Webasto Thermo Top BlueHeat Manual
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Webasto Thermo Top BlueHeat Manual

Webasto Thermo Top BlueHeat Manual

Vw passat coolant heater
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Download this manual See also: Manual
BlueHeat
Thermo Top
1
2
3
Legend
1 BlueHeat Coolant Heater, Exhaust Tube, and Combustion Air Intake Silencer
2 Fuse Holder, Relays and Resistor Assembly
3 Timer Control
4 Fuel Pump
Special Tools
- Hose Clamping pliers
- Torque Wrench

Table of Contents

Installation
DOC P/N 5001101A
KIT P/N 5001100A
Coolant Heater
4
3
Integration into the Blower System - Climatronic 11
3
3
4
5
5
5
6
7
8
Printed in USA
VW Passat
2.0L, 4CYL- FSI, Gasoline
Beginning Model Year: 2006
Special instructions for these models
Part locations may differ slightly dependent on
the vehicle model.
Be sure to check WWW.techwebasto.com for
the latest addition of this manual.
9
13
14
15
16
19
23
23
24
25
Webasto Product N.A., Inc.

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Summary of Contents for Webasto Thermo Top BlueHeat

  • Page 1: Table Of Contents

    Blower Control Settings - Climatronic Installation Blower Control Settings - Climatic Electrical - Overview Final Inspection, Initial Start-up and Concluding Electrical Harness Installation Work Timer Installation Heater Lockout Reset Procedure DOC P/N 5001101A KIT P/N 5001100A Printed in USA Webasto Product N.A., Inc.
  • Page 2 – Installation and repair of Webasto heating and cooling systems requires special Webasto training, technical information, special tools and special equipment. – NEVER attempt to install or repair a Webasto heating or cooling system unless you have successfully completed the factory training course and have the technical skills, technical information, tools and equipment required to properly complete the necessary procedures.

  • Page 3: Foreword

    This installation requires special expertise from a Webasto training course to install a Webasto Thermo Top heater, which means that it may only be installed by a specially trained workshop or dealership. Webasto cannot accept any liability for faults and damage caused by the system being installed by untrained personnel.

  • Page 4: Symbol Identification

    BlueHeat VW Passat Symbol Identification Symbols that define sections in manual Mechanical Preparation Fuel Electrical Exhaust Coolant Combustion Air Intake General Symbol Descriptions Warning Refer to Webasto or Manufacturer Manual Caution Attention...

  • Page 5: General References

    – Protect vehicle fenders, panels and interior with covers Heater Installation Site ATTENTION The Webasto Auxiliary Coolant Heater is installed on the left side of the vehicle behind the front bumper. Front bumper cover was removed for photographic purposes only.

  • Page 6: Electrical - Overview

    – (2) Heater relay, fuses and mounting bracket – (2) Vehicle fuel tank Fuel Line and Fuel Pump Harness Bulkhead Pass-through Interior Fuse/Relay Center – (1) Bulkhead opening – (1) Webasto blower integration point – (2) Timer Harness – (2) Interior fuse/relay center...

  • Page 7: Electrical Harness Installation

    – (2) Existing vehicle screw – (3) Electrical mounting bracket Fig. 4 Webasto Power wire Connection Secure webasto power wire to the vehicle power strip located on the underhood fuse/relay center. – (1) Fuse/relay power strip – (2) Webasto power wire (+12V)

  • Page 8: Timer Installation

    VW Passat Webasto Harness Ground Wire Connection Secure the webasto harness ground wire to an existing vehicle ground located below the front headlight. – (1) Existing vehicle ground location – (2) Below front headlight – (3) Webasto harness ground wire Fig.

  • Page 9: Integration Into The Blower System - Climatic

    VW Passat Integration into the Blower System With Man- ual Temp. Controls - Climatic Loosen vehicle interior fuse center. Disengage contact (3). Remove black/red wire (2) from fuse block. – (1) Interior fuse/relay center – (2) Black/Red wire – (3) Contact Fig.
  • Page 10 Fig. 12 Climatic Control System TABLE 1. Webasto Heater Comp. Vehicle Components Wire Colors HG = Webasto Heater SC40 = Blower Fuse rd = red F3 = Fuse J301 = Climate Control Module wt = white K3 = Blower Relay...
  • Page 11 – (1) Black/White wire - webasto harness – (2) Black/White wire - blower control – (3) HVAC blower control module – (4) Black/White wire at connector – (5) Red wire from webasto harness to climate control module – (6) IPCU harness Fig. 15...
  • Page 12 Fig. 16 Climatronic Control System TABLE 2. Webasto Heater Comp. Vehicle Components Wire Colors HG = Webasto Heater SC39 = Blower Fuse rd = red F3 = Fuse J255 = Climatronic Control Unit wt = white K3 = Blower Relay...

