Volkswagen Golf 2006, Golf Plus 2006, Touran 2006 User Manual

Water Heater Unit

Thermo Top E Additional Heater
Thermo Top C Additional Heater
Thermo Top P Additional Heater

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Installation Instructions

VW Golf V, Golf Plus, Touran

Gasoline
from Model Year 2006
Left-hand drive vehicle

Feel the drive

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 tool s 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.:1312760A_EN Fee Euro 10.00 © Webasto AG

VW Golf V, Golf Plus, Touran

Table of Contents

Validity 2
Heater Unit/Installation Kit 3
Foreword 3
General Instructions 3
Special Tools 3
Explanatory Notes on Document 4
Preliminary Work 5
Heater unit installation location 5
Electrical system 6
Fuse holder and relay K3 7
Climatic fan controller 8
Climatronic fan controller 10
Digital timer, summer/winter switch option 14
Remote option (Telestart) 14

Premounting heater unit 17
Installing heater unit 19
Fuel Connection 21
Coolant on 1.4 TSI 25
Coolant on 1.6 FSI 29
Final Work 34
Operating Instructions for End Customer 35

Validity

Manufacturer Model Type EG-BE No./ABE

VW Golf V 1K e1 * 2001/116 * 0242 * ...
VW Golf Plus 1KP e1 * 2001/116 * 0304 * ...
VW Touran 1T e1 * 2001/116 * 0211 * ...

VW Golf V and Golf Plus

Engine type Engine model Output in kW Displacement in cm³

BMY Gasoline/TSI 103 1390
BLG Gasoline/TSI 125 1390

VW Touran

Engine type Engine model Output in kW Displacement in cm³

BMY Gasoline/TSI 103 1390
BLG Gasoline/TSI 125 1390
BLF Gasoline/FSI 85 1598

Vehicle and en gine types, equipment variant s and national specifications not listed in these inst allation
instructions have not been tested. However , installation according to these installation instructions may
be possible.

The installation location of a digital timer and summer/winter switch sho uld be co nfirm ed with th e end
customer before installation.

1312760A_EN

2

VW Golf V, Golf Plus, Touran

Heater Unit/Installation Kit

Quantity Description Order No.:

1 Retail accessories with desired heater control See price list
1 Installation kit for VW Golf V, Golf Plus, Touran Gasoline 1312759A

Also required with Climatronic

Quantity Description Order No.:

1 IPCU Kit for Climatronic 9013645A

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
level of comfort required by the customer!

Foreword

These installation instructions apply to VW Golf V, Golf Plus, Touran Gasoline vehicles - for validity,
see page 2 - from model year 2006 and later, assuming technical modifications to the vehicle do not
affect installation, any liability claims excluded. Depending on the vehicle version and equipment,
modifications may be necessary during installation with respect to these installation instructions.

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.

General Instructions

Installation should be carried out according to the general, standard rules of technology. Unless
specified otherwise, fasten hoses, lines and wiring harnesses to original vehicle lines and wiring
harnesses using cable ties.
Sharp edges should be fitted with edge protectors (split-open plastic hose).
Spray unfinished body areas, e.g. drilled holes, with anti-corrosion wax (Tectyl 100K, Order No.

111329).

Special Tools

- Torque wrench for 2.0 - 10 Nm

- Hose clamping pliers

- Metric thread-setter kit

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3

VW Golf V, Golf Plus, Touran

Explanatory Notes on Document

T o 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

Water

Fuel

Exhaust gas

Combustion air

Special features are highlighted using the following symbols:

Specific risk of injury or fatal accidents.

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 vehicle­specific documents.

Reference to a special technical feature.

The arrow in the vehicle icon indicates the position on
the vehicle and the

All dimensions are in mm!
Tightening torque of hose clamps = 2.0 + 0.5 Nm!
Tightening torque of Ejot screws, Ejot studs = 10 Nm!

1312760A_EN

viewing angle.

4

VW Golf V, Golf Plus, Touran

Preliminary Work

WARNING!

- Open the fuel tank cap, ventilate the 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.

