Webasto Thermo Top Evo Installation Documentation
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Webasto Thermo Top Evo Installation Documentation

Webasto Thermo Top Evo Installation Documentation

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See also: Workshop Manual , Installation Documentation
Water Heater
Thermo Top Evo Parking Heater
Installation documentation
VW Passat
Petrol and Diesel
from model year 2011
Left-hand drive vehicle
Manual transmission / Direct gear transmission
Passenger compartment monitoring not checked!
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, specialised tools and equipment are
required to install and repair Webasto heating and cooling systems.
Only original Webasto parts must be used. For this, also see the catalog of air and water heat-
er accessories from Webasto.
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.: 1317226C_EN
e1
00 0258
Fee Euro 10.00
Feel the drive
© Webasto AG

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Summary of Contents for Webasto Thermo Top Evo

  • Page 1 Specialist company training, technical documentation, specialised tools and equipment are required to install and repair Webasto heating and cooling systems. Only original Webasto parts must be used. For this, also see the catalog of air and water heat- er accessories from Webasto.

  • Page 2: Table Of Contents

    VW Passat Table of Contents Validity Preparing installation location Heater/Installation Kit Preparing heater Foreword Installing heater General Instructions Coolant circuit 1.4 TSI Special Tools Coolant circuit 2.0 TSI Explanatory Notes on Document Coolant circuit diesel Preliminary Work Fuel Heater installation location Mounting retaining plate / connector Preparing electrical system Wheel-well inner panel...

  • Page 3: Heater/Installation Kit

    However, the stipulations in the "installation documentation" and "operating instructions" and the "in- stallation instructions" for the Thermo Top Evo 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

    VW Passat Explanatory Notes on Document You will find an identification mark on the outside top right corner of the page in question to provide you with a quick overview of the individual working steps. Mechanical system Electrical system Coolant circuit Fuel Exhaust gas Combustion air...

  • Page 5: Preliminary Work

    VW Passat Preliminary Work WARNING! - Open the fuel tank cap, ventilate the tank. - Close the fuel tank cap again. - Disconnect the battery earth connection. - Depressurise 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 Passat Preparing electrical system Wire sections retain their numbering in the entire document. Climatronic Removing wire Detach red (rt) wire 1 from fuse F4 and dis- card. IPCU view on contact side. The IPCU provided in the kit is pre-pro- grammed with the following settings.
  • Page 7 VW Passat Climatic rt/sw gn/ws Connect wires to socket of K1 relay. Install F4 0,5² 4² 0,75² 25A fuse.  Red (rt) wire of K1/87a Preparing  Black (sw) wire from K1/30 K1 relay 4² 0,5² 4² 1 K1 relay 2 M5x16 bolt, large diameter washer, fuse holder 3 Angle bracket...

  • Page 8: Electrical System

    VW Passat Electrical system Positive and earth wire Wiring harness routing 1 Positive wire to positive battery distributor Route wiring harnesses in original vehicle cable 2 Earth wire on original vehicle earth support duct 1 point Wiring har- ness rout- diagram Do not install the metering pump wiring harness until later togeth-...

  • Page 9: Climatic Fan Control

    0,5² 0,5² 4² 0,75² J301 rt/sw T4bp 0,5² 0,5² Webasto components Vehicle components Colours and symbols TT-Evo heater Resistor group 6-pin heater connector T4bp 4-pin connector N24 black 2-pin heater connector J301 A/C control unit yellow 4-pin connector...
  • Page 10 VW Passat Fuse socket depends on vehicle equipment. Uncrimp black/red (sw/rt) wire 2 from socket of fan fuse. Red (rt) wire from K1/87a with crimped standard- power timer in the fan fuse socket. Produce connections as shown in wiring diagram. Connect- ing wires 1 Connector...

  • Page 11: Climatronic Fan Control

    0,5² 0,5² 0,5² 4² 0,75² IPCU T6be J126 0,5² 0,5² Webasto components Vehicle components Colours and symbols TT-Evo heater J126 Fan unit 6-pin heater connector T6be 6-pin connector J126 black 2-pin heater connector J255 A/C control unit yellow...
  • Page 12 VW Passat 1 Angle bracket 2 Original vehicle bolt Mounting fuse holder in passen- ger com- partment Connect the wiring harness of the fuse holder in passenger compartment 2 to the wiring harness of heater 1 according to the wiring di- agram, with same colour wires connected to each other.

