ALWAYS follow all Webasto installation and repair instructions and observe all warnings.

Transcription

1 Water Heater Feel the drive Thermo Top E Parking Heater Thermo Top C Parking Heater e e Installation documentation VW Golf VI, Golf Plus, Golf Variant.6 and.0 TDI Common Rail from Model Year 008 Left-hand drive vehicle Adaptation of the sensitivity of the passenger compartment monitoring not checked. 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 heater 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 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 installation by untrained staff. Ident. No.: 44D_EN Fee Euro 0.00 Webasto AG

2 Table of Contents Validity Heater/Installation Kit Foreword General Instructions Special Tools Explanatory Notes on Document 4 Preliminary Work 5 Heater installation location 5 Electrical system 6 Fuse holder and K relay 7 Climatic fan control 8 Climatronic fan control 0 Digital timer, summer/winter switch option Remote option (Telestart) Premounting heater 4 Preparing exhaust system 5 Preparing coolant circuit 6 heater 0 Fuel Coolant circuit.6 TDI 4 Coolant circuit.0 TDI 7 Exhaust gas Final Work Operating Instructions for End Customer 4 Validity Manufacturer Model Type EG-BE No./ABE VW Golf VI K e * 00/6 * 04 *... VW Golf Plus KP e * 00/6 * 004 *... VW Golf Variant KM e * 00 / 6 * 08 *... Engine type Engine model Output in kw Displacement in cm³ CAYC Diesel CBDC Diesel CBAB Diesel CBBB Diesel Vehicle and engine types, equipment variants and national specifications not listed in this installation documentation have not been tested. However, installation according to this installation documentation may be possible. The installation location of a digital timer and summer/winter switch should be confirmed with the end customer before installation. 44D_EN

3 Heater/Installation Kit Quantity Description Order No.: Retail accessories Thermo Top E / C See price list Installation Kit for VW Golf VI.6 and.0 TDI Common Rail 44C Heater control See price list Also required with Climatronic: Quantity Description Order No.: IPCU Kit for Climatronic 90645A Heater recommended for the respective vehicle class: Vehicle Compact car Mid-size car, station wagon Heater Thermo Top E Thermo Top C 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.6 and.0 TDI Common Rail - for validity, see page - from model year 008 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 documentation. However, the stipulations in the "installation documentation", the "operating instructions" and the "installation instructions" for the Thermo Top C / 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 specified 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 00K, Order No. 9). When installing an IPCU, check or adjust the corresponding settings before installation. Special Tools - Torque wrench for.0-0 Nm - Hose clamping pliers 44D_EN

4 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. Mechanical system Electrical system Coolant circuit Fuel Exhaust gas Combustion air Special features are highlighted using the following symbols: 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. The arrow in the vehicle icon indicates the position on the vehicle and the viewing angle. All dimensions are in mm! Tightening torque of hose clamps = Nm! Tightening torque of Ejot screws, Ejot studs = 0 Nm! 44D_EN 4

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 Heater installation location Heater Remove page 4 "Operating Instructions for End Customer" and add to the vehicle operating instructions. Installation location 44D_EN 5

6 Electrical system Wiring harness routing Route excess lengths from wiring harness in cable duct below battery and secure with cable ties. Wiring harness pass through Original vehicle wiring harness pass through Do not install the metering pump wiring harness until later together with fuel pipe along the original vehicle fuel line on the underbody Wiring harness routing diagram Fuse holder, K relay 4 Wiring harness pass through 5 Installation of K relay and fuse carrier on Page 7 Original vehicle wiring harness pass through 44D_EN 6

7 Fuse holder and K relay Countersink holes from behind for M5 countersunk head screws. Cover of fuse/relay carrier in engine compartment Cut away bar in shaded area 5 mm dia. hole [x] Holes in cover 6 M5x countersunk head screw [x] fuse holder and relay K 7 On vehicles with Climatronic, replace 5 A fuse F 7 with A fuse provided M5 flanged nut Large diameter washer (between cover and retaining plate) Retaining plate 4 M5 flanged nut 5 Relay K 6 Fuse holder fuse holder and relay K 8 Fuse/relay carrier Original main vehicle fuse Red (rt) positive wire Route brown (br) earth wire to original vehicle earth support point below headlight and connect. Connecting positive and earth wire 9 44D_EN 7

