Webasto thermo top evo Operator's manual

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. For this, also see the catalog of air and water heat-
er 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 acquired the required tech-
nical 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.
The initial startup is to be executed with the Webasto Thermo Test Diagnosis.
Webasto does not accept any liability for defects and damage that are attributable to installa-
tion by untrained staff.
Water Heater
Installation documentation
Ident. No.: 1317226C_EN Fee Euro 10.00 © Webasto AG
VW Passat
Petrol and Diesel
from model year 2011
Left-hand drive vehicle
Manual transmission / Direct gear transmission
Passenger compartment monitoring not checked!
Feel the drive
Thermo Top Evo Parking Heater
e1
00 0258

VW Passat
1317226C_EN 2
Table of Contents
Validity
Vehicle and engine types, equipment variants and national specifications not listed in this installation
documentationhavenot beentested. However,installationaccordingtothis installationdocumentation
may be possible.
The installation location of the digital timer should be confirmed with the end customer before installa-
tion.
Manufacturer Model Type EG-BE-No. / ABE
VW Passat 3C e1 * 2001 / 116 * 0307 * ...
VW Passat 3C e1 * 2007 / 46 * 0547 * ...
Engine type / transmis-
sion type Engine model Output in kW Displacement in cm³
CAXA / SG Petrol TSI 90 1390
CCZB / SG Petrol TSI 155 1984
CCZB / DSG Petrol TSI 155 1984
CFFB / SG Diesel 103 1968
CFGB / DSG Diesel 125 1968
Validity 2
Heater/Installation Kit 3
Foreword 3
General Instructions 3
Special Tools 3
Explanatory Notes on Document 4
Preliminary Work 5
Heater installation location 5
Preparing electrical system 6
Electrical system 8
Climatic fan control 9
Climatronic fan control 11
Digital timer 13
Remote option (Telestart) 13
Preparing installation location 14
Preparing heater 15
Installing heater 19
Coolant circuit 1.4 TSI 21
Coolant circuit 2.0 TSI 22
Coolant circuit diesel 27
Fuel 32
Mounting retaining plate / connector 37
Wheel-well inner panel 37
Final Work 38
Template for Fuel Standpipe Petrol 39
Template for Fuel Standpipe Diesel 40
Operating Instructions for End Customer 41

VW Passat
1317226C_EN 3
Heater/Installation Kit
Also required with automatic air-conditioning
Foreword
This installation documentation applies to the VW Passat Petrol and Diesel vehicles - for validity, see
page 2 - from model year 2011 and later, assuming technical modifications to the vehicle do not affect
installation, any liability claims excluded. Depending on the vehicle version and equipment, modifica-
tions may be necessary during installation with respect to this installation documentation.
However, the stipulations in the "installation documentation" and "operating instructions" and the "in-
stallation instructions" for the Thermo Top Evo 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 spec-
ified otherwise, fasten hoses, lines and wiring harnesses to original vehicle lines and wiring harnesses
using cable ties. Insulate loose wires and tie back.
Sharp edges should be fitted with rub protection (split-open fuel hose).
Spray unfinished body areas, e.g. drilled holes, with anti-corrosion wax (Tectyl 100K, Order No. 111329).
When installing an IPCU, check or adjust the corresponding settings before installation.
Special Tools
- Torque wrench for 2.0 - 10 Nm
- Hose clamping pliers
- Deburring tool
- Spiral drill 5.5 / 6.0 / 8.5 mm dia.
- Centre bit 60mm dia.
Quantity Description Order No.:
1 Basic delivery scope Thermo Top Evo See Price list
1 Installation kit VW Passat 2011 Petrol and Diesel 1317225B
1 Heater control See Price list
Quantity Description Order No.:
1 Automatic air-conditioning kit 1317273A

VW Passat
1317226C_EN 4
Special features are highlighted using the following symbols:
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.
Referenceto generalinstallationinstructions ofWebas-
tocomponentsortothemanufacturer'svehicle-specific
documents.
Reference to a special technical feature.
Mechanical system
Electrical system
Coolant circuit
Fuel
Exhaust gas
Combustion air
Software
All dimensions are in mm!
Tightening torque of 5x13 heater bolts = 8Nm!
Tightening torque of 5x15 bolt of water connection piece retaining plate = 7Nm!
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.