- Disconnect the battery "earth" or "ground" connection.

- Remove the battery

- Remove the battery carrier.

- Remove the engine cover

- Remove the left front wheel

- Remove the front section of the left front wheel well trim

- Remove the left-hand front fog light or, on vehicles without front fog lights, the left-hand cover

- Remove the underride protection

- Remove the right-hand underbody trim

- Golf only: Remove the rear bench seat

- Golf Plus only: Remove the right rear seat

- Open the right-hand fuel sender service lid.

- Remove the footwell trim on the driver's side

- Remove the lower instrument panel trim on the driver's side

- Only vehicles with Climatronic: Remove the footwell trim on the front passenger side

Remove page 35 "Operating Instructions for End Customer" and add to the vehicle operating
instructions.

1

Heater unit installation location

1 Heater unit

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Installation
location

1

5

VW Golf V, Golf Plus, Touran

Electrical system

Wiring harness pass through
1 Original vehicle wiring harness pass through

1

2

Do not install the metering pump
cable harness until later together
with fuel pipe along the original
vehicle fuel lines on the
underbody

1

2

1

Wiring
harness
installation
diagram

3

Fuse holder, relay K3

Description of installation for K3 relay 1 and fuse
carrier 2 on Page 7

1312760A_EN

4

Wiring harness pass through
1 Original vehicle wiring harness pass through

6

VW Golf V, Golf Plus, Touran

40

1

2

99

20

3

3

11

Fuse holder and relay K3

Countersink holes 3 from behind for M5
countersunk head screws.

1 Cover of fuse/relay carrier in engine

compartment

2 Cut away bar in shaded area
3 5.0 mm dia. hole [2x]

5

1 M5x12 countersunk head screw [2x]

Holes in
cover

Installing
fuse holder
and K3
relay

6

2

1

7

6

21

On vehicles with Climatronic, replace 25 A
fuse F3 7 with 3 A fuse provided.

1 M5 flanged nut
2 Large diameter washer (between cover

3
4

5

7

3

and retaining plate)

3 Retaining plate
4 M5 flanged nut
5 Relay K3
6 Fuse holder

Route brown (br) ground wire to original
vehicle ground support point below headlight
and connect.

1 Fuse/relay carrier
2 Original main vehicle fuse
3 Red (rt) positive wire

Installing
fuse holder
and K3
relay

Con­necting
positive
and
ground
wire

1312760A_EN

8

7

VW Golf V, Golf Plus, Touran

2

Climatic fan controller
Golf V

Detach original vehicle fuse carrier 1
(instrument panel at upper left) and unlock
contact lock 2.

1

2

1

5

Uncrimp 4² black/yellow (sw/ge) wire 3 on
fuse output SC40

3

9

Produce connections as shown in wiring
diagram.

1 AMP housing
3 Red (rt) wire from K3/87a with crimped-on

standard power timer engaged in fuse
output SC40

2 Black/yellow (sw /ge) wire with original

3

standard power timer

4 Black (sw) wire K3/30 with crimped-on tab

connector

5 AMP housing

Un­crimping
wire

Con­necting
wires

4

1

3

5

4

10

11

Lock contact lock again.

Golf Plus and Touran

Fuse socket dependent on vehicle equipm ent
SC33 or SC 35; wire color black (sw) or
black/yellow (sw/ge)
Detach original vehicle fuse carrier 1
(instrument panel at lower left) and unlock
contact lock 2.
Uncrimp 4² black (sw) or black/yellow ( sw/ge)

2

wire 3 on fuse output SC33 or SC35

Produce connections as shown in wiring
diagram.

1 Red (rt) wire from K3/87a with crimped-on

1

standard power timer engaged in fuse
output SC33 or SC35

2 AMP housing
3 AMP housing
4 Black (sw) or black/yellow (sw/ge) wire

11/3 with original standard power timer

5 Black (sw) wire K3/30 with crimped-on tab

connector

Un­crimping
wire

Con­necting
wires

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3

2

12

Lock contact lock again.

