Webasto Thermo Top Evo Installation Documentation Audi A1

Water Heater

Thermo Top Evo Parking Heater

E1

00 0258

With FuelFix

Installation Documentation Audi A1

Validity

Manufacturer Model Type EG BE No. / ABE

Audi A1 8X e1 * 2007 / 46 * 0414

Motorisation Fuel

1.0 TSFI Petrol SG 70 999 CHZB

1.4 TSFI Petrol SG 92 1422 CZCA

1.4 TSFI Petrol AG 92 1422 CZCA

1.4 TDi ultra Diesel SG 66 1422 CUSB

1.6 TDi Diesel SG 85 1598 CXMA

SG = manual transmission AG = 7-gear S tronic

From model year 2015 Left-hand drive vehicle

Verified equipment v ariant s:

Not verified: Manual air-conditioning

Total installation time: approx. 9 hours

Automatic air-conditioning Front fog lights Xenon headlights LED daytime running lights Start - Stop system

Passenger compartment monitoring Alarm system Keyless start button

Transmission type

Output in kW

Displacement in cm³

Engine code

Ident. No.: 1324052C_EN Status: 06.10.2016 © Webasto Thermo & Comfort SE

Audi A1

Validity 1 Necessary Components 2 Installation Overview 2 Information on Total Installation Time 2 Information on Operating and Installation Instructions 3 Information on Validity 4 Technical Information 4 Explanatory Notes on Document 4 Preliminary Work 5 Heater Installation Location 5 Preparing Electrical System 6 Electrical System for Petrol Vehicles 8 Electrical System for Diesel Vehicles 9 Automatic Air-Conditioning Fan Controller 10 MultiControl CAR Option 12 Remote Option (Telestart) 12 ThermoCall Option 13

Preparing Installation Location 14 Preparing Heater 17 Installing Heater 19 Exhaust Part 1 20 Fuel 22 Installing FuelFix for Petrol Vehicles 26 Installing FuelFix for Diesel Vehicles 31 Combustion Air 35 Petrol Coolant Circuit 36 Coolant Circuit 1.4 TDI 42 Coolant Circuit 1.6 TDI 50 Exhaust Part 2 57 Final Work 60 FuelFix Template for Petrol Vehicles 61 FuelFix Template for Diesel Vehicles 62 Automatic A/C Operating Instructions for Petrol Vehicles 63 Automatic A/C Operating Instructions for Diesel Vehicles 64

• Basic delivery scope of Thermo Top Evo based on price list

• Installation kit with FuelFix for Audi A1 2015 Petrol and diesel: 1324051C

• To be ordered additionally in case of automatic air-conditioning, automatic air-conditioning kit:

1324211_

• Heater control in accordance with price list and upon consultation with end customer

• In case of Telestart, indicator lamp in accordance with price list and in consultation with end cus-

tomer

Installation instructions:

• Arrange for the vehicle to be delivered with the tank only about ¼ full.

• The installation location of the push button in case of Telestart or Thermo Call should be confirmed

with the end customer.

• Depending on the space required and the vehicle manufacturer's instructions, we recommend the

use of a vehicle battery with a higher electrical capacity.

1

2

5

3

4

6

7

8

Necessary Components

Installation Overview

Legend:

1. Heater

2. Engine compartment fuse holder

3. Passenger compartment relay and

fuse holder

4. PWM Gateway

5. Circulating pump

6. MultiControl CAR

7. Metering pump

8. FuelFix

Information on Total Installation Time

The total installation time includes the time needed for mounting and demounting the vehicle-specific components, the heater specific installation time and all other times required for the system integration and initial start-up of the heater. The total installation time may vary for vehicle equipment other than provided.

Ident. No.: 1324052C_EN Status: 06.10.2016 © Webasto Thermo & Comfort SE

2

Audi A1 Information on Operating and Installation Instructions

1 Important information (not complete)

1.1 Installation and repair

The improper installation or repair of Webasto heating and cooling systems can cause fire or the leakage of deadly carbon monoxide, leading to serious injury or death.

To install and repair Webasto heating and cooling systems you need to have completed a special company training course and have the appropriate technical documentation, special tools and special equipment.

Installation and repair may ONLY be carried out by persons trained and certified in a Webasto training course. NEVER try to install or repair Webasto heating or cooling systems if you have not completed a Webasto training course, you do not have the necessary technical skills and you do not have the technical documentation, tools and equipment available to ensure that you can complete the installation and repair work properly.

Only use genuine Webasto parts. See the Webasto air and water heaters ac-

cessories catalogue for this purpose.

1.2 Operation

To ensure safe operation, we recommend having the heater checked every two years by an authorised Webasto dealer, especially when used over a long period and/or under extreme environmental conditions.

Do not operate the heater in closed rooms due to the danger of poisoning and suffocation.

Always switch off the heater before refuelling.

The heater may only be used with the prescribed fuel diesel (DIN EN 590) or petrol (DIN EN 228).

The heater may not be cleaned with a high-pressure cleaner.

1.3 Please note

ALWAYS follow all Webasto installation and operating instructions and observe all warnings.

To become familiar with and understand all functions and properties of the heater, the operating instructions must be read carefully and observed at all times.

For proper, safe installation and repair work, the installation instructions with all warnings and safety information must be carefully read and observed at all times. Please always contact a workshop authorised by Webasto for all installation and repair work.

Important

Webasto shall assume no liability for defects, damage and injuries r esulting from a failure to observe the installation, repair and operating instructions of the information contained in them.

This liability exclusion particularly applies to improper installations and rep airs, installations and repairs by untrained persons or in the case of a failure to use genuine spare parts.

The liability due to culpable disregard to life, limb or health and due to damage or injuries caused by a wilful or reckless breach of duty remain unaffected, as does the obligatory product liability.

Installation should be carried out according to the general, standard rules of technology. Unless specifie d otherwise, fasten hoses, lines and wiring harnesses to original vehicle lines and wiring harnesses using cable ties. Insulate loose wire ends and tie back. Connectors on electronic components must audibly click into place during installation.

Sharp edges should be fitted with rub protection. Spray unfinished body areas, e.g. drilled holes, with anti-corrosion wax (Tectyl 100K).

