Webasto Thermo Top E Manual del operador

Water Heater

Installation documentation

Ident. No.: 1313622D_EN Fee Euro 10.00 © Webasto AG

Audi A3

1.2 and 1.4 TFSI

from model year 2008

Left-hand drive vehicle

1.2 TFSI automatic transmission not checked!

Feel the drive

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 heat-

er 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 tech-

nical 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.

The initial startup is to be executed with the Webasto Thermo Test Diagnosis. See sec-

tion "Final Work".

Webasto does not accept any liability for defects and damage that are attributable to installa-

tion by untrained staff.

Thermo Top E Parking Heater

00 0003

Thermo Top C Parking Heater

00 0002

Audi A3

1313622D_EN 2

Table of Contents

Validity

Vehicle and engine types, equipment variants and national specifications not listed in this installation

documentationhavenot beentested. However, installationaccordingto thisinstallationdocumentation

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

Audi A3 8P e1 * 2001/116 * 0217 * ...

Engine type Engine model Output in kW Displacement in cm³

CBZB Petrol TFSI 77 1197

CAXC Petrol TFSI 92 1390

Validity 2

Heater/Installation Kit 3

Foreword 3

General Instructions 3

Special Tools 3

Explanatory Notes on Document 4

Preliminary Work 5

Heater installation location 5

Electrical system 6

Fuse holder and K3 relay 7

Climatronic fan control 8

Climatic fan control 9

Digital timer 10

Summer/winter switch option 10

Remote option (Telestart) 10

Premounting heater 11

Preparing installation location 12

Installing heater 13

Fuel Connection 15

Coolant circuit 18

1.2 manual transmission 19

1.4 manual transmission 21

1.4 Automatic transmission 24

Exhaust gas 29

Final Work 30

Operating Instructions for End Customer 31

Audi A3

1313622D_EN 3

Heater/Installation Kit

Heater recommended for the respective vehicle class:

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 Audi A3 1.2 and 1.4 TFSI vehicles - for validity, see page 2

- from model year 2008 and later, assuming technical modifications to the vehicle do not affect instal-

lation, 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 "installa-

tion 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.

When installing an IPCU, the appropriate settings must be checked and set prior to the installation.

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 rub protection (split-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

- Unlocking tool

Quantity Description Order No.:

1 Retail accessories for Thermo Top E / C See price list

1 Installation kit for Audi A3 1.2 and 1.4 TFSI 1313621B

1 Heater control See price list

Vehicle Heater

Compact car Thermo Top E

Mid-size car, estate car Thermo Top C

Full-size car, van, offroader Thermo Top P

Audi A3

1313622D_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.

Referenceto generalinstallationinstructions ofWebas-

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 circuit

Fuel

Exhaust gas

Combustion air

Explanatory Notes on Document

You will find an identification mark on the outside top right corner of the pagein question to provide you

with a quick overview of the individual working steps.

Audi A3

1313622D_EN 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.

- Remove the air filter box

- Remove the battery

- Remove the battery carrier.

- Remove the left front wheel

- Remove the front section of the left front wheel well trim

- 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 with Climatronic: remove the A/C control panel.

Remove page 31 "Operating Instructions for End Customer" and add to the vehicle operating instruc-

tions.

Heater installation location

1Heater

Installa-

tion loca-

tion

Audi A3

1313622D_EN 6

Electrical system

Wiring harness routing

Route excess lengths from wiring harness of

heater 1in cable duct below battery and secure

with cable ties.

Wiring harness pass through in engine com-

partment

1Original vehicle wiring harness pass through

Wiring har-

ness rout-

ing

diagram

Fuse holder, K3 relay

Description of installation for K3 relay 1and fuse

carrier 2on Page 7

Wiring harness pass through of passenger

compartment

1Original vehicle wiring harness pass through

1 1

Do not installthe metering pump

wiring harness until later togeth-

er with fuel pipe along the origi-

nal vehicle fuel lines on the

underbody

Audi A3

1313622D_EN 7

Fuse holder and K3 relay

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

1M5x12 countersunk head screw [2x]

Installing

fuseholder

and K3 re-

lay

On vehicles with Climatronic, replace 25 A

fuse F3 7with 5 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)earthwiretooriginal vehicle

earth support point below headlight and con-

nect.

1Fuse/relay carrier

2Original main vehicle fuse

3Red (rt) positive wire Connect-

ing posi-

tive and

earth wire

Audi A3

1313622D_EN 8

Climatronic fan control

Produce connection as shown in wiring dia-

gram.

1Black (sw) wire from K3/30

2Beige connector T16e

3Green/white (gn/ws) wire

Connect-

ing air-con-

ditioning

control

panel

Climatron-

ic Wiring

Diagram

Webasto components Components of Audi A3 Colours and symbols

Legend

HG Heater TT-C/E J255 Control unit of A/C control

panel rt red

X1 6-pin connector T16e Connector, beige ws white

F3 Replace 25 A fuse F3

with 5 A fuse. sw black

br brown

K3 Fan relay gn green

Insulatewire endsand

tie back

Wiring colours may vary.

1 2

Webasto

Audi

85 30

87a87

T16e 16

J255

gn/ws

Audi A3

1313622D_EN 9

Climatic fan control

Detach vehicle fuse carrier 4 and unlock con-

tact lock. Unlock and remove black/yellow

(sw/ge) 4² wire 1 on fuse carrier. Produce

connection as shown in wiring diagram - cut-

ting point .

2Red (rt) wire from K3/87a

3Black (sw) wire from K3/30

For vehicles from model year 2008, cut

black/yellow (sw/ge) 4² wire from relay J59 of

connector T10a and connect red (rt) 4²

K3/87a wire and black (sw) K3/30 wire (see

Wiring Diagram dashed - cutting point ).

Alternative cutting point on connector T5d.

Fan motor

connection

Climatic

Wiring Dia-

gram

Webasto components Components of Audi A3 Colours and symbols

Legend

HG Heater TT-C/E J65

Control unit of A/C control panel

rt red

X1 6-pin connector N24 Resistor group ws white

F3 25 A fuse F3 SC40 Fuse 40A sw black

K3 Fan relay SC22*

40A fuse from Model Year 2008

br brown

J59* Release relay gn green

T.... Connector ge yellow

* from Model Year 2008

T10a 10-pin connector behind

glove compartment Wiring colours may vary.

Webasto

Audi

sw/ge

rt/sw

rt/ws

sw/ge

85 30

87a87

SC40

-V2

5T5d

T5d

31 24

J65

T4m

34 21

N24

T10a

J59*

sw/ge

SC22*

sw/ge

rt/bl

Audi A3

1313622D_EN 10

Digital timer

Summer/winter switch option

1Digital timer

212 mm dia. hole, summer/winter switch Installing

digital tim-

Remote option (Telestart)

If M6 bolt 2is not present, then use suitable

M6 bolt with spring lockwasher.

Drill out upper hole of bracket to 6.5 mm dia.

1Receiver

2M6 bolt in existing threaded hole

3Bracket

Installing

receiver

1Antenna

Installing

antenna

Temperature sensor HTM100

1Fasten temperature sensor with adhesive

tape

Installing

tempera-

ture sensor

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