8

VW Golf V, Golf Plus, Touran

HG

4

X1

86

85 30

Webasto

87a87

K3

VW

30

15

F3

4²

rt

F1

4²

sw

(sw/ge)

T10k

5

T5

KB

31 24

T5

sw

4²

+

M

GM

-

34 21

T4r

WG

Wiring
diagram

Webasto components Vehicle components Colors and symbols

HG Heater unit TT-C/E GM Fan motor rt red
X1 6-pin heater unit

F1 Fuse SC33 or SC35 with 40 Aws white

connector
F3 Fuse, 25 A sw black
K3 Fan relay KB Air-conditioning control unit

or heater switch E16

br brown

gn green
WG Resistor group N24 bl blue
T10k Connector ge yellow

Insulate wire ends and
tie back

X Cutting point

Wiring colors may vary.

31

Legend

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9

VW Golf V, Golf Plus, Touran

1

Climatronic fan controller
Golf V

2

Produce connections as shown in wiring

3

diagram.
Position of free sockets dependent on vehicle
equipment.

1 IPCU socket
2 Red (rt) and black/white (sw/ws) wires from

IPCU

3 Green/white (gn/ws) wire to IPCU/86 with

13

1

2

AMP connector

Brown (br) wire from IPCU/85 to original
vehicle ground point.
Insulate and tie back red (rt) wire from
K3/87a.
Connect black (sw) wire from K3/30 to
green/white (gn/ws) wire (AMP connector)

1 IPCU

Installing
wiring
harness of
Clima­tronic

2.

Con­necting
wires

14

1

2

1

15

Route wiring harness IPCU 1 along cross
member

1

2 to center console

Golf Plus

Produce connections as shown in wiring
diagram.
Position of free sockets dependent on vehicle
equipment.

2

1 IPCU socket
2 Green/white (gn/ws) wire to IPCU/86 with

3

AMP connector

3 Red (rt) and black/white (sw/ws) wires from

IPCU

Routing
wiring
harness
from IPCU

Installing
wiring
harness of
Clima­tronic

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16

10

VW Golf V, Golf Plus, Touran

1

17

23

Brown (br) wire from IPCU/85 to original
vehicle ground point.
Insulate and tie back red (rt) wire from
K3/87a.
Connect black (sw) wire from K3/30
green/white (gn/ws) wire (AMP connector)

1 IPCU

Route wiring harness IPCU 2 along cross
member

1

1 to center console.

3 to

2.

Con­necting
wires

Routing
wiring
harness
from IPCU

18

2

1

1

2

Touran

Produce connections as shown in wiring
diagram.
Position of free sockets dependent on vehicle

19

equipment.

2

1 IPCU socket
2 Green/white (gn/ws) wire to IPCU/86 with

AMP connector

3 Red (rt) and black/white (sw/ws) wires from

3

IPCU

Fasten brown (br) wire from IPCU/85 to
original vehicle ground point
Insulate and tie back red (rt) wire from
K3/87a.
Connect black (sw) wire from K3/30 to
green/white (gn/ws) wire (AMP connector)

1 IPCU

2.

Installing
wiring
harness of
Clima­tronic

3.

Con­necting
wires

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2

3

20

11

VW Golf V, Golf Plus, Touran

Route wiring harness from IPCU 1 to fan unit.

Routing
wiring
harness
from IPCU

1

21

1 2

1

3 42

Golf V, Golf Plus, Touran

1 Wiring harness with red (rt) wire from

IPCU/E and black/white (sw/ws) wire from
IPCU/A

2 Fan unit

22

Position of connector T6t is dependent on
vehicle. 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

5

4 Black/white (sw/ws) wire from Climatronic

control unit

5 Connector T6t
6 Black/white (sw/ws) wire to connector

T6t/2

6

23

Routing
wiring
harness
from IPCU

Con­necting
wires

6

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1 2

5

24

Picture shows version without having to
disconnect fan unit.