Observe the instructions and guidelines of the respective vehicle manufa cturer for demounting and mounting vehicle specific components!

The initial startup is to be executed with the Webasto Thermo Test Diagnosis. When installing a programmable control module (e.g. a PWM Gateway), the cor-

responding settings must be checked or adjusted.

2 Statutory regulations governing installation

Guidelines Thermo Top Evo

Heating Directive ECE R122 E1 00 0258 EMC Directive ECE R10 E1 04 5627

Note

The regulations of these guidelines are binding in the scope of the Directive 70/156/EEC and/or 2007/46/EC (for new vehicle models from 29/04/2009) and should also be observed in countries in which there are no special regulations.

Important

Failure to follow the installation instructions will result in the invalidation of the type approval for the heater and therefore invalidation of the general homologation of the vehicle.

The heater is licensed in accordance with paragraph 19, section 3, No. 2b of the StVZO (German Road Traffic Licensing Authority).

Note

2.1 Excerpt from ECE regulation 122 (heating system) paragraph 5 for the installation of the heater

Beginning of excerpt.

ANNEX VII

REQUIREMENTS FOR COMBUSTION HEATERS

AND THEIR INSTALLATION

1. GENERAL REQUIREMENTS

1.7.1. A clearly visible tell-tale in the operator's field of view shall inform when the combustion heater is switched on or off.

2. VEHICLE INSTALLATION REQUIREMENTS

2.1. Scope

2.1.1. Subject to paragraph 2.1.2. combustion heaters shall be installed according to the requirements of this Annex.

2.1.2. Vehicles of category O having liquid fuel heaters are deemed to comply with the requirements of this Annex.

2.2. Positioning of heater

2.2.1. Body sections and any other components in the vicinity of the heater must be protected from excessive heat and the possibility of fuel or oil contamination.

2.2.2. The combustion heater shall not constitute a risk of fire, even in the case of overheating. This requirement shall be deemed to be fulfilled if the installation ensures an adequate distance to all parts and suitable ventilation, by the use of fire resistant materials or by the use of heat shields.

2.2.3. In the case of M2 and M3 vehicles, the heater must not be positioned in the passenger compartment. However, an installation in an effectively sealed envelope which also complies with the conditions in paragraph 2.2.2 may be used.

2.2.4. The label referred to in paragraph 1.4 or a duplicate, must be positioned so that it can be easily read when the heater is installed in the vehicle.

2.2.5. Every reasonable precaution should be taken in positioning the heater to minimise the risk of injury and damage to personal property.

2.3. Fuel supply

2.3.1. The fuel filler must not be situated in the passenger compartment and must be provided with an effective cap to prevent fuel spillage.

2.3.2. In the case of liquid fuel heaters, where a supply separate to that of the vehicle is provided, the type of fuel and its filler point must be clearly labelled.

2.3.3. A notice, indicating that the heater must be shut down before refuelling, must be affixed to the fuelling point. In addition a suitable instruction must be included in the manufacturer's operating manual.

2.4. Exhaust system

2.4.1. The exhaust outlet must be located so as to prevent emissions from entering the vehicle through ventilators, heated air inlets or opening windows.

2.5. Combustion air inlet

2.5.1. The air for the combustion chamber of the heater must not be drawn from the passenger compartment of the vehicle.

2.5.2. The air inlet must be so positioned or guarded that blocking by rubbish or luggage is unlikely.

2.6. Heating air inlet

2.6.1. The heating air supply may be fresh or recirculated air and must be drawn from a clean area not likely to be contaminated by exhaust fumes emitted either by the propulsion engine, the combustion heater or any other vehicle source.

2.6.2. The inlet duct must be protected by mesh or other suitable means.

2.7. Heating air outlet

2.7.1. Any ducting used to route the hot air through the vehicle must be so positioned or protected that no injury or damage could be caused if it were to be touched.

2.7.2. The air outlet must be so positioned or guarded that blocking by rubbish or luggage is unlikely.

End of excerpt.

In multilingual versions the German language is binding.

Ident. No.: 1324052C_EN Status: 06.10.2016 © Webasto Thermo & Comfort SE

3

Audi A1

F

Special Tools

• Hose clamp pliers for auto-tightening hose clamps

• Hose clamp pliers for Clic hose clamps of type W

• Automatic wire stripper 0.2 - 6mm²

• Crimping pliers for cable lug / tab connector 0.5 - 6mm²

• Torque wrench for 2.0 - 10 Nm

• Hose clamping pliers

• Metric thread-setter kit

• Deep-hole marker

• Webasto Thermo Test diagnosis with current software

Dimensions

• All dimensions are in mm.

Tightening torque values

• Tightening torque values of 5x13 heater bolts and 5x11 heater stud bolts = 8Nm.

• Tightening torque value of 5x15 water connection piece retaining plate bolt = 7Nm.

• Tighten other bolt connections in accordance with manufacturer's instructions or in accordance with state-of-the-arttechnology.

Information on Validity

This installation documentation applies to Audi A1 Petrol and diesel vehicles - for validity, see page 1 - from model year 2015 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 this ‘installation documentation’.

Vehicle and engine types, equipment variants and other specifications not listed in this installation documentation have not been tested. However, installation according to this installation documentation may be possible.

Technical Information

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

Combustion Air

Fuel

Exhaust Gas

Software

Ident. No.: 1324052C_EN Status: 06.10.2016 © Webasto Thermo & Comfort SE

Special features are highlighted using the following symbols:

Specific risk of damage to components.

Specific risk due to electrical voltage.

Specific risk of injury or fatal accidents.

Specific risk of fire or explosion.

Reference to the manufacturer's vehiclespecific documents or to the general installation instructions of Webasto components.

Reference to a special technical feature. The arrow in the vehicle

icon indicates the position on the vehicle and the viewing angle.

Tightening torque according to the manufacturer's vehicle-specific documents.

Nm

!

4

Audi A1

1

Preliminary Work

Vehicle

• Open the fuel tank cap.

• Ventilate the fuel tank.

• Close the fuel tank cap again.

•Depressurise the cooling system.

• Disconnect the battery.

