Webasto Thermo Top P, Thermo Top E, Thermo Top C Installation Instructions Manual

Page 1
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, specialised tools and equipment are required to install and repair Webasto heating and cooling systems. Only original Webasto parts must be used. Fo r this, also see the catalog of air and water heat­er accessories from Webasto.
NEVER attempt to install or repair Webasto heating or cooling systems if you have not successfully completed the company training and thereby acquir ed 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 installa-
tion by untrained staff.
Feel the drive
Ident. No.: 9015699D_EN Fee Euro 10.00 © Webasto AG
VW Polo
Diesel from Model Year 2006 For left-hand drive vehicles only
Water Heater
Thermo Top Parking Heater E Thermo Top Parking Heater C Thermo Top Parking Heater P
Installation Instructions
e1
00 0003
e1
00 0002
e1
00 0104
Page 2
22
VW Polo
Validity
Vehicle and en gine types, equipment variants a nd 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 co nfirm ed with th e e nd customer before installation.
Manufacturer Model Type EG-BE No./ABE
VW Polo 9N e1 * 2001/116 * 0174 * ...
Engine type Engine model Output in kW Displacement in cm³
AMF Diesel 55 1422 BNM Diesel 51 1422 BNV Diesel 59 1422
Validity 2 Heater/Installation Kit 3 Foreword 3 General Instructions 3 Special Tool 3 Explanatory Notes on Document 4 Preliminary Work 5 Heater installation location 5 Electrical system 7 Climatic fan controller 8 Climatronic fan controller 9 Remote option (Telestart) 11 Remote option (Thermo Call) 12
Preparing heater 13 Preparing installation location 15 Installing heater 16 Coolant circuit with engine code letters: AMF 17 Coolant circuit with engine code letters: BNV and BNM 21 Combustion air 26 Fuel 27 Exhaust gas 30 Final Work 31 Template for Fuel Standpipe and Fuel-Tank Sending Unit 32 Operating Instructions for End Customer 33
Table of Contents
Page 3
33
VW Polo
Heater/Installation Kit
Also required with Climatronic:
Heater recommended for the respective vehicle class:
The selection of the heater is based on the passenger comp artment size of the vehicle and the level of comfort required by the customer!
Foreword
These installation instructions apply to VW Polo vehicles with a Diesel engine - 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 this installation documentation.
However, the stipulations in the "installation instructions" and "o perating 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 tech nology. Unless spec­ified otherwise, fasten hoses, lines and wiring harnesses to original vehicle lines and wiring harne sses 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 10 0K, Order No. 111329).
Special Tool
- Torque wrench
- Hose clamping pliers
- M8 metric thread-setter kit
Quantity Description Order No.:
1 Retail accessories Thermo Top E / C / P See price list 1 Installation kit for VW Polo Diesel 9015698A 1 Heater control See Price list
Quantity Description Order No.:
1 Climatronic kit 9013645A
Vehicle Heater
Compact car Thermo Top E Mid-size car, station wagon Thermo Top C Full-size car, van, offroader Thermo Top P
Page 4
44
Mechanical system
Electrical system
Coolant circuit
Fuel
Exhaust gas
Combustion air
VW Polo
The arrow in the vehicle icon indicates the position on the vehicle and the
viewing angle.
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 W ebas­to components or to the manufacturer's vehicle-specific documents.
Reference to a special technical feature.
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.
Page 5
5
VW Polo
Heater installation location
1 Heater
Installa­tion loca­tion
1
1
Preliminary Work
WARNING!
- Disconnect the battery "earth" or "ground" connection.
-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.
- Remove the air filter together with the intake hose.
- Remove the wiper arms.
- Remove the coolant reservoir cap.
- Remove the coolant reservoir.
- Open the fuel tank cap, ventilate the tank.
- Close the tank cap again.
- Open the right-hand fuel sender service lid.
- Remove the fuel-tank sending unit in accordance with the manufacturers specifications.
- Remove the underride protection
- Remove the fuse box of the central electrical box.
- Take off the cover of the relay box for the central electrical box (only with Climatronic).
- Remove the A/C control panel according to the manufacturer's instructions (only with Climatronic).
Please remove page 33 of the “Oper ating instructions for the end customer” and add this to the ve hicle operating instructions.
Page 6
6
VW Polo
Preparing electrical system
Only with Climatronic
Produce connections as shown in wiring dia­gram. Fasten wire section 1 with insulating tape on the fan wiring harness.
