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

successfully 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

warning instructions.

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

an installation by untrained staff.

Feel the drive

Audi A4 1.9 + 2.0 TDI

Diesel

From model year 2006

For left-hand drive vehicles only

Also for vehicles without diesel particle filters

Ident. No.: 9015522A €10 fee © Webasto AG

Water Heater Unit

Thermo Top E Auxiliary

Heating

Thermo Top C Auxiliary

Heating

Thermo Top P Auxiliary

Heating

Installation Instructions

00 0003

00 0002

00 0104

Audi A4 1.9 + 2.0 TDI

Validity

Vehicle and engine types, equipment variants as well as national specifications, which are not listed in

these installation instructions, have not been tested. Installation according to these installation

instructions may, however, be possible.

The installation location of a time switch and summer / winter switch should be confirmed with the end

customer before installation.

Manufacturer Model Type EG-BE No. / ABE

Audi A4 8E e1 * 2001 / 116 * 0151 * ...

Engine type Engine Power in kW Engine capacity in cm³

BKE Diesel 85 1896

BRB Diesel 85 1896

AWX Diesel 96 1896

BLB Diesel 103 1968

BPW Diesel 103 1968

BRE Diesel 103 1968

Validity 2

Heater Unit / Installation Kit 3

Foreword 3

General Instructions 3

Special Tools 3

Explanatory Notes on the Document 4

Preliminary Work 5

Heater Unit Installation Location 5

Electrical Connections 6

Blower Control 7

Remote Start Option 8

Preparing the Installation Location 9

Preparing the Heater Unit 9

Installing the Heater Unit 10

Water Connection 11

Combustion Air 15

Fuel Connection 16

Exhaust System 19

Final Work 21

Operating instructions for the end customer 22

Fastening Strap Template 23

Tank Extracting Device Template 24

Table of Contents

Audi A4 1.9 + 2.0 TDI

Heater Unit / Installation Kit

Recommended heater unit for the relevant vehicle class:

Select the heater unit based on the size of the vehicle passenger compartment and the customer's

comfort requirements.

Foreword

These installation instructions apply to vehicles Audi A4 1.9 + 2.0 TDI with Diesel engines.

– Re. validity, see page 2 – from model year 2006 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, the stipulations in the "installation instructions" and "operating and maintenance instructions"

for the Thermo Top C/P/E are to be observed in any event.

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

specified otherwise, fasten hoses, lines and cable harnesses to original vehicle lines and cable

harnesses using cable clips.

Sharp edges should be fitted with edge protectors (split open plastic hose).

Spray unfinished body areas, such as for example bore holes, with anti-corrosion wax (Tectyl 100K,

Order No. 111329)!

Special Tools

- Torque spanner for 2.0 - 10 Nm

- Vise-grip wrench

- Riveting nut tool

Amount Description Order no.:

1 Commercial supply of required control See price list

1 Installation kit for Audi A4 1.9 + 2.0 TDI Diesel 9015441A

Vehicle Heater unit

Compact car Thermo Top E

Mid-class, station wagon Thermo Top C

Luxury, van, off-roader Thermo Top P

Special features are highlighted using the following symbols:

Mechanics

Electrics

Water connection

Fuel connection

Exhaust system

Combustion air

The arrow in the vehicle icon indicates the position on

the vehicle and the

viewing

angle.

Audi A4 1.9 + 2.0 TDI

Specific risk of injury or fatal accidents.

Specific risk of damage to components.

Specific risk of fire or explosion.

Reference to general installation instructions of

Webasto components or to the manufacturer's vehicle-

specific documents.

Reference to a special technical feature.

Explanatory Notes on the 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.

Audi A4 1.9 + 2.0 TDI

Heater Unit Installation Location

1Heater unit

Installation

location

Preliminary Work

WARNING!

- Let off pressure in 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 cooling water reservoir cover

- Completely remove the battery.

- Completely remove the air filter with intake hose.

- Loosen the engine control unit in the cooling water reservoir.

