Webasto Thermo Top P 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, 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.
Webasto does not accept any liability for defects and damage that are attributable to installa-
tion by untrained staff.
Feel the drive
Ident. No.: 9015699D_EN Fee Euro 10.00 © Webasto AG
VW Polo
Diesel
from Model Year 2006
For left-hand drive vehicles only
Water Heater
Thermo Top Parking Heater E
Thermo Top Parking Heater C
Thermo Top Parking Heater P
Installation Instructions
e1
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00 0104
22
VW Polo
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 Polo 9N e1 * 2001/116 * 0174 * ...
Engine type Engine model Output in kW Displacement in cm³
AMF Diesel 55 1422
BNM Diesel 51 1422
BNV Diesel 59 1422
Validity 2
Heater/Installation Kit 3
Foreword 3
General Instructions 3
Special Tool 3
Explanatory Notes on Document 4
Preliminary Work 5
Heater installation location 5
Electrical system 7
Climatic fan controller 8
Climatronic fan controller 9
Remote option (Telestart) 11
Remote option (Thermo Call) 12
Preparing heater 13
Preparing installation location 15
Installing heater 16
Coolant circuit with engine code letters: AMF 17
Coolant circuit with engine code letters: BNV and BNM 21
Combustion air 26
Fuel 27
Exhaust gas 30
Final Work 31
Template for Fuel Standpipe and Fuel-Tank Sending Unit 32
Operating Instructions for End Customer 33
Table of Contents
33
VW Polo
Heater/Installation Kit
Also required with Climatronic:
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
These installation instructions apply to VW Polo vehicles with a Diesel engine - for validity, see page 2
- from model year 2006 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,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 Tool
- Torque wrench
- Hose clamping pliers
- M8 metric thread-setter kit
Quantity Description Order No.:
1 Retail accessories Thermo Top E / C / P See price list
1 Installation kit for VW Polo Diesel 9015698A
1 Heater control See Price list
Quantity Description Order No.:
1 Climatronic kit 9013645A
Vehicle Heater
Compact car Thermo Top E
Mid-size car, station wagon Thermo Top C
Full-size car, van, offroader Thermo Top P
44
Mechanical system
Electrical system
Coolant circuit
Fuel
Exhaust gas
Combustion air
VW Polo
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.
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.
5
VW Polo
Heater installation location
1Heater
Installa-
tion loca-
tion
11
Preliminary Work
WARNING!
- 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.
- Remove the air filter together with the intake hose.
- Remove the wiper arms.
- Remove the coolant reservoir cap.
- Remove the coolant reservoir.
- Open the fuel tank cap, ventilate the tank.
- Close the tank cap again.
- Open the right-hand fuel sender service lid.
- Remove the fuel-tank sending unit in accordance with the manufacturers specifications.
- Remove the underride protection
- Remove the fuse box of the central electrical box.
- Take off the cover of the relay box for the central electrical box (only with Climatronic).
- Remove the A/C control panel according to the manufacturer's instructions (only with Climatronic).
Please remove page 33 of the “Operating instructionsfor the end customer” and add this to the vehicle
operating instructions.
6
VW Polo
Preparing electrical system
Only with Climatronic
Produce connections as shown in wiring dia-
gram. Fasten wire section 1with insulating
tape on the fan wiring harness. Preparing
exhaust
pipe
Connect the included lines to IPCU. Crimp
8mm dia. cable lug on brown (br) wire. The
following IPCU adjustment values should be
verified or adjusted before installation:
Duty cycle: 100%
Frequency:14 KHz
Voltage: 3,3 - 3.7V
Function: High side active
The voltage value (the rotation speed of the
fanmotor)shouldbe verified or adjustedafter
the function check.