Preparing exhaust pipe
Connect the included lines to IPCU. Crimp 8mm dia. cable lug on brown (br) wire. The following IPCU adjustment values should be verified or adjusted before installation:
Duty cycle: 100% Frequency: 14 KHz Voltage: 3,3 - 3.7V Function: High side active
The voltage value (the rotation speed of the fan motor) should be verified or adjusted after the function check.
Preassem­bling IPCU
1 Perforated bracket
Angling down per­forated bracket
gn/ws
rt
rt/ws
br
1
sw
86
85 30
87a87
K3
gn/ws
86 85
A
E
IPCU
sw
rt
br
A
15
86
85
E
90°
80
1
Page 7
7
VW Polo
Electrical system
Wiring harness pass through 1
Protective rubber plug of Bowden cable
Digital timer 1
Digital timer
Wiring har­ness in­stallation diagram
Fuse holder, K3 relay 1
M6x20 bolt, large diameter washer, M6 flang­ed nut
2 Perforated bracket 3 M5x12 bolt, washer, fuse holder, K3 relay, M5
flanged nut
4 Original vehicle bracket, drill out hole to 6 mm
dia.
Summer/winter switch option 1
Summer/winter switch, drilled hole 12 mm dia.
2113
1
sw
rt
br
bl
Do not install the metering pump cable harness until later together with fuel pipe along the original vehicle fuel lines on the under­body
i
4
2 3
1
4
5
1
Page 8
8
VW Polo
Climatic fan controller
Climatic wiring dia­gram
Webasto components Components of VW Polo Colours and symbols
Legend
HG Heater GM Fan motor - V2 rt red X1 6-pin heater connector SB36 25 A fuse ws white F3 25 A fuse N24 Resistor group sw black K3 Fan relay E9 Switch unit br brown
T... Connector gn green
bl blue
X Cutting point
Wiring colours may vary.
Connection on central electrical box
5 to fan
module. Produce connections as shown in wiring dia­gram.
1 Black/red (sw/rt) wire from fuse SB36, 25 A 2 Black (sw) wire from K3/30 4 Black/red (sw/rt) wire to connector T6ac 3 Red (rt) wire K3/87a
Connec­tion to cen­tral electrical box
1
sw
br
Webasto
31
30 15
VW Polo
rt
sw/rt
br
rt
5
E9
4
2
3
T5h
T5h
sw/rt
rt/sw
gn/ws
rt/
ws
T10c/1
HG
4
X1
86
85 30
87a87
K3
F3
+
-
GM
M
SB36
T4e
21
3
N24
4
i
6
2
4
3
5
1
Page 9
9
VW Polo
Climatronic fan controller
Climatron­ic wiring diagram
Webasto components Components of VW Polo Colours and symbols
Legend
HG Heater J127 Fan unit rt red X1 6-pin heater connector J255 A/C control panel ws white F3 25 A fuse SB36 25 A fuse sw black K3 Fan relay T... Connector br brown IPCU Pulse width modulator gn green
IPCU adjustment values:
Duty cycle 100% Frequency 14 kHz Function High side active
X Cutting point
Voltage 3,3 - 3.7V Wiring colours may vary.
Connection on central electrical box
5 to fan
module. Produce connections as shown in wiring dia­gram.
1 Black/red (sw/rt) wire from fuse SB36, 25A 2 Black (sw) wire from K3/30 4 Black/red (sw/rt) wire to connector T6ac 3 Red (rt) wire K3/87a
Connec­tion to cen­tral electrical box
Webasto
31
30 15
VW Polo
86 85
E
A
IPCU
sw
sw
sw/
rt
gn/
ws
rt
rt/ws
rt
sw/ws
rt
sw
br
br
HG
4
X1
gn/ws
F3
T12g
3
J255
SB36
T6ac
26
J127
M
sw/
rt
86
85 30
87a87
K3
i
7
2
4
3
5
1
Page 10
10
VW Polo
Insert IPCU base in free socket. Produce connections as shown in wiring dia­gram.
1 IPCU
Connec­tion to re­lay carrier
Connection on connector T12g 3, Pin 3 of A/C control panel
4.
Produce connections as shown in wiring dia­gram.
1 Black/white (sw/ws) wire of IPCU/A 2 Black (sw) wire from fan unit 5 Black (sw) wire of connector T12g 6 Red (rt) wire of IPCU/E
Connect­ing air-con­ditioning control ele­ment
819
1
5
4
6
2
3
Page 11
11
VW Polo
Remote option (Telestart)
1 Receiver 2 4 mm dia. ho le [2 x], 4.8x13 self-tapping
screw [2x]
3 Bracket
Installing receiver
1
Antenna
Installing antenna
Temperature sensor for HTM100 only 1
Cable tie
2 Temperature sensor
Installing tempera­ture sensor
1
3
2
10
2
i
1
11
1
12
2
Page 12
12
VW Polo
Remote option (Thermo Call)
Mount TC receiver on A-pillar as shown; mounting materials not included in delivery scope!