8 Climatic fan control Webasto VW 0 HG X 4 F F * SC/SC40 (SC/SC5) ** rt/ge 4² (sw oder sw/ge) 4² T0k rt/ws 4² 5 Climatic wiring diagram rt 4² 5 T a 85 0 K sw 4² M br V rt/sw J0 4 T5 rt/ sw rt/ sw ge rt/ ge sw/ ws 4 T4f N4 Webasto components Vehicle components Colours and symbols HG Heater TT-C/E GM Fan motor rt red X 6-pin heater connector F* Fuse 40A (depending on respective ge yellow F 5 A fuse fuse assignment) sw black K Fan relay Golf VI = SC or SC40 Golf Plus = SC or SC5 ** Wire depends on J0 Control unit of air conditioning the respective vehicle T5 5-pin connector J0 equipment N4 Resistor group Golf VI = red/yellow T4f 4-pin connector N4 (rt/ge) T0k Connector Golf Plus = black (sw) or black/yellow (sw/ge) X Cutting point Wiring colours may vary. Legend 44D_EN 8

9 Golf and Golf Variant Connection on fuse carrier (instrument panel at upper left). Remove red/yellow (rt/ge) 4² wire on fuse output of fan SC or SC40 (depending on respective vehicle equipment). Connection to fuse carrier 0 Red/yellow (rt/ge) wire of fuse SC or SC40 AMP housing Black (sw) wire to K/0 Red (rt) wire from K/87a 4 with crimped-on standard power timer engaged in fuse output SC or SC40. Produce connections as shown in wiring diagram. Connecting wires 4 Golf Plus Fuse socket dependent on vehicle equipment SC or SC 5; wire colour black (sw) or black/yellow (sw/ge) Detach original vehicle fuse carrier (instrument panel at lower left) and unlock contact lock. Uncrimp 4² black (sw) or black/yellow (sw/ge) wire on fuse output SC or SC5 Uncrimping wire Produce connections as shown in wiring diagram. 5 4 Red (rt) wire from K/87a with crimped-on standard power timer engaged in fuse output SC or SC5 AMP housing AMP housing 4 Black/yellow (sw/ge) wire with original standard power timer 5 Black (sw) wire K/0 with crimped-on tab connector Connecting wires Lock contact lock again. 44D_EN 9

10 Climatronic fan control HG X 4 86 Webasto 87 rt 4² 87a F! J sw/ bl/ ws ws 0,5² 0,5² VW T6d rt rt/ ge 4² F * SC/ SC Climatronic wiring diagram 85 0 sw 4² K IPCU E rt 0,75² sw/ws 0,75² rt/ws 4² T0k A sw/ ws 0,5² 4 T6t br gn/ws br V M J6 Webasto components Vehicle components Colours and symbols HG Heater TT-C/P/E F* Fuse 40A (depending on respective rt red X 6-pin heater connector fuse assignment) of ws white K Fan relay SC or SC56 sw black F Replace 5 A fuse T0k Plug connections br brown with A fuse J55 Climatronic control unit gn green IPCU Pulse width modulator T6d 6-pin connector J55 ge yellow V Fan motor bl blue IPCU adjustment values: T6t 6-pin connector J6 Insulate wire end Duty cycle: 0% and tie back. Frequency: 400Hz X Cutting point Voltage: 8V Wiring colours may vary. Function: High side Golf and Golf Variant Produce connections as shown in wiring diagram. Position of free sockets dependent on vehicle equipment. IPCU socket Legend IPCU socket 4 44D_EN 0

11 Insulate red (rt) wire K/87a and tie back. Produce connections as shown in wiring diagram. 6 AMP connector Brown (br) wire of IPCU/85, original vehicle earth support point 4 Green/white (gn/ws) wire of IPCU/86 5 IPCU mounted 6 Black (sw) wire from K/0 Connecting IPCU Golf Plus 4 Insulate red (rt) wire K/87a and tie back. Position of free sockets depends on respective vehicle equipment. Produce connections as shown in wiring diagram. IPCU socket Black (sw) wire from K/0 4 Green/white (gn/ws) IPCU/86 wiring harness of Climatronic 6 Brown (br) wire from IPCU/85 to original vehicle earth point. IPCU mounted Wiring harness of IPCU Connecting wires 7 All vehicles Route wiring harness of IPCU to centre console. Routing wiring harness from IPCU 8 44D_EN

