Webasto BlueHeat Thermo Top User manual

DOC P/N 5001101A KIT P/N 5001100A Printed in USA Webasto Product N.A., Inc.
BlueHeat Coolant Heater
Thermo Top
Legend
1BlueHeat Coolant Heater, Exhaust Tube, and Combustion Air Intake Silencer
2 Fuse Holder, Relays and Resistor Assembly
3TimerControl
4FuelPump
Special Tools
– Hose Clamping pliers
– Torque Wrench
Table of Contents
4
23 1
VW Passat
2.0L, 4CYL- FSI, Gasoline
Beginning Model Year: 2006
Special instructions for these models
Part locations may differ slightly dependent on
the vehicle model.
Be sure to check WWW.techwebasto.com for
the latest addition of this manual.
Foreword
Parts List 3
Vehicle Information 3
Scope and Purpose 3
Symbol Identification 4
General References 5
Preparation 5
Heater Installation Site 5
Installation
Electrical - Overview 6
Electrical Harness Installation 7
Timer Installation 8
Integration into the Blower System - Climatic 9
Integration into the Blower System - Climatronic 11
Heater Preparation/Installation 13
Air Intake tube Installation 14
Exhaust Installation 15
Integration into the Coolant System 16
Integration into the Fuel System 19
Blower Control Settings - Climatronic 23
Blower Control Settings - Climatic 23
Final Inspection, Initial Start-up and Concluding
Work 24
Heater Lockout Reset Procedure 25

– 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.
– Installation and repair of Webasto heating and cooling systems requires special
Webasto training, technical information, special tools and special equipment.
– NEVER attempt to install or repair a Webasto heating or cooling system unless you
have successfully completed the factory training course and have the technical skills,
technical information, tools and equipment required to properly complete the
necessary procedures.
– ALWAYS carefully follow Webasto installation and repair instructions and heed all
WARNINGS.
– Webasto rejects any liability for problems and damage caused by the system being
installed by untrained personnel.

3
VW Passat
Parts List
Vehicle Information
Foreword
This installation requires special expertise from a Webasto training course to install a Webasto Thermo Top
heater, which means that it may only be installed by a specially trained workshop or dealership. Webasto
cannot accept any liability for faults and damage caused by the system being installed by untrained personnel.
Scope and Purpose
These installation instructions are intended to support authorized Webasto trained distributors, dealers and
personnel in the installation of the Thermo Top (BlueHeat) Coolant Heaters.
These installation instructions apply to the vehicles listed on the front cover of this installation
document unless technical modifications on the vehicle influence the installation, excluding all liability claims.
Depending on the version and equipment in the vehicle, changes may be required to the installation work set
out in these installation instructions. In any event, the directives in the “installation manual” and “operating
manual” must be followed.
ATTENTION
All relevant state and provincial licensing regulations if any, governing the installation and use of auxiliary
heating devices must be observed!
CAUTION
Location of heater, installation of coolant lines, fuel system and components, wiring and control devices
are important for proper operation. Failure to comply with the installation instructions provided may result
in poor operation or damage to heater and vehicle components.
Quantity Part Part Number
1 Installation Kit For Vehicles With Automatic
Temperature Controls (Climatronic)
9013645A
1 Installation Kit For Vehicles With Manual
Temperature Controls (Climatic)
5001100A
Manufacturer Model Year Engine Type
Volkswagen Passat Beginning 2006 2.0L, 4CYL FSI

4
BlueHeat
TM
VW Passat
Symbol Identification
Symbols that define sections in manual
Mechanical Preparation
Electrical
Coolant
General Symbol Descriptions
Warning
Caution
Fuel
Exhaust
Combustion Air Intake
Refer to Webasto or Manufacturer Manual
Attention

VW Passat
5
General References
– Bare body parts, for example around drilled holes, must be treated with anti-corrosive coating.
– Secure hoses, cables and wiring harnesses with cable ties and fit protective hoses around them at chafing
points.
– Fit edge protectors (opened fuel hose) to sharp edges.
Preparation
Heater Kit
– Verify and identify all contents of kit.
Vehicle
– Open fuel cap and vent tank
– Release radiator pressure
– Remove battery and battery tray
– Remove air filter assembly and hoses
– Remove front left wheel well splashshield
– Remove left front fog lamp or trim panel
– Remove underbody splash shields
– Remove rear seat bottom
– Remove driver’s side floor trim
– Remove driver’s side dash trim panel
CAUTION
For reasons of safety due to possible fuel spillage, it is recommended that there be no more than 1/2 tank of fuel
present. If fuel quantity is greater than 1/2 of capacity, make provisions to reduce quantity of fuel.
– Protect vehicle fenders, panels and interior with covers
Heater Installation Site
ATTENTION
The Webasto Auxiliary Coolant Heater is installed on
the left side of the vehicle behind the front bumper.
Front bumper cover was removed for photographic
purposes only.
– (1) Webasto Auxiliary Coolant Heater (Installed)
1
Fig. 1
BlueHeat
TM