Preassem-
bling IPCU
1Perforated bracket
Angling
down per-
forated
bracket
gn/ws rt
rt/ws
br
1
sw
86
85 30
87a87
K3
gn/ws
86 85
A
E
IPCU
sw
rt
br
A
15
86 85
E
90°
80
1
7
VW Polo
Electrical system
Wiring harness pass through
1Protective rubber plug of Bowden cable
Digital timer
1Digital timer
Wiring har-
ness in-
stallation
diagram
Fuse holder, K3 relay
1M6x20 bolt, large diameter washer, M6 flang-
ed nut
2Perforated bracket
3M5x12 bolt, washer, fuse holder, K3 relay, M5
flanged nut
4Original vehicle bracket, drill out hole to 6 mm
dia.
Summer/winter switch option
1Summer/winter switch, drilled hole 12 mm dia.
2
11
3
1
sw
rt
br
bl
Do not install the metering pump
cableharnessuntillatertogether
with fuel pipe along the original
vehicle fuel lines on the under-
body
i
4
2
3
1
4
5
1
8
VW Polo
Climatic fan controller
Climatic
wiring dia-
gram
Webasto components Components of VW Polo Colours and symbols
Legend
HG Heater GM Fan motor - V2 rt red
X1 6-pin heater connector SB36 25 A fuse ws white
F3 25 A fuse N24 Resistor group sw black
K3 Fan relay E9 Switch unit br brown
T... Connector gn green
bl blue
XCutting point
Wiring colours may vary.
Connection on central electrical box 5to fan
module.
Produce connections as shown in wiring dia-
gram.
1Black/red (sw/rt) wire from fuse SB36, 25 A
2Black (sw) wire from K3/30
4Black/red (sw/rt) wire to connector T6ac
3Red (rt) wire K3/87a
Connec-
tion to cen-
tral
electrical
box
1
sw
br
Webasto
31
30
15
VW Polo
rt
sw/rt
br
rt
5
E9
4
23T5h
T5h
sw/rt
rt/sw
gn/ws
rt/
ws
T10c/1
HG
4
X1
86
85 30
87a87
K3
F3
+
-GM
M
SB36
T4e
21 3
N24
4
i
6
2
4
3
5
1
9
VW Polo
Climatronic fan controller
Climatron-
ic wiring
diagram
Webasto components Components of VW Polo Colours and symbols
Legend
HG Heater J127 Fan unit rt red
X1 6-pin heater connector J255 A/C control panel ws white
F3 25 A fuse SB36 25 A fuse sw black
K3 Fan relay T... Connector br brown
IPCU Pulse width modulator gn green
IPCU adjustment values:
Duty cycle 100%
Frequency 14 kHz
Function High side active XCutting point
Voltage 3,3 - 3.7V Wiring colours may vary.
Connection on central electrical box 5to fan
module.
Produce connections as shown in wiring dia-
gram.
1Black/red (sw/rt) wire from fuse SB36, 25A
2Black (sw) wire from K3/30
4Black/red (sw/rt) wire to connector T6ac
3Red (rt) wire K3/87a
Connec-
tion to cen-
tral
electrical
box
Webasto
31
30
15
VW Polo
86 85
E
A
IPCU
sw
sw
sw/
rt
gn/
ws
rt
rt/ws
rt
sw/ws
rt
sw
br
br
HG
4
X1
gn/ws
F3
T12g
3
J255
SB36
T6ac
26
J127
M
sw/
rt
86
85 30
87a87
K3
i
7
2
4
3
5
1
10
VW Polo
Insert IPCU base in free socket.
Produce connections as shown in wiring dia-
gram.
1IPCU
Connec-
tion to re-
lay carrier
ConnectiononconnectorT12g3,Pin3ofA/C
control panel 4.
Produce connections as shown in wiring dia-
gram.
1Black/white (sw/ws) wire of IPCU/A
2Black (sw) wire from fan unit
5Black (sw) wire of connector T12g
6Red (rt) wire of IPCU/E
Connect-
ing air-con-
ditioning
control ele-
ment
8
1
9
1
5
4
6
2
3
Este manual sirve para los siguientes modelos
2
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