * 0304 * ...

VW Golf Variant 1KM e1 * 2001 / 116 * 0328 * ...

Engine type Engine model Output in kW Displacement in cm³

CBZA Petrol/TSI 63 1197

CBZB Petrol/TSI 77 1197

CAXA Petrol/TSI 90 1390

CAVD Petrol/TSI 118 1390

Validity 2

Heater/Installation Kit 3

Foreword 3

General Instructions 3

Special Tools 3

Explanatory Notes on Document 4

Preliminary Work 5

Heater installation location 5

Electrical system 6

Fuse holder and K3 relay 7

Climatic fan control 8

Climatronic fan control 10

Digital timer, summer/winter switch option 13

Remote option (Telestart) 13

Premounting heater 15

Preparing exhaust system 16

Installing heater 17

Fuel 18

Coolant circuit 21

1.2 Manual transmission 22

1.4 90kW manual transmission 24

1.4 90kW DSG 27

1.4 118 kW manual transmission 31

All vehicles 35

Exhaust gas 36

Final Work 37

Reduce sensitivity of passenger compartment

monitoring 37

Operating Instructions for End Customer 38

VW Golf VI, Golf Plus, Golf Variant

1314421C_EN 3

Heater/Installation Kit

Also required with Climatronic:

Heater recommended for the respective vehicle class:

The selection of the heater is based on the passenger compartment size of the vehicle and the level of

comfort required by the customer.

Foreword

This installation documentation applies to the vehicles VW Golf VI, Golf Plus, Golf Variant 1.2 and 1.4

TSI - for validity, see page 2 - from model year 2008 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 this installation docu-

mentation.

However, the stipulations in the "installation documentation", the "operating instructions" and the "in-

stallation 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 should be fitted with rub protection (split-open plastic hose).

Spray unfinished body areas, e.g. drilled holes, with anti-corrosion wax (Tectyl 100K, Order No.

111329).

When installing an IPCU, check or adjust the corresponding settings before installation.

Special Tools

- Torque wrench for 2.0 - 10 Nm

- Hose clamping pliers

- Metric thread-setter kit

Quantity Description Order No.:

1 Retail accessories Thermo Top E / C / P See price list

1 Installation kit for VW Golf VI, Golf Plus, Golf Variant 1.2 and

1.4 TSI 1314420B

1 Heater control See Price list

Quantity Description Order No.:

1 IPCU Kit for Climatronic 9013645A

Vehicle Heater

Compact car Thermo Top E

Mid-size car, station wagon Thermo Top C

Full-size car, van, offroader Thermo Top P

VW Golf VI, Golf Plus, Golf Variant

1314421C_EN 4

Special features are highlighted using the following symbols:

The arrow in the vehicle icon indicates the position on

the vehicle and the viewing angle.

Specific risk of injury or fatal accidents.

Specific risk of damage to components.

Specific risk of fire or explosion.

Referenceto generalinstallationinstructions ofWebas-

tocomponentsortothemanufacturer'svehicle-specific

documents.

Reference to a special technical feature.

All dimensions are in mm!

Tightening torque of hose clamps = 2.0 + 0.5 Nm!

Tightening torque of Ejot screws, Ejot studs = 10 Nm!

Mechanical system

Electrical system

Coolant circuit

Fuel

Exhaust gas

Combustion air

Explanatory Notes on Document

You will find an identification mark on the outside top right corner of the page in question to provide you

with a quick overview of the individual working steps.

VW Golf VI, Golf Plus, Golf Variant

1314421C_EN 5

Preliminary Work

WARNING!

- Open the fuel tank cap, ventilate the tank.

- Close the fuel tank cap again.

- Depressurise the 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.

- Disconnect the battery "earth" or "ground" connection.

- Completely remove the battery with the battery carrier.

- Remove the engine cover.

- Detach the coolant reservoir cap.

- Remove the left front wheel.

- Remove the front section of the left front wheel well trim.

- Remove the left-hand front fog light or, on vehicles without front fog lights, the left-hand cover.

- Remove the underride protection

- Remove the right-hand underbody trim.

- Remove the rear bench seat.

- Open the right-hand tank-fitting service lid.

- Remove the footwell trim on the driver's side

- Remove the lower instrument panel trim on the driver's side

- Only vehicles with Climatronic: Remove the footwell trim on the front passenger side

Remove page 38 "Operating Instructions for End Customer" and add to the vehicle operating instruc-

tions.

Heater installation location

1Heater

Installa-

tion loca-

tion

VW Golf VI, Golf Plus, Golf Variant

1314421C_EN 6

Electrical system

Wiring harness routing

Route excess lengths from wiring harness 1in

cable duct 2below battery and secure with cable

ties.