1 Black/white (sw/ws) wire from IPCU/A
2 Black/white (sw/ws) wire to connector

3

4

T6t/2

3 Connector T6t
4 Black/white (sw/ws) wire from Climatronic

control unit

5 Red (rt) wire from IPCU/E
6 Wiring harness from IPCU

Con­necting
wires

12

VW Golf V, Golf Plus, Touran

1

Kabelbaum

Hg

HG

4

X1

rt

86

85 30

87a87

K3

2

If previously removed, reinstall fan unit.
Fasten wiring harness on original vehicle
wires with cable ties.

1 Wiring harness from IPCU
2 Fan unit

25

Kabelbaum

Climatronic

F3

! 0,75²

IPCU

86 85

gn/

ws

E

rt

A

sw/ws

0,75²

0,75²

0,75²

KB

15 16
sw/

bl/

ws

ws

sw/

ws

VW

T16f

ge

rt/ws

Installing
fan unit

30

Wiring

15

diagram

F1

rt/

T10k

31 42

sw

M

T6t

GE

br

br

31

Webasto components Vehicle components Colors and symbols

HG Heater unit TT-C/E F1 Fuse SC22 or SC56 with 40 A rt red
X1

6-pin heater unit connector

K3 Fan relay KB Climatronic control unit - J255 sw black
F3 Fuse (25 A replaced

with 3 A!)

IPCU Pulse width modulator ge yellow

T10k Plug connections br brown
ge Fan control unit - J126 and fan

motor - V2

IPCU adjustment values bl blue

Voltage: 8 V
Frequency: 400 Hz Insulate wire end
Duty cycle: 30 %
Function: High-side

1312760A_EN

ws white

gn green

and tie back

X Cutting point

Legend

13

VW Golf V, Golf Plus, Touran

1

Digital timer, summer/winter switch option

Golf V

Do not press on display!

1 Digital timer

2

2 Summer/winter switch

26

1

Golf Plus

Do not press on display!

1 Summer/winter switch
2 Digital timer

2

Digital
timer

Digital
timer

1 2

1

27

Touran

1 Digital timer
2 Summer/winter switch

Summer/
winter
switch
option

28

2

Remote option (Telestart)
Golf V

If M6 screw 2 is not present, then use suitable
M6 screw with spring lockwasher.
Drill out upper hole of bracket to 6.5 mm dia.

3

1 Receiver
2 M6 bolt
3 Bracket

Installing
receiver

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29

14

VW Golf V, Golf Plus, Touran

1

30

1

1 Antenna

Golf Plus

Bend down lower tab of bracket by 90° and
drill out hole to 6.5 mm dia. as shown.

1 Receiver
2 Bracket
3 M6 bolt, large diameter washer (between

2

bracket instrument carrier), large diameter
washer (from outside), flanged nut

4 Instrument carrier, existing hole

3

Installing
antenna

Installing
receiver

4

31

1

1

32

1

Antenna

Touran

1 Instrument carrier
2 Existing hole, M6x20 bolt, large diameter

washer, flanged nut

3 Bracket, drill out hole to 6.5 mm dia.
4 Receiver

Installing
antenna

Installing
receiver

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234

33

15

VW Golf V, Golf Plus, Touran

1

34

1 Antenna

Installing
antenna

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16

VW Golf V, Golf Plus, Touran

1

a

X

1

Premounting heater unit

1 Combustion air pipe

a = 250
Discard section

Ejot stud, tightening torque 10 Nm.

1 Ejot stud

X

Cutting
com­bustion air
pipe to
length

Pre­mounting
heater unit

152 3

2

2

1

3 3

35

4

36

Insert one washer each between heater unit
and bracket at positions

1

M6x30 spacer nut

2 Washer, Ejot screw [2x]
3 Hose clamp
4 Prepared combustion air pipe (slotted side

on heater unit)

5 Bracket

Hose section

1
2 Strut
3 Ejot screw [2x]
4 Combustion-air intake muffler
5 Retaining clip in hole of heater unit
6 Combustion air pipe
7 10 mm dia. hose clamp [2x]
8 Mecanyl line

