Webasto Thermo Top E Installation Instructions Manual
For audi 2006 a4
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Also See for Thermo Top E:
- Installation documentation (41 pages) ,
- Installation instructions manual (36 pages) ,
- Manual (31 pages)
Table of Contents
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Water Heater Unit
Thermo Top E Auxiliary
Heating
Thermo Top C Auxiliary
Heating
Thermo Top P Auxiliary
Heating
Installation Instructions
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
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.
Ident. No.: 9015522A
e1
00 0003
e1
00 0002
e1
00 0104
€10 fee
Feel the drive
© Webasto AG
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Table of Contents
Related Manuals for Webasto Thermo Top E
Summary of Contents for Webasto Thermo Top E
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Page 1: Installation Instructions
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. -
Page 2: Table Of Contents
Audi A4 1.9 + 2.0 TDI Table of Contents Validity Preparing the Installation Location Heater Unit / Installation Kit Preparing the Heater Unit Foreword Installing the Heater Unit General Instructions Water Connection Special Tools Combustion Air Explanatory Notes on the Document Fuel Connection Preliminary Work Exhaust System... -
Page 3: Heater Unit / Installation Kit
9015441A Recommended heater unit for the relevant vehicle class: Vehicle Heater unit Compact car Thermo Top E Mid-class, station wagon Thermo Top C Luxury, van, off-roader Thermo Top P Select the heater unit based on the size of the vehicle passenger compartment and the customer's comfort requirements. -
Page 4: Explanatory Notes On The Document
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. The arrow in the vehicle icon indicates the position on the vehicle and the angle. -
Page 5: Preliminary Work
Audi A4 1.9 + 2.0 TDI 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. -
Page 6: Electrical Connections
Audi A4 1.9 + 2.0 TDI Electrical Connections Fuse holder, K3 relay Positive and ground wire 2 K3 relay Run the positive wire 1 through the protective 3 Fuse holder retaining plate rubber sleeve to the battery. 1 M5x12 bolt, washer, M5 nut 4 Fuse holder 3 Ground wire 2 Original vehicle cable harness... -
Page 7: Blower Control
10 Webasto Audi gn/ws Automatic air condi- tioning circuit diagram gn/ws Webasto components Components Audi A4 1.9 + 2.0 TDI Colors and symbols Heater unit TT-C/E Fuse 6-pin heater unit connector KB Air conditioning control white Fuse Connector KB black... -
Page 8: Remote Start Option
Audi A4 1.9 + 2.0 TDI Remote Start Option 1 Receiver 2 Double-sided Velcro tape (self adhesive) Assem- bling the receiver 1 Antenna Assem- bling the antenna Temperature sensor for HTM100 only 1 Temperature sensor 2 Double-sided Velcro tape (self adhesive) Assem- bling the tempera-... -
Page 9: Preparing The Installation Location
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. 2 Ø 9.1mm bore hole, insert rivet nut Inserting rivet nut 2 Servo hose 1 Rubberised tube clamp, plastic nut on existing stay bolt... -
Page 10: Installing The Heater Unit
Audi A4 1.9 + 2.0 TDI 1 Mecanyl fuel line 2 Hose section, Ø 10 mm hose clamps [2x] Pre- assem- bling the fuel line Installing the Heater Unit Insert the bracket 3 with the heater unit as shown in the figure. Tighten bolt in position 4. -
Page 11: Water Connection
Audi A4 1.9 + 2.0 TDI Water Connection WARNING! Tighten all hose clamps with 2.0 + 0.5 Nm. 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 clips. Position hose clamps and spring band clamps so that no other hose can be damaged. - Page 12 Audi A4 1.9 + 2.0 TDI a = 270 mm b = 530 mm Dispose of sections X Cutting water hoses into sections Remove the original vehicle engine outlet hose to the heat exchanger inlet 2 (spring band clamp 1 will be used again). Removing the water hose...
- Page 13 Audi A4 1.9 + 2.0 TDI Connec- ting the heater unit inlet Fasten the hose A to the engine outlet. Refasten the hose A to the stay bolt 2 with original vehicle hose clamps. 3 Align the black (sw) rubber profile on the cable harness.
- Page 14 Audi A4 1.9 + 2.0 TDI 1 Align the black (sw) rubber profile according to the figure. Connec- ting the heater unit outlet Run the hose B through the original vehicle rubber sleeve 2 into the cooling water reservoir. Before connecting, fill the water hoses with coolant.
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Page 15: Combustion Air
Audi A4 1.9 + 2.0 TDI Combustion Air 1 Combustion air pipe a = 250 mm Cutting the Dispose of section X combus- tion air pipe into sections Punch out the perforation in the header unit cover at position 1 and insert the retaining clip. -
Page 16: Fuel Connection
Audi A4 1.9 + 2.0 TDI Fuel Connection CAUTION! Open the vehicle's tank-cap lock, 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 cable harness so that they are protected against stone impact. Unless specified otherwise, always fasten using cable clips. - Page 17 Audi A4 1.9 + 2.0 TDI Note the installation position of the metering pump 4, see the “Installation Instructions”. Installation location is to the right next to the vehicle tank. 2 Angle bracket 1 Original vehicle bolt Metering 5 Rubberized tube clamp pump 3 Silentblock, flanged nut [2x] on the angle installation...
- Page 18 Audi A4 1.9 + 2.0 TDI Cut the tank extracting device to size according to the template. 1 Tank extracting device Inserting tank extracting device Install the tank mounting according to manufacturer's instructions. Check that the fuel injector can be freely accessed. 1 Tank extracting device 3 Additional Mecanyl pipe Connec-...
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Page 19: Exhaust System
Audi A4 1.9 + 2.0 TDI Exhaust System 1 Exhaust pipe a = 380 mm 2 Exhaust end section b = 140 mm Preparing Dispose of section X exhaust pipe The illustration shows a standard gear shift vehicle. 1 Exhaust pipe 2 Hose clamp Assem- bling the... - Page 20 Audi A4 1.9 + 2.0 TDI The illustration shows a standard gear shift vehicle. 3 Exhaust silencer 2 Exhaust end section 4 Hose clamp Assem- 1 Red (rt) rubber profile bling the exhaust section Informative illustration shows a vehicle with an automatic transmission.
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Page 21: Final Work
- Attach the "Switch off auxiliary heating before re-fuelling" sticker onto the left side of the B-pillar. Feel the drive Webasto AG Postfach 80 - 82132 Stockdorf - Hotline 0 18 05 / 93 22 78 Hotfax (0395) 55 92-353 - http://www.webasto.de Printed in Germany 04/06Printed by: Steffen... -
Page 22: Operating Instructions For The End Customer
Operating instructions for the end customer Please remove page and add to the vehicle operating instructions. Before parking the vehicle, make the following settings: 1 Temperature to "HI" vehicles with automatic conditio- ning... -
Page 23: Fastening Strap Template
Audi A4 1.9 + 2.0 TDI Fastening Strap Template Torsion line 50 mm 90° 100mm Scale 1:1 Compare the size of the printed version with dimension lines. Permitted tolerance a maximum of 2%. Set the printer settings to “no margin” or “minimize margins” and 100% of the normal size. -
Page 24: Tank Extracting Device Template
Audi A4 1.9 + 2.0 TDI Tank Extracting Device Template 100mm Scale 1:1 Compare the size of the printed version with dimension lines. Permitted tolerance a maximum of 2%. Set the printer settings to “no margin” or “minimize margins” and 100% of the normal size. 100mm...