Webasto Thermo Top E Manual de usuario

WARNING!

Hazard warning:

The 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.

To install and repair Webasto heating and cooling systems you need to have completed a

special company training course and have the appropriate technical documentation, special

tools and special equipment.

Only use genuine Webasto parts. See the Webasto air and water heaters accessories cata-

logue for this purpose.

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.

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

tion by untrained staff.

Water Heater

Installation Documentation

Audi A4 / A5

2.7 and 3.0 TDI

Model year 2008 up to 2011

Left-hand drive vehicle

Automatic transmission

Automatic air-conditioning

Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE

Thermo Top E Parking Heater

00 0002

Thermo Top C Parking Heater

00 0003

Audi A4 / A5

Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE

Table of Contents

Validity

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

documentationhavenotbeentested.However,installationaccordingtothisinstallationdocumentation

may be possible.

The installation location of the digital timer should be confirmed with the end customer before installa-

tion.

Manufacturer Model Type EG-BE-No. / ABE

Audi A4 B8 e1 * 2001 / 116 * 0430 * ...

Audi A5 B8 e1 * 2001 / 116 * 0430 * ...

Engine type Engine model Output in kW Displacement in cm³

CAMA Diesel 140 2698

CLAB Diesel 150 2967

CAPA Diesel 176 2967

CDUC Diesel 180 2967

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

Fan Controller 7

Digital Timer, Summer/Winter Switch Option 9

Remote Option (Telestart) 9

Preparing Heater 10

Preparing Installation Location 11

Installing Heater 12

Combustion Air 13

Coolant Circuit 3.0l 150KW / 180KW 14

Coolant Circuit 2.7l 140KW / 3.0l 176KW 17

Fuel 20

Exhaust Gas 24

Final Work 25

Adaptation of Climatronic J255 Control Unit 25

Operating Instructions for End Customer 26

Audi A4 / A5

Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE

Heater/Installation Kit

Foreword

This installation documentation applies to the vehicles Audi A4 / A5 2.7 and 3.0 TDI - for validity, see

page 2 - model year 2008 up to 2011 and later, assuming technical modifications to the vehicle do not

affect installation, any liability claims excluded. Depending on the vehicle version and equipment, mod-

ifications 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 E / C 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. Insulate loose wires and tie back!

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).

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

Special Tools

- Torque wrench for 2.0 - 10 Nm

- Hose clamping pliers

- Metric thread-setter kit

- VAS tester (adjustment of Climatronic control unit)

Quantity Description Order No.:

1 Basic delivery scope for Thermo Top E / C See price list

1 Installation Kit for Audi A4 / A5 2.7 / 3.0 TDI with Automatic

Transmission 1313526B

1 Heater control See price list

Audi A4 / A5

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.

Mechanical system

Electrical system

Coolant circuit

Fuel

Exhaust gas

Combustion air

Software

All dimensions are in mm!

Tightening torque of hose clamps = 2.0 + 0.5 Nm!

Tightening torque of Ejot screws, Ejot studs = 10 Nm!

Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE 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.

Audi A4 / A5

Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE 5

Preliminary Work

WARNING!

- Open the fuel tank cap, ventilate the tank.

- Close the fuel tank cap again.

- Disconnect the battery "earth" or "ground" connection.

- 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.

- Remove the air filter together with the intake hose.

- Remove the coolant reservoir cap.

- Removing the filler neck of the washer fluid reservoir.

- Remove the cover of the fuse and relay box.

- Pull out the control unit and lay it aside.

- Detach the wheel well trim on the right and left.

- Remove the bumper.

- Remove the right-hand underride protection.

- Remove the 3-piece underbody cover.

- Remove the rear bench seat.

- Open the right-hand tank-fitting service lid.

- Remove the A/C control panel in accordance with the manufacturer's instructions.

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

Remove page 26 "Operating Instructions for End Customer" and add to the vehicle operating instruc-

tions.

Heater Installation Location

1Heater

Installa-

tion loca-

tion

Audi A4 / A5

Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE 6

Electrical System

Wiring harness routing

1Original vehicle line duct

2Wiring harnesses of heater, metering pump in

corrugated tube

3Cut open original vehicle protective rubber

plug

Fuse holder, K3 relay

1Positive wire on positive support point

2Angle bracket

3Mount M6x20 bolt, large diameter washer,

flanged nut in existing hole

4M5x16 bolt, retaining plate for fuse holder, K3

relay, washer, flanged nut on angle bracket

5Wiring harness of heater and metering pump

Wiring har-

ness rout-

ing

diagram

Wiring harness pass through

1Control unit pulled out

2Wiring harness of fan controller, digital timer

3Earth wire on earth support point

Wiring harness pass through

1Control unit mounted again

2Wiring harness of digital timer

3Wiring harness of fan controller

2 1

Do not install the metering pump

wiring harness until later togeth-

er with fuel pipe along the origi-

nal vehicle fuel lines on the

underbody

Audi A4 / A5

Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE 7

Fan Controller

Wiring dia-

gram

Webasto components Vehicle components Colours and symbols

Legend

HG Heater TT-C/E J255 Air-conditioning control

panel rt red

X1 6-pin heater connector T20e 20-pin connector J255 ws white

F3 Replace 25 A with 1 A

fuse sw black

gn green

K3 Fan relay

Insulate wire ends and

tie back

XCutting point

Wiring colours may vary.

Webasto

Audi

85 30

87a87

X1 4

!J255

T20e

4² gn/ws

0,75²

4²

Audi A4 / A5

Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE 8

Produce connections as shown in wiring dia-

gram.

1Black (sw) wire from K3/30

2Green/white (gn/ws) additional wire in pro-

tective sleeving

3Insulate red (rt) wire K3/87a and tie back Preparing

fan wiring

harness

Connection to 20-pin connector T20e 1from

A/C control panel.

Produce connections as shown in wiring dia-

gram.

1Remove connector T20e of A/C control

panel

2Free socket, PIN 3

3Green/white (gn/ws) additional line

Connec-

tion of air-

condition-

ing con-

trols

1Complete 20-pin connector of A/C control

panel

Reinsert-

ing con-

nector

Audi A4 / A5

Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE 9

Digital Timer, Summer/Winter

Switch Option

1Summer/winter switch, drilled hole 12 mm

dia.

2Digital timer Installing

digital tim-

Remote Option (Telestart)

Drill out bracket 3to 6.5mm dia. at position 1.

1M6x16 bolt in existing threaded hole

2Receiver Installing

receiver

1Antenna

Installing

antenna

Temperature sensor only in case of T100

HTM

1Fasten temperature sensor with adhesive

tape Installing

tempera-

ture sensor

310

1 2

Audi A4 / A5

Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE 10

Preparing Heater

Discard section X

1Combustion air pipe

a = 350 Cutting

combus-

tion air

pipe to

length

1Combustion air pipe

2Clamp

Premount-

ing com-

bustion air

pipe

190° moulded hose, 10 mm dia. clamp [2x]

2Fuel line

Premount-

ing fuel

line

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