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.:9013722D_EN Fee Euro 10.00 © Webasto AG
VW Caddy
1.6 Liter Gasoline and 2.0 Liter Gasoline Eco Fuel; 2.0 Liter SDI
from Model Year 2005
Left-hand drive vehicle
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 Caddy
9013722D_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 Caddy 2KN L 320
VW Caddy 2K150 e1*2001/116*0252*...
Engine type Engine model Output in kW Displacement in cm³
BSE Gasoline 75 1595
BSX Gasoline [Eco Fuel] 80 1984
BDJ Diesel 51 1968
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
Electrical system 6
Fuse holder and relay K3 7
Climatic fan controller 8
Climatronic fan controller 10
Remote option (Telestart) 12
Preparing heater unit 13
Preparing installation location 13
Installing heater unit 14
Fuel 16
Coolant for gasoline engine 21
Coolant for diesel engine 25
Combustion air 29
Exhaust gas 30
Final Work 31
Operating Instructions for End Customer 32
VW Caddy
9013722D_EN 3
Heater Unit/Installation Kit
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 Caddy 1.6 Liter Gasoline and 2.0 Liter Gasoline Eco Fuel;
2.0 Liter SDI vehicles - for validity, see page 2 - from model year 2005 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
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 should be fitted with edge protectors (split-open plastic 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
- Metric thread-setter kit
Quantity Description Order No.:
1 Retail accessories with desired heater control See price list
1 Installation kit for VW Caddy 1.6 Liter Gasoline and 2.0 Liter
Gasoline Eco Fuel; 2.0 Liter SDI 9013723B
Quantity Description Order No.:
1 IPCU Kit for Climatronic 9013645A
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 Caddy
9013722D_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
Water
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 Caddy
9013722D_EN 5
Preliminary Work
WARNING!
- Open fuel tank cap, ventilate tank.
- Close the tank cap again.
- Disconnect the battery "earth" or "ground" connection.
-Depressurizethe 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.
- Completely remove the battery.
- Remove the battery carrier.
- Remove the engine cover.
- Remove the air filter together with the intake hose.
- Remove the right front wheel.
- Remove the front section of the right front wheel well trim.
- Remove the underride protection (if present).
- Remove the bumper.
- Remove the washer reservoir.
- Remove the right-hand underbody trim
- Remove the footwell trim on the driver's side and front passenger side
- Remove the lower instrument panel trim on the driver's side
- Remove the fuel-tank sending unit according to the manufacturer's instructions (with gasoline
only).
Remove page 32 "Operating Instructions for End Customer" and add to the vehicle operating instruc-
tions.
Heater unit installation location
1Heater unit
Installa-
tion loca-
tion
1
1
VW Caddy
9013722D_EN 6
Electrical system
Wiring harness of heater unit
Guide wiring harness of heater unit 2in front of
radiator at position 1and route to right along up-
per edge of radiator. Then route into engine com-
partment again at position 3. Fastening is not
carried out until after heater unit is installed!
Fuse holder, relay K3
For information on installing fuse holder and K3
relay, see page 7.
1Relay K3
2Fuse holder
Wiring har-
ness in-
stallation
diagram
Wiring harness pass through
1Original vehicle wiring harness pass through
2Wiring harnesses for fan controller and heater
control
Digital timer, summer/winter switch option
1Digital timer
2Summer/winter switch, drilled hole 12 mm dia.
2
2
1
2
3
3
1
2
Do not installthe metering pump
cableharnessuntillatertogether
with fuel pipe along the original
vehicle fuel lines on the under-
body
4
1
2
5
2
1
VW Caddy
9013722D_EN 7
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 for
fuseholder
and K3 re-
lay
1 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
1
6
40
99
3
20
2
3
7
11
6
2
3
8
74
5
1
21
3
9
VW Caddy
9013722D_EN 8
Climatic fan controller
Fusesocketdependentonvehicleequipment
SC33 or SC35; wire color black (sw) or
black/yellow (sw/ge).
Detach original vehicle fuse carrier 2(instru-
ment panel at lower left) and unlock contact
lock 3.
Uncrimp black (sw) or black/yellow (sw/ge)
wire 1on fuse output SC33 or SC35.
Uncrimp-
ing wire
Produce connection as shown in wiring dia-
gram.
1Black (sw) or black/yellow (sw/ge) wire
with original standard power timer
2AMP housing [2x]
3Contact lock locked
4Black (sw) wire to K3/30
5Red (rt) wire from K3/87a with standard
power timer engaged in fuse output SC33
or SC35
Installing
wiring har-
ness
10
3
21
11
3 3
1
2
45
2
VW Caddy
9013722D_EN 9
Climatic fan controller
Wiring dia-
gram
Webasto components Vehicle components Colors and symbols
Legend
HG Heater unit TT-C/E SC33 Fan fuse rt red
X1 6-pin heater unit connec-
tor SC35 Fan fuse ws white
F3 25 A fuse J301 Control unit of air condi-
tioning sw black
K3 Fan relay E16 Heater switch br brown
N24 Resistor group ge yellow
V2 Fan motor
T... Plug connections
4
sw
Webasto
31
30
15
VW Caddy
rt
sw oder
sw/ge
br
rt/sw
T4r
5
J301 oder E16
312 T5
342
N24
T5
rt/ws
1
T10k
K3
87a8786
85 30
4
HG X1 F3 SC33
oder
SC35
sw oder
sw/ge
M
+
-
V2
4²
4²
4²
4²
VW Caddy
9013722D_EN 10
Climatronic fan controller
Produce connections as shown in wiring dia-
gram.
Positionof freesocketsdependentonvehicle
equipment.
Connect black (sw) wire from K3/30 3to
green/white (gn/ws) wire 2(AMP connector).
Insulate red (rt) wires K3/87a 4and tie back.
1IPCU socket
Installing
wiring har-
ness of Cli-
matronic
Fasten brown (br) wire IPCU/85 2on original
vehicle ground point.
1IPCU
Installing
ground
wire
Route wiring harness from IPCU 1to original
vehicle wires to fan unit.
Routing
wiring har-
ness of
IPCU
1Connector T6t
2Black/white (sw/ws) wire to connector
T6t/2
3Black/white (sw/ws) wire from IPCU/A
4Red (rt) wire from IPCU/E
5Black/white (sw/ws) wire from Climatronic
control unit
6Wiring harness from IPCU
Connect-
ing wires
12
1
2
3
4
13
2
1
1
14
1
63
15
4
2
1
5
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42
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