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
e1
00 0003
e1
00 0002
e1
00 0104
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
1312760A_EN
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
1312760A_EN
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
1312760A_EN
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
1312760A_EN
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
1312760A_EN
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
1312760A_EN
2
3
20
11
Loading...