4

2

Pre­mounting
heater unit

Pre­mounting
heater unit

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5

6778

37

17

VW Golf V, Golf Plus, Touran

1 2

a b

X

21

2

1 Exhaust pipe

a = 190

2 Exhaust end section

b = 240
Discard section

M6x16 bolt, spring lockwasher

1
2 Hose clamp [2x]
3 Red (rt) rubber isolator, without groove
4 Exhaust pipe with insulation
5 Muffler

X

Cutting
exhaust
pipe to
length

Pre­mounting
exhaust
system

5

1

4

1

3

38

Hose clamp

1
2 Red (rt) rubber isolator, without groove
3 Exhaust end section

2

3

39

12

Preparing installation location

Secure large diameter washer against falling
with putty etc.

1 Large diameter washer on original vehicle

stud bolt [3x]

2 Edge protection section

1

Pre­mounting
exhaust
system

Preparing
installation
location

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40

18

VW Golf V, Golf Plus, Touran

1

41

3 1

Installing heater unit

1 Large diameter washer, flanged nut M8

1

1

1

2

[3x]

Ensure freedom of movement of exhaust
system relative to original vehicle component
and lines.

1 Original vehicle wiring harnesses (secured

with cable ties)

2 Horn
3 Exhaust pipe

Installing
heater unit

Aligning
exhaust
system

42

Ensure freedom of movement of exhaust
system relative to original vehicle component
and lines.

1

Position rubber isolator
(Picture shows Golf Plus with headlight
washer system)

1 Headlight washer system (Golf Plus)

4

1

3

43

2

3 Horn
4 Horn bracket

3

Watch routing of wiring harness. Dang er of
rubbing!

1 Wiring harness of heater unit
2 Clip cab le tie in pr e-perforated hole of

heater unit cover

3 Cable tie

2

2 as shown.

Aligning
exhaust
system

Mounting
and
routing
wiring
harness

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44

19

VW Golf V, Golf Plus, Touran

Watch routing of wiring harness. Dang er of

1

rubbing!
Route excess lengths from wiring harness

in cable duct
cable ties.

1 Wiring harness from heater unit
2 Cable duct

22

45

2 below battery and secure with

1

Routing
wiring
harness

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20

VW Golf V, Golf Plus, Touran

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 cont ainer.
Install fuel line and metering-pump wiring harness so that they are protected against stone impact.

Unless specified otherwise, always fasten using cable ties.
Mount the fuel line and wiring harness with rub protection on sharp edges.

WARNING!

The fuel line and wiring harness are routed to the metering pump in as shown in the wir i ng harness
routing diagram.

1 1 1

1 2

46

47

1 Mecanyl line

Coolant reservoir cap detached

1
2 Existing pass through
3 Mecanyl line and wiring harness of

metering pump

3

Routing
mecanyl
line to
firewall

Routing
mecanyl
line and
wiring
harness of
metering
pump into
coolant
reservoir

1 1

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48

Fasten mecanyl line and wiring harness of
metering pump
original vehicle lines with cable tie.
Pay particular attention to freedom of
movement of wiper linkage.

1 in coolant reservoir on

Routing
mecanyl
line and
wiring
harness of
metering
pump to
right

21

VW Golf V, Golf Plus, Touran

1

1

2

2

49

1 Metering pump wiring harness
2 Existing pass through
3 Mecanyl line

3

Route mecanyl line and wiring harness of
metering pump along original vehicle fuel

2 to fuel tank.

lines

1 Line duct

Routing
mecanyl
line and
wiring
harness of
metering
pump

Routing
mecanyl
line and
wiring
harness of
metering
pump

50

1

Silentblock, large diameter washer, M6
flanged nut

2 Remove sealing plug

Installing

1

2

2

1 364

8

6

51

Metering pump wiring harness

1
2 Connector housing, single-wire seals,

plug-in contacts

3 Secure rubber-coated p-clamp on silent

block with flanged nut

4 Metering pump
5 Plug remounted
6 10 mm dia. hose clamp [2x]
7 Hose section
8 Mecanyl line

noise
isolation
mount

Mounting
metering
pump and
connecting
pressure
side

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7

5

52

22

VW Golf V, Golf Plus, Touran

.

