BlueHeat Coolant Heater Thermo Top VW Jetta Beginning Model Year: 00 Special instructions for these models Part locations may differ slightly dependent on the vehicle model. Legend BlueHeat Coolant Heater, Exhaust Tube, and Combustion Air Intake Silencer Fuse Holder, Relays and Resistor Assembly Timer Control Fuel Pump Special Tools Hose Clamping pliers Torque Wrench Table of Contents Foreword Parts List Vehicle Information Scope and Purpose Symbol Identification General References Preparation Heater Installation Site Installation Electrical - Overview 6 Electrical Harness 7 Timer Installation 8 Integration into the Blower System - Climatic 8 Integration into the Blower System - Climatronic 0 Heater Preparation/Installation Pre-assemble Exhaust Pre-assemble Coolant Hoses Heater Mounting Site Preparation 6 Heater Mounting 6 Integration into the Coolant System 8 Coolant Hose Connections at Heat Exchanger 9 Webasto Heater Hose Integration Point 0 Webasto Heater Outlet Hose Installation 0 Webasto Heater Inlet Hose Installation 0 Coolant Hose Routing in Engine Compartment Integration into the Fuel System Standpipe Preparation / Installation Fuel Pump Installation Fuel Line and Electrical Harness Routing Connecting Fuel Line and Electrical Harness to Fuel Pump Blower Control Settings - Climatic Blower Control Settings - Climatronic Final Inspection, Initial Start-up and Concluding Work 6 Heater Lockout Reset Procedure 7 DOC P/N 000A KIT P/N 0000A or 00A Printed in USA Webasto Product N.A., Inc.
Improper installation or repair of Webasto heating and cooling systems can cause fire or the leakage of deadly carbon monoxide leading to serious injury or death. Installation and repair of Webasto heating and cooling systems requires special Webasto training, technical information, special tools and special equipment. NEVER attempt to install or repair a Webasto heating or cooling system unless you have successfully completed the factory training course and have the technical skills, technical information, tools and equipment required to properly complete the necessary procedures. ALWAYS carefully follow Webasto installation and repair instructions and heed all WARNINGS. Webasto rejects any liability for problems and damage caused by the system being installed by untrained personnel.
Parts List Quantity Part Part Number Heater Kit 89D Installation Kit For Vehicles With Automatic Temperature Controls (Climatronic) Installation Kit For Vehicles With Manual Temperature Controls (Climatic) 0000A 0000A Vehicle Information Manufacturer Model Year Engine Type Foreword Volkswagen Jetta Beginning 00.9L TDI This installation requires special expertise from a Webasto training course to install a Webasto Thermo Top heater, which means that it may only be installed by a specially trained workshop or dealership. Webasto cannot accept any liability for faults and damage caused by the system being installed by untrained personnel. Scope and Purpose These installation instructions are intended to support authorized Webasto trained distributors, dealers and personnel in the installation of the Thermo Top (BlueHeat) Coolant Heaters. These installation instructions apply to the vehicles listed on the front cover of this installation document unless technical modifications on the vehicle influence the installation, excluding all liability claims. Depending on the version and equipment in the vehicle, changes may be required to the installation work set out in these installation instructions. In any event, the directives in the installation manual and operating manual must be followed. All relevant state and provincial licensing regulations if any, governing the installation and use of auxiliary heating devices must be observed! CAUTION Location of heater, installation of coolant lines, fuel system and components, wiring and control devices are important for proper operation. Failure to comply with the installation instructions provided may result in poor operation or damage to heater and vehicle components.
BlueHeat TM VW Jetta Symbol Identification Symbols that define sections in manual Mechanical Preparation Fuel Electrical Exhaust Coolant Combustion Air Intake General Symbol Descriptions Warning Refer to Webasto or Manufacturer Manual Caution Attention Flammable or Combustible Line of Sight/Item Location on Vehicle
BlueHeat TM General References Bare body parts, for example around drilled holes, must be treated with anti-corrosive coating. Secure hoses, cables and wiring harnesses with cable ties and fit protective hoses around them at chafing points. Fit edge protectors (opened fuel hose) to sharp edges. Preparation Heater Kit Verify and identify all contents of kit. Vehicle Open fuel cap and vent tank Release radiator pressure Remove battery and battery tray Remove air filter assembly and hoses Remove front left wheel Remove front left wheel well splashshield Remove left front fog lamp or trim panel Remove underbody splash shields Remove rear seat bottom Remove driver s side floor trim Remove driver s side dash trim panel Remove passenger side floor trim CAUTION For reasons of safety due to possible fuel spillage, it is recommended that there be no more than / tank of fuel present. If fuel quantity is greater than / of capacity, make provisions to reduce quantity of fuel. Protect vehicle fenders, panels and interior with covers Heater Installation Site The Webasto Auxiliary Coolant Heater is installed on the left side of the vehicle behind the front bumper. Front bumper cover was removed for photographic purposes only. () Webasto Auxiliary Coolant Heater (Installed) Fig.