• Remove the windscreen wipers.

• Remove the coolant reservoir cap.

• Remove the drain pipe of the air filter box.

• Remove the air filter (not in case of 1.4TDI).

• Remove the air filter intake hose (not in case of 1.4TDI).

• Remove the engine control unit.

• Remove the coolant reservoir partition wall.

• Remove the windscreen wiper motor.

• Remove the left front wheel.

• Remove the left wheel-well inner panel.

• Remove the horn(s) (there can be one or two) together with the bracket.

• Remove the underride protection.

• Remove the right vehicle underbody trim.

• Remove the left and right lateral instrument panel trim.

• Remove the lower instrument panel trim on the left.

• Remove the glove box completely.

• Fold up the seating area of the rear bench seat or remove it (depends on the equipment).

• Open the tank-fitting service lid.

Heater

• Remove years that do not apply from the type and duplicate label.

• Attach the duplicate label (type label) visibly in the appropriate place in the engine compartment.

Heater Installation Location

1 Heater

Ident. No.: 1324052C_EN Status: 06.10.2016 © Webasto Thermo & Comfort SE

Installation Location

5

Audi A1

4²

rt

sw

4²

0,75²

sw

rt

0,75²

1

2

sw

0,5²

rt

0,5²

4

3

2

1

2

3

4

IN

SH

OUT

KL 15

GND

3

PWM

__

2.8

OUT

6.3

__

2.8

SH

6.3

__

2.8

KL15

6.3

IN

6.3

__

2.8

GND

6.3

sw

4²

rt

4²

rt

0,5²

sw

0,5²

4

3

87

6.3

RSH

30

6.3

85

6.3

86

6.3

__

2.8

__

2.8

__

2.8

__

2.8

F4

4.8

F4

4.8

F3

4.8

F3

4.8

F5

4.8

F5

4.8

87a

6.3

gn/ws

0,5²

rt/sw

0,5²

br

0,5²

rt

4²

2

1

4

Preparing Electrical System

Wire sections retain their numbering in the entire document.

Produce all following electrical connections as shown in the wiring diagram.

Red (rt) wire of fan wiring harness Black (sw) wire of fan wiring harness Red (rt) wire of PWM control system wiring harness Black (sw) wire of PWM control system wiring harness

Check the PWM Gateway settings when starting up the heater and adjust if necessary.

Settings:

Duty cycle: 100% (DC) Frequency: not relevant Voltage: 3.6V Function: High side

Assigning wires

View of PWM GW

Ident. No.: 1324052C_EN Status: 06.10.2016 © Webasto Thermo & Comfort SE

Interlocking PWM GW and passenger compartment relay and fuse holder sockets, inserting connector into bushing and connecting wires

6

Audi A1

5

10

6

4

2

3

171

3

2

Diesel only

1 Copy hole pattern, 7mm dia. hole

All vehicles

1 Passenger compartment relay and

fuse holder

2 PWM GW socket 3 Angle bracket 4 M5x16 bolt, large diameter washer

[2x], nut

Hole for fuse holder

Premounting passenger compartment relay and fuse holder

1 25A fuse F4 2 PWM GW 3 Relay K1

Installing passenger compartment relay and fuse holder

Ident. No.: 1324052C_EN Status: 06.10.2016 © Webasto Thermo & Comfort SE

7

Audi A1

8

1

9

2

3

1

Route the metering pump wiring harness later, together with the fuel line, along the original vehicle fuel lines on the underbody.

10

3

1 2

4

11

Nm

!

1

Electrical System for Petrol Vehicles

Engine compartment fuse holder Positive wire

1 Positive wire on positive distributor

Nm

Passenger compartment wiring harness p ass through

1

Passenger compartment rubber plug pass through

2 Wiring harnesses of heater, heater control 3 Rubber plug pass through, coolant reservoir

!

Wiring harness routing diagram

Engine compartment fuse holder

1 Fuses F1-2 2 Angle bracket 3 M6x20 bolt, large diameter washer, existing

hole, flanged nut

4 M5x16 bolt, large diameter washer [2x],

retaining plate of fuse holder, nut

Ident. No.: 1324052C_EN Status: 06.10.2016 © Webasto Thermo & Comfort SE

Earth wire

1 Earth wire on original vehicle earth support

point

8

Audi A1

12

1

13

2

3

1

Route the metering pump wiring harness later, together with the fuel line, along the original vehicle fuel lines on the underbody.

14

3

1

2

4

15

Nm

!

1

Electrical System for Diesel Vehicles

Engine compartment fuse holder Positive wire

1 Positive wire on positive distributor

Nm

Passenger compartment wiring harness p ass through

1

Passenger compartment rubber plug pass through

2 Wiring harnesses of heater, heater control 3 Rubber plug pass through, coolant reservoir

!

Wiring harness routing diagram

Engine compartment fuse holder

1 Fuses F1-2 2 Angle bracket 3 M6x20 bolt, large diameter washer, drilled

hole, flanged nut

4 M5x16 bolt, large diameter washer [2x],

retaining plate of fuse holder, nut

Ident. No.: 1324052C_EN Status: 06.10.2016 © Webasto Thermo & Comfort SE

Earth wire

1 Earth wire on original vehicle earth support

point

9

Audi A1

31

30 15

Audi

Webasto

vi/bl

T20e

15

J255

T6y

26

J126

M

0,5²

86

85 30

87

J59

SC2

sw

4,0²

vi/bl

0,5²

sw

4,0²

HG

F2 F1

gn/ws

0,75²

rt

4²

gn/ws

0,5²

rt

4²

rt/sw

0,5²

sw

4²

rt

4²

rt/sw

0,5²

rt

0,5²

sw

0,5²

br

0,5²

br

0,5²

K1

F3F4

30

87a

IN

OUT

rt

6²

X10

1

2

4

3

PWM

GW

br

4²

Automatic Air-Conditioning Fan Controller

System wiring diagram

Webasto components Vehicle components Colours and symbols

HG TT-Evo heater SC2 40A fuse rt red F1 20A fuse J59 Relay X- contact ws white F2 30A fuse J126 Fan unit sw black X10 4-pin connector of

heater control

F3 1A fuse gn green F4 25A fuse vi violet K1 Fan relay PWM GW Pulse width modulator

Settings of PWM GW:

Duty cycle: 100% (DC) Frequency: not relevant Voltage: 3.6V Function: High side Wiring colours may vary.

