Webasto Thermo Top E Installation Instructions Manual
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Webasto Thermo Top E Installation Instructions Manual

For volkswagen 2005 caddy
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See also: Instructions for Using , Instruction and Installation Manual
Water Heater Unit
Thermo Top E Additional Heater
Thermo Top C Additional Heater
Thermo Top P Additional Heater

Installation Instructions

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
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.
Ident. No.:9013722D_EN
e1
00 0003
e1
00 0002
e1
00 0104
Fee Euro 10.00
Feel the drive
© Webasto AG

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Summary of Contents for Webasto Thermo Top E

  • Page 1: Installation Instructions

    Left-hand drive vehicle 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.

  • Page 2: Table Of Contents

    VW Caddy Table of Contents Validity Preparing heater unit Heater Unit/Installation Kit Preparing installation location Foreword Installing heater unit General Instructions Fuel Special Tools Coolant for gasoline engine Explanatory Notes on Document Coolant for diesel engine Preliminary Work Combustion air Heater unit installation location Exhaust gas Electrical system...

  • Page 3: Heater Unit/Installation Kit

    9013645A Heater unit recommended for the respective vehicle class: Vehicle Heater unit Compact car Thermo Top E Mid-size car, station wagon Thermo Top C Full-size car, van, offroader Thermo Top P The selection of the heater unit is based on the passenger compartment size of the vehicle and the...

  • Page 4: Explanatory Notes On Document

    VW Caddy 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. Mechanical system Electrical system Water Fuel Exhaust gas Combustion air...

  • Page 5: Preliminary Work

    VW Caddy Preliminary Work WARNING! - Open fuel tank cap, ventilate tank. - Close the tank cap again. - Disconnect the battery "earth" or "ground" connection. - 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.

  • Page 6: Electrical System

    VW Caddy Electrical system Wiring harness of heater unit Fuse holder, relay K3 Guide wiring harness of heater unit 2 in front of For information on installing fuse holder and K3 radiator at position 1 and route to right along up- relay, see page 7.

  • Page 7: Fuse Holder And Relay K3

    VW Caddy Fuse holder and relay K3 Countersink holes 3 from behind for M5 coun- tersunk head screws. 1 Cover of fuse/relay carrier in engine com- Holes for partment fuse holder 2 Cut away bar in shaded area and K3 re- 3 5.0 mm dia.

  • Page 8: Climatic Fan Controller

    VW Caddy Climatic fan controller Fuse socket dependent on vehicle equipment SC33 or SC35; wire color black (sw) or black/yellow (sw/ge). Detach original vehicle fuse carrier 2 (instru- Uncrimp- ment panel at lower left) and unlock contact ing wire lock 3. Uncrimp black (sw) or black/yellow (sw/ge) wire 1 on fuse output SC33 or SC35.
  • Page 9 T10k rt/ws oder sw/ge 4² 4² J301 oder rt/sw 4² Webasto components Vehicle components Colors and symbols Heater unit TT-C/E SC33 Fan fuse 6-pin heater unit connec- SC35 Fan fuse white 25 A fuse J301 Control unit of air condi-...

  • Page 10: Climatronic Fan Controller

    VW Caddy Climatronic fan controller Produce connections as shown in wiring dia- gram. Position of free sockets dependent on vehicle equipment. Installing Connect black (sw) wire from K3/30 3 to wiring har- green/white (gn/ws) wire 2 (AMP connector). ness of Cli- Insulate red (rt) wires K3/87a 4 and tie back.
  • Page 11 0,75² 0,75² IPCU T10k 0,75² sw/ws 4² 0,75² rt/ws 0,75² 0,75² 4² Webasto components Vehicle components Colors and symbols Heater unit TT-C/E SC52 Fan fuse 6-pin heater unit connec- Air-conditioning control white panel Replace 25 A fuse F3 Fan controller...

  • Page 12: Remote Option (Telestart)

    VW Caddy Remote option (Telestart) Drill out upper hole of bracket to 6.5 mm dia. 1 Receiver 2 Mount M6x12 bolt, large diameter washer, Installing flanged nut in existing hole receiver 3 Bracket 1 Antenna Installing antenna 9013722D_EN...

  • Page 13: Preparing Heater Unit

    VW Caddy Preparing heater unit 1 Replace circulating pump cover with cover with straight inlet Convert- ing circu- lating pump Preparing installation location 1 Washer reservoir 2 Drill 6.5 mm dia. hole Preparing washer reservoir Install washer reservoir and copy hole pat- tern.

  • Page 14: Installing Heater Unit

    VW Caddy Position rivet nut in center between A/C lines. 1 Edge protection 50 2 9.1 mm dia. hole; M6 rivet nut Installing rivet nut Installing heater unit Loosely mounting strut 1 Strut 2 M6x35 bolt, spring lockwasher, large diam- Installing eter washer, 5 mm shim, 20 mm shim strut...
  • Page 15 VW Caddy 1 M6x60 bolt, spring lockwasher, washer, 30 mm spacer, existing threaded hole 2 M6x60 bolt, spring lockwasher, large diam- eter washer, 30 mm spacer, large diameter washer, rivet nut 3 Washer reservoir Installing washer reservoir 1 Washer reservoir 2 M6x25 bolt, spring lockwasher, large diam- eter washer [2x each], premount spacer nuts...

