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

Feel the drive

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Installation Instructions

VW Golf V, Golf Plus, Touran

Gasoline

from Model Year 2006 Left-hand drive vehicle

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.: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 engine types, equipment variants and national specifications not listed in these installation 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 should be confirmed with the end customer before installation.

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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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VW Golf V, Golf Plus, Touran

Explanatory Notes on Document

To 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 viewing angle.

All dimensions are in mm!

Tightening torque of hose clamps = 2.0 + 0.5 Nm!

Tightening torque of Ejot screws, Ejot studs = 10 Nm!

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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
	Installation
	location
	1
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VW Golf V, Golf Plus, Touran

Electrical system

Wiring harness pass through

1 Original vehicle wiring harness pass through

1

2

Wiring

Do not install the metering pump

harness

cable harness until later together

installation

with fuel pipe along the original

diagram

vehicle fuel lines on the

underbody

1

1

2

3	4
Fuse holder, relay K3	Wiring harness pass through
Description of installation for K3 relay 1 and fuse	1 Original vehicle wiring harness pass through
carrier 2 on Page 7

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VW Golf V, Golf Plus, Touran
1	2	Fuse holder and relay K3
		Countersink holes 3 from behind for M5
		countersunk head screws.
9	9	1	Cover of fuse/relay carrier in engine	Holes in
	20
		2	compartment	cover
			Cut away bar in shaded area
		3	5.0 mm dia. hole [2x]
40

3

3

5

					1 M5x12 countersunk head screw [2x]
	1		1

Installing fuse holder and K3 relay

					6
						On vehicles with Climatronic, replace 25 A
	1		2
						fuse F3 7 with 3 A fuse provided.

1M5 flanged nut

2Large diameter washer (between cover

7									3			and retaining plate)	Installing
		4									3	Retaining plate	fuse holder
											4	M5 flanged nut	and K3
									5
											5	Relay K3	relay
6
											6	Fuse holder

7

1	2	Route brown (br) ground wire to original
		vehicle ground support point below headlight
		and connect.
		1	Fuse/relay carrier
		2	Original main vehicle fuse	Con-
		3	Red (rt) positive wire	necting
		3		positive
				and
				ground
				wire

8

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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	Un-
1	contact lock 2.	crimping
	Uncrimp 4² black/yellow (sw/ge) wire 3 on	wire
	fuse output SC40
	3

9

1	2	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	Con-
		2	output SC40	necting
	3		Black/yellow (sw/ge) wire with original	wires
5		4	standard power timer
			Black (sw) wire K3/30 with crimped-on tab
			connector
		5	AMP housing
4	10	Lock contact lock again.
	1	Golf Plus and Touran
		Fuse socket dependent on vehicle equipment
		SC33 or SC 35; wire color black (sw) or
		black/yellow (sw/ge)
		Detach original vehicle fuse carrier 1		Un-
		(instrument panel at lower left) and unlock		crimping
		contact lock 2.		wire
	2	Uncrimp 4² black (sw) or black/yellow (sw/ge)
		wire 3 on fuse output SC33 or SC35

	3	11
			Produce connections as shown in wiring
			diagram.
			1	Red (rt) wire from K3/87a with crimped-on
		1		standard power timer engaged in fuse
5				output SC33 or SC35	Con-
			2	AMP housing	necting
			3	AMP housing	wires
4			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
3	2	12	Lock contact lock again.
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VW Golf V, Golf Plus, Touran

Webasto

VW

30

15

Wiring

diagram

HG

F3

F1

X1

4

sw

T10k

4²

(sw/ge)

rt

4²

5

T5

86

87

87a

KB

85

30

K3

4

1

2

3

T5

sw

4²

+

1

4

2

3

T4r

M GM

-

WG

31

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 ws			white
	connector		A
F3	Fuse, 25 A				sw	black	Legend
K3	Fan relay	KB	Air-conditioning control unit		br	brown
			or heater switch E16		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.

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VW Golf V, Golf Plus, Touran

1	Climatronic fan controller
2	Golf V
	Produce connections as shown in wiring
3
	diagram.	Installing
	Position of free sockets dependent on vehicle	wiring
	equipment.	harness of
	1 IPCU socket	Clima-
		tronic

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

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

13
1	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) 2.	Con-
2	1 IPCU	necting
		wires

14

				Route wiring harness IPCU 1 along cross
	1
				member 2 to center console

Routing 1 wiring

harness from IPCU

2

15

			Golf Plus
	1

					Produce connections as shown in wiring
					diagram.
					Position of free sockets dependent on vehicle
					equipment.		Installing
			2
				1		IPCU socket	wiring
							harness of
			3		2	Green/white (gn/ws) wire to IPCU/86 with	Clima-
						AMP connector	tronic

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

16

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VW Golf V, Golf Plus, Touran

1	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 3 to
	green/white (gn/ws) wire (AMP connector) 2.	Con-
	1 IPCU	necting
		wires

3 2 17

	Route wiring harness IPCU 2 along cross
	member 1 to center console.
	Routing
	wiring
1	harness
	from IPCU

2

2

18

1

Touran

			Produce connections as shown in wiring
			diagram.
			Position of free sockets dependent on vehicle
			equipment.		Installing
					wiring
	2	1		IPCU socket
					harness of
		2		Green/white (gn/ws) wire to IPCU/86 with	Clima-
		3		AMP connector	tronic
				Red (rt) and black/white (sw/ws) wires from
	3			IPCU

19

1	Fasten brown (br) wire from IPCU/85 to
	original vehicle ground point 2.
	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) 3.	Con-
	1 IPCU	necting
		wires
	2

3 20

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