Webasto Thermo Top C Installation Instructions Manual
Water heater unit; seat leon
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Also See for Thermo Top C:
- Installation instructions manual (56 pages) ,
- Operating instructions manual (40 pages) ,
- Operating and installation instructions (39 pages)
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Water Heater Unit
Thermo Top C Additional Heater
Thermo Top P Additional Heater
Thermo Top E Additional Heater
Installation Instructions
Seat Leon
Gasoline
from Model Year 2005
Left-hand drive vehicle
Not with "SEAT Sport" aerodynamics kit
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
warnings.
Webasto does not accept any liability for defects and damage that are attributable to
installation by untrained staff.
Ident. No.: 1311820B_EN
e1
00 0002
e1
00 0104
e1
00 0003
Fee Euro 10
Feel the drive
© Webasto AG
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Summary of Contents for Webasto Thermo Top C
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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
Seat Leon Table of Contents Validity Preassemble exhaust system Heater Unit/Installation Kit Combustion air Foreword Preparing installation location General Instructions Installing heater unit Special Tools Combustion air connection Explanatory Notes on the Document Fuel Connection Preliminary Work Fuel removal Heater Unit Installation Location Coolant connection Fuse holder and relay K3 Final Work... -
Page 3: Heater Unit/Installation Kit
However, the stipulations in the "installation instructions" and "operating and maintenance instructions" 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. -
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
Seat Leon Preliminary Work WARNING! - Open fuel tank cap, ventilate 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. - Attach the duplicate label (type label) in the appropriate place. -
Page 6: Fuse Holder And Relay K3
Seat Leon Fuse holder and relay K3 Countersink holes 3 from behind for M5 countersunk head screws. 1 Cover of fuse/relay carrier in engine compartment Holes for 2 Cut away bar in shaded area fuse 3 Drill 5.0 mm dia. hole [2x] holder and K3 relay 1 M5x12 countersunk head screw [2x]... -
Page 7: Electrical Connections
Seat Leon Electrical Connections Wiring harness of heater unit Fuse holder Route the wiring harness of the heater unit along 1 Relay K3 the original vehicle wiring up to the right-hand 2 Fuse holder headlight. 3 Route wiring harness of heater control, fan controller and metering pump in cable duct to firewall. -
Page 8: Climatic Fan Controller
Seat Leon Climatic fan controller 2 Uncrimp- ing wire 1 Unlock 40 A fan fuse, remove 4 mm² black (sw) wire 2 Fuse carrier Produce connections as shown in wiring Connect- diagram. ing wires 1 4 mm² black (sw) wire 2 AMP/housing 3 Red (rt) wire to K3/87a 4 Black (sw) wire from K3/30... - Page 9 Seat Leon Webasto rt/ws rt/ws T10c/2 gn/ws rt/ws Climatic wiring diagram rt/sw Webasto components Components of Seat Leon Colors and symbols Heater unit TT-C/E Climatic control unit 6-pin connector Resistor group white 25 A fuse Fuse 40A black Fan relay...
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Page 10: Climatronic Fan Controller
Seat Leon Climatronic fan controller Position of free sockets dependent on vehicle equipment! 1 IPCU socket 2 Red (rt) and black (sw) wire from IPCU 3 Green/white (gn/ws) wire of IPCU/86 with IPCU connector socket Brown (br) wire from IPCU/85 to original vehicle ground point. - Page 11 Seat Leon If necessary, disconnect fan unit in accordance with manufacturer's instructions. Produce connections as shown in wiring diagram. 1 Wiring harness from IPCU 2 Black/white (sw/ws) wire from IPCU/A 3 Red (rt) wire from IPCU/E 4 Black/white (sw/ws) wire from Climatronic Connect- control unit ing wires...
- Page 12 Webasto Seat Leon rt/ws Climatron- rt/ge IPCU ic wiring diagram sw/ws rt/ws sw/ws gn/ws Webasto components Vehicle components Colors and symbols Heater unit TT-C/E Climatronic control unit 6-pin heater unit Fan unit white connector Fan relay Fuse 40A black Fuse (25 A replaced...