1 Receiver 2 M5x16 bolt, large diameter washer, M5
flanged nut
Installing receiver
Copy hole pattern 2 of TC receiver 1 to right­hand A-pillar as shown. Fasten receiver with self-tapping screws.
Installing receiver
1
Antenna
Installing antenna
1
Push button
Installing push but­ton
1
2
13
i
1
14
2
2
1
15
i
1
16
i
Page 13
13
VW Polo
Preparing heater
Only on vehicles with engine code letters: AMF!
Discard section X Cut heat protection hose in half, compress and push onto hose
B and E.
b = 1050mm c = 210mm e = 730mm d = 40mm
Cutting coolant hose to length
Discard section X a = 210mm
Cutting coolant hose to length
Vehicles BNV and BNM
Discard section X Compress heat protection hose and push onto hose
D.
a = 930mm b = 210mm d = 880 mm c = 40 mm
Cutting coolant hose to length
All vehicles
Remove heater cover 1 and replace cable of circulating pump with wiring harness exten­sion. The spring clips will be reused.
2 Heater 3 Discar d hose s ect ion 4 Circulating pump 5 Discard clamp
Removing circulating pump
bc e
XCB
F
E
D
d





X A
a

abd
BA
X
D
C
c

1
2
3
4
5
Page 14
14
VW Polo
Hose D with engine code letters: AMF! Hose
C with engine code letters: BNV and
BNM!
1 27 mm dia. spring clip from water pump 2 20x20 connecting pipe 3 27 mm dia. spring clip from water pump
Installing coolant hose on heater
Ejot screw, tightening to rque 10 Nm!
1 Strut 2 Loosely mount Ejot screw
Installing strut on heater
1
M6x16 bolt, M6 flanged nut
2 29 mm dia. rubber-coated p-clamp
Installing p-clamp
1
M6x16 bolt, pin lock
2 M6x12 bolt, pin lock
Preparing bracket
2
3
1
17
D/C
18
1
2
2
1191 2
20
Page 15
15
VW Polo
Preparing installation location
Discard original vehicle bolts from engine mount and replace with included double bolts. Observe tightening torque according to manufacturer.
1 Double bolt [2x]
Preparing installa­tion loca­tion
1
Right-hand frame side member.
2 M8 rivet nut
Installing rivet nut
1
Loosely mount bracket
2 M8 flanged nut [2x]
Installing bracket
Loosen clamp at position 2 and twist hose from turbocharger
3 as shown. (Distance to
heater)
1 Bracket 4 M8x30 Torx screw 5 Frame side member
Installing bracket
21
1 1
22
2
1
23
21 2
24
4
1
5
2
3
Page 16
16
VW Polo
Installing heater
Before installing heater, tighten fastening bolts of bracket. Tighten Ejot screws to 10 Nm! Insert two 6 mm dia. washers between heater and bracket at position
2.
1 Ejot screw 2 Ejot screw, washer [2x]
Installing heater
Tighten strut on heater following installation. Tighten Ejot screws to 10 Nm!
1 Strut 2 M6 flanged nut
Installing heater
25
2
11
26
2
1
Page 17
17
VW Polo
Coolant circuit with engine code letters: AMF
WARNING!
Any coolant running off should be collected using an appropriate 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 hoses, the heater must be filled with coolant! The connection should be "inline" based on the following diagram:
Hose in­stallation diagram
All spring clips = 27 mm dia.! Al connecting pipes = 20x20 mm
C
E
B
B
F
A
Page 18
18
VW Polo
1 Original vehicle bolt 2 Angle bracket with long leg under bolt 3 M6x16 bolt, M6 flanged nut 4 Circulating pump 5 Rubber-coated pipe clamp, 48 mm dia.
Fastening circulating pump
1
Circulating pump
Connec­tion to heater and circulating pump
Before producing electrical connection, cut connector off cable of circulating pump and cut wiring harness extension to length.
1 Wiring harness extension 2 Cable of circ ula tin g pu m p 3 Connector [2x]
Electrical connec­tion to cir­culating pump
Before installing coolant hoses, connect wirin g harness to heater. Guide coolant hose
E
through premounted rubber-coated p-clamp
1
.