  • Page 13: Digital Timer

    VW Passat Digital timer 1 Digital timer Mounting digital tim- Remote option (Telestart) Degrease adhesive area. Fasten receiver 1 with adhesive tape. Mounting receiver 1 Antenna Mounting antenna Temperature sensor T100 HTM Fasten temperature sensor 1 with adhesive tape. Mounting tempera- ture sensor 1317226C_EN...

  • Page 14: Preparing Installation Location

    VW Passat Preparing installation location Pull out connector and put it aside. Remove retaining plate 1 , will be remounted later. Removing retaining plate 1 Wiring harness of heater Routing wiring har- ness 1 Discard section 2 Hose section Shorten- ing hose section Remove clip for coupling line, will be reused...

  • Page 15: Preparing Heater

    VW Passat 2.0 TSI and 2.0 D Manual transmission Premount clip of coupling line 1 on hose bracket 2 - only with petrol and diesel manual transmission. Preparing 1 M6x12 countersunk head screw hose bracket Preparing heater 1 Water connection piece, sealing ring [2x each] 2 5x15mm self-tapping bolt, retaining plate of water connection piece...
  • Page 16 VW Passat 1 Exhaust pipe 2 Hose clamp Mounting exhaust pipe 1 Hose clamp 2 Silencer 3 M6x16 bolt, spring lockwasher Mounting silencer 1 Exhaust end section 2 Hose clamp Mounting exhaust end sec- tion 1 Bracket section B 2 5x13 self-tapping bolt [2x] Mounting bracket section B...
  • Page 17 VW Passat 1 51mm dia. clamp 2 Mount M5x16 bolt, flanged nut loosely Mounting combus- tion air pipe 1 Combustion air pipe 2 25 mm dia. clamp 3 Tighten M5x16 bolt, flanged nut 4 Intake silencer Mounting combus- tion air pipe 1.4 TSI and 2.0 D Hose E is used only for 1.4 TSI.
  • Page 18 VW Passat 2.0 TSI Discard section X . Hose A = 20mm dia. 180° moulded hose Hose C = 18mm dia. 90° moulded hose Cutting hoses to length E = 1050 1 Discard section [2x] Cutting hose A to length 1.4 TSI / 2.0 D = hoses A and D 2.0 TSI = hoses B and E...

  • Page 19: Installing Heater

    VW Passat 1.4 TSI / 2.0 D = hose D 2.0 TSI = hose E All spring clips = 25mm dia. Mounting hose of heater out- All vehicles 1 90° moulded hose, 10mm dia. clamp [2x] 2 Fuel line Premount- ing fuel line Installing heater...
  • Page 20 VW Passat Diesel with direct gear transmission (DSG) Ensure sufficient distance from neighbouring components, especially between exhaust si- lencer and direct gear transmission (DSG) at Mounting position 1 (25mm), correct if necessary. heater All vehicles If stud bolt is not available at position 1 , copy hole pattern from bracket, drill 8.5mm dia.

  • Page 21: Coolant Circuit 1.4 Tsi

    VW Passat Coolant circuit 1.4 TSI WARNING! Any coolant running off should be collected in an appropriate container. Install hoses so that they are kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that other hos- es cannot be damaged. The heater must be filled with coolant when installing the hoses. The connection should be "inline"...

  • Page 22: Coolant Circuit 2.0 Tsi

    VW Passat Coolant circuit 2.0 TSI WARNING! Any coolant running off should be collected in an appropriate container. Install hoses so that they are kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that other hos- es cannot be damaged. The heater must be filled with coolant when installing the hoses. The connection should be "inline"...
  • Page 23 VW Passat 1.4 and 2.0 TSI Route hose A to brake booster Align hoses A and D behind hose bracket 1 . Ensure suffi- cient distance from neighbouring compo- nents. Routing to frame side 2 Original vehicle stud bolt, M8 flanged nut member Figure shows manual transmission (SG).
  • Page 24 VW Passat 1.4 TSI / SG Route hoses A and D through rubber-coated p-clamp 1 . Ensure sufficient distance from coupling hose 2 . Routing in 3 23x23mm hose bracket (retaining clip re- engine moved) compart- ment Pull out coolant hose of expansion tank 1 from connection piece, shorten by 10mm and remount.
  • Page 25 VW Passat 1 25x25mm lockable spacer bracket [2x] 2 Hose of engine outlet 3 Hose for heat exchanger outlet Routing in engine compart- ment Align hose A and D . Tighten M8 nut 1 and M6 flanged nut 2 . Ensure sufficient distance from adjacent components, especially from origi- nal vehicle wire 3 , adjust if necessary.
  • Page 26 VW Passat 1 Hose on heat exchanger inlet Connect- ing heat exchanger inlet 1 25x25mm lockable spacer bracket 2 Hose of engine outlet Connect- ing engine outlet Figure shows direct gear transmission (DSG). Align hose B and E . Tighten M8 nut 1 and M6 flanged nut 2 .