Electrical - Overview If not described differently, securing of wiring and cables is done with cable ties to the vehicle s own wires and cable harnesses. Timer control location is a recommendation only. Please consult with the customer before mounting. Fuse Block/Relays/Resistor () Fuse Holder () Relays br bl Fuel Line and Fuel Pump Harness br - rt + rt sw Bulkhead Pass-through Driver Footwell Area () Grommet () Grommet () Timer and Blower Harnesses () Timer and Blower Harnesses 6
9 9 Electrical Harness Remove underhood fuse/relay center cover and drill two mm holes as shown in Figure. () Underhood fuse/relay center cover () mm hole 0 0 Fig. Secure Webasto fuse holder and relay to fuse/relay cover with two M x 0 screws. () Underhood fuse/relay center cover () M x 0 screws Fig. 7 6 Fig. For vehicles with climatronic, replace A fuse (F) with the supplied A fuse. () M nut () Washer () Mounting plate () M nut () Relay K (6) Fuse holder (7) Fuse F Connect harness ground wire to vehicle ground below head lamp. () Fuse/relay center () Vehicle fuse () Webasto power wire (+V) Fig. 7
Timer Installation CAUTION Check behind panels for obstructions before drilling holes. Before installing the timer, please confirm the installation location with the customer. Affix supplied template to panel. Drill 0 mm (/6 in.) and. mm (/ in.) holes where indicated on template. Figure 6 shows a translated sample of the template supplied. Fig. 6 Before installing the timer, please confirm the installation location with the customer. () Timer Example of Timer Mounting Fig. 7 Integration into the Blower System With Manual Temp. Controls - Climatic Loosen vehicle interior fuse center. Disengage contact (). Remove bk/yl wire () from fuse block. () Interior fuse/relay center () Contact () bk/yl wire Fig. 8 Make connections as shown in wiring schematic (fig. 0). () bk/yl wire () Red wire from relay K pin 87 to vehicle SC0 () Black wire from relay K pin 0 to bk/yl wire Fig. 9 8
Webasto Vehicle VW Golf V Climatic 0 +V HG Pin X rt/ws rd/bk F A rd rt sw/ge bk/yl SC0 0A +Ignition gn/ws gn/wt rt/ws rd/bk sw/ge bk/yl T0k rd/bk rt/ws T 86 87 87a J0 8 0 K bksw rt/sw rd/bk T bn br + Tr M V N - bn br GND Fig. 0 TABLE. Webasto Heater Comp. Vehicle Components Wire Colors HG = Webasto Heater SC0 = Blower Fuse rd = red F = Fuse J0 = Climate Control Module wt = white K = Blower Relay N = Resistor Pack bk = black V = Blower Motor bn = brown gn = green yl = yellow 9
Integration into the Blower System With Automatic Temp. Controls - Climatronic Remove vehicle fuse block () cover (left side under dashboard) and remove fuse (). Remove green / black wire from fuse outlet SC. () Fuse block () Fuse () Green / black wire Fig. Location of available mounting depends on vehicle options. () Socket for relay K. (black) () Socket for PCU (red) () Wire (green / white) from relay K. terminal 0 () Harness with red wire from PCU terminal E and black / white wire from PCU terminal A () Green / black wire from relay K. terminal 86 (6) Green / black wire from relay K. terminal 86 6 Red wire from relay K terminal 87A must be insulated and secured. Fig. Make connections per diagram, see Figure 9. () Green / black wire (fig. /) with Webasto standard timer () AMP connector housing () Black wire from relay