1 2

0

1

7.5 mm dia.

235

1

7.5 mm dia.

4.5 mm dia

53

3

2

4.5 mm dia.

1 Standpipe
2 Molded hose

Caillau clamp 2 in center between beads on
end of standpipe.

1 Standpipe
2 10 mm dia. Caillau clamp
3 Molded hose

Cutting
standpipe
and
molded
hose to
length

Pre­mounting
standpipe
and
molded
hose

54

1

1

2

55

Cut 3 mm off blind plug.

1 Tip cut off blind plug
2 Fuel sender

Should the standpipe be slightly curved on
delivery, then it must be aligned so that the
end points toward the rear right.
Otherwise there is a danger of the fuel gauge
being impaired.

1 13.5 mm dia. Caillau clamp
2 Preassembled molded hose with

2

3

standpipe

3 10 mm dia. Caillau clamp
4 Remaining piece of mecanyl line

Cutting off
blind plug

Con­nection to
fuel-tank
sending
unit

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4

56

23

VW Golf V, Golf Plus, Touran

1

3

3

57

1 Hose section
2 Mecanyl line from fuel-tank sending unit
3 10 mm dia. hose clamp [2x]

2

Con­necting
intake side
of metering
pump

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24

VW Golf V, Golf Plus, Touran

Coolant on 1.4 TSI

WARNING!

Any coolant running off should be collected using an appropr i ate container. Install hoses so that they
are 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" based on the following diagram:

Coolant
routing
diagram

1

C

A

B

All spring clips without a specific designation = 27 mm dia. 1 = Original vehicle spring clip .
All hose clamps = 20-27 mm dia.!
All connecting pipes = 20x20 dia..

1312760A_EN

25

VW Golf V, Golf Plus, Touran

a = 600
b = 50
c = 770

CA

1 1

C

X

B

Discard section

X

Push braided protection hoses onto hose A

C, cut to length and shrink.

and

1 Heat shrink plastic tubing [4x]

1

Cutting
coolant
hoses to
length

Pre­mounting
coolant
hoses

B

1

A

11

58

1

Cable ties with clip [2x]

2 Bracket for coolant hoses

Preparing
bracket for
coolant
hoses

2

1

2

59

Loosen original vehicle bolt 2 and position
bracket for coolant hoses
carrier

1 and body 3.

5 between battery

4 M6x20 bolt, original vehicle hole, flanged

nut

Installing
bracket for
coolant

5

hoses

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4 3

26

VW Golf V, Golf Plus, Touran

1

2

1

60

1 Pull hose off heat exchanger inlet
2 Original spring clip will be reused

Cutting
point

Ensure sufficient distance to neighboring
components.

1 Hose on heat exchanger inlet

Con­necting
heat
exchanger
inlet

C

61

Routing in
engine
compart­ment

C

B

62

C

Con­nection to
heater unit

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27

VW Golf V, Golf Plus, Touran

A

64

3

2

1

A

4

Install hose A with 180° elbow on connection
piece of engine outlet.

C

Drill out perforated bracket 2 to 8.5 mm dia. at
position 3.

1 M6x20 bolt, flanged nut
3 Original vehicle bolt
4 29 mm dia. rubber-coated p-clamp [2x]

Con­necting
engine
outlet

Fastening
hoses

C

4

A

C

A

1 1

65

66

Ensure sufficient distance to neighboring
components.

C

Fix hose A and C in place with clip-type cable

1 [2x].

ties

Aligning
hoses

Fastening
hoses

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28

VW Golf V, Golf Plus, Touran

Coolant on 1.6 FSI

WARNING!

Any coolant running off should be collected using an appropr i ate container. Install hoses so that they
are 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" based on the following diagram:

Coolant
routing
diagram

1

2

B

A

All spring clips without a specific designation = 27 mm dia. 1 = Original vehicle spring clip .
All hose clamps = 20-27 mm dia.! Connecting pipe = 20x20 dia.

2 = Black (sw) rubber isolator .

