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

Webasto Thermo Top E Installation Manual

Audi a4 / a5
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Water Heater
Thermo Top E Parking Heater
Thermo Top C Parking Heater
Installation Documentation
Audi A4 / A5
2.7 and 3.0 TDI
Model year 2008 up to 2011
Left-hand drive vehicle
Automatic transmission
Automatic air-conditioning
WARNING!
Hazard warning:
The improper installation or repair of Webasto heating and cooling systems can cause fire or
the leakage of deadly carbon monoxide, leading to serious injury or death.
To install and repair Webasto heating and cooling systems you need to have completed a
special company training course and have the appropriate technical documentation, special
tools and special equipment.
Only use genuine Webasto parts. See the Webasto air and water heaters accessories cata-
logue for this purpose.
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.
The initial startup is to be executed with the Webasto Thermo Test Diagnosis.
Webasto does not accept any liability for defects and damage that are attributable to installa-
tion by untrained staff.
Ident. No.: 1313525D_EN
e1
00 0002
e1
00 0003
Status: 25.09.2012
© Webasto Thermo & Comfort SE

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Summary of Contents for Webasto Thermo Top E

  • Page 1 WARNING! Hazard warning: The improper installation or repair of Webasto heating and cooling systems can cause fire or the leakage of deadly carbon monoxide, leading to serious injury or death. To install and repair Webasto heating and cooling systems you need to have completed a special company training course and have the appropriate technical documentation, special tools and special equipment.
  • Page 2: Table Of Contents

    However, installation according to this installation documentation may be possible. The installation location of the digital timer should be confirmed with the end customer before installa- tion. Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE...
  • Page 3: Heater/Installation Kit

    However, the stipulations in the "installation documentation", the "operating instructions" and "installa- tion instructions" for the Thermo Top E / C 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 Document

    All dimensions are in mm! Tightening torque of hose clamps = 2.0 + 0.5 Nm! Tightening torque of Ejot screws, Ejot studs = 10 Nm! Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE...
  • Page 5: Preliminary Work

    - Remove the lower instrument panel trim on the driver's side. Remove page 26 "Operating Instructions for End Customer" and add to the vehicle operating instruc- tions. Heater Installation Location 1 Heater Installa- tion loca- tion Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE...
  • Page 6: Electrical System

    1 Control unit mounted again 2 Wiring harness of fan controller, digital timer 2 Wiring harness of digital timer 3 Earth wire on earth support point 3 Wiring harness of fan controller Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE...
  • Page 7: Fan Controller

    T20e 20-pin connector J255 white Replace 25 A with 1 A black Legend fuse green Fan relay Insulate wire ends and tie back Cutting point Wiring colours may vary. Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE...
  • Page 8 2 Free socket, PIN 3 condition- 3 Green/white (gn/ws) additional line ing con- trols 1 Complete 20-pin connector of A/C control panel Reinsert- ing con- nector Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE...
  • Page 9: Digital Timer, Summer/Winter Switch Option

    1 M6x16 bolt in existing threaded hole 2 Receiver Installing receiver 1 Antenna Installing antenna Temperature sensor only in case of T100 1 Fasten temperature sensor with adhesive tape Installing tempera- ture sensor Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE...
  • Page 10: Preparing Heater

    1 Combustion air pipe 2 Clamp Premount- ing com- bustion air pipe 1 90° moulded hose, 10 mm dia. clamp [2x] 2 Fuel line Premount- ing fuel line Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE...
  • Page 11: Preparing Installation Location

    All vehicles 1 27 mm dia. spring clip [2x] 2 20x20 connecting pipe Premount- ing hose Preparing Installation Location 1 7 mm dia. hole [2x] Drilling hole in cross member Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE...
  • Page 12: Installing Heater

    Insert two 5 mm shims between heater and cross member 1 at position 3 . 2 Mount wiring harness of heater 3 Ejot screw, 5 mm shim [2x each] Installing heater Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE...
  • Page 13: Combustion Air

    Audi A4 / A5 Combustion Air 1 Retaining clip in hole of bracket 2 Silencer Installing silencer Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE...
  • Page 14: Coolant Circuit 3.0L 150Kw / 180Kw

    The connection should be "inline" based on the following diagram: Hose in- stallation diagram All spring clips without a specific designation = 27 mm dia. All connecting pipes = 20x20mm dia. 1 = Original vehicle spring clip Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE...
  • Page 15 Insert insulation protection strips 1 between hoses and frame side member. Routing in engine compart- ment Connect- ing heater outlet Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE...
  • Page 16 Audi A4 / A5 Connect- ing heater inlet Align hoses. Ensure sufficient distance to neighbouring components, adjust, if neces- sary. Routing in engine compart- ment Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE...
  • Page 17: Coolant Circuit 2.7L 140Kw / 3.0L 176Kw

    All spring clips without a specific designation = 27 mm dia. 1 = original vehicle spring clip 2 = Coupling piece on engine inlet! All connecting pipes without a specific designation = dia. 20x20 mm. Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE...
  • Page 18 Do not damage coupling piece 3 when cutting open clamp 2 ! 1 Discard hose section with protective hose Removing coupling piece 1 Coupling piece on engine inlet Preparing hose E Connect- ing heater outlet Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE...
  • Page 19 1 Coupling piece on engine inlet 2 Spacer bracket Connect- 3 Original vehicle spring clip ing to en- gine inlet and heat exchanger outlet Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE...
  • Page 20: Fuel

    1 Wiring harness of metering pump and fuel line in corrugated tube Installing lines 1 Clamping bracket [3x] 2 Fuel line, wiring harness of metering pump Installing lines Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE...
  • Page 21 Mount retaining clamp 1 on fuel-tank sending Installing unit. fuel stand- pipe 2 10 mm dia. clamp 3 Prepared fuel standpipe Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE...
  • Page 22 1 Fuel line in corrugated tube Connect- 2 10 mm dia. clamp ing meter- ing pump Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE...
  • Page 23 3 10 mm dia. clamp 4 Fuel line and wiring harness for metering pump in corrugated tube 5 15 mm dia. rubber-coated p-clamp Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE...
  • Page 24: Exhaust Gas

    1 Hose clamp [2x] 2 Exhaust pipe Installing exhaust pipe 1 Exhaust end section 2 Hose clamp 3 Red (rt) rubber isolator with groove Installing exhaust end sec- tion Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE...
  • Page 25: Final Work

    1 . Align exhaust end section 3 flush on red rubber isolator 2 . Inserting rubber iso- lator Webasto Thermo & Comfort SE Postfach 1410 82199 Gilching Germany Internet: www.webasto.com Technical Extranet: http://dealers.webasto.com Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE...
  • Page 26: Operating Instructions For End Customer

    Audi A4 / A5 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 c

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