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.:9013722D_EN Fee Euro 10.00 © Webasto AG

VW Caddy

1.6 Liter Gasoline and 2.0 Liter Gasoline Eco Fuel; 2.0 Liter SDI

from Model Year 2005

Left-hand drive vehicle

Feel the drive

Thermo Top E Additional Heater e1

00 0003

Thermo Top C

Additional Heater

00 0002

Thermo Top P Additional Heater e1

00 0104

VW Caddy

9013722D_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 Caddy 2KN L 320

VW Caddy 2K150 e1*2001/116*0252*...

Engine type Engine model Output in kW Displacement in cm³

BSE Gasoline 75 1595

BSX Gasoline [Eco Fuel] 80 1984

BDJ Diesel 51 1968

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

Electrical system 6

Fuse holder and relay K3 7

Climatic fan controller 8

Climatronic fan controller 10

Remote option (Telestart) 12

Preparing heater unit 13

Preparing installation location 13

Installing heater unit 14

Fuel 16

Coolant for gasoline engine 21

Coolant for diesel engine 25

Combustion air 29

Exhaust gas 30

Final Work 31

Operating Instructions for End Customer 32

VW Caddy

9013722D_EN 3

Heater Unit/Installation Kit

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 Caddy 1.6 Liter Gasoline and 2.0 Liter Gasoline Eco Fuel;

2.0 Liter SDI vehicles - for validity, see page 2 - from model year 2005 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

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 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

- Torque wrench for 2.0 - 10 Nm

- Hose clamping pliers

- Metric thread-setter kit

Quantity Description Order No.:

1 Retail accessories with desired heater control See price list

1 Installation kit for VW Caddy 1.6 Liter Gasoline and 2.0 Liter

Gasoline Eco Fuel; 2.0 Liter SDI 9013723B

Quantity Description Order No.:

1 IPCU Kit for Climatronic 9013645A

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 Caddy

9013722D_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

Water

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 Caddy

9013722D_EN 5

Preliminary Work

WARNING!

- Open fuel tank cap, ventilate tank.

- Close the tank cap again.

- 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.

- Completely remove the battery.

- Remove the battery carrier.

- Remove the engine cover.

- Remove the air filter together with the intake hose.

- Remove the right front wheel.

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

- Remove the underride protection (if present).

- Remove the bumper.

- Remove the washer reservoir.

- Remove the right-hand underbody trim

- Remove the footwell trim on the driver's side and front passenger side

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

- Remove the fuel-tank sending unit according to the manufacturer's instructions (with gasoline

only).

Remove page 32 "Operating Instructions for End Customer" and add to the vehicle operating instruc-

tions.

Heater unit installation location

1Heater unit

Installa-

tion loca-

tion

VW Caddy

9013722D_EN 6

Electrical system

Wiring harness of heater unit

Guide wiring harness of heater unit 2in front of

radiator at position 1and route to right along up-

per edge of radiator. Then route into engine com-

partment again at position 3. Fastening is not

carried out until after heater unit is installed!

Fuse holder, relay K3

For information on installing fuse holder and K3

relay, see page 7.

1Relay K3

2Fuse holder

Wiring har-

ness in-

stallation

diagram

Wiring harness pass through

1Original vehicle wiring harness pass through

2Wiring harnesses for fan controller and heater

control

Digital timer, summer/winter switch option

1Digital timer

2Summer/winter switch, drilled hole 12 mm dia.

Do not installthe metering pump

cableharnessuntillatertogether

with fuel pipe along the original

vehicle fuel lines on the under-

body

VW Caddy

9013722D_EN 7

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 for

fuseholder

and K3 re-

lay

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

VW Caddy

9013722D_EN 8

Climatic fan controller

Fusesocketdependentonvehicleequipment

SC33 or SC35; wire color black (sw) or

black/yellow (sw/ge).

Detach original vehicle fuse carrier 2(instru-

ment panel at lower left) and unlock contact

lock 3.

Uncrimp black (sw) or black/yellow (sw/ge)

wire 1on fuse output SC33 or SC35.

Uncrimp-

ing wire

Produce connection as shown in wiring dia-

gram.

1Black (sw) or black/yellow (sw/ge) wire

with original standard power timer

2AMP housing [2x]

3Contact lock locked

4Black (sw) wire to K3/30

5Red (rt) wire from K3/87a with standard

power timer engaged in fuse output SC33

or SC35

Installing

wiring har-

ness

3 3

VW Caddy

9013722D_EN 9

Climatic fan controller

Wiring dia-

gram

Webasto components Vehicle components Colors and symbols

Legend

HG Heater unit TT-C/E SC33 Fan fuse rt red

X1 6-pin heater unit connec-

tor SC35 Fan fuse ws white

F3 25 A fuse J301 Control unit of air condi-

tioning sw black

K3 Fan relay E16 Heater switch br brown

N24 Resistor group ge yellow

V2 Fan motor

T... Plug connections

Webasto

VW Caddy

sw oder

sw/ge

rt/sw

T4r

J301 oder E16

312 T5

342

N24

rt/ws

T10k

87a8786

85 30

HG X1 F3 SC33

oder

SC35

sw oder

sw/ge

4²

VW Caddy

9013722D_EN 10

Climatronic fan controller

Produce connections as shown in wiring dia-

gram.

Positionof freesocketsdependentonvehicle

equipment.

Connect black (sw) wire from K3/30 3to

green/white (gn/ws) wire 2(AMP connector).

Insulate red (rt) wires K3/87a 4and tie back.

1IPCU socket

Installing

wiring har-

ness of Cli-

matronic

Fasten brown (br) wire IPCU/85 2on original

vehicle ground point.

1IPCU

Installing

ground

wire

Route wiring harness from IPCU 1to original

vehicle wires to fan unit.

Routing

wiring har-

ness of

IPCU

1Connector T6t

2Black/white (sw/ws) wire to connector

T6t/2

3Black/white (sw/ws) wire from IPCU/A

4Red (rt) wire from IPCU/E

5Black/white (sw/ws) wire from Climatronic

control unit

6Wiring harness from IPCU

Connect-

ing wires

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