J255 A/C control panel br brown T... Connector bl blue

Legend

Ident. No.: 1324052C_EN Status: 06.10.2016 © Webasto Thermo & Comfort SE

10

Audi A1

16

2

1

17

1

2

18

1

19

1

1 Passenger compartment relay and

fuse holder

2 M6x30 bolt, large diameter washer,

original vehicle hole, 10mm spacer, flanged nut

Installing passenger compartment relay and fuse holder

1 Wiring harness of passenger com-

partment relay and fuse holder

2 Wiring harness of heater

Connecting same colour wires of wiring harnesses

1 Remove LWR control unit

Removing control unit

6-pin connector T6y

1

Removing fan unit connector

Ident. No.: 1324052C_EN Status: 06.10.2016 © Webasto Thermo & Comfort SE

11

Audi A1

20

3

2

4

3

1

3

4

21

1

3

1

2

1

2

22

1

23

1 Violet/blue (vi/bl) wire from J255 2 Violet/blue (vi/bl) wire of connector

T6y, pin 6

3 6-pin connector T6y

Red (rt) wire of PWM control system wiring harness Black (sw) wire of PWM control system wiring harness

1 Black (sw) wire of fan relay 2 Black (sw) wire of connector T6y,

pin 2

3 6-pin connector T6y

Red (rt) wire of K1/87a, fan wiring harness Black (sw) wire of K1/30, fan wiring harness

Connecting fan unit / PWM control

Connecting fan unit/ fan wiring harness

MultiControl CAR Option

Installing MultiControl CAR

Remote Option (Telestart)

Fasten receiver 1 with double-sided adhe-

sive tape.

Installing receiver

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Audi A1

1241

25

1

26

1

27

1 Aerial

Installing aerial

Temperature sensor T100 HTM

Fasten temperature sensor 1 with double-

sided adhesive tape.

Installing temperature sensor

ThermoCall Option

Fasten receiver 1 with double-sided adhe-

sive tape.

Aerial (optional)

1

Installing receiver

Installing aerial

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13

Audi A1

28

1

65

175

29

1 2

3

30

1

2

31

1

Preparing Installation Location

1 Copy hole pattern, 9.1mm dia. hole;

rivet nut

Installing rivet nut

Install bracket 1.

2 M6x20 bolt 3 Copy hole pattern, hole

Copying hole pattern

1 M10 rivet nut, original vehicle hole 2 9.1mm dia. hole; M6 rivet nut

Drill out hole to 8.5 mm dia.

1

Installing rivet nuts

Drilling angle bracket

Ident. No.: 1324052C_EN Status: 06.10.2016 © Webasto Thermo & Comfort SE

14

Audi A1

3

32

2

1

33

1

20

15

34

1

25

40

35

1

1 Horn 2 Original vehicle nut 3 Angle bracket

Installing angle bracket

1 Copy hole pattern, 7mm dia. hole

Drilling hole

1 M6x20 bolt, flanged nut

Installing horn

Drill out hole to 8.5 mm dia.

1

Preparing perforated bracket A

Ident. No.: 1324052C_EN Status: 06.10.2016 © Webasto Thermo & Comfort SE

15

Audi A1

30

40

36137

4

1 2 3

38

1

2 1

3 35 4

20°

50

39

1 Drill out hole to 10.5 mm dia.

1 Perforated bracket A

M8x20 bolt, spring lockwasher, exist-

2

ing threaded hole

3 Perforated bracket B

M10x16 bolt, spring lockwasher

4

Preparing perforated bracket B

Installing perforated brackets loosely

Tighten loose screw connections.

1 M6x20 bolt, spring lockwasher [2x

each]

2 Bracket 3 M6x12 bolt, flanged nut [2x each] 4 Perforated bracket B

Perforated bracket A

5

1.6 TDI

Installing bracket

Preparing perforated bracket C

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16

Audi A1

40

1

3 2411

1

2

21

42

2 2

43

1

1 Perforated bracket B 2 Perforated bracket C 3 M6x12 bolt, flanged nut

Preparing Heater

All vehicles

1

Water connection piece, sealing ring [2x each]

2 5x15 self-tapping bolt, retaining plate

of water connection piece

Installing perforated bracket C

Installing water connection piece

Petrol and 1.4 TDI

Screw self-tapping stud bolt M5 / M6 x

15.5

1 and 5x13 self-tapping bolts 2 [3x] in

existing holes by a maximum of 3 thread turns.

90° moulded hose, 10mm dia. clamp

1

Premounting bolts loosely

Premounting moulded hose

Ident. No.: 1324052C_EN Status: 06.10.2016 © Webasto Thermo & Comfort SE

17

Audi A1

11

44

1 1

45

1

C

A G

B D

E F

46

1

47

1 C

D

E

1.6 TDI

Screw 5x13 self-tapping bolts 2 [4x] into

existing holes by a maximum of 3 thread turns.

Premounting bolts loosely

1 90° moulded hose, 10mm dia. clamp

Premounting moulded hose

A =800 B =60 C = 90°, 18mm dia. D =60 E =60 F =90 G =840

All spring clips = 25mm dia.

1 90°, 18x18mm dia. connecting pipe

[2x]

Cutting hoses to length

Premounting hoses

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18

Audi A1

48

1

2

49

1

50

1

51

21

2

Installing Heater

Petrol and 1.4 TDI

Tighten 5x13 self-tapping bolt

1 2 Tighten M5/M6x15 self-tapping stud

bolts

1.6 TDI

Tighten 5x13 self-tapping bolt [2x]

1

Installing heater

All vehicles

Tighten 5x13 self-tapping bolt [2x]

1

Installing heater

Circulating pump wiring harness con-

1

nector

2 Heater wiring harness connector [2x]

Connecting wiring harness

Ident. No.: 1324052C_EN Status: 06.10.2016 © Webasto Thermo & Comfort SE

19

Audi A1

a1

a2

X

52353

2

1541 2

3

55

1 2

Exhaust Part 1

a1 = 270 a2 = 180

X =

1 Silencer 2 M6x16 bolt, spring lockwasher 3 Angle bracket

Preparing exhaust pipe

Premounting exhaust silencer

1 10mm shim 2 M8x20 bolt, spring lockwasher,

washer

3 Premounted silencer

Ensure sufficient distance from neighbouring components, correct if necessary.