12 Route wiring harness of IPCU to fan unit. Connection on connector of fan unit. 5 Black/white (sw/ws) wire of connector T6t/ Black/white (sw/ws) wire of IPCU/A 4 Red (rt) wire of IPCU/E 5 Black/white (sw/ws) wire of A/C control panel Connecting fan unit 4 9 Digital timer, summer/winter switch option Golf and Golf Variant Digital timer mm dia. hole; summer/winter switch Digital timer 0 Golf Plus Summer/winter switch Digital timer Digital timer Remote option (Telestart) Golf and Golf Variant Drill out bracket to 6.5 mm dia. at position. Existing hole, M6x0 bolt, flanged nut Receiver receiver 44D_EN

13 Antenna antenna Golf Plus Bend down lower tab of bracket by 90 and drill out hole to 6.5 mm dia. as shown. 4 4 Receiver Bracket M6 bolt, large diameter washer (between bracket instrument carrier), large diameter washer (from outside), flanged nut 4 Instrument carrier, existing hole receiver Antenna antenna 5 Temperature sensor T00 HTM Figure shows Golf VI. Fasten temperature sensor with double-sided adhesive tape. temperature sensor 6 44D_EN

14 Premounting heater Ejot stud Premounting heater 7 Combustion air pipe a = 50 Discard section X a Cutting combustion air pipe to length X 4 Insert one washer each between heater and bracket at positions. 5 M6x0 spacer nut Ejot screw, washer [x each] 7 mm dia. hose clamp 4 Combustion air pipe 5 Bracket Premounting heater 8 Strut Ejot screw [x] Silencer 4 Retaining clip in hole 5 Combustion air pipe 6 Hose section, 0 mm dia. hose clamp [x] 7 Fuel line Premounting heater D_EN 4

15 Preparing exhaust system Exhaust pipe a = 90 Exhaust end section b = 40 Discard section X Cutting exhaust pipe to size a b X Slide insulation onto exhaust pipe. Hose clamp [x] Premounting exhaust pipe Hose clamp Silencer M6x6 bolt, spring lockwasher on spacer nut 4 Exhaust end section 5 Red (rt) protective rubber isolator Premounting silencer and exhaust end section Exhaust end section Aligning exhaust end section 44D_EN 5

16 B D X C Preparing coolant circuit.6 TDI only Discard section X B = 840 C = 00 D = 70 Cutting hoses to length A B Push braided protection hoses onto hose A and C and cut to length. Cut heat shrink plastic tubing to length. 5 mm long heat shrink plastic tubing [4x] Preparing coolant hoses D 4 C 7 mm dia. spring clip Cable tie [x] 7 mm dia. hose clamp 4 0x0 connecting pipe hose C 0x0 mm connecting pipe, 7 mm dia. spring clip [x] 8x0 connecting pipe, 7mm dia. spring clip B A Preparing hose A and B A B 4 44D_EN 6

17 D C 7 mm dia. spring clip 7 mm dia. hose clamp Premounting hoses B 5 Remove hose from heat exchanger inlet. Engine outlet Cutting point Cutting point 6 After pre-installing hose, re-install heat exchanger inlet in vehicle. 4 Black (sw) protective rubber profile. 5 mm dia. spring clip 4 8x0 connecting pipe Premounting hose on heat exchanger inlet 7 Align original vehicle hose clamps [x] as shown. Aligning clamps 8 44D_EN 7

18 ,0 TDI only A C X B Hose D = 80 elbow Discard section X X A = 90 B = 00 C = 90 Cutting hoses to length D A Push braided protection hoses onto hose A and C and cut to length. Cut heat shrink plastic tubing to length. 5 mm long heat shrink plastic tubing [4x] Preparing coolant hoses C 9 4 B 7 mm dia. spring clip Cable tie [x] 7 mm dia. hose clamp 4 0x0 connecting pipe hose B 40 D C 0x0 mm connecting pipe, 7 mm dia. spring clip [x] Preparing hose C and D D C 4 44D_EN 8