K terminal 0 with crimp on terminal () AMP connector housing () Green / white wire (fig. /) from relay K. terminal 0 (6) Green / black wire (fig. /) from relay K. terminal 86 (7) Green / black wire (fig. /6) from relay K. terminal 86 connected to vehicle fuse outlet SC 7 6 Fig. Plug PCU into red socket. Plug relay K. into black socket. () Vehicle screw M6 () Brown wires from relay K. terminal 8 and PCU terminal 8 () Relay K. (black socket) () PCU (red socket) () Harness to timer (6) Harness from relay K 6 Fig. 0
Harness routing from PCU () along bracket () to center console. () Harness with red wire from PCU terminal E and black/ white wire from PCU terminal A () Bracket Fig. Harness routing from PCU to vehicle blower motor assembly along existing vehicle harnesses. () Harness with red wire from PCU terminal E and black / white wire from PCU terminal A () Vehicle blower assembly 7 Fig. 6 6 Fig. 7 Secure harness to vehicle harness with nylon cable ties. Remove vehicle blower assembly and make the connections shown, also see Figure 9. Cut black / white wire approximately inches from connector. Crimp and heat shrink the splices. () Harness from PCU () Black / white wire from PCU terminal A () Red wire from PCU terminal E () Black / white wire from climatronic control unit () Vehicle harness (6) Black / white wire to plug T6t terminal (7) Connector T6t Secure harness to vehicle harness with nylon cable ties. Install vehicle blower assembly. () Harness from PCU () Vehicle blower assembly Fig. 8
Kabelbaum Webasto Hg HG X Pin gn/ws gn/wt rd/bk rt/ws rd/bk rt/ws rd rt F A! Kabelbaum Climatronic Harness Climatronic K. 87a gn/ws gn/bk 0 8 87 86 gn/sw gn/bk gn/sw gn/bk gn VW Golf JettaV Climatronic SC A gn/sw gn/bk rd/yl rt/ge T0k F J 0 SC 0A rd/wt rt/ws +V +Ignition 86 87 87a 8 0 K PCU E rt rd sw/ws bk/wt 6 T6f bl/ws bl/wt sw bk A sw/ws bk/wt 86 8 sw/ws bk/wt bn br bn br bn br T6t J6 T6t V bn br M GND Fig. 9 TABLE. Webasto Heater Comp. Vehicle Components Wire Colors HG = Webasto Heater SC = Blower Fuse rd = red F = Fuse SC = Backup Lights Fuse wt = white K = Blower Relay F = Backup Lights Switch bk = black K. = Additional Relay J = Climatronic Control Unit bn = brown PCU = Pulse Control Unit J6 = Blower Motor Control Unit gn = green V = Blower Motor yl = yellow X = Cut Here
90 888888888888 Heater Preparation/Installation Cut supplied air intake tube as shown in Figure 0. () Air intake tube - a= 0 mm (9.8 in.) (X) Scrap a X Fig. 0 I Observe torque specifications. Install heater mounting bracket with two EJOT screws and EJOT stud as shown. Tighten EJOT screws to 0 Nm (88. lb.-in.). () EJOT screws () Mounting bracket () EJOT stud Fig. Install spacer nut on EJOT stud. () Spacer nut Fig. Assemble heater as shown in Figure. () Mounting bracket () EJOT screws () Air intake silencer () Silencer mounting clamp () Air intake tube (6) Hose clamps (7) Fuel line coupler (8) Fuel line 8 7 6 Fig.
Pre-assemble Exhaust Cut supplied exhaust tubing as shown in figure. () Exhaust tube - a=90 mm (7. in.) () Exhaust endpiece - b=0 mm (9. in.) (X) Scrap a b X Fig. Assemble exhaust tubing using supplied exhaust wrap as shown in Figure. () Exhaust endpiece () Exhaust clamp () Spacer M6x0 () Exhaust tube with wrap installed () Muffler (6) Rubber insulator 6 Fig.
