Webasto Thermo Top E Manuale utente
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 suc-
cessfully completed the company training and thereby acquired the required technical 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.
Water Heater Unit
Installation Instructions
Ident. No.:1313475D_EN Fee Euro 10.00 © Webasto AG
VW Tiguan
Gasoline and Diesel
from Model Year 2008
Left-hand drive vehicle
Climatronic
Feel the drive
Thermo Top E Additional Heater e1
00 0003
Thermo Top C Additional Heater e1
00 0002
Thermo Top P Additional Heater e1
00 0104
VW Tiguan
1313475D_EN 2
Table of Contents
Validity
Vehicle and engine types, equipment variants and national specifications not listed in these installation
instructionshavenotbeentested.However,installation according to these installationinstructions 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 Tiguan 5N e1 * 2001/116 * 0450
Engine type Engine model Output in kW Displacement in cm³
BWK Gasoline 110 1390
CAWA Gasoline 125 1984
CAWB Gasoline 147 1984
CBAB Diesel 103 1986
CAHB Diesel 125 1986
Validity 2
Heater Unit/Installation Kit 3
Foreword 3
General Instructions 3
Special Tools 3
Explanatory Notes on Document 4
Preliminary Work 5
Heater unit installation location 5
Preparing electrical system 6
Electrical system 7
Fuse holder and relay K3 8
Fan controller 9
Digital timer 11
Remote option (Telestart) 11
Preparing bracket 12
Premounting heater unit 12
Installing heater unit 14
Coolant on 1.4 liter and 2.0 liter TSI 16
Coolant on 2.0 liter TDI 21
Fuel Connection 25
Exhaust gas 29
Final Work 30
Operating Instructions for End Customer 31
VW Tiguan
1313475D_EN 3
Heater Unit/Installation Kit
Other required parts
Also required with Climatronic
Heater unit recommended for the respective vehicle class:
The selection of the heater unit is based on the passenger compartment size of the vehicle and the
level of comfort required by the customer!
Foreword
These installation instructions apply to VW Tiguan Gasoline and Diesel vehicles - 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, modifica-
tions may be necessary during installation with respect to these installation instructions.
However,thestipulations in the "installationinstructions"and"operating and maintenanceinstructions"
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 must be provided with rub protection (cut-open fuel hose)!
Spray unfinished body areas, e.g. drilled holes, with anti-corrosion wax (Tectyl 100K,
Order No. 111329).
Special Tools
- Torque wrench for 2.0 - 10 Nm
- Hose clamping pliers
Quantity Description Order No.:
1 Retail accessories with desired heater control See price list
1 Installation kit for VW Tiguan Gasoline and Diesel 1313473B
Quantity Description VW Order No.:
1 Plate washer 191 411 331
Quantity Description Order No.:
1 Kit for Climatronic VW Tiguan 1313474A
Vehicle Heater Unit
Compact car Thermo Top E
Mid-size car, station wagon Thermo Top C
Full-size car, van, offroader Thermo Top P
VW Tiguan
1313475D_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.
ReferencetogeneralinstallationinstructionsofWebas-
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
Fuel
Exhaust gas
Combustion air
Explanatory Notes on Document
To 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.
VW Tiguan
1313475D_EN 5
Preliminary Work
WARNING!
- Open the fuel tank cap and vent the fuel tank.
- Close the tank cap again.
- Depressurize 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.
- Remove the battery
- Remove the battery carrier
- Remove the engine cover
- Remove the air filter (only on 2.0 TSI).
- Remove the right-hand charge-air tube.
- Remove the charge-air tube completely (only on 2.0 TSI).
- Remover the front right wheel well trim and detach on the left.
- Remove the bumper
- Remove the underride protection
- Remove the right-hand underbody trim
- Remove right rear single seat
- Open the right-hand fuel sender service lid
- Remove the footwell trim on the driver's side
- Remove the lower instrument panel trim on the driver's side
- Remove the footwell trim on the front passenger side
Remove page 31 "Operating Instructions for End Customer" and add to the vehicle operating instruc-
tions.
Heater unit installation location
1Heater unit
Installa-
tion loca-
tion
11
VW Tiguan
1313475D_EN 6
Preparing electrical system
Lines for
IPCU
Install lines according to wiring diagram.
Preparing
IPCU
3
500
br
0,75²
2
500
sw
0,75²
1
500
rt
0,75²
2
86 85
A
E
15
IPCU
1
2
3
A
15
86 85
E
3
VW Tiguan
1313475D_EN 7
Electrical system
Wiring harness pass through
1Original vehicle wiring harness pass through
Wiring harness pass through
1Original vehicle wiring harness pass through
Wiring har-
ness in-
stallation
diagram
Routing wiring harness
1Wiring harness of heater unit and wiring har-
ness of metering pump in corrugated tube
2Adhesive base [2x]
Fuse holder, K3 relay
Description of installation for K3 relay 1and fuse
carrier 2on Page 7
4
1
5
1
Do not installthe metering pump
cableharnessuntillatertogether
with fuel pipe along the original
vehicle fuel lines on the under-
body
6
2
2
1
7
2
1
VW Tiguan
1313475D_EN 8
Fuse holder and relay K3
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
35.0 mm dia. hole [2x]
Holes in
cover
1
M5x12 countersunk head screw [2x]
Installing
fuseholder
and K3 re-
lay
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 K3 re-
lay
Route brown (br) ground wire to original vehi-
cle ground support point below headlight and
connect.
1Fuse/relay carrier
2Original main vehicle fuse
3Red (rt) positive wire Connect-
ing posi-
tive and
ground
wire
1
8
40
99
3
20
2
3
9
11
6
2
3
10
74
5
1
21
3
11
VW Tiguan
1313475D_EN 9
Fan controller
Wiring dia-
gram
Webasto components Vehicle components Colors and symbols
Legend
HG Heater unit TT-C/E F1 Fuse SC22 or SC56 with 40 A rt red
X1 6-pin heater unit con-
nector ws white
K3 Fan relay KB Climatronic control unit - J255 sw black
F3 Fuse (25 A replaced
with 3 A!) T10k Plug connections br brown
ge Fan control unit - J126 and fan
motor - V2 gn green
IPCU Pulse width modulator ge yellow
IPCU adjustment values bl blue
Voltage: 8 V Insulate wire ends
and tie back
Frequency: 400 Hz
Duty cycle: 30 %
Function: High-side XCutting point
31
30
15
VW
br
sw/
ws rt/
ge
T10k
rt/ws
bl/
ws
Webasto
rt
sw
br
sw
86 85
A
E
IPCU
HG
4
X1 F3
86
85 30
87a87
K3
GE
T6t
31 42
M
KB
T16f
15 16 F1
sw/
ws
0,75²
0,75²
0,75²
0,75²
rt
!
VW Tiguan
1313475D_EN 10
1Original vehicle bolt
2IPCU socket
Installing
IPCU
1Original vehicle bolt
2Brown (br) wire of IPCU/85
Connec-
tion to
ground of
IPCU
1Black (sw) wire of IPCU/A
2Black/white (sw/ws) wire of connector
T6t/2
3Connector T6t
4Black/white (sw/ws) wire of Climatronic
connector T6t/15
5Red (rt) wire of IPCU/E Connect-
ing wires
12
1
2
13
1
2
3
14
4
5
1 2
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