Wiring harness pass through

1Original vehicle wiring harness pass through

Wiring har-

ness rout-

ing

diagram

Fuse holder, K3 relay

Description of installation for K3 relay 1and fuse

carrier 2on Page 7

Wiring harness pass through

1Original vehicle wiring harness pass through

Do not install the metering pump

wiring harness until later togeth-

er with fuel pipe along the origi-

nal vehicle fuel line on the

underbody

VW Golf VI, Golf Plus, Golf Variant

1314421C_EN 7

Fuse holder and K3 relay

Countersink holes 3from behind for M5 coun-

tersunk head screws.

1Cover of fuse/relay carrier in engine com-

partment

2Cut away bar in shaded area

35 mm dia. hole [2x]

Holes in

cover

1M5x12 countersunk head screw [2x]

Installing

fuseholder

and relay

On vehicles with Climatronic, replace 25 A

fuse F3 7with 3 A fuse provided.

1M5 flanged nut

2Large diameter washer (between cover

and retaining plate)

3Retaining plate

4M5 flanged nut

5Relay K3

6Fuse holder

Installing

fuseholder

and relay

Route brown (br)earthwireto original vehicle

earth support point below headlight and con-

nect.

1Fuse/relay carrier

2Original main vehicle fuse

3Red (rt) positive wire Connect-

ing posi-

tive and

earth wire

VW Golf VI, Golf Plus, Golf Variant

1314421C_EN 8

Climatic fan control

Climatic

wiring dia-

gram

Webasto components Vehicle components Colours and symbols

Legend

HG Heater TT-C/P/E GM Fan motor rt red

X1 6-pin heater connector F1*Fuse 40A (depending on respec-

tive fuse assignment)

Golf VI = SC22 or SC40

Golf Plus = SC33

ge yellow

F3 25 A fuse sw black

K3 Fan relay ** Wire depends on

the respective vehi-

cle equipment

Golf VI = red/yellow

(rt/ge)

Golf Plus = red yel-

low (rt/ge) or

black/yellow (sw/ge)

J301 Control unit of air conditioning

T5 5-pin connector J301

N24 Resistor group

T4f 4-pin connector N24

T10k Connector

XCutting point

Wiring colours may vary.

Webasto

X1 F3 F1

85 30

87a87

4²

3241 T4f

N24

J301

5T5

3214 T5

2V2

rt/sw

rt/

ge rt/

ge sw/

rt/

4²

rt/ws

rt/ge 4² T10k

*SC22/SC40

(SC33)

(sw/ge) 4²

VW Golf VI, Golf Plus, Golf Variant

1314421C_EN 9

Golf VI and Variant

Connection on fuse carrier 2(instrument pan-

el at upper left). Remove red/yellow (rt/ge) 4²

wire 1on fuse output SC 22 or SC40 (de-

pending on respective vehicle equipment). Connec-

tion to fuse

carrier

Red (rt) wire 4from K3/87a with crimped-on

standard power timer interlocked in fuse out-

put SC 22 or SC40.

Produce connections as shown in wiring dia-

gram.

1Red/yellow (rt/ge) wire of fuse SC22 or

SC40

2AMP housing

3Black (sw) wire to K3/30

Connect-

ing wires

Golf Plus

Connection on fuse carrier 1(instrument pan-

elatbottomleft).Removered/yellow(rt/ge)4²

wire 2on fuse output SC33 (depending on re-

spective vehicle equipment). Connec-

tion to fuse

carrier

Red (rt) wire 1from K3/87a with crimped-on

standard power timer interlocked in fuse out-

put SC33.

Produce connections as shown in wiring dia-

gram.

2AMP connector

3Red/yellow (rt/ge) wire from fuse S33

4Black (sw) wire to K3/30

Connect-

ing wires

VW Golf VI, Golf Plus, Golf Variant

1314421C_EN 10

Climatronic fan control

Climatron-

ic wiring

diagram

Webasto components Vehicle components Colours and symbols

Legend

HG Heater TT-C/P/E F1*Fuse 40A (depending on re-

spective fuse assignment) of

SC22 or SC56

rt red

X1 6-pinheater connector ws white

K3 Fan relay sw black

F3 Replace 25 A fuse

with 3 A fuse T10k Plug connections br brown

J255 Climatronic control unit gn green

IPCU Pulse width modulator T16d 16-pin connector J255 ge yellow

J126 Fan controller

IPCU adjustment values: V2 Fan motor bl blue

Duty cycle: 30% T6t 6-pin connector J126 Insulate wire ends and

tie back

Frequency: 400Hz

Voltage: 8V XCutting point

Function: High side Wiring colours may vary.

Webasto

85 30

87a87

X1 4

4²

J126

T6t

3412

J255

T16d

1516

sw/

ws bl/

0,35² 0,35²

86 85

IPCU

4²

gn/ws

2T10k

sw/

0,35²

sw/ws

rt/ws

4²

rt/

4²

0,75²

SC22/

SC56

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