X ab db X c Fig. 6 Pre-assemble Coolant Hoses Cut supplied coolant hose as shown in Figure 6. () Coolant hose from heater coolant pump to 90 hose at engine outlet - a=60 mm (. in.) () Coolant hose from 90 hose at heater outlet to heat exchanger inlet - b=80 mm (.8 in.) () 90 hose from heater outlet to heat exchanger inlet hose - c=00 mm (.9 in.) () 90 hose connects to engine outlet and coolant pump inlet hose (X) Scrap 8 Ensure the fuel line is fully seated within the fuel line coupler and tighten clamps to.0 -. Nm (8.8 -. lb.-in.) Connect fuel line to heater with fuel line coupler. Connect 90 hose () to heater using supplied clamp. Install coolant hose adapter and secure with clamp. 7 6 Fig. 7 () 90 hose () Hose coupler (6) Clamp (7) Heater fuel line (8) Coolant hose adapter Install 90 end of hose () on heater coolant pump as shown in Figure 8. Connect hose () to 90 hose (). 9 9 Fig. 8 () Coolant hose from heater coolant pump to 90 hose at engine outlet. () Coolant hose from 90 hose at heater outlet to heat exchanger inlet () 90 hose from heater outlet to heat exchanger inlet hose (9) Hose clamps -torque to.0 -. Nm (8 - lbin.) Connect the 90 hose () to hose () with clamp. Install coolant hose adapter on hose () with clamp. 9 8 9 Fig. 9 () Coolant hose from heater coolant pump to 90 hose at engine outlet () Coolant hose from 90 hose at heater outlet to heat exchanger inlet () 90 hose connects to engine outlet and coolant pump inlet hose (8) Coolant hose adapter (9) Hose clamps -torque to.0 -. Nm (8 - lbin.)
Heater Mounting Site Preparation Install washers on heater mounting studs. Install edge guard as shown in Figure 0. () Washer positioned on vehicle studs () edge guard Heater Mounting Mount the heater to the vehicle studs with three washers and M8 nuts. () Washer and M8 nut ( ea.) () Heater (mounted) Fig. 0 Fig. CAUTION Ensure there is sufficient room between vehicle components and the heater exhaust tube. Secure vehicle wiring harnesses with nylon cable ties. () Vehicle harnesses (secured with nylon cable ties) () Horn () Heater exhaust tube Fig. CAUTION Ensure there is sufficient room between vehicle components and the heater exhaust tube. Secure vehicle wiring harnesses with nylon cable ties. () Heater exhaust tube () Horn bracket () Horn () Vehicle wiring harnesses Fig. 6
Protect harness from sharp surfaces and secure with nylon cable ties. Route the heater control harness to the heater mounting location and connect to the heater. () Heater control harness () Top of heater Fig. Secure extra harness length under battery tray. () Heater control harness Fig. 7
Integration into the Coolant System Torque hose clamps to.0 -. Nm (8 - lb-in.) Avoid sharp bends and kinks when installing coolant hoses. Position hose clamps in such a way to avoid cutting or damaging adjacent components. Clamp vehicle coolant hose with hose clamping pliers prior to cutting to prevent coolant spillage. The coolant heater integration into the vehicle heater circuit is done in an INLINE fashion. Refer to Figure 6. Heat Exchanger Wärmetauscher A D A B Motor C B Fig. 6 8
Coolant Hose Connections at Heat Exchanger CAUTION Move wiring out of the way before drilling into harness cover. Drill a 6 mm hole through the electrical harness cover in order to mount cable tie clip. () Electrical harness cover () Drill a 6 mm hole () Cable tie with clip Fig. 7 For Manual Transmissions CAUTION Use the bracket and cable ties provided to prevent the coolant hoses from interfering with the shift linkage. Identify the vehicle configuration you are working with by previewing Figures 8 through 0. Perform the appropriate procedures. Variant Fig. 8 Install bracket using existing hole and M6x0 bolt. Insert cable ties where shown. () Cable tie with clip () Unused hole () Shift linkage () M6x0 bolt (existing hole) () Bracket Install bracket using existing hole and M6x0 bolt. Insert cable ties where shown. () Cable tie with clip () Unused hole () Shift linkage () M6x0 bolt (existing hole) () Bracket Variant Fig. 9 Install bracket using existing hole and M6x0 bolt. Insert cable ties where shown. () Cable tie with clip () Unused hole () Rotate hose clamp downward () M6x0 bolt (existing hole) () Bracket Variant Fig. 0 9