  • Page 27: Coolant Circuit Diesel

    VW Passat Coolant circuit diesel WARNING! Any coolant running off should be collected in an appropriate container. Install hoses so that they are kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that other hos- es cannot be damaged. The heater must be filled with coolant when installing the hoses. The connection should be "inline"...
  • Page 28 VW Passat 1 M6x20 bolt, M6 flanged nut Mount loosely 2 38mm dia. rubber-coated p-clamp 3 8.5mm dia. hole Preparing perforated bracket Manual transmission (SG) Route hose A to brake booster Align hoses A and D behind hose bracket 1 . Ensure suffi- cient distance from neighbouring compo- nents.
  • Page 29 VW Passat 1 Original vehicle bolt, M8 nut Mount loosely 2 Premounted perforated bracket Mounting perforated bracket Route hoses A and D behind the coupling line 1 and through rubber-coated p-clamp 1. Routing in engine compart- ment Ensure sufficient distance from coupling line 1. Routing in engine compart-...
  • Page 30 VW Passat Ensure sufficient spacing between hose bracket 1 and transmission. Routing to frame side member Route hoses A and D through rubber-coated p-clamp 1 . Routing in engine compart- ment All vehicles Cut off hose on engine outlet/heat exchanger inlet 1 at marking.
  • Page 31 VW Passat 1 Spacer bracket 2 22x8 spacer bracket 3 Hose of engine outlet Connect- ing engine outlet Figure shows manual transmission (SG). Align hose A and D . Tighten M8 nut 1 and M6 flanged nut 2 . Routing in engine compart- ment...

  • Page 32: Fuel

    VW Passat Fuel CAUTION! Open the vehicle's fuel tank cap, ventilate the tank and then re-close the tank lock. Catch any fuel running off in an appropriate container. Route 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 33 VW Passat Cut off approx. 300mm from the 10mm dia. corrugated tube and slide on to fuel line and wiring harness of metering pump. Guide fuel line and wiring harness of metering pump 1 into original vehicle line duct 2 and route to underbody.
  • Page 34 VW Passat Slide approx 500mm of 10mm dia. corrugat- ed tube 1 onto fuel line. 2 M6x25 bolt, flanged nut 3 Mounting of metering pump Mounting metering pump 1 Wiring harness of metering pump, connec- tor mounted 2 Fuel line of heater, 10mm dia. clamp Connect- ing meter- ing pump...
  • Page 35 VW Passat 1 6 mm dia. hole 2 Overhanging, circumferential edge of ap- prox. 1 mm 3 Drilled-out blind connection piece View of un- derside of fuel-tank sending unit Carefully remove overhanging edge with de- burring tool. 1 Deburring tool Removing edge Shape fuel standpipe 1 according to tem-...
  • Page 36 VW Passat Diesel Remove fuel-tank sending unit 1 in accord- ance with manufacturer's instructions. Posi- tion large diameter washer 2 dia. d = 21.6mm midway between the connection pieces. Removing fuel 3 Copy hole pattern, 6.0mm dia. hole Shape fuel standpipe 1 according to tem- plate, cut to length and install.

  • Page 37: Mounting Retaining Plate / Connector

    VW Passat Mounting retaining plate / connec- Figure shows diesel. Insert retaining plate 1 in hole of perforated Mounting bracket and fasten with cable tie 2 . Remount retaining connector. plate Wheel-well inner panel Cut out wheel-well inner panel 1 at the mark- ing 2 .

  • Page 38: Final Work

    2 . Aligning exhaust end sec- tion Feel the drive Webasto AG Postfach 80 D-82132 Stockdorf / Germany National Hotline: 01805 93 22 78 (14 Cent aus dem deutschen Festnetz) Hotfax: 0395 5592 353 Hotmail: technikcenter@webasto.com http://www.webasto.com...

  • Page 39: Template For Fuel Standpipe Petrol

    VW Passat Template for Fuel Standpipe Petrol 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 “minimise mar- gins” and 100% of the normal size. 100mm 1317226C_EN...

  • Page 40: Template For Fuel Standpipe Diesel

    VW Passat Template for Fuel Standpipe Diesel 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 “minimise mar- gins” and 100% of the normal size. 100mm 1317226C_EN...

  • Page 41: Operating Instructions For End Customer

    VW Passat 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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