1 Housing of front fog light 2 ≥ 5 mm

Installing silencer

Aligning silencer

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20

Audi A1

a1 1

1

56

1 Hose clamp [2x]

Installing exhaust pipe a1

Ident. No.: 1324052C_EN Status: 06.10.2016 © Webasto Thermo & Comfort SE

21

Audi A1

Connector X7

57

S T

58

59

S

1

2

3

Fuel

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. Unless specified otherwise, always fasten using cable ties. Provide rub protection for fuel line and wiring harness in areas where there are sharp edges.

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

Dismantling metering pump connector

S =800 T =600

Cutting corrugated tube to length

Pull wiring harness of metering pump 1

and fuel line route in the engine compartment.

2 10 mm dia. clamp

3 into corrugated tube S and

Connecting heater

Ident. No.: 1324052C_EN Status: 06.10.2016 © Webasto Thermo & Comfort SE

22

Audi A1

60

S

61

1

2

62

T

1

T

63

1

Route corrugated tube S to the firewall.

Routing lines

1 Fuel line and wiring harness of meter-

ing pump attached to the original vehicle wiring harness

2 Coolant reservoir pass through

Routing lines

Pull wiring harness of metering pump and fuel line into corrugated tube the engine compartment and along the original vehicle fuel line to the underbody.

1 Coolant reservoir pass through

Fuel line and wiring harness of meter-

1

ing pump

T, route in

Routing lines

Ident. No.: 1324052C_EN Status: 06.10.2016 © Webasto Thermo & Comfort SE

23

Audi A1

62

64

65

1 2

34

66

1

3

2

Pin assignment is not relevant.

Connector X7

67

Petrol and 1.4 TDI

Insert cable tie 4 between perforated

bracket

2 and body.

Cutting perforated bracket to length

1 Premount M6x25 bolt, pin lock 3 M6x20 bolt, flanged nut, original vehi-

cle hole

Attach metering pump mount 1 with a sup-

port angle bracket and a flanged nut to the M6x25 bolt. Close cable tie tering pump mount

2 Metering pump

1 .

3 around me-

Installing perforated bracket

Installing metering pump

Ident. No.: 1324052C_EN Status: 06.10.2016 © Webasto Thermo & Comfort SE

Completing metering pump connector

24

Audi A1

68

1

3 2

69

1 2

3

70

1 2

Pin assignment is not relevant.

Connector X7

71

1 Metering pump wiring harness, con-

nector X7 mounted

2 Hose section, 10mm dia. clamp [2x] 3 Fuel line of heater

1.6 TDI

Premount M6x25 bolt, pin lock

1 2 Perforated bracket 3 M6x20 bolt, flanged nut, original vehi-

cle hole

Connecting metering pump

Installing perforated bracket

Attach metering pump mount 1 with a sup-

port angle bracket and a flanged nut to the M6x25 bolt.

2 Metering pump

Installing metering pump

Completing metering pump connector

Ident. No.: 1324052C_EN Status: 06.10.2016 © Webasto Thermo & Comfort SE

25

Audi A1

F

72

1

2

3

73

X

74

1

3

2

22

75

1

1 Metering pump wiring harness, con-

nector X7 mounted

2 Hose section, 10mm dia. clamp [2x] 3 Fuel line of heater

Connecting metering pump

Installing FuelFix for Petrol Vehicles

X =

Drilling template

Version 1

Work steps F1 and F2.

1 Fuel tank sending unit 2 Position 22mm template at raised part

and lettering

3 Hole pattern

Work step F3.

1 Hole made with provided drill

Copying hole pattern

Hole for FuelFix

Ident. No.: 1324052C_EN Status: 06.10.2016 © Webasto Thermo & Comfort SE

26

Audi A1

76

1

2

77

1

78

79

2

1

3

Work steps F4 and F5.

Bend FuelFix cut to length. Insert into hole

2 according to template and

1. Inserting

FuelFix

Inserting FuelFix

Work steps F5.3 and F5.4.

Turn FuelFix

Work step F6.

1 FuelFix 2 Fuel line 3 Hose section, 10mm dia. clamp [2x]

1 as shown to align it.

Aligning FuelFix

Connecting fuel line

Ident. No.: 1324052C_EN Status: 06.10.2016 © Webasto Thermo & Comfort SE

27

Audi A1

F

0 mm

F 7.1.

<1... 0 mm

F 7.2.

200 min

-1

90°

50 - max

F 7.3.

F 7.4.

F 7.5.

F 7.6.

80

81

82

2

1

3

83

2

4

3

5

1

2

Work step F7.

Installing FuelFix

Work step F8.

Checking firm seating of FuelFix

1 FuelFix installed 2 Cable tie as tension relief 3 Fuel line of FuelFix

Securing fuel line

Version 2

Work steps F1 and F2.

1 Fuel tank sending unit 2 Position 22mm dia. template, copy

hole pattern

3 Copy hole pattern 4 Contact point, rim of fuel tank sending

unit

Hole for FuelFix

5 Contact point, edge of raised part

Ident. No.: 1324052C_EN Status: 06.10.2016 © Webasto Thermo & Comfort SE

28

Audi A1

84

1

2

85

2

1

86

87

Work step F3.

1 Hole made with provided drill 2 Move label

Hole for FuelFix

Work steps F4 and F5.

Bend FuelFix cut to length. Insert into hole

1 according to template and

2. Preparing

and inserting FuelFix

Inserting FuelFix

Ident. No.: 1324052C_EN Status: 06.10.2016 © Webasto Thermo & Comfort SE

Inserting FuelFix

29

Audi A1

F

88189

1

3

2

90

1

0 mm

F 7.1.

<1... 0 mm

F 7.2.

200 min

-1

90°

50 - max

F 7.3.