Connec­tion to heater out­let
27
5
1
2
3
4
28
1
C
29
3
1 2
30
1
E
Page 19
19
VW Polo
Install hose B with 90° elbow on circulating pump
1.
Connec­tion to cir­culating pump
1
Spacer bracket
Routing in engine compart­ment
1
Spacer bracket [2x]
Routing in engine compart­ment
Install individual spacer bracket 3 with brack- et for air intake silencer
1. Dispose of mount-
ing clip
2.
Premount­ing spacer bracket
31
B
1321
B
D
E
33
1
1
B
E
1
3 2
Page 20
20
VW Polo
1 Charge-air tube 2 Premounted spacer bracket
Routing in engine compart­ment
Remove and dispose of original vehicle cool­ant hose
1. The spring clips will be reused.
Removing coolant hose
1
Heat exchanger inlet
2 Heat protection hose
Connec­tion to heat exchanger inlet
Fasten hose A on connection piece of engine outlet with original spring clip
1 Heat protection hose 2 Spacer bracket
Connec­tion to en­gine outlet
34
2
1 2
B
E
35
1
36
1
2
E
F
37
B
A
1
2
Page 21
21
VW Polo
Coolant circuit with engine code letters: BNV and BNM
WARNING!
Any coolant running off should be collected using an appropriate 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 hoses, the heater must be filled with coolant! The connection should be "inline" based on the following diagram:
Hose in­stallation diagram
All spring clips = 27 mm dia.! Connecting pipe = 20x20 mm!
A
D
B
C
Page 22
22
VW Polo
1 Original vehicle bolt 2 Angle bracket with long leg under bolt 3 M6x16 bolt, M6 flanged nut 4 Circulating pump 5 Rubber-coated pipe clamp, 48 mm dia.
Fastening circulating pump
1
Circulating pump
Connec­tion to heater and circulating pump
Before producing electrical connection, cut connector off cable of circulating pump and cut wiring harness extension to length.
1 Wiring harness extension 2 Cable of circ ula tin g pu m p 3 Connector [2x]
Electrical connec­tion to cir­culating pump
Before installing coolant hoses, connect wirin g harness to heater. Guide coolant hose
D
through premounted rubber-coated p-clamp
1
.
Connec­tion to heater out­let
38
5
1
2
3
4
39
1
B
40
3
1 2
41
1
D
Page 23
23
VW Polo
Install hose A with 90° elbow on circulating pump
1.
Connec­tion to cir­culating pump
1
Spacer bracket
Routing in engine compart­ment
1
Spacer bracket [2x]
Routing in engine compart­ment
Install individual spacer bracket 3 with brack- et for air intake silencer
1. Dispose of mount-
ing clip
2.
Premount­ing spacer bracket
42
A
1431
A
C
D
44
1
A
D
1
1
3 2
Page 24
24
VW Polo
1 Charge-air intake pipe 2 Premounted spacer bracket
Routing in engine compart­ment
Pull original vehicle coolant hose 1 off con­nection piece and turn toward right-hand side of vehicle. Spring clip
2 will be reused.
Preparing coolant
Before installing, push black (sw) rubber iso­lator
2 onto original vehicle coolant hose 1.
Connec­tion to en­gine outlet
1
Original spring clip
Connec­tion to heat exchanger inlet
45
2
1 2
A
D
46
1 2
47
2
A
1
48
D
1
Page 25
25
VW Polo
1 Spacer bracket
Installing spacer bracket
49
D
1
A
Page 26
26
VW Polo
Combustion air
1 Flexible tube 2 20-27 mm dia. hose clamp
Installing intake pipe
1
Combustion-air intake pipe
2 Intake silencer 3 48 mm dia. clamp, flanged nut on pre-
mounted M6x16 bolt
Installing silencer
50
1
2
i
51
2 3
1
Page 27
27
VW Polo
Fuel
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 container. Install fuel line and metering-pump wiring harness so that they are protected ag ainst stone impact. Un-
less 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 wiring harness routing diagram.
1 Fuel line 2 10 mm dia. hose clamp 3 Hose section
Connec­tion on heater
Route fuel line 1 along wiring harness of heater.
2 Flexible tube 3 Wiring harness of heater
Routing line
Route fuel line and wiring harness of meter­ing pump along original vehicle fuel lines to installation location of metering pump.
1 Wiring harness of metering pump and fuel
line
2 Original vehicle fuel line [2x]
Routing line
52
3
1 2
53
3
21
54
2
1 2
Page 28
28
VW Polo
Remove stoneguard in area of hole.
