Webasto Thermo Top E Manual de usuario

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 suc-

cessfully 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 installa-

tion by untrained staff.

Water Heater Unit

Installation Instructions

Ident. No.:1313475D_EN Fee Euro 10.00 © Webasto AG

VW Tiguan

Gasoline and Diesel

from Model Year 2008

Left-hand drive vehicle

Climatronic

Feel the drive

Thermo Top E Additional Heater e1

00 0003

Thermo Top C Additional Heater e1

00 0002

Thermo Top P Additional Heater e1

00 0104

VW Tiguan

1313475D_EN 2

Table of Contents

Validity

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

instructionshavenotbeentested.However,installation according to these installationinstructions 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

VW Tiguan 5N e1 * 2001/116 * 0450

Engine type Engine model Output in kW Displacement in cm³

BWK Gasoline 110 1390

CAWA Gasoline 125 1984

CAWB Gasoline 147 1984

CBAB Diesel 103 1986

CAHB Diesel 125 1986

Validity 2

Heater Unit/Installation Kit 3

Foreword 3

General Instructions 3

Special Tools 3

Explanatory Notes on Document 4

Preliminary Work 5

Heater unit installation location 5

Preparing electrical system 6

Electrical system 7

Fuse holder and relay K3 8

Fan controller 9

Digital timer 11

Remote option (Telestart) 11

Preparing bracket 12

Premounting heater unit 12

Installing heater unit 14

Coolant on 1.4 liter and 2.0 liter TSI 16

Coolant on 2.0 liter TDI 21

Fuel Connection 25

Exhaust gas 29

Final Work 30

Operating Instructions for End Customer 31

VW Tiguan

1313475D_EN 3

Heater Unit/Installation Kit

Other required parts

Also required with Climatronic

Heater unit recommended for the respective vehicle class:

The selection of the heater unit is based on the passenger compartment size of the vehicle and the

level of comfort required by the customer!

Foreword

These installation instructions apply to VW Tiguan Gasoline and Diesel vehicles - for validity, see

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

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

tions may be necessary during installation with respect to these installation instructions.

However,thestipulations in the "installationinstructions"and"operating and maintenanceinstructions"

for the Thermo Top C/P/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 spec-

ified otherwise, fasten hoses, lines and wiring harnesses to original vehicle lines and wiring harnesses

using cable ties.

Sharp edges must be provided with rub protection (cut-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

Quantity Description Order No.:

1 Retail accessories with desired heater control See price list

1 Installation kit for VW Tiguan Gasoline and Diesel 1313473B

Quantity Description VW Order No.:

1 Plate washer 191 411 331

Quantity Description Order No.:

1 Kit for Climatronic VW Tiguan 1313474A

Vehicle Heater Unit

Compact car Thermo Top E

Mid-size car, station wagon Thermo Top C

Full-size car, van, offroader Thermo Top P

VW Tiguan

1313475D_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.

ReferencetogeneralinstallationinstructionsofWebas-

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

Fuel

Exhaust gas

Combustion air

Explanatory Notes on 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.

VW Tiguan

1313475D_EN 5

Preliminary Work

WARNING!

- Open the fuel tank cap and vent the fuel tank.

- Close the tank cap again.

- Depressurize 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 battery

- Remove the battery carrier

- Remove the engine cover

- Remove the air filter (only on 2.0 TSI).

- Remove the right-hand charge-air tube.

- Remove the charge-air tube completely (only on 2.0 TSI).

- Remover the front right wheel well trim and detach on the left.

- Remove the bumper

- Remove the underride protection

- Remove the right-hand underbody trim

- Remove right rear single seat

- Open the right-hand fuel sender service lid

- Remove the footwell trim on the driver's side

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

- Remove the footwell trim on the front passenger side

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

tions.

Heater unit installation location

1Heater unit

Installa-

tion loca-

tion

VW Tiguan

1313475D_EN 6

Preparing electrical system

Lines for

IPCU

Install lines according to wiring diagram.

Preparing

IPCU

500

0,75²

500

0,75²

500

0,75²

86 85

IPCU

86 85

VW Tiguan

1313475D_EN 7

Electrical system

Wiring harness pass through

1Original vehicle wiring harness pass through

Wiring harness pass through

1Original vehicle wiring harness pass through

Wiring har-

ness in-

stallation

diagram

Routing wiring harness

1Wiring harness of heater unit and wiring har-

ness of metering pump in corrugated tube

2Adhesive base [2x]

Fuse holder, K3 relay

Description of installation for K3 relay 1and fuse

carrier 2on Page 7

Do not installthe metering pump

cableharnessuntillatertogether

with fuel pipe along the original

vehicle fuel lines on the under-

body

VW Tiguan

1313475D_EN 8

Fuse holder and relay K3

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 in

cover

M5x12 countersunk head screw [2x]

Installing

fuseholder

and K3 re-

lay

On vehicles with Climatronic, replace 25 A

fuse F3 7with 3 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) ground wire to original vehi-

cle ground support point below headlight and

connect.

1Fuse/relay carrier

2Original main vehicle fuse

3Red (rt) positive wire Connect-

ing posi-

tive and

ground

wire

VW Tiguan

1313475D_EN 9

Fan controller

Wiring dia-

gram

Webasto components Vehicle components Colors and symbols

Legend

HG Heater unit TT-C/E F1 Fuse SC22 or SC56 with 40 A rt red

X1 6-pin heater unit con-

nector ws white

K3 Fan relay KB Climatronic control unit - J255 sw black

F3 Fuse (25 A replaced

with 3 A!) T10k Plug connections br brown

ge Fan control unit - J126 and fan

motor - V2 gn green

IPCU Pulse width modulator ge yellow

IPCU adjustment values bl blue

Voltage: 8 V Insulate wire ends

and tie back

Frequency: 400 Hz

Duty cycle: 30 %

Function: High-side XCutting point

sw/

ws rt/

T10k

rt/ws

bl/

Webasto

86 85

IPCU

X1 F3

85 30

87a87

T6t

31 42

T16f

15 16 F1

sw/

0,75²

VW Tiguan

1313475D_EN 10

1Original vehicle bolt

2IPCU socket

Installing

IPCU

1Original vehicle bolt

2Brown (br) wire of IPCU/85

Connec-

tion to

ground of

IPCU

1Black (sw) wire of IPCU/A

2Black/white (sw/ws) wire of connector

T6t/2

3Connector T6t

4Black/white (sw/ws) wire of Climatronic

connector T6t/15

5Red (rt) wire of IPCU/E Connect-

ing wires

1 2

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