F 7.4.

F 7.5.

F 7.6.

91

Work steps F5.3 and F5.4.

Align FuelFix

1 as shown.

Work step F6.

1 Fuel line 2 Hose section, 10mm dia. clamp [2x] 3 FuelFix

Aligning FuelFix

Connecting fuel line

Install original vehicle connector. Align and install FuelFix

1 as shown in

next figure.

Installing FuelFix

Work step F7.

Installing FuelFix

Ident. No.: 1324052C_EN Status: 06.10.2016 © Webasto Thermo & Comfort SE

30

Audi A1

F

92

93

2

194X

95

2

4

1

22

2

22

3

Work step F8.

Checking firm seating of FuelFix

1 Cable tie as tension relief 2 Fuel line of FuelFix

Securing fuel line

Installing FuelFix for Diesel Vehicles

X =

Drilling template

Work steps F1 and F2.

Move label

1 Fuel tank sending unit 2 Position 22mm template at raised

parts

3 Hole pattern

4 as shown.

Fuel extraction

Ident. No.: 1324052C_EN Status: 06.10.2016 © Webasto Thermo & Comfort SE

31

Audi A1

96197

1

2

98

99

Work step F3.

1 Hole made with provided drill

Hole for FuelFix

Work steps F4 and F5.

Bend FuelFix cut to length. Insert into hole

1 according to template and

2.

Inserting FuelFix

Ident. No.: 1324052C_EN Status: 06.10.2016 © Webasto Thermo & Comfort SE

Inserting FuelFix

32

Audi A1

100

101

2

1

102

1

103

2

1

3

Move FuelFix connection piece 2 over

closed stub

1.

Inserting FuelFix

Work steps F5.3 and F5.4.

Turn FuelFix

Work step F6.

1 FuelFix 2 Hose section, 10mm dia. clamp [2x] 3 Fuel line

1 in position as shown.

Positionning FuelFix

Connecting fuel line

Ident. No.: 1324052C_EN Status: 06.10.2016 © Webasto Thermo & Comfort SE

33

Audi A1

F

0 mm

F 7.1.

<1... 0 mm

F 7.2.

200

min

-1

90°

50

- max

F 7.3.

F 7.4.

F 7.5.

F 7.6.

104

105

106

2

1

3

107

2

3

1

Work step F7.

Installing FuelFix

Work step F8.

Checking firm seating of FuelFix

1 FuelFix installed 2 Fuel line of FuelFix 3 Cable tie as tension relief

Securing fuel line

All vehicles.

Ensure sufficient distance from neighbouring components, correct if necessary.

2 Fuel line of FuelFix 3 Hose section, 10mm dia. clamp [2x]

1 Cable tie

Connecting metering pump

Ident. No.: 1324052C_EN Status: 06.10.2016 © Webasto Thermo & Comfort SE

34

Audi A1

108

30

10

1

109

1

110

3

1 2

Combustion Air

1 Copy hole pattern, drill 7mm dia. hole

Copying hole pattern

1 Combustion air pipe

Installing combustion air pipe

1 M5x16 bolt, flanged nut 2 Silencer 3 51mm dia. clamp

Installing silencer

Ident. No.: 1324052C_EN Status: 06.10.2016 © Webasto Thermo & Comfort SE

35

Audi A1

B

C

D

A

E

1

2

1

Petrol Coolant Circuit

Any coolant running off should be collected in an appropriate container. Route hoses kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that other hoses cannot be damaged. The heater must be filled with coolant when installing the hoses.

The connection should be modelled on an ‘inline’ circuit and based on the following diagram:

Hose routing diagram

All spring clips without a specific designation = 25 mm dia. All connecting pipes and = 18x18mm dia.

1

= Original vehicle spring clip .

2

= Black (sw) rubber isolator .

Ident. No.: 1324052C_EN Status: 06.10.2016 © Webasto Thermo & Comfort SE

36

Audi A1

C

B E

D

A

111

B

E

1

1 1

112

1 2

2

113

D

114

C

12

A = 180°, 18mm dia. B = 800 C = 90°, 18mm dia.

= 90°, 18mm dia.

D E = 960

Slide on braided protection hoses and cut to length.

1 Cut heat shrink plastic tubing to size,

50mm long [4x]

2 Black (sw) rubber isolator [2x]

Cutting hoses to length

Installing braided protection hoses

Connecting hose D

Circulating pump

1 2 Circulating pump mount

Connecting circulating pump

Ident. No.: 1324052C_EN Status: 06.10.2016 © Webasto Thermo & Comfort SE

37

Audi A1

115

1

3

4

2

116

1

117

1 X

2

118

E

1

1 Flanged nut on stud bolt of heater 2 Wiring harness of circulating pump 3 M6x25 bolt, flanged nut 4 Perforated bracket C

Installing circulating pump

Remove hose 1 from engine outlet/heat

exchanger inlet. Spring clips will be reused.

Removing hose

Cut off hose of engine outlet/heat exchanger inlet

1 Heat exchanger inlet hose section 2 Remove heat shrink plastic tubing

and discard

X =

Heat exchanger inlet hose section

1

1 at the marking.

Cutting point

Premounting hose E

Ident. No.: 1324052C_EN Status: 06.10.2016 © Webasto Thermo & Comfort SE

38

Audi A1

119

1

2

120

E

1

121

1

E

1 E

122

2

E

1

1 Cable tie 2 Heat exchanger inlet hose section

Connecting heat exchanger inlet

1 Heat exchanger inlet hose section

Routing in engine compartment

1 Cable tie [2x]

Routing in engine compartment

Black (sw) rubber isolator

1 2 90° connecting pipe of hose D

Connecting engine outlet

Ident. No.: 1324052C_EN Status: 06.10.2016 © Webasto Thermo & Comfort SE

39

Audi A1

123

A

B

124

A

B

1

125

2

B 1

E

126

1

Connecting engine outlet

1 Cable tie

Routing in engine compartment

1 Black (sw) rubber isolator 2 Circulating pump

Connecting circulating pump

Ensure freedom of movement of shift system

1 in case of manual transmission.

Shift gears to check this.

