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
successfully 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
warning instructions.
Webasto does not accept any liability for defects and damage that are attributable to
an installation by untrained staff.
Feel the drive
Audi A4 1.9 + 2.0 TDI
Diesel
From model year 2006
For left-hand drive vehicles only
Also for vehicles without diesel particle filters
Ident. No.: 9015522A €10 fee © Webasto AG
Water Heater Unit
Thermo Top E Auxiliary
Heating
Thermo Top C Auxiliary
Heating
Thermo Top P Auxiliary
Heating
Installation Instructions
e1
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00 0104
22
Audi A4 1.9 + 2.0 TDI
Validity
Vehicle and engine types, equipment variants as well as national specifications, which are not listed in
these installation instructions, have not been tested. Installation according to these installation
instructions may, however, be possible.
The installation location of a time switch and summer / winter switch should be confirmed with the end
customer before installation.
Manufacturer Model Type EG-BE No. / ABE
Audi A4 8E e1 * 2001 / 116 * 0151 * ...
Engine type Engine Power in kW Engine capacity in cm³
BKE Diesel 85 1896
BRB Diesel 85 1896
AWX Diesel 96 1896
BLB Diesel 103 1968
BPW Diesel 103 1968
BRE Diesel 103 1968
Validity 2
Heater Unit / Installation Kit 3
Foreword 3
General Instructions 3
Special Tools 3
Explanatory Notes on the Document 4
Preliminary Work 5
Heater Unit Installation Location 5
Electrical Connections 6
Blower Control 7
Remote Start Option 8
Preparing the Installation Location 9
Preparing the Heater Unit 9
Installing the Heater Unit 10
Water Connection 11
Combustion Air 15
Fuel Connection 16
Exhaust System 19
Final Work 21
Operating instructions for the end customer 22
Fastening Strap Template 23
Tank Extracting Device Template 24
Table of Contents
33
Audi A4 1.9 + 2.0 TDI
Heater Unit / Installation Kit
Recommended heater unit for the relevant vehicle class:
Select the heater unit based on the size of the vehicle passenger compartment and the customer's
comfort requirements.
Foreword
These installation instructions apply to vehicles Audi A4 1.9 + 2.0 TDI with Diesel engines.
– Re. validity, see page 2 – from model year 2006 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, the stipulations in the "installation instructions" and "operating and maintenance instructions"
for the Thermo Top C/P/E are to be observed in any event.
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
specified otherwise, fasten hoses, lines and cable harnesses to original vehicle lines and cable
harnesses using cable clips.
Sharp edges should be fitted with edge protectors (split open plastic hose).
Spray unfinished body areas, such as for example bore holes, with anti-corrosion wax (Tectyl 100K,
Order No. 111329)!
Special Tools
- Torque spanner for 2.0 - 10 Nm
- Vise-grip wrench
- Riveting nut tool
Amount Description Order no.:
1 Commercial supply of required control See price list
1 Installation kit for Audi A4 1.9 + 2.0 TDI Diesel 9015441A
Vehicle Heater unit
Compact car Thermo Top E
Mid-class, station wagon Thermo Top C
Luxury, van, off-roader Thermo Top P
44
Special features are highlighted using the following symbols:
Mechanics
Electrics
Water connection
Fuel connection
Exhaust system
Combustion air
The arrow in the vehicle icon indicates the position on
the vehicle and the
viewing
angle.
Audi A4 1.9 + 2.0 TDI
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 vehicle-
specific documents.
Reference to a special technical feature.
i
Explanatory Notes on the 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.
5
Audi A4 1.9 + 2.0 TDI
Heater Unit Installation Location
1Heater unit
Installation
location
11
Preliminary Work
WARNING!
- Let off pressure in 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.
- Remove the cooling water reservoir cover
- Completely remove the battery.
- Completely remove the air filter with intake hose.
- Loosen the engine control unit in the cooling water reservoir.
- Open the tank cap, ventilate the tank.
- Close the tank cap again.
- Remove the underride protection
- Remove the right underbody panel.