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Page 13: Remote Option (Telestart)
Seat Leon Remote option (Telestart) 1 M6x20 bolt, large diameter washer, flanged nut 2 Telestart bracket, hole drilled out to 6.5 mm dia. 3 Antenna connector Installing receiver 1 Antenna Installing antenna Temperature sensor only with HTM 100 1 Fasten temperature sensor with suitable means Installing tempera-... -
Page 14: Remote Option (Thermo Call)
Seat Leon Remote option (Thermo Call) 1 Fasten receiver with suitable means Installing receiver 1 Antenna Installing antenna... -
Page 15: Preassembling Heater Unit
Seat Leon Preassembling heater unit Ejot stud, tightening torque 10 Nm. 1 Adapter wiring harness connected 2 Long Ejot screw 3 Short Ejot screw Premount- 4 Replace circulating pump cover with cover ing heater with straight inlet unit 1 Bracket 2 M6x30 spacer nut, M6x16 bolt, spring lockwasher Preassem-... -
Page 16: Combustion Air
Seat Leon Shape exhaust pipe as shown in picture 26 and 27 1 Red (rt) rubber profile [2x] 2 Exhaust pipe 3 Hose clamp [3x] 4 Exhaust end section Preassem- 5 M6x16 bolt, spring lockwasher ble ex- 6 Exhaust muffler haust system 1 M6x20 bolt, flanged nut... -
Page 17: Preparing Installation Location
Seat Leon Preparing installation location Existing screws and nut will be reused! 1 Cross member Removing washer reservoir and cross member Insert rivet nut 2 only loosely, but do not rivet 1 Holes drilled out to 9 mm dia., M6 rivet nut [2x] 2 M6 rivet nut centered in oblong hole Installing... -
Page 18: Installing Heater Unit
Seat Leon Installing heater unit Position replacement washer reservoir 2 as shown. Cut away cable duct 1 at marking. Installing washer reservoir Loosely mount bolt 2 and nuts 3 ! 1 5 mm shim 2 M6x30 bolt, spring lockwasher 3 Original vehicle nut [2x] Installing heater unit Loosely mount original vehicle bolt 1. - Page 19 Seat Leon 1 Drill out nut to 7 mm dia. [2x] Preparing cross member 1 Original vehicle bolts [2x] 2 M6x20 bolt, spring lockwasher [2x each] Installing cross member Bracket 1 will be reused. Removing bracket for A/C line 1 9 mm dia. hole, M6 rivet nut Installing rivet nut...
- Page 20 Seat Leon 1 6.5 mm dia. hole Drilling out bracket 1 50 mm edge protection 2 Bracket laid on loosely Installing bracket Loosely mount bolt 2 ! 1 Strut 2 M6x50 bolt, spring lockwasher, large diameter washer Installing strut Loosely mount Ejot screw 2. 1 Strut 2 Ejot screw Installing...
- Page 21 Seat Leon Test mounting of bumper. Check position of all components and adjust if necessary. Check that they have free clearance. Aligning and fasten- ing compo- nent 1 Adapter wiring harness to heater unit 2 Wiring harness of heater unit Connect- ing wiring harnesses...
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Page 22: Combustion Air Connection
Seat Leon Combustion air connection 1 Clip-type cable tie in original vehicle hole Cutting combus- tion air pipe to length First close clip-type cable tie 2 , then push in combustion-air intake muffler 1 . Installing combus- tion-air in- take muffler... -
Page 23: Fuel Connection
Seat Leon 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. Unless specified otherwise, always fasten using cable ties. -
Page 24: Fuel Removal
Seat Leon Route mecanyl line and wiring harness of metering pump along original vehicle lines 2 to fuel tank! 1 Line duct Installing lines 1 Silentblock, large diameter washer, M6 flanged nut 2 Remove sealing plug Installing silent block 1 Wiring harness of metering pump, connector mounted 2 Rubber-coated p-clamp, flanged nut 3 Metering pump... - Page 25 Seat Leon 10 mm dia. clamp 1 centered between beads at end of standpipe. Preassem- 7.5 mm dia. bling standpipe and mold- 4.5 mm ed hose Cut 3 mm off blind plug. 1 Tip cut off blind plug 2 Fuel sender Cutting off blind plug Align curved standpipe toward rear right to...
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Page 26: Coolant Connection
Seat Leon Coolant connection WARNING! Tighten all hose clamps to 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 ties. Position hose clamps and spring band clamps so that no other hose can be damaged. - Page 27 Seat Leon a = 900 mm b = 950 mm Discard sections X Cutting coolant hoses to length Push braided protection hoses onto hose A and B . Push on heat shrink plastic tubing and shrink. y = 25 mm 1 50 mm heat shrink plastic tubing [4x] Preparing coolant...
- Page 28 Seat Leon 1 Heat exchanger inlet 2 Original vehicle spring clip Connec- tion on heat ex- changer in- Route hose B through upper p-clamp. 1 Rubber-coated pipe clamp, 29 mm dia. Hose routing Ensure proper spacing between strut 3 and A/C line.
- Page 29 Seat Leon Hose routing Route hose A through lower p-clamp. 1 27x27 spacer, lockable Hose routing Route hose A through lower p-clamp. 1 Rubber-coated pipe clamp, 29 mm dia. Hose routing Before connecting, fill hoses with coolant. Check routing of hoses A, B along entire length and correct if necessary.
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Page 30: Final Work
Correct position if necessary. Exhaust- gas pass through Feel the drive Webasto AG Postfach 80 - 82132 Stockdorf, Germany - Hotline +49- (0)1805-932278 Hotfax +49-(0)395-5592-353 - http://www.webasto.de Printed in Germany 12/07 Printed by: Steffen... -
Page 31: Operating Instructions For End Customer
Seat Leon 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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