Routing in engine compartment

40

Audi A1

127

20 20

U V X

128

U

V

U

V

U =20 V =20

X =

Cutting hose section to length

Push hose sections U and V onto original

vehicle stud bolts

Installing hose sections U and V

41

Audi A1

A

B

C

D

2

1

Coolant Circuit 1.4 TDI

Any coolant running off should be collected in an appropriate container. Route hoses kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that other hoses cannot be damaged. The heater must be filled with coolant when installing the hoses.

The connection should be modelled on an ‘inline’ circuit and based on the following diagram:

Hose routing diagram

All spring clips without a specific designation = 25 mm dia. All connecting pipes and = 18x18mm dia.

1

= Original vehicle spring clip .

2

= Coupling piece on engine outlet.

42

Audi A1

D

A

CB

129

A

D

1

1 1

130

1

131

1

2

132

1

A = 800 B = 90°, 18mm dia. C = 90°, 18mm dia. D = 960

Cutting hoses to length

Slide on braided protection hoses and cut to length.

1 Cut heat shrink plastic tubing to size,

50mm long [4x]

Installing braided protection hoses

Remove hose of engine outlet / heat exchanger inlet piece. Spring clip

1 with engine outlet coupling

2 will be reused.

Cutting point

Pull off heat protection hose 1 and cut at

the marking.

Cutting point

43

Audi A1

133X134

1 2

55

90°

135

136

1

2

Cut off hose on engine outlet/heat exchanger inlet at markings.

X =

Cutting point

1 Engine outlet hose section 2 Heat exchanger inlet hose section

Preparing hoses

Cable tie through both holes, do not

1

tighten

2 Perforated bracket D

Preparing perforated bracket D

44

Audi A1

1371138

1

2

139

1

90°

11

140

1 Wiring harness bracket

Removing wiring harness bracket

1 Plate nut on original vehicle stud bolt 2 Perforated bracket D

Installing perforated bracket

1 Drill out hole to 8.5 mm dia.

Drilling out hole in angle bracket 1

Countersinking hole in angle bracket 2

45

Audi A1

141

2 1

142

1

2

143

1

144

C

1 Pin lock 2 M6x25 countersunk head screw

Preparing angle bracket 2

1 M8x20 bolt, spring lockwasher, in

original vehicle thread

2 Position angle bracket 1 (see next fig-

ure)

Installing angle bracket 2

1 Original vehicle nut

Installing angle bracket 1

Connecting hose C

46

Audi A1

145

B

12

146

1

3

4

2

147

D

C

148

1 D

1 Circulating pump 2 Circulating pump mount

Connecting circulating pump

1 Flanged nut on stud bolt of heater 2 Wiring harness of circulating pump 3 M6x25 bolt, flanged nut 4 Perforated bracket C

Installing circulating pump

Routing hose D and installing on C

Heat exchanger inlet hose section

1

Connecting heat exchanger inlet

47

Audi A1

149A150

1

2

A

D

151

1

A

152

D

A

1

2

Route hose section A and connect to cir-

culating pump

Connecting circulating pump

1 10x25 hose bracket 2 25x28 hose bracket

Inserting hose bracket

1 Engine outlet hose section

Connecting engine outlet

Attach original vehicle wiring harness 2 if

necessary with cable ties.

1 Cable ties

Routing in engine compartment

48

Audi A1

153

1

1A

D

154

1

155

1

A

D

2

1 Cable ties

Routing in engine compartment on angle bracket 1

1 Shape 48 mm dia. rubber-coated p-

clamp

Preparing hose bracket

1 Flanged nut 2 Rubber-coated p-clamp

Routing in engine compartment

49

Audi A1

A

G

2

1

C

E

B

F

3

D

Coolant Circuit 1.6 TDI

Any coolant running off should be collected in an appropriate container. Route hoses kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that other hoses cannot be damaged. The heater must be filled with coolant when installing the hoses.

The connection should be modelled on an ‘inline’ circuit and based on the following diagram:

Hose routing diagram

All spring clips without a specific designation = 25 mm dia. All connecting pipes = 18x18 mm dia.

1 = Original vehicle spring clip . 2 = Coupling piece on engine outlet.

50

Audi A1

A

G

1 1

156

2

157

1

3

2

4

158

1

B

159

2

3

1

Slide on braided protection hoses and cut to length.

1 Cut heat shrink plastic tubing to size,

50mm long [4x]

2 Black (sw) rubber isolator [2x]

Use lower hole of perforated bracket C 4 !

1 M6x25 bolt, flanged nut 2 Circulating pump 3 Circulating pump mount

Installing braided protection hoses

Installing circulating pump

1 Circulating pump wiring harness con-

nector

Connecting circulating pump

Remove hose of engine outlet / heat exchanger inlet piece. Heat protection

2 with engine outlet coupling

1 and spring clip 3

will be reused.

Cutting point

51

Audi A1

1601161

X

162

1 2

163

1

150

Pull off heat protection hose 1 and cut at

the marking.

Cutting point

Cut off hose on engine outlet/heat exchanger inlet at markings.

X =

Cutting point

1 Engine outlet hose section 2 Heat exchanger inlet hose section

Copy hole pattern, 9mm dia. hole; riv-

1

et nut

Preparing hoses

Installing rivet nut

52

Audi A1

20

90°

1641165

1

2

20

80°

90°

166

167

2

1

1 Drill out hole to 8.5 mm dia.

Preparing perforated bracket D

1 Perforated bracket D 2 M8x20 bolt, spring lockwasher

Installing perforated bracket D

Preparing perforated bracket E

Install perforated bracket E 2 with 80° an-

gle bracket on frame side member.