- Remove the trunk cover (sedans only)
- Completely remove the lower plastic panel for the trunk floor (Avant only)
- Open the tank mounting service lid
- Remove tank mounting according to manufacturer's instructions.
- Remove air conditioning control according to manufacturer's instructions.
- Remove the dashboard panel on the driver’s side.
6
Audi A4 1.9 + 2.0 TDI
Electrical Connections
Fuse holder, K3 relay
2K3 relay
3Fuse holder retaining plate
1M5x12 bolt, washer, M5 nut
4Fuse holder
Positive and ground wire
Run the positive wire 1through the protective
rubber sleeve to the battery.
3Ground wire
2Original vehicle cable harness
Cable
harness
installation
diagram
Cable harness installation
Run the cable harnesses for the time switch and
blower control 1 through the protective rubber
sleeve 2in the control box and down under the
engine control unit into the passenger
compartment.
Time switch and summer / winter switch
option
1Time switch
2Summer / winter switch, bore hole Ø 12 mm.
2
42
1
33
2
13
br
sw
rt
br
bl
Wait to install the metering pump
cable harness until later,
together with fuel pipe along the
original vehicle fuel lines on the
underbody.
i
4
1
2
15
1
2
7
Audi A4 1.9 + 2.0 TDI
Blower Control
Connection the air conditioning control
connector D
(use enclosed micro timer).
Connect according to the circuit diagram.
1Connector D
2Insulate the red (rt) wire to K3/87a and tie
back
3Black (sw) wire from K3/30
4Green/white (gn/sw) wire to connector D
pin 10
Connec-
ting the air
conditio-
ning
control
Automatic
air condi-
tioning
circuit
diagram
Webasto components Components Audi A4 1.9 + 2.0 TDI Colors and symbols
Legend
HG Heater unit TT-C/E Fx Fuse rt red
X1 6-pin heater unit connector KB Air conditioning control ws white
F3 Fuse D Connector KB sw black
K3 Blower relay br brown
gn green
Insulate and tie
back wire ends
XSplitting point
Cable colors may vary.
6
1
4
2
3
Webasto
31
30
15
Audi
F3
5A
HG
4
X1
86
85 30
87a87
K3
gn/ws rt
sw
!
D
10
KB
F
br
rt
gn/ws
i
8
Audi A4 1.9 + 2.0 TDI
Remote Start Option
1Receiver
2Double-sided Velcro tape (self adhesive)
Assem-
bling the
receiver
1Antenna
Assem-
bling the
antenna
Temperature sensor for HTM100 only
1Temperature sensor
2Double-sided Velcro tape (self adhesive)
Assem-
bling the
tempera-
ture sensor
1
2
7
i
1
8
1
9
2
9
Audi A4 1.9 + 2.0 TDI
Preparing the Installation Location
Remove the original vehicle bolt at position 1
and 3(will be used here again). Drill hole at
position 2.
2Ø 9.1mm bore hole, insert rivet nut
Inserting
rivet nut
2Servo hose
1Rubberised tube clamp, plastic nut on
existing stay bolt
Tie back
servo hose
Preparing the Heater Unit
Remove the enclosed bracket for the
mounting, this will be replaced with the
fastening strap.
Bend the fastening strap 1to 90°according to
the template and loosely pre-assemble.
2M6x20 bolt, flanged nut
Loosely
fitting the
fastening
strap on
the bracket
Insert two washers between the heater unit
and the bracket 3in position 2.
Ejot screw bolts tightening torque 10 Nm!
1Ejot screw bolt [2x]
2Ejot screw bolt, washer [2x]
Assem-
bling the
bracket
10
321
11
2
1
12
1
2
13
1
3
2
1
10
Audi A4 1.9 + 2.0 TDI
1Mecanyl fuel line
2Hose section, Ø 10 mm hose clamps [2x]
Pre-
assem-
bling the
fuel line
Installing the Heater Unit
Insert the bracket 3with the heater unit as
shown in the figure.
Tighten bolt in position 4.
1Original vehicle nuts [4x] on the pre-
assembled bolts
2M6x20 bolt, spring washer on pre-
assembled rivet nut
Assem-
bling the
heater unit
14
1
2
15
1
1
4
3
2
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