VW Passat
1317226C_EN 5
Preliminary Work
WARNING!
- Open the fuel tank cap, ventilate the tank.
- Close the fuel tank cap again.
- Disconnect the battery earth connection.
-Depressurisethe 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.
- Completely remove the battery.
- Remove the air filter together with the intake hose.
- Remove the coolant reservoir cap.
- Remove the underride protection
- Remove the wheel-well inner panel on the left
- Remove the rear bench seat
- Open the right-hand tank-fitting service lid.
- Remove the fuel-tank sending unit in accordance with manufacturer's instructions.
- Remove the footwell trim on front passenger side
- Remove the fuse holder trim in the passenger compartment on the driver's side
- Remove the instrument panel trim at the left
Remove page 41 "Operating Instructions for End Customer" and add to the vehicle operating instruc-
tions.
Heater installation location
1Heater
Installa-
tion loca-
tion
11

VW Passat
1317226C_EN 6
Preparing electrical system
Wire sections retain their numbering in the
entire document.
Climatronic
Detach red (rt) wire 1from fuse F4 and dis-
card.
Removing
wire
IPCU view on contact side.
The IPCU provided in the kit is pre-pro-
grammed with the following settings.
Duty cycle: 30%
Frequency: 400Hz
Voltage: 8V
Function: High side
The adjustment values must be checked dur-
ing the function check of the vehicle and ad-
justed, if necessary.
Preparing
IPCU
IPCU is to be inserted only after fuse holder
has been premounted. Connect wires to
socket IPCU. Draw wire and into the
protective sleeving
Red (rt) wire of IPCU/E
Black (sw) wire of IPCU/A Preparing
IPCU
1IPCU
2M5x16 bolt, large diameter washer [2x], re-
taining plate of fuse holder, self-locking M5
flanged nut
3Angle bracket
Red (rt) wire of IPCU/E
Black (sw) wire of IPCU/A
Premount-
ing pas-
senger
compart-
ment fuse
holder
2
1
86 85
A
E
IPCU
A
15
86 85
E
1
2sw
0,5²
rt
0,5²
gn/ws
0,75²
br
0,5²
rt
4²
rt/sw
0,5²
F3
A
E
IPCU
85
86
3
1
1 2
2
3

VW Passat
1317226C_EN 7
Climatic
Connectwires tosocket ofK1relay. InstallF4
25A fuse.
Red (rt) wire of K1/87a
Black (sw) wire from K1/30 Preparing
K1 relay
1K1 relay
2M5x16 bolt, large diameter washer, fuse
holder
3Angle bracket
Red (rt) wire of K1/87a
Black (sw) wire from K1/30 Premount-
ing pas-
senger
compart-
ment fuse
holder
86
85 30
87a87
K1
gn/ws
0,75²
F4
br
0,5²
rt
4²
rt/sw
0,5²
F3
3
4sw
4²
rt
4²
4
1
43
2
3

VW Passat
1317226C_EN 8
Electrical system
Positive and earth wire
1Positive wire to positive battery distributor
2Earth wire on original vehicle earth support
point
Wiring harness routing
Route wiring harnesses in original vehicle cable
duct 1
Wiring har-
ness rout-
ing
diagram
Fuse holder of engine compartment
5.5mm hole at position 1. When drilling, watch
for components located behind.
1M5x16 bolt, washer [2x], retaining plate of
fuse holder, self-locking M5 flanged nut
2Fuses F1-2
Wiring harness pass through
1Use free protective rubber plug
2Wiring harnesses of heater, heater control
5
1
2
6
1
Do not install the metering pump
wiring harness until later togeth-
er with fuel pipe along the origi-
nal vehicle fuel line on the
underbody
7
2
45
1
8
2
1

VW Passat
1317226C_EN 9
Climatic fan control
Wiring dia-
gram
Webasto components Vehicle components Colours and symbols
Legend
HG TT-Evo heater N24 Resistor group rt red
X1 6-pin heater connector T4bp 4-pin connector N24 sw black
X2 2-pin heater connector J301 A/C control unit ge yellow
X10 4-pin connector
Heater control T5r 16-pin connector J301 gn green
SC41 40 A fan fuse bl blue
K1 Fan relay T10f 10-pin connector ws white
F1 20A fuse br brown
F2 30A fuse
F3 1A fuse
F4 25 A fuse
XCutting point
Wiring colours may vary.
Webasto
31
30
15
VW
HG
X2 1 2 X1
52
F2 F1
gn/ws
0,75²
ge
0,5²
rt/sw
0,5² rt
4²
br
0,5²
X10
3
4
sw
4²
rt
4²
br
0,5² br
rt/sw
N24
rt/ws
T10f
T5r
31 24
T4bp
34 21
5T5r
SC41
sw/rt
J301
+
-V2
M
86
85 30
87a87
K1
gn/ws
0,75²
F4
br
0,5²
rt
4²
rt/sw
0,5²
F3