1 M6x20 bolt, spring lockwasher

Installing perforated bracket E

53

Audi A1

55

90°

168

169

1

2

170

1

171

1

2

Preparing perforated bracket F

1 Cable tie through both holes, do not

tighten

2 Perforated bracket

Preparing perforated bracket F

1 Wiring harness bracket

Removing wiring harness bracket

Plate nut on original vehicle stud bolt

1 2 Perforated bracket F

Installing perforated bracket F

54

Audi A1

172

F

E

B

A G

173

1

2A

G

3

1

174

1

2

G

A

1

3

175

G

1

1 Cable ties

Connecting heater

1 Cable tie [2x] 2 Perforated bracket E 3 Perforated bracket D

Routing

1 Position black (sw) rubber isolator 2 Attach original vehicle wiring harness

using a cable tie

3 Tighten cable tie

Routing

Heat exchanger inlet hose section

1

Connecting heat exchanger inlet

55

Audi A1

176

A

G

1

2

177

G

1A2

4

3

1 Engine outlet hose section 2 Heat exchanger inlet hose section

1 Attach original vehicle wiring harness

using a cable tie

2 25x25 hose bracket between hose A

and hose Install original vehicle heat protection

3 4 13x25 hose bracket between gear-

shift cable and hose

G

A

Connecting engine outlet

Fastening hoses A and G

56

Audi A1

2

1

178

a2

1

179

180

1

181

1

2

40

60

Exhaust Part 2

Route original vehicle wiring harness 2 as shown and secure using clip-type cable tie

1 Hose clamp

1

.

Routing wiring harness

Installing exhaust pipe a2

Ensure sufficient distance from neighbouring components, correct if necessary.

1 ≥ 15 mm

Aligning exhaust pipe a2

Petrol

1

Underride protection

2 Hole (as per work step 1 of the instal-

lation instructions)

Hole in underride protection

57

Audi A1

182

1

2

183

1

35

60

2

184

2

1

185

1

Diesel

1

Underride protection

2 Remove insulation

1 Hole (as per work step 1 of the instal-

lation instructions)

Hole in underride protection

Petrol and diesel

Position exhaust end fastener 1 as per

work step 3 of the installation instructions and copy hole pattern

Hole 1 [2x] as per work step 4 of the instal-

lation instructions.

2 [2x].

Copying hole pattern

Holes in underride protection

58

Audi A1

186

1

187

1 a2

1 5x13 self-tapping screw [2x] as per

work step 5 of the installation instructions

Install underride protection 1. Install ex-

haust pipe installation instructions.

a2 as per work steps 6 - 8 of the

Installing exhaust end fastener

Installing exhaust pipe a2

59

Audi A1

188a2189

2 3

1

2

Final Work

Reassemble the components in reverse order. Check all hoses, clamps and all electrical connections for firm seating. Insulate and tie back loose lines. Only use manufacturer-approved coolant. Spray the heater components with anti-corrosion wax (Tectyl 100K).

• Connect the battery.

• Fill and bleed the coolant circuit according to the vehicle manufactu rer’s specifications.

• Program MultiControl CAR, teach Telestart transmitter.

• Make settings on the A/C control panel according to the ‘Operating Instructions’.

• Place the ‘Switch off parking heater before refuelling’ caution label near the filler neck.

• For initial startup and function check, please see installation instructions.

Ensure sufficient distance from neighbouring components, correct if necessary.

Aligning exhaust pipe a2

Install rubber isolator 3, route air filter box

drain pipe cable tie

2 as shown and attach using

1.

Installing drain pipe of air filter box

Webasto Thermo & Comfort SE Postfach 1410 82199 Gilching Germany Internet: www.webasto.com Technical Extranet: http://dealers.webasto.com

60

Audi A1

FuelFix Template for Petrol Vehicles

Top view

100mm

Scale 1:1

Compare size of printout with dimension lines. Allowed tolerance a maximum of 2%.

Set the printer settings to ‘no margin’ or ‘minimise margins’ and 100% of the normal size.

100mm

0

61

Audi A1

FuelFix Template for Diesel Vehicles

Top view

100mm

Scale 1:1

Compare size of printout with dimension lines. Allowed tolerance a maximum of 2%.

Set the printer settings to ‘no margin’ or ‘minimise margins’ and 100% of the normal size.

100mm

0

62

Audi A1

190

1 2

19121192

2

1

Automatic A/C Operating Instructions for Petrol Vehicles

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.

Passenger compartment monitoring, if installed, must be deactivated in addition to the vehicle settings for the heating operation. For instructions on deactivation, please refer to the operating instructions of the vehicle.

Before parking the vehicle, make the following settings:

The fan speed does not have to be set!

1 Set temperature to ‘max.’ 2 Air outlet to windscreen

A/C control panel

1

20A heater fuse F1

2 30A main fuse F2 of passenger compartment

1A fuse F3 of heater control

1 2 25A fan fuse F4

Engine compartment fuses

Passenger compartment fuses

Audi A1

193

1 2

194

2

1

195

2

1

Automatic A/C Operating Instructions for Diesel Vehicles

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.

Passenger compartment monitoring, if installed, must be deactivated in addition to the vehicle settings for the heating operation. For instructions on deactivation, please refer to the operating instructions of the vehicle.

Before parking the vehicle, make the following settings:

The fan speed does not have to be set!

1 Set temperature to ‘max.’ 2 Air outlet to windscreen

A/C control panel

1

20A heater fuse F1

2 30A main fuse F2 of passenger compartment

1A fuse F3 of heater control

1 2 25A fan fuse F4

Engine compartment fuses

Passenger compartment fuses

Webasto Thermo Top Evo Installation Documentation Audi A1

Validity

Table of Contents

Necessary Components

Installation Overview

Information on Total Installation Time

Information on Validity

Technical Information

Explanatory Notes on Document

Preliminary Work

Heater Installation Location

Preparing Electrical System

Electrical System for Petrol Vehicles

Electrical System for Diesel Vehicles

Automatic Air-Conditioning Fan Controller

MultiControl CAR Option

Remote Option (Telestart)

ThermoCall Option

Preparing Installation Location

Preparing Heater

Installing Heater

Exhaust Part 1

Fuel

Installing FuelFix for Petrol Vehicles

Installing FuelFix for Diesel Vehicles

Combustion Air

Petrol Coolant Circuit

Coolant Circuit 1.4 TDI

Coolant Circuit 1.6 TDI

Exhaust Part 2

Final Work

FuelFix Template for Petrol Vehicles

FuelFix Template for Diesel Vehicles

Automatic A/C Operating Instructions for Petrol Vehicles

Automatic A/C Operating Instructions for Diesel Vehicles