Webasto Thermo Top E Installation Instructions Manual
Volkswagen 2008 tiguan
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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 Additional Heater
Thermo Top C Additional Heater
Thermo Top P Additional Heater
Installation Instructions
VW Tiguan
Gasoline and Diesel
from Model Year 2008
Left-hand drive vehicle
Climatronic
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.:1313475D_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
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Page 1: Installation Instructions
Climatronic 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. -
Page 2: Table Of Contents
VW Tiguan Table of Contents Validity Preparing bracket Heater Unit/Installation Kit Premounting heater unit Foreword Installing heater unit General Instructions Coolant on 1.4 liter and 2.0 liter TSI Special Tools Coolant on 2.0 liter TDI Explanatory Notes on Document Fuel Connection Preliminary Work Exhaust gas Heater unit installation location... -
Page 3: Heater Unit/Installation Kit
1313474A 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 Tiguan 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 Coolant Fuel Exhaust gas Combustion air... -
Page 5: Preliminary Work
VW Tiguan Preliminary Work WARNING! - Open the fuel tank cap and vent the fuel tank. - Close the tank cap again. - 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: Preparing Electrical System
VW Tiguan Preparing electrical system 0,75² Lines for IPCU 0,75² 0,75² Install lines according to wiring diagram. IPCU Preparing IPCU 1313475D_EN... -
Page 7: Electrical System
VW Tiguan Electrical system Wiring harness pass through Wiring harness pass through 1 Original vehicle wiring harness pass through 1 Original vehicle wiring harness pass through Wiring har- Do not install the metering pump ness in- cable harness until later together stallation with fuel pipe along the original diagram... -
Page 8: Fuse Holder And Relay K3
VW Tiguan 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 in partment cover 2 Cut away bar in shaded area 3 5.0 mm dia. hole [2x] 1 M5x12 countersunk head screw [2x] Installing fuse holder... -
Page 9: Fan Controller
T16f 0,75² IPCU 0,75² T10k 0,75² rt/ws 0,75² Webasto components Vehicle components Colors and symbols Heater unit TT-C/E Fuse SC22 or SC56 with 40 A rt 6-pin heater unit con- white nector Fan relay Climatronic control unit - J255... - Page 10 VW Tiguan 1 Original vehicle bolt 2 IPCU socket Installing IPCU 1 Original vehicle bolt 2 Brown (br) wire of IPCU/85 Connec- tion to ground of IPCU 1 Black (sw) wire of IPCU/A 2 Black/white (sw/ws) wire of connector T6t/2 3 Connector T6t 4 Black/white (sw/ws) wire of Climatronic connector T6t/15...
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Page 11: Digital Timer
VW Tiguan Digital timer 1 12 mm dia. hole, summer/winter switch 2 Digital timer Installing digital tim- Remote option (Telestart) Bend down lower tab of bracket by 90° and drill out hole to 6.5 mm dia. as shown. 1 Receiver Installing 2 Bracket receiver... -
Page 12: Preparing Bracket
VW Tiguan Preparing bracket 16 mm dia. hole in bracket 1 at position 2 . Hole in bracket 87,5 Premounting heater unit 1 Combustion air pipe a = 270 Discard section X Cutting combus- tion air pipe to length 1.4 and 2.0 TSI b = 70 c = 160 e = 70... - Page 13 VW Tiguan All vehicles 1 15x20 connecting pipe 2 Hose clamp [3x] 3 Black (sw) rubber isolator 4 Angle bracket Premount- 5 Ejot screw ing heater unit 1 Bracket 2 Combustion air pipe, 10 mm dia. hose clamp 3 15x20 connecting pipe 4 10 mm dia.
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Page 14: Installing Heater Unit
VW Tiguan Installing heater unit Connect wiring harness of heater unit prior to installation. Insert plate washer (VW Order No. 191 411 331) at position 1 . Installing 1 Original vehicle stud bolt, plate washer, M8 heater unit 2 M10x30 bolt with locking pawl in existing thread Before installation, glue sponge rubber 2 onto strut 3 . - Page 15 VW Tiguan 1 Intake muffler 2 M5x16 bolt, large diameter washer, M5 flanged nut 3 51 mm dia. p-clamp Installing intake muf- fler 1313475D_EN...