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29

VW Golf V, Golf Plus, Touran

a = 1000
b = 1050

A

1 1

B

3

Discard section

B

X

Cutting
coolant
hoses to
length

Push braided protection hoses onto hose A

B, cut to length and shrink.

and

1 Heat shrink plastic tubing [4x]

Pre­mounting
coolant
hoses

1

2

A

2

1

68

1

Pull off hose on engine outlet to heat
exchanger inlet
exchanger inlet

3 on connection piece of heat

2. Spring clip 1 will be reused.

Install battery carrier.

Cutting
point

3

69

Connection piece of heat exchanger inlet

1

B

1

Con­necting
heat
exchanger
inlet

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30

VW Golf V, Golf Plus, Touran

B

Routing in
engine
compart­ment

71

B

C

Con­nection to
heater unit

72

Routing in
engine
compart­ment

A

B

1

A

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73

74

Engine-outlet hose section

1
2 Alig n ru bb er profile

2

Con­necting
engine
outlet

31

VW Golf V, Golf Plus, Touran

1

2
2

A

B

75

1 M6x20 screw, spring lockwasher on

existing thread

2 29 mm dia. rubber-coated p-clamp [2x]

Fastening
hoses

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32

VW Golf V, Golf Plus, Touran

1

76

Exhaust gas

Align exhaust end section and rubber isolator
as shown.
Ensure sufficient spacing of exhaust end

1

section to transmission and to wheel well
trim.
(Picture shows vehicle with direct shift
transmission)

1 Wheel well trim

Underride protection

1
2 42 mm dia. hole

Installing
wheel well
trim

Hole in
underride
protection

2

77

1

1 2

2

78

Picture shows Golf V!
Align exhaust end section
rubber isolator

3 Un de r rid e protection

3

Cut off section

1
2 Front fog light trim piece (depending on

equipment)

2.

3 flush on red

Mounting
rubber
isolator

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Cutting
front fog
light trim
piece to
size

79

33

VW Golf V, Golf Plus, Touran

Final Work

WARNING!
Reassemble the disassembled components in reverse order.

Check all hoses, spring and Caillau clamps, as well as all electrical connections for firm seating.
Secure all loose cables using cable ties.
Spray heater unit components with anti-corrosion wax (Tectyl 100K, Order No. 111 329).

- Connect the battery

- Fill and bleed the coolant circuit according to the vehicle manufacturer’s specifications.

- Set the digital timer.

- Adjust vehicle heater in accordance with "Operating Instructions for End Customer"

- Check the proper operation of the additional heater, see the operating instructions/installation
instructions.

- File included vehicle-specific "Operating Instructions for End Customer“ in vehicle logbook

- Attach the "Switch off additional heater before refueling" sticker to the left-hand B-pillar.

Adjust the sensitivity of the passenger compartment monitoring

WARNING!
This can only be carried out at an authorized workshop! Observe the applicable repair manual of the
respective vehicle.

- Connect the VAS tester.

- Open Item 46 (Central Module of Comfort System)

- Go to Item 10 (Adjustment)

- Follow the request for the code entry and enter the code 15

- Reduce the sensitivity of the passenger compartment monitoring to 50 %

- Save this setting

- The adjustment of the sensitivity of the passenger compartment monitoring is completed.

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Feel the drive

Webasto AG
Postfach 80 - 82132 Stockdorf
Hotline 01805 / 932278 - Hotfax 0395 / 5592-353
http://www.webasto.de

Printed in Germany 09/2007 Printing:

Steffen

VW Golf V, Golf Plus, Touran

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 recomme nd not exceeding a switch- on time
of 20 min.

If the summer/winter switch option has been installed, this must be switched in accordance with the
time of year. The heater unit will then only switch on the vehicle fan to ventilate the vehicle interior in
the position Winter heat and in the position Summer .

Before parking the vehicle, make the following settings:

1 2

3

1 2 1

80

1 Set temperature to "max."
2 Air outlet to winds hield
3 Set fan to level "1", or possibly "2"

Set temperature to "HI“ [2x]

1
2 Air outlet fac es upward

Climatic

Clima­tronic

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