VW Passat
1317226C_EN 10
Fuse socket depends on vehicle equipment.
Uncrimp black/red (sw/rt) wire 2from socket
of fan fuse. Red (rt) wire from K1/87a with
crimped standard-
power timer in the fan fuse socket. Produce
connections as shown in wiring diagram.
1Connector
Black (sw) wire from K1/30
Connect-
ing wires
1Angle bracket
2Original vehicle bolt
Mounting
fuseholder
in passen-
ger com-
partment
Connectthe wiring harnessof thefuse holder
in passenger compartment 2to the wiring
harness of heater 1according to the wiring di-
agram, with same colour wires connected to
each other. Connect-
ing wiring
harnesses
9
1
3
4
2
3
10
2
1
11
1
2

VW Passat
1317226C_EN 11
Climatronic fan control
Wiring dia-
gram
Webasto components Vehicle components Colours and symbols
Legend
HG TT-Evo heater J126 Fan unit rt red
X1 6-pin heater connector T6be 6-pin connector J126 sw black
X2 2-pin heater connector J255 A/C control unit ge yellow
X10 4-pin connector
Heater control T16h 16-pin connector J255 gn green
SC39 40A fuse bl blue
K1 Fan relay T10f 10-pin
connection ws white
F1 20A fuse br brown
F2 30A fuse
F3 1A fuse
IPCU Pulse width modulator
IPCU adjustment values:
Duty cycle: 30%
Frequency: 400Hz
Voltage: 8V XCutting point
Function: High side Wiring colours may vary.
Webasto
31
30
15
VW
HG
X2 1 2 X1
52
F2 F1
gn/ws
0,75²
ge
0,5²
rt/sw
0,5² rt
4²
br
0,5²
X10
sw/
ws
T10f
bl/
ws
J126
T6be
31 42
M
J255
T16h
15 16 SC
39
sw/
ws
1
2
sw
0,5²
rt
0,5²
gn/ws
0,75²
br
0,5²
rt
4²
rt/sw
0,5²
F3
A
E
IPCU
85
86
br
0,5²

VW Passat
1317226C_EN 12
1Angle bracket
2Original vehicle bolt
Mounting
fuseholder
in passen-
ger com-
partment
Connectthe wiring harnessof thefuse holder
in passenger compartment 2to the wiring
harness of heater 1according to the wiring di-
agram, with same colour wires connected to
each other. Connect-
ing wiring
harnesses
Connection to 6-pin connector T6be 2from
the fan unit. Produce connections as shown
in wiring diagram.
1Black/white (sw/ws) wire from 6-pin con-
nector T6be pin 2
3Black/white (sw/ws) wire from A/C control
unit
Red (rt) wire of IPCU/E
Black (sw) wire of IPCU/A
Connect-
ing fan unit
12
2
1
13
1
2
14
1 2
31
2

VW Passat
1317226C_EN 13
Digital timer
1Digital timer
Mounting
digital tim-
er
Remote option (Telestart)
Degrease adhesive area. Fasten receiver 1
with adhesive tape.
Mounting
receiver
1Antenna
Mounting
antenna
Temperature sensor T100 HTM
Fasten temperature sensor 1with adhesive
tape.
Mounting
tempera-
ture sensor
1
15
1
16
1
17
1
18

1317226C_EN 14
VW Passat
Preparing installation location
Pull out connector and put it aside. Remove
retaining plate 1, will be remounted later.
Removing
retaining
plate
1Wiring harness of heater
Routing
wiring har-
ness
1Discard section
2Hose section
Shorten-
ing hose
section
Remove clip for coupling line, will be reused
(petrol and diesel manual transmission only).
Slide 20mm moulded hose 1on original vehi-
cle stud bolt (on frame side member over the
transmission). Mounting
hose sec-
tion
19
1
20
1
1
21
20
1
2
22
1