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Page 16: Coolant On 1.4 Liter And 2.0 Liter Tsi
VW Tiguan Coolant on 1.4 liter and 2.0 liter TSI WARNING! Any coolant running off should be collected using an appropriate container! Route coolant hoses 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 coolant. - Page 17 VW Tiguan a = 1200 d = 1200 Discard section X Cutting 15 mm dia. coolant hose to length Push braided protection hoses onto hose A and D , cut to length and shrink. 1 Heat shrink plastic tubing [4x] Premount- ing coolant hoses...
- Page 18 VW Tiguan Position 10 mm shim 2 between 34 mm dia. rubber-coated p-clamp 4 . 1 M6x20 bolt, spring lockwasher 3 M6x40 spacer nut on existing thread Preparing installa- tion of coolant hoses Connec- tion to heater unit Routing in engine compart- ment...
- Page 19 VW Tiguan Routing in engine compart- ment 1.4 TSI Dispose of hose section 1 . Original vehicle clamp will be reused. 2 Cutting point Cutting point Ensure sufficient distance to neighboring components. 1 Hose of engine outlet Connect- ing engine outlet 1 Cable tie 2 Original vehicle spring clip...
- Page 20 VW Tiguan 2.0 TSI Remove trim of heat exchanger inlet/output 1 and discard. Cutting point Slide back heat shield on hose on heat ex- changer inlet/engine outlet. Dispose of hose section 2 . Original vehicle clamp 1 will be reused. 3 Cutting point Cutting point...
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Page 21: Coolant On 2.0 Liter Tdi
VW Tiguan Coolant on 2.0 liter TDI WARNING! Any coolant running off should be collected using an appropriate container! Route coolant hoses 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 coolant. The connection should be "inline"... - Page 22 VW Tiguan a = 1,050 d = 1200 Discard section X Cutting 15 mm dia. coolant hose to length Push braided protection hoses onto hose A and D , cut to length and shrink. 1 Heat shrink plastic tubing [4x] Premount- ing coolant hoses...
- Page 23 VW Tiguan Position 10 mm shim 2 between 34 mm dia. rubber-coated p-clamp 4 . 1 M6x20 bolt, spring lockwasher 3 M6x40 spacer nut on existing thread Preparing installa- tion of coolant hoses Hose section 1 and original vehicle clamp 2 will be reused.
- Page 24 VW Tiguan Push through hoses A and D between body and plastic duct at position 1 . Routing in engine compart- ment 1 Cable tie Routing in engine compart- ment 1 Hose section turned by 180° 2 Engine outlet hose section Connect- ing engine outlet...
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Page 25: Fuel Connection
VW Tiguan Fuel Connection 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 26 VW Tiguan 1 Fuel line and wiring harness for metering pump in corrugated tube Routing fuel line and wiring harness of metering pump 1 Original vehicle bolt 2 Bracket of metering pump Installing metering pump 1 Metering pump 2 Rubber-coated pipe clamp 3 Noise isolation mounts, flanged nut M6 [2x] Installing metering...
- Page 27 VW Tiguan 1.4 liter TSI only 1 Remove 3 mm blind plug 2 Fuel-tank sending unit Cutting off blind plug 1 Preassembled molded hose with stand- pipe 2 10 mm dia. Caillau clamp 3 Cable tie 4 Fuel line 5 13.5 mm dia. Caillau clamp Connec- tion to fuel- tank send-...
- Page 28 VW Tiguan All vehicles Before installation, pull fuel line into remain- ing section of corrugated tube 1 . 2 Molded hose, 10 mm dia. hose clamp [2x] Connect- ing intake side of me- tering pump 1313475D_EN...
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Page 29: Exhaust Gas
VW Tiguan Exhaust gas 1 Exhaust pipe a = 150 2 Exhaust end section b = 90 Preparing exhaust Discard section X pipe Align exhaust muffler 4 following installation as shown. 1 M6 flanged nut 2 Perforated bracket 3 M6x35 bolt, M6 flanged nut Mounting 5 20 mm shim muffler... -
Page 30: Final Work
2 . 3 Wheel well trim 3 Underride protection Mounting rubber iso- lator Feel the drive Webasto AG Postfach 80 - 82132 Stockdorf Hotline 01805 / 932278 - Hotfax 0395 / 5592-353 http://www.webasto.de Printed in Germany 06/2009 Printing: Stef-... -
Page 31: Operating Instructions For End Customer
VW Tiguan 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.
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