Webasto Heater Hose Integration Point Do not discard hose clamps, they will be re-used. Disconnect heater core supply hose from coolant outlet tube exiting engine block. () Coolant outlet tube from engine () Heater core supply hose Fig. Install rubber insulator on heater core supply hose as shown in Figure. () Coolant outlet tube from engine () Heater core supply hose () Rubber Insulator Fig. Webasto Heater Outlet Hose Installation Connect heater outlet hose to heater core supply hose with coolant hose coupler and two hose clamps. () Webasto heater outlet hose (D) () Heater core supply hose () Hose clamp ( ea.) Fig. Webasto Heater Inlet Hose Installation Connect 90 end of Webasto heater inlet hose to coolant outlet tube from engine with clamp. () Coolant outlet tube from engine () Hose clamp () 90 end of heater inlet hose (A) () Hose retainer for hoses A and D Fig. 0
D B Coolant Hose Routing in Engine Compartment CAUTION Use the cable ties installed earlier to prevent the coolant hoses from interfering with the shift linkage. Identify the vehicle configuration you are working with by previewing Figures through 7. Perform the appropriate procedures. Route coolant hoses as shown and secure with cable ties. () Cable ties Variant Variant Fig. B Route coolant hoses as shown and secure with cable ties. D () Cable ties Variant Fig. 6 B Route coolant hoses as shown and secure with cable ties. D () Cable ties Variant Fig. 7 Cables and retaining clips vary depending on vehicle equipment. () Vehicle clip on hose A and harness () () Vehicle harness () Heater core outlet hose () Heater core supply hose () Rubber spacer (6) Cable tie B A 6 Fig. 8
Integration into the Fuel System The vehicle fuel sender can be accessed from inside the vehicle. Carefully remove mm from the end of the auxiliary fuel nipple. () Auxiliary fuel nipple (end removed) () Fuel sender Fig. 9 Standpipe Preparation Trim the wide end of the fuel line coupler as shown in Figure 0. Cut the standpipe to the length specified at a angle. () Standpipe () Fuel line coupler 0 Ø7, Ø, Fig. 0 Ensure the standpipe is fully seated within the fuel line coupler. Assemble the fuel standpipe as shown in Figure. () Standpipe () Fuel line clamp () Fuel line coupler Ø7, Ø, Fig.
Ensure the fuel line is fully seated within the fuel line coupler and tighten clamps to.0 -. Nm (8.8 -. lb.-in.) Install Fuel line into fuel line coupler. Route fuel line to the underside of the vehicle. () Fuel line coupler () Mecanyl fuel line () Fuel line clamp Fig. Fuel Pump Installation Install fuel pump insulator with M6 nut where shown in Figure. () Vehicle fuel line connections () Vehicle fuel tank () Fuel pump insulator Fig. Always cut Mecanyl fuel line with a sharp razor knife or razor edged cutter. Using side cutters, scissors or similar tools will cause a restriction inside the fuel line. Pre-assemble fuel line couplers on fuel pump before installation. Install fuel pump on fuel pump insulator with p-clamp. Connect fuel line to inlet side of fuel pump. Fig. () Mecanyl fuel line () Fuel line coupler () Fuel line clamp () Fuel pump () P-clamp
Fuel Line and Electrical Harness Routing Route Mecanyl fuel line (from heater) across the front of the vehicle toward the right side of the engine compartment. Secure Mecanyl fuel line to vehicle with nylon cable ties. () Mecanyl fuel line () Front of vehicle Fig. Route the Mecanyl fuel line from the right side of the engine compartment toward the rear of the vehicle following the vehicle fuel lines. () Right side of the engine compartment () Mecanyl fuel line Fig. 6 Route the Mecanyl fuel line to the fuel pump mounting location following the vehicle fuel lines. Route fuel pump electrical harness to fuel pump mounting location following Mecanyl fuel line. Secure Mecanyl fuel line and electrical harness to vehicle with nylon cable ties () Vehicle fuel line () OE fuel line clip () Mecanyl fuel line Fig. 7
Connecting Fuel Line and Electrical Harness to Fuel Pump Fig. 8 Always cut Mecanyl fuel line with a sharp razor knife or razor edged cutter. Using side cutters, scissors or similar tools will cause a restriction inside the fuel line. Ensure the fuel line is fully seated within the fuel line coupler and tighten clamps to.0 -. Nm (8.8 -. lb.-in.) Cut the fuel line to the appropriate length and insert into fuel line coupler at the fuel pump outlet. Cut the fuel pump electrical harness to the appropriate length and follow the instructions provided to install the connector end. Connect the fuel pump harness. () Mecanyl fuel line () Fuel line coupler () Fuel pump harness connector () fuel pump () Fuel line clamp Blower Control Settings - Climatic () Temperature max heat () Defrost Position Fig. 9 Blower Control Settings - Climatronic () Defrost position () Blower speed between and () Temperature max heat Fig. 60