19 Pull hose off engine outlet. Spring clip will be reused. Remove coupling from heat exchanger inlet. Cutting point 4 C Original vehicle spring clip Coupling of heat exchanger inlet D Premounting hose C and D 4 C B 7 mm dia. spring clip 7 mm dia. hose clamp Premounting hoses A 44 Preparing installation location Prevent large diameter washer from falling by securing with putty etc. Large diameter washer on original vehicle stud bolt [x] 00 mm edge protection Preparing installation location 45 44D_EN 9

20 heater Large diameter washer, flanged nut M8 [x] heater 46 Ensure freedom of movement of exhaust system in relation to original vehicle components and lines. Exhaust pipe Original vehicle wiring harnesses (secured with cable ties) Horn Aligning exhaust system 47 Punch through perforation of heater cover at position. Mount clip cable tie and fasten wiring harness of heater. Connecting wiring harness 48 Combustion air silencer tied back for demonstration purposes. Cable tie Wiring harness of heater 50 mm edge protection Fastening wiring harness 49 44D_EN 0

21 Fuel CAUTION! Open the vehicle's fuel tank cap, ventilate the tank and then re-close the tank lock. Catch any fuel running off in an appropriate container. Install fuel line and metering pump wiring harness so that they are protected against stone impact. Unless specified otherwise, always fasten using cable ties. Mount the fuel line and wiring harness with rub protection on sharp edges. WARNING! The fuel line and wiring harness are routed to the metering pump as shown in the wiring harness routing diagram. Fuel line fuel line 50 Route fuel line and wiring harness of metering pump in coolant reservoir to right and fasten on original vehicle lines with cable ties. Pay particular attention to freedom of movement of wiper linkage. Route fuel line and wiring harness of metering pump to underbody in wiring duct. Existing pass through [x] lines 5 Route fuel line and wiring harness of metering pump along original vehicle fuel lines to fuel tank. Line duct lines 5 44D_EN

22 Remove sealing plug for installation. Remove bracket of handbrake cable at position and install at position. Offsetting bracket 5 Silent block, large diameter washer, flanged nut silent block 54 Following installation, remount sealing plug at position 4. Wiring harness of metering pump, connector mounted Rubber-coated p-clamp, flanged nut, silent block Metering pump 5 Fuel line, hose section, 0 mm dia. hose clamp [x] metering pump Standpipe Moulded hose 0 7.5mm dia mm dia. Cutting standpipe and moulded hose to size 56 44D_EN

23 7.5mm dia. 4.5mm dia. 0 mm dia. Caillau clamp in centre between beads on end of standpipe. Standpipe Moulded hose Premounting standpipe and moulded hose 57 Cut mm off blind plug. Fuel-tank sending unit Cutting off blind plug 58 Ensure sufficient distance from adjacent components, especially from fuel gauge. 4.5mm dia. Caillau clamp Fuel line 0 mm dia. Caillau clamp 4 Moulded hose with standpipe Connecting fueltank sending unit 59 Hose section, 0mm dia. hose clamp [x] Fuel line Connecting metering pump 60 44D_EN

24 Coolant circuit.6 TDI WARNING! Any coolant running off should be collected in an appropriate container. Install hoses so that they are kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that other hoses cannot be damaged. The heater must be filled with coolant when installing the hoses. The connection should be "inline" based on the following diagram: A Hose installation diagram D B C All spring clips without a specific designation = 7mm dia. All connecting pipes without a specific designation = 0x0mm dia. All hose clamps = 0-7mm dia. = Black (sw) protective rubber isolator. = 5mm dia. spring clip. = 8x0mm dia. connecting pipe. 44D_EN 4

25 Drill 6mm hole at position. When drilling, watch lines located behind. Mount clip-type cable tie. 50 mm edge protection clip-type cable tie 6 Insert clip-type cable tie [x] in holes of bracket for coolant hoses. M6x0 bolt, flanged nut, existing hole bracket 6 Close clip-type cable tie [x]. D B 6 Hose of engine outlet A Routing in engine compartment Connecting engine outlet 64 44D_EN 5

