Webasto Thermo Top C User manual

Water Heater Unit
Installation Instructions
WARNING!
Hazard warning:
Incorrect installation or repair of Webasto heating systems may cause a fire or result
in the emission of carbon monoxide, which can be fatal. Serious or fatal injuries can
be caused as a result.
Specialist company training, technical documentation, specialized tools and
equipment are required to install and repair Webasto heating and cooling systems.
NEVER attempt to install or repair Webasto heating or cooling systems if you have not
successfully completed the company training and thereby acquired the required
technical skills, or if you do not have access to the required technical documentation,
tools and equipment needed to carry out correct installation and repairs.
ALWAYS follow all Webasto installation and repair instructions and observe all
warnings.
Webasto does not accept any liability for defects and damage that are attributable to
installation by untrained staff.
Feel the drive
Seat Leon
Gasoline
from Model Year 2005
Left-hand drive vehicle
Not with "SEAT Sport" aerodynamics kit
Thermo Top C Additional Heater
Thermo Top P Additional Heater
Thermo Top E Additional Heater
e1
00 0002
e1
00 0104
e1
00 0003
Ident. No.: 1311820B_EN Fee Euro 10 © Webasto AG

2
Seat Leon
Validity
Vehicle and engine types, equipment variants and national specifications not listed in these installation
instructionshavenotbeentested.However, installationaccordingtotheseinstallationinstructionsmay
be possible.
The installation location of a digital timer and summer/winter switch should be confirmed with the end
customer before installation.
Manufacturer Model Type EG-BE No./ABE
Seat Leon 1P e1 * 2001 / 116 * 0052
Engine type Engine model Output in kW Displacement in cm³
BSE Gasoline 75 1595
BVY Gasoline 110 1984
Validity 2
Heater Unit/Installation Kit 3
Foreword 3
General Instructions 3
Special Tools 3
Explanatory Notes on the Document 4
Preliminary Work 5
Heater Unit Installation Location 5
Fuse holder and relay K3 6
Electrical Connections 7
Climatic fan controller 8
Climatronic fan controller 10
Remote option (Telestart) 13
Remote option (Thermo Call) 14
Preassembling heater unit 15
Preassemble exhaust system 15
Combustion air 16
Preparing installation location 17
Installing heater unit 18
Combustion air connection 22
Fuel Connection 23
Fuel removal 24
Coolant connection 26
Final Work 30
Operating Instructions for End Customer 31
Table of Contents

33
Seat Leon
Heater Unit/Installation Kit
Also required:
Also required with Climatronic:
Heater unit recommended for the respective vehicle class:
The selection of the heater unit is based on the passenger compartment size of the vehicle and the
level of comfort required by the customer!
Foreword
These installation instructions apply to Seat Leon vehicles with a Gasoline engine - for validity, see
page 2 - from model year 2005 and later, assuming technical modifications to the vehicle do not affect
installation, any liability claims excluded. Depending on the vehicle version and equipment,
modifications may be necessary during installation with respect to these installation instructions.
However,thestipulations in the "installationinstructions"and"operatingandmaintenanceinstructions"
for the Thermo Top C/P/E must always be observed.
The corresponding rules of technology and any information from the vehicle manufacturer should be
observed during the installation work.
General Instructions
Installation should be carried out according to the general, standard rules of technology. Unless
specified otherwise, fasten hoses, lines and wiring harnesses to original vehicle lines and wiring
harnesses using cable ties.
Sharp edges should be fitted with edge protectors (split-open plastic hose).
Spray unfinished body areas, e.g. drilled holes, with anti-corrosion wax (Tectyl 100K, Order No.
111329).
Special Tools
- Torque wrench for 2.0 - 10 Nm
- Hose clamping pliers
- Metric thread-setter kit
Quantity Description Order No.:
1 Retail accessories with desired heater control See price list
1 Installation kit for Seat Leon Gasoline 1311798A
Quantity Description VW Order No.:
1 Washer reservoir for vehicles with additional heater 1K6 955 453H
1 Plug 8E0 955 465A
1 Plug 444 955 647
1 Seal 431 955 465A
Quantity Description Order No.:
1 IPCU Kit for Climatronic 9013645A
Vehicle Heater unit
Compact car Thermo Top E
Mid-size car, station wagon Thermo Top C
Full-size car, van, offroader Thermo Top P