  • Page 13: Heater Preparation/Installation

    VW Passat Heater Preparation/Installation ATTENTION Observe torque specifications. Install heater mounting bracket with three EJOT screws. Tighten EJOT screws to 10 Nm (88.5 lb.-in.). – (1) Mounting bracket – (2) EJOT screws Fig. 17 Install heater on existing vehicle studs with two nuts provided.

  • Page 14: Air Intake Tube Installation

    VW Passat Air Intake Tube Installation ATTENTION 90° Cut supplied air intake tube as shown in Figure 20. 888888888888 – (1) Air intake tube - a= 250 mm (9.8 in.) – (X) Scrap Fig. 20 Bend and install L-bracket on heater with EJOT screw as shown in Figure 21.

  • Page 15: Exhaust Installation

    VW Passat Exhaust Installation Cut supplied exhaust tubing as shown in figure 23. – (1) Exhaust tube - a=165 mm (6.5 in.) – (2) Exhaust endpiece - b=240 mm (9.4 in.) – (X) Scrap Fig. 23 Install EJOT stud, spacer nut, and muffler on heater as shown in Figure 24.

  • Page 16: Integration Into The Coolant System

    VW Passat Integration into the Coolant System ATTENTION Torque hose clamps to 2.0 - 2.5 Nm (18 - 22 lb-in.) Avoid sharp bends and kinks when installing coolant hoses. Position hose clamps in such a way to avoid cutting or damaging adjacent components. ATTENTION Clamp vehicle coolant hose with hose clamping pliers prior to cutting to prevent coolant spillage.
  • Page 17 VW Passat Coolant Hose Preparation Cut supplied coolant hoses to the lengths shown and trim to fit under the hood. Coolant Hose A = 280 (11 in.) Coolant Hose B = 620 mm(24.5 in.) Coolant Hose C = 900 mm (36 in.) X = Discard Fig.
  • Page 18 VW Passat Route coolant hoses to the left side of the engine compartment. Secure coolant hoses in the engine compartment with nylon cable ties. – (1) Nylon cable tie – (2) Heater outlet hose – (3) Heater inlet hose Fig. 32 ATTENTION Trim coolant hoses to fit before making connections under the hood.

  • Page 19: Integration Into The Fuel System

    VW Passat Integration into the Fuel System ATTENTION The vehicle fuel sender can be accessed from inside the vehicle. Remove the sending unit from the fuel tank following the manufactures service instructions. – (1) Under rear seat - passenger side –...
  • Page 20 VW Passat ATTENTION 90 Degree Banjo Fitting Refer to figure 38 for banjo fitting installation sequence. Tighten locknut to 9.0 - 9.5 Nm (80 - 84 lb.- in.) Legend for Figure 38 1 Banjo Bolt 2 Banjo Fitting 3 Standpipe 4 Upper Sealing Washer 5 Fuel Tank Sending Unit 4 Lower Sealing Washer...
  • Page 21 VW Passat Fuel Pump Preparation/Installation Pre-assemble fuel pump as shown in Figure 42. – (1) 90° fuel line connector – (2) P-clamp – (3) L-bracket – (4) M6 nut and bolt – (5) Straight fuel line connector – (6) Fuel line clamps - 4ea. Fig.
  • Page 22 VW Passat Locate grommet in the engine compartment that is installed in the top of the channel and remove it. Bore a hole in the grommet large enough to fit the fuel line and the fuel pump harness. Route mecanyl fuel line through the grommet towards the front of the vehicle.

  • Page 23: Blower Control Settings - Climatronic

    VW Passat Blower Control Settings - Climatronic – (1) Temperature “max” heat – (2) Defrost Position Fig. 50 Blower Control Settings - Climatic – (1) Defrost position – (2) Blower speed between 1 and 2 – (3) Temperature “max” heat Fig.

  • Page 24: Final Inspection Initial Start-Up And Concluding Work

    2 Set interior heater control to maximum heat position (hot), fan speed between low and medium, and switch off air conditioning system. 3 Start the vehicle engine and run on fast idle for 5 minutes to purge any remaining air from the Webasto heater and coolant system. While the engine is running check: •...

  • Page 25: Heater Lockout Reset Procedure

    Heater should attempt to start after inserting fuse. ATTENTION – The engine coolant must be below 86 °F (30 °C) before the Webasto heater will attempt to start. – Should the heater fail to start or operate correctly, contact your Webasto technical representative at:...
  • Page 26 Rate the completeness and clarity of the instructions: did the procedures provide enough detail? What could be added or clarified? Please list any other comments, concerns, or suggestions. Mail to: Webasto Product N. A., Inc. 15083 North Road Fenton, MI 48430 Attention: Documentation Group...
  • Page 27 VW Passat NOTES:...
  • Page 28 Webasto Product N.A., Inc. Technical Assistance Hotline USA: (800) 555-4518 Canada: (800) 667-8900 www.webasto.us Org. 05/2006 Rev. N/A P/N 5001101A www.techwebasto.com...

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