1 Silent block, M6 flanged nut in existing hole
Installing metering pump
1
Metering pump
2 Rubber-coated p-clamp, M6 flanged nut on
silent block
3 Hose section 4 Hose section from heater, 10 mm dia. hose
clamp [2x]
Installing metering pump
1
Fuel sender
2 Template 3 Copy hole pattern, 6 mm dia. hole
Copying hole pat­tern
Cut fuel standpipe 3, fuel hose 1 and stand­pipe
2 to length and install in accordance with
template. Watch for possible kinking!
Installing fuel stand­pipe
55156
3
1
2
4
2
3
1
2
2
1
1
3
Page 29
29
VW Polo
Install fuel-tank sending unit according to manufacturer's specifications. Shorten moulded hose by 10 mm on 3.5 mm dia. side and mount on fuel standpipe.
1 Moulded hose, 3.5 mm dia. 4.5 mm 2 Fuel line 3 10mm dia. Caillau clamp 4 8mm dia. Caillau clamp
Connect­ing fuel line
Connect fuel line from fuel standpipe 1 on in­take side of metering pump [side without con­nector]. Check the position of the components; adjust if necessary . Check that they have free clear­ance.
2 180° moulded hose, hose clamp
10mm dia. [2x]
Connec­tion to me­tering pump
57
3
4
1
2
58
1 2
Page 30
30
VW Polo
Exhaust gas
Exhaust pipe a = 380 mm Exhaust end section b = 320 mm
Discard section
Preparing exhaust pipe
1
Perforated bracket
Angling down per­forated bracket
1
Original vehicle nut
2 Angled-down perforated bracket 3 M6x12 bolt, flanged nut M6 4 Exhaust silencer 5 Exhaust pipe 6 Red rubber isolator 7 Exhaust p-clamp [2x]
Installing silencer and ex­haust pipe
42 mm dia. hole in wheel well trim at position 3 (see the following figure).
1 Exhaust end section 2 Hose clamp 3 Red rubber isolator with groove
Installing end piece
X
a b
90°
80
1
59
4
5
6
3
172
60
3
21
Page 31
VW Polo
Printed in Germany 16.03.2011 Printing: Steffen
31
Feel the drive
Webasto AG Postfach 80 D-82132 Stockdorf / Germany National Hotline: 01805 93 22 78 (14 Cent aus dem deutschen Festnetz) Hotfax: 0395 5592 353 Hotmail: hotline@webasto.de http://www.webasto.de
Final Work
WARNING!
Reassemble the disassembled components in reverse order. Check all hoses, hose, spring and Caillau clamps, as well as all electrical connections for firm seating. Secure all loose cables using cable ties. Only use manufacturer-approved coolant. Spray the heater components with anti-corrosion wax (Tectyl 100K, Order No. 111329).
- Connect the battery
- Bleed and fill the coolant circuit according to the vehicle manufacturer’s specifications.
- Set the digital timer.
- Set the manual air conditioning or automatic air conditioning according to the "operating instruc­tions for the end customer".
- Check the proper operation of the parking heater, see the operating instructions/installation in­structions.
- Attach the "Switch off parking heater before refueling" sticker to the left-hand B-pillar.
1 Wheel well trim 2 42 mm dia. hole, red rubber isolator with
groove
Cutting out wheel well trim
i
2
1
61
Page 32
32
VW Polo
Template for Fuel Standpipe and Fuel-Tank Sending Unit
No. Description
1 Fuel hose 2 90° moulded hose 3 Standpipe 4 Fuel standpipe 5
Single-lug clamp, 8.0mm dia.
6
Single-lug clamp, 6.6mm dia.
7 Caillau clamp, 9.0mm dia. 8 Caillau clamp, 10.0mm dia. 9 Fuel line 10 Cut to length slantwise
Page 33
33
VW Polo
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 recommend not exceeding a switch-on time of 20 min.
For vehicles with passenger comp artment monitoring, it must be deactivated a dditionally , besides mak­ing the vehicle settings for the heating operation. Instructions on deactivation can be taken from the operating instructions of the vehicle.
If the summer/winter switch option has been installed, this must be switched in accordance with the time of year. The heater 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 Air outlet to "windscreen" 2 Set fan to level "1", or possibly "2" 3 Set temperature to "max."
Climatic
1
Set defrost switch to "on"
2 Set temperature to "max."
Climatron­ic
62
2 1
3
63
1
1
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