26 Hose on heat exchanger inlet Position black (sw) rubber isolator Connecting heat exchanger inlet 65 D Fix hose B and D with cable tie. Aligning hoses 66 44D_EN 6

27 Coolant circuit.0 TDI WARNING! Any coolant running off should be collected in an appropriate container. Install hoses so that they are kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that other hoses cannot be damaged. The heater must be filled with coolant when installing the hoses. The connection should be "inline" based on the following diagram: D Hose installation diagram C A B All spring clips = 7 mm dia.. = Original vehicle spring clip. All connecting pipes = dia. 0x0. All hose clamps = 0-7 mm dia. 44D_EN 7

28 Align original vehicle hose clamps [x] as shown (turn to right). Aligning clamps 67 Drill 6mm hole at position. When drilling, watch lines located behind. Mount clip-type cable tie. 50 mm edge protection clip-type cable tie 68 Insert clip-type cable tie [x] in holes of bracket for coolant hoses. M6x0 bolt, flanged nut, existing hole bracket 69 Close clip-type cable tie [x]. A Routing in engine compartment C 70 44D_EN 8

29 Hose of engine outlet Connecting engine outlet A 7 90 connection on heat exchanger inlet Original vehicle spring clip Spacer bracket D Connecting heat exchanger inlet C 7 Lockable spacer bracket C spacer bracket A 7 Fix hose A and C in place with cable tie. Aligning hoses 74 44D_EN 9

30 C Fix hose A and C in place with cable tie. Ensure sufficient distance from neighbouring components. A Aligning hoses 75 All vehicles Position of drain pipe may vary. Glue rub protection [x] onto air filter box as shown. Preparing air filter box 76 Version : If drain pipe is present as shown, then route parallel to coolant hose C/D. air cleaner housing C 77 If drain pipe is present as shown, then fasten on strut with cable tie. Fastening drain pipe on air filter box 78 44D_EN 0

31 A Version : If drain pipe is present as shown, route between coolant hoses A/B and C/D. air cleaner housing C 79 44D_EN

32 Exhaust gas Align exhaust end section and rubber isolator as shown. Ensure sufficient distance between exhaust end section and wheel well trim. wheel well trim 80 Remove insulation at position if present. Underride protection 4 mm dia. hole Hole in underride protection 8 Align exhaust end section flush on red rubber isolator. Underride protection Inserting rubber isolator 8 44D_EN

33 Final Work WARNING! Mount removed parts in reverse order. Check all hoses, clamps and all electrical connections for firm seating. Insulate and tie back all loose lines. Only use manufacturer-approved coolant. Spray the heater components with anti-corrosion wax (Tectyl 00K, Order No. 9). - Connect the battery - Fill and bleed the coolant circuit according to the vehicle manufacturer s specifications. - Set digital timer, teach telestart transmitter - Make settings on A/C control panel according to the "Operating Instructions for End Customer". - Place the "Switch off parking heater before refuelling" sticker near the filler neck. - See installation instructions for initial start-up and function test Feel the drive Webasto AG Postfach 80 D-8 Stockdorf / Germany National Hotline: (4 Cent aus dem deutschen Festnetz) Hotfax: Hotmail: hotline@webasto.de 44D_EN Printed in Germany 08/0 Printing: Steffen

34 Operating Instructions for End Customer Please remove page and add to the vehicle operating instructions. Note: We recommend matching the heating time to the driving time. Heating time = driving time Example: For a driving time of approx. 0 min. (in one direction), we recommend not exceeding a switch-on time of 0 min. If the summer/winter switch option has been installed, this must be switched in accordance with the time of year. The heater will then heat in the position Winter and in the position Summer it will only switch on the vehicle fan to ventilate the vehicle interior. Warning: The passenger compartment monitoring must be deactivated for the duration of the heater operation. Before parking the vehicle, make the following settings: Air outlet to windscreen Set temperature to "max." Set fan to level "", or possibly "" Climatic 8 Air outlet to windscreen Set temperature on both sides to "HI". Climatronic 84 44D_EN 4