6
VW Passat
Electrical - Overview
ATTENTION
If not described differently, securing of wiring and cables is done with cable ties to the vehicle’s own wires and
cable harnesses.
ATTENTION
Timer control location is a recommendation only. Please consult with the customer before mounting.
2
1
br
rt sw
rtbr
+
-
bl
FuelLineandFuel
Pump Harness
1
2
1
2
12
Relay and Fuse Holder
– (1) Vehicle underhood fuse/relay center
– (2) Heater relay, fuses and mounting bracket
Fuel Pump Mounting Location
– (1) Webasto fuel pump
– (2) Vehicle fuel tank
Bulkhead Pass-through
– (1) Bulkhead opening
– (2) Timer Harness
Interior Fuse/Relay Center
– (1) Webasto blower integration point
– (2) Interior fuse/relay center

VW Passat
7
Electrical Harness Installation
ATTENTION
The two holes in the top of the relay/fuse mounting
bracket need to be enlarged to a accommodate two
existing vehicle screws.
Using a 21/64 drill bit enlarge the two holes in the top of
the relay/fuse mounting bracket.
– (1) Relay/fuse mounting bracket
– (2) 21/64 hole
Secure Webasto fuse holder and relay to mounting
bracket as shown in Figure 3.
– (1) Relay/fuse mounting bracket
– (2) Fuse holder
– (3) Relay
Remove hood stop and adjacent vehicle screw.
Position electrical mounting bracket where shown in
Figure 4 and re-install hood stop and existing screw.
– (1) Hood stop
– (2) Existing vehicle screw
– (3) Electrical mounting bracket
Webasto Power wire Connection
Secure webasto power wire to the vehicle power strip
located on the underhood fuse/relay center.
– (1) Fuse/relay power strip
– (2) Webasto power wire (+12V)
Fig. 2
12
Fig. 3
1
32
Fig. 4
3
1
2
Fig. 5
1
2

8
VW Passat
Webasto Harness Ground Wire Connection
Secure the webasto harness ground wire to an existing
vehicle ground located below the front headlight.
– (1) Existing vehicle ground location
– (2) Below front headlight
– (3) Webasto harness ground wire
Timer Harness Routing
Route the timer harness from the engine compartment to
the interior of the vehicle through the bulkhead grommet
next to the brake booster.
– (1) Brake booster
– (2) Bulkhead grommet location
– (3) Timer harness
Timer Installation
CAUTION
Check behind panels for obstructions before drilling
holes.
ATTENTION
Before installing the timer, please confirm the
installation location with the customer.
Affix supplied template to panel. Drill 10 mm (25/64 in.)
and 2.5 mm (3/32 in.) holes where indicated on template.
Figure 6 shows a translated sample of the template
supplied.
ATTENTION
Before installing the timer, please confirm the
installation location with the customer.
– (1) Timer
Fig. 6
1
3
2
Fig. 7
12
3
Fig. 8
Fig. 9
Example of Timer Mounting

VW Passat
9
Integration into the Blower System With Man-
ual Temp. Controls - Climatic
Loosen vehicle interior fuse center.
Disengage contact (3).
Remove black/red wire (2) from fuse block.
– (1) Interior fuse/relay center
– (2) Black/Red wire
– (3) Contact
ATTENTION
Make connections as shown in wiring schematic (fig.
12).
– (1) Black wire from K3 relay pin 30
– (2) Red wire from relay K3 pin 87 to vehicle SC40
– (3) Connector
– (3) Black/Red wire from fuse panel
Fig. 10
1
3
2
Fig. 11
1
2
4
3

10
VW Passat
TABLE 1. Climatic Control System
Webasto Heater Comp. Vehicle Components Wire Colors
HG = Webasto Heater SC40 = Blower Fuse rd = red
F3 = Fuse J301 = Climate Control Module wt = white
K3 = Blower Relay N24 = Resistor Pack bk = black
V2 = Blower Motor bn = brown
T = Harness Connections gn = green
4
sw
br
rt/ws
Webasto
31
30
15
VW Passat Climatic
rt
4
HG
X1
F3
25A SC41
40A
M
+
-
V2
sw/rt
br
rt/sw
T4r
5
J301
31 2 T5
34 2
N24
T5
rt/ws
sw/rt
gn/ws
1
rt/ws
T10k
K3
87a
87
86
85 30
bn
bn
rd/wt
rd/wt
rd/bk
rd
rd/bk
rd
rd
bk
gn/wt
+12V
+Ignition
Fig. 12
GND