Final Inspection Initial Start-up and Concluding Work Connect battery ground terminal Final Inspection Inspect installation for: Loose fasteners. Exhaust system routing and clamp tightness. Combustion air intake tube routing and clamp tightness. Loose coolant line clamps. Pinched coolant lines. Routing of coolant lines and coolant lines securely tied and protected against chafing and related damage. Loose fuel line clamps. Routing of fuel lines and fuel lines securely tied and protected against chafing and related damage. Loose wiring connections and battery connections. routing of wiring harness and wiring harness securely tied and protected against chafing and related damage. Check operation of vehicle heater fan with Webasto heater OFF. Initial Start-up Top off cooling system with coolant per engine/vehicle manufacturers recommendations. The fan speed control knob has to be between low and medium for blower operation while the Webasto heater is on. The position of the control knob determines the speed of the blower while the heater is on. Set interior heater control to maximum heat position (hot), fan speed between low and medium, and switch off air conditioning system. Start the vehicle engine and run on fast idle for minutes to purge any remaining air from the Webasto heater and coolant system. While the engine is running check: Hose connections for leaks. Coolant level in expansion tank. (Add coolant as needed) Switch off the engine. More than one start-up attempt of the heater may be required to purge air from fuel system before heater will start. Cycle heater Off and On after each failed start attempt until heater starts successfully. After consecutive unsuccessful start attempts, the Webasto control unit enters into heater lockout. See Heater Lockout section for reset instructions. Switch on the Webasto heater by means of the instant heat button on timer and check: Timer panel and instant heat indicator illuminates. Circulating pump in operation. Initiation of start-up sequence. Successful start-up and operation. 6 Allow heater to run for 0 minutes or until coolant is heated to temperature. Re-tighten all hose clamps. Engine coolant temperature gauge may read lower than actual Webasto heater output temperature. This is due to the location of the temperature gauge sensor on engine. Concluding Work Check that all hose lines, hose clamps, pipe clips and electrical connections are secure. Secure all loose lines and cables with nylon cable ties. Spray the heater components and electrical connections with an anti-corrosive wax coating. Install all vehicle parts, panels and components removed during heater installation. 6
Heater Lockout Reset Procedure The BlueHeat is designed with a lockout safety feature built into the control unit. After consecutive unsuccessful startup attempts, the heater will lock itself out from any further start attempts. The heater may also enter the lockout mode after experiencing an overheat condition. Reset Heater Lockout mode by performing the following procedure: Ensure timer or switch is in the OFF position. Turn timer or switch to the On position. Remove main fuse F (0 Amp), reinsert after seconds. Cycle timer or switch off and then back on once more. Remove fuse F once again and reinsert after seconds. Heater should attempt to start after inserting fuse. The engine coolant must be below 86 F (0 C) before the Webasto heater will attempt to start. Should the heater fail to start or operate correctly, contact your Webasto technical representative at: -800--8 or visit: www.techwebasto.com 7
BlueHeat TM VW Jetta Documentation Feedback Form Detailed user feedback is extremely valuable to us in producing accurate, comprehensive, and useful documentation. Please complete the relevant parts of the form below; your comments and suggestions will help us improve our documentation. Thank you. Unsatisfactory Excellent Please rate the overall usefulness of the documentation. Rate the completeness and clarity of the instructions: did the procedures provide enough detail? What could be added or clarified? Please list any other comments, concerns, or suggestions. Please provided contact information below. Name: Company Name: City / State: Phone: Email: Mail to: Webasto Product N. A., Inc. 08 North Road Fenton, MI 80 Attention: Documentation Group or Fax to: (80) 9-67 8
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Webasto Product N.A., Inc. Technical Assistance Hotline USA: (800) -8 Canada: (800) 667-8900 Org. 08/00 Rev. /00 P/N 000A www.webasto.us www.techwebasto.com