  • Page 16: Fuel

    VW Caddy Fuel CAUTION! Open the vehicle's fuel tank cap, ventilate the tank and then re-close the tank lock. Catch any fuel running off with an appropriate container. Install fuel line and metering-pump wiring harness so that they are protected against stone impact. Un- less specified otherwise, always fasten using cable ties.
  • Page 17 VW Caddy Route fuel line and wiring harness of meter- ing pump along original vehicle fuel lines 2 to rear. 1 Line duct Installing lines Metering pump of 1.6 liter gasoline and diesel engine 1 Rubber-coated p-clamp, silent block, flanged nut [2x] 2 Metering pump Installing 3 Perforated bracket...
  • Page 18 VW Caddy Preparing fuel standpipe 1 Standpipe 2 Molded hose Cutting standpipe and mold- 4.5 mm dia. 7.5 mm dia. ed hose to length 10 mm dia. Caillau clamp 2 in center between beads on end of standpipe. 1 Standpipe 3 Molded hose Premount- ing stand-...
  • Page 19 VW Caddy Check the position of the components; adjust if necessary. Check that they have free clear- ance. 1 Fuel line from fuel-tank sending unit 2 Hose section, 10 mm dia. hose clamp [2x] Connect- ing meter- ing pump Metering pump of Eco Fuel Angle down perforated bracket 3 by 90°.
  • Page 20 VW Caddy Fuel standpipe of 1.6 liter gasoline and 2.0 liter Eco Fuel Remove the fuel tank according to the manu- facturer's instructions. Cut 3 mm off blind plug. Cutting off blind plug 1 Fuel sender 2 Tip cut off blind plug Position guide clip 1 for standpipe.

  • Page 21: Coolant For Gasoline Engine

    VW Caddy Coolant for gasoline engine WARNING! Any coolant running off should be collected using an appropriate container. Install hoses so that they are kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that no other hose can be damaged! When installing the coolant hose, the heater unit must be filled with cool- ant.
  • Page 22 VW Caddy a = 940 b = 1000 Discard section X Cutting coolant hoses to length Push braided protection hoses onto hose A and B and cut to length. Cut heat shrink plastic tubing to length. y = 25 Preparing 1 50 mm long heat shrink plastic tubing [4x] coolant hoses...
  • Page 23 VW Caddy Spring clip 2 will be reused. 1 Pull off original vehicle hose section to heat exchanger inlet and discard 3 Original vehicle hose section from engine outlet Cutting point 1 Original vehicle spring clip Connect- ing heat exchanger inlet Route hose B through front p-clamp.
  • Page 24 VW Caddy Hose A with 90° elbow on heater unit inlet! 1 27x27 double clip, lockable Connect- ing heater unit Route hose A through lower p-clamp. After routing, tighten M6x20 bolt and flanged nut at position 1. 2 27x27 double clip, lockable 3 29 mm dia.

  • Page 25: Coolant For Diesel Engine

    VW Caddy Coolant for diesel engine WARNING! Any coolant running off should be collected using an appropriate container. Install hoses so that they are kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that no other hose can be damaged! When installing the coolant hose, the heater unit must be filled with cool- ant.
  • Page 26 VW Caddy a = 900 b = 950 Discard section X Cutting coolant hoses to length Push braided protection hoses onto hose A and B and cut to length. Cut heat shrink plastic tubing to length. y = 25 Preparing 1 50 mm long heat shrink plastic tubing [4x] coolant hoses...
  • Page 27 VW Caddy Spring clip 1 will be reused. 2 Original vehicle hose section from engine outlet 3 Pull off original vehicle hose section to heat exchanger inlet and discard Cutting point Hose B with 90° elbow on heat exchanger in- let! 1 Original vehicle spring clip Connect-...
  • Page 28 VW Caddy Hose A with 90° elbow on heater unit inlet! 1 27x27 double clip, lockable Connect- ing heater unit Route hose A through lower p-clamp. After routing, tighten M6x20 bolt and flanged nut at position 1 . 2 27x27 double clip, lockable 3 29 mm dia.

  • Page 29: Combustion Air

    VW Caddy Combustion air 1 Intake muffler 2 Intake pipe, 27 mm dia. clamp 3 Cable tie Installing muffler and intake pipe 9013722D_EN...

  • Page 30: Exhaust Gas

    VW Caddy Exhaust gas 1 Exhaust pipe a = 250 2 Exhaust end section b = 115 Preparing exhaust Discard section X pipe Align muffler following installation. Ensure sufficient distance to neighboring components. 1 Exhaust muffler 2 M6x20 bolt, large diameter washer, M6 Installing flanged nut muffler...

  • Page 31: Final Work

    - Reduce the sensitivity of the passenger compartment monitoring to 50 % - Save this setting - The adjustment of the sensitivity of the passenger compartment monitoring is completed. Feel the drive Webasto AG Postfach 80 - 82132 Stockdorf Hotline 01805 / 932278 - Hotfax 0395 / 5592-353 http://www.webasto.de...

  • Page 32: Operating Instructions For End Customer

    VW Caddy Operating Instructions for End Customer Please remove page and add to the vehicle operating instructions. Note: We recommend matching the heating time to the driving time. Heating time = driving time Example: For a driving time of approx. 20 min. (in one direction), we recommend not exceeding a switch-on time of 20 min.

This manual is also suitable for:

Thermo top pThermo top c

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