- Open the tank cap, ventilate the tank.

- Close the tank cap again.

- Remove the underride protection

- Remove the right underbody panel.

- Remove the trunk cover (sedans only)

- Completely remove the lower plastic panel for the trunk floor (Avant only)

- Open the tank mounting service lid

- Remove tank mounting according to manufacturer's instructions.

- Remove air conditioning control according to manufacturer's instructions.

- Remove the dashboard panel on the driver’s side.

Audi A4 1.9 + 2.0 TDI

Electrical Connections

Fuse holder, K3 relay

2K3 relay

3Fuse holder retaining plate

1M5x12 bolt, washer, M5 nut

4Fuse holder

Positive and ground wire

Run the positive wire 1through the protective

rubber sleeve to the battery.

3Ground wire

2Original vehicle cable harness

Cable

harness

installation

diagram

Cable harness installation

Run the cable harnesses for the time switch and

blower control 1 through the protective rubber

sleeve 2in the control box and down under the

engine control unit into the passenger

compartment.

Time switch and summer / winter switch

option

1Time switch

2Summer / winter switch, bore hole Ø 12 mm.

Wait to install the metering pump

cable harness until later,

together with fuel pipe along the

original vehicle fuel lines on the

underbody.

Audi A4 1.9 + 2.0 TDI

Blower Control

Connection the air conditioning control

connector D

(use enclosed micro timer).

Connect according to the circuit diagram.

1Connector D

2Insulate the red (rt) wire to K3/87a and tie

back

3Black (sw) wire from K3/30

4Green/white (gn/sw) wire to connector D

pin 10

Connec-

ting the air

conditio-

ning

control

Automatic

air condi-

tioning

circuit

diagram

Webasto components Components Audi A4 1.9 + 2.0 TDI Colors and symbols

Legend

HG Heater unit TT-C/E Fx Fuse rt red

X1 6-pin heater unit connector KB Air conditioning control ws white

F3 Fuse D Connector KB sw black

K3 Blower relay br brown

gn green

Insulate and tie

back wire ends

XSplitting point

Cable colors may vary.

Webasto

Audi

85 30

87a87

gn/ws rt

gn/ws

Audi A4 1.9 + 2.0 TDI

Remote Start Option

1Receiver

2Double-sided Velcro tape (self adhesive)

Assem-

bling the

receiver

1Antenna

Assem-

bling the

antenna

Temperature sensor for HTM100 only

1Temperature sensor

2Double-sided Velcro tape (self adhesive)

Assem-

bling the

tempera-

ture sensor

Audi A4 1.9 + 2.0 TDI

Preparing the Installation Location

Remove the original vehicle bolt at position 1

and 3(will be used here again). Drill hole at

position 2.

2Ø 9.1mm bore hole, insert rivet nut

Inserting

rivet nut

2Servo hose

1Rubberised tube clamp, plastic nut on

existing stay bolt

Tie back

servo hose

Preparing the Heater Unit

Remove the enclosed bracket for the

mounting, this will be replaced with the

fastening strap.

Bend the fastening strap 1to 90°according to

the template and loosely pre-assemble.

2M6x20 bolt, flanged nut

Loosely

fitting the

fastening

strap on

the bracket

Insert two washers between the heater unit

and the bracket 3in position 2.

Ejot screw bolts tightening torque 10 Nm!

1Ejot screw bolt [2x]

2Ejot screw bolt, washer [2x]

Assem-

bling the

bracket

321

Audi A4 1.9 + 2.0 TDI

1Mecanyl fuel line

2Hose section, Ø 10 mm hose clamps [2x]

Pre-

assem-

bling the

fuel line

Installing the Heater Unit

Insert the bracket 3with the heater unit as

shown in the figure.

Tighten bolt in position 4.

1Original vehicle nuts [4x] on the pre-

assembled bolts

2M6x20 bolt, spring washer on pre-

assembled rivet nut

Assem-

bling the

heater unit

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