1317226C_EN 15
VW Passat
2.0 TSI and 2.0 D Manual transmission
Premount clip of coupling line 1on hose
bracket 2- only with petrol and diesel manual
transmission.
1M6x12 countersunk head screw Preparing
hose
bracket
Preparing heater
1Water connection piece, sealing ring [2x
each]
25x15mm self-tapping bolt, retaining plate
of water connection piece Mounting
water con-
nection
pieces
1Bracket section A
25x13 self-tapping bolt [3x]
Mounting
bracket
section A
Discard section X.
1Exhaust pipe
a = 470
2Exhaust end section
b = 45 Preparing
exhaust
pipe
23
12
24
1
1
2
2
25
2
1
2
a b
1 2
X

VW Passat
1317226C_EN 16
1Exhaust pipe
2Hose clamp
Mounting
exhaust
pipe
1Hose clamp
2Silencer
3M6x16 bolt, spring lockwasher
Mounting
silencer
1Exhaust end section
2Hose clamp
Mounting
exhaust
end sec-
tion
1Bracket section B
25x13 self-tapping bolt [2x]
Mounting
bracket
section B
26
1
2
27
2
3
1
28
2
1
29
22
1

1317226C_EN 17
VW Passat
151mm dia. clamp
2Mount M5x16 bolt, flanged nut loosely
Mounting
combus-
tion air
pipe
1Combustion air pipe
225 mm dia. clamp
3Tighten M5x16 bolt, flanged nut
4Intake silencer
Mounting
combus-
tion air
pipe
1.4 TSI and 2.0 D
Hose Eis used only for 1.4 TSI.
Discard section X.
Hose B= 18mm dia. 90° moulded hose
Hose E= 20 mm dia. moulded hose 180°
A=1050
C=65
D=1130
Cutting
hoses to
length
1.4 TSI
1Discard section
Cutting
hose E to
length
30
1
2
31
2
1
4 3
AX C
EB
X
D
32
E
42
1

1317226C_EN 18
VW Passat
2.0 TSI
Discard section X.
Hose A= 20mm dia. 180° moulded hose
Hose C= 18mm dia. 90° moulded hose
B=960
D=65
E=1050
Cutting
hoses to
length
1Discard section [2x]
Cutting
hose A to
length
1.4 TSI / 2.0 D = hoses Aand D
2.0 TSI = hoses Band E
Slide on braided protection hoses and cut to
length. Cut heat shrink plastic tubing to
length.
150 mm long heat shrink plastic tubing [4x] Preparing
hoses A
and D
1.4 TSI / 2.0 D = hose C
2.0 TSI = hose D
All spring clips = 25mm dia.
1Mount wiring harness of circulating pump
2Mounting of circulating pump
3Circulating pump Mounting
hose and
circulating
pump
BX D
AC
X
E
33
A
48
1
58
1
A/B
D/E
1
11
1
34
C/D
2
1
3

1317226C_EN 19
VW Passat
1.4 TSI / 2.0 D = hose D
2.0 TSI = hose E
All spring clips = 25mm dia.
Mounting
hose of
heater out-
let
All vehicles
190° moulded hose, 10mm dia. clamp [2x]
2Fuel line
Premount-
ing fuel
line
Installing heater
1Angle down perforated bracket
2Drill 8.5mm dia. hole
Preparing
perforated
bracket
Figure shows diesel with manual transmis-
sion (SG).
Route hose Dto brake booster
1Original vehicle stud bolt, angled down
perforated bracket, M8 flanged nut
2Bracket section AMounting
heater
35
D/E
36
1
2
75
82
90°
1
2
37
1 D
2

1317226C_EN 20
VW Passat
Diesel with direct gear transmission
(DSG)
Ensure sufficient distance from neighbouring
components, especially between exhaust si-
lencer and direct gear transmission (DSG) at
position 1(25mm), correct if necessary. Mounting
heater
All vehicles
If stud bolt is not available at position 1, copy
hole pattern from bracket, drill 8.5mm dia.
holein cross memberand fastenbracket with
M8x20 bolt and flanged nut.
1Original vehicle stud bolt, M8 flanged nut
2Bracket section B
Mounting
heater
1Wiring harness of heater [2x]
Connect-
ing wiring
harness
38
1
39
1
2
40
1
1