44
Special features are highlighted using the following symbols:
Mechanical work
Electrical connection
Coolant connection
Fuel connection
Exhaust system
Combustion air
The arrow in the vehicle icon indicates the position on
the vehicle and the viewing angle.
Seat Leon
Specific risk of injury or fatal accidents.
Specific risk of damage to components.
Specific risk of fire or explosion.
Reference to general installation instructions of
Webasto components or to the manufacturer's vehicle-
specific documents.
Reference to a special technical feature.
i
Explanatory Notes on Document
To 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.

5
Seat Leon
Heater unit installation location
1Heater unit
Installation
location
1
1
Preliminary Work
WARNING!
- Open fuel tank cap, ventilate tank.
- Close the tank cap again.
- Depressurize the cooling system.
- Copy the factory number from the original type label to the duplicate type label.
- Remove years that do not apply from the duplicate label.
- Attach the duplicate label (type label) in the appropriate place.
- Disconnect the battery "earth" or "ground" connection.
- Only 2.0 FSI: Remove the air filter together with the intake hose.
- Remove the battery.
- Remove the battery carrier.
- Remove the engine cover.
- Remove the right front wheel.
- Remove the front section of the right front wheel well trim.
- Remove the underride protection
- Remove the bumper.
- Remove the right-hand underbody trim
- Remove the right rear seat
- Open the right-hand fuel sender service lid.
- Remove the footwell trim on the driver's side
- Remove the lower instrument panel trim on the driver's side
- Only vehicles with Climatronic: Remove the footwell trim on the front passenger side
Please remove page 31 “Operating instructions for the end customer” and add this to the vehicle
operating instructions.

6
Seat Leon
Fuse holder and relay K3
Countersink holes 3from behind for M5
countersunk head screws.
1Cover of fuse/relay carrier in engine
compartment
2Cut away bar in shaded area
3Drill 5.0 mm dia. hole [2x]
Holes for
fuse
holderand
K3 relay
1 M5x12 countersunk head screw [2x]
Installing
fuseholder
and K3
relay
On vehicles with Climatronic, replace 25 A
fuse F3 with 3 A fuse.
1Large diameter washer (between cover
and retaining plate)
2Retaining plate, M5 flanged nut
3K3 relay, M5 flanged nut
4Fuse holder
5F3 fuse Installing
fuseholder
and relay
K3
Connect brown (br) ground wire to original
vehicle ground support point.
1Fuse/relay carrier
2Red (rt) positive wire
Connect-
ing posi-
tive and
ground
wire
1
2
40
99
3
20
2
3
3
11
4
1
2
4
5
3
21
5

7
Seat Leon
Electrical Connections
Wiring harness of heater unit
Route the wiring harness of the heater unit along
the original vehicle wiring up to the right-hand
headlight.
Fuse holder
1Relay K3
2Fuse holder
3Route wiring harness of heater control, fan
controller and metering pump in cable duct to
firewall.
Diagram of
wiring
harness
routing for
all
equipment
Wiring harness pass through
1Original vehicle wiring harness pass through
2Wiring harnesses for fan controller and heater
control
Wiring harness pass through
2Original vehicle wiring harness pass through
1Wiring harnesses for fan controller and heater
control
6
2
3
3
7
1
3
rtbr +
-
br
bl
rt sw
Wait until later to install wiring
harness for metering pump
i
8
1
2
1
29

8
Seat Leon
Climatic fan controller
1Unlock 40 A fan fuse, remove 4mm² black
(sw) wire
2Fuse carrier
2Uncrimp-
ing wire
Produce connections as shown in wiring
diagram.
14 mm² black (sw) wire
2AMP/housing
3Red (rt) wire to K3/87a
4Black (sw) wire from K3/30
Connect-
ing wires
1
10
2
11
1
4
2
3
2

9
Seat Leon
Climatic
wiring
diagram
Webasto components Components of Seat Leon Colors and symbols
Legend
HG Heater unit TT-C/E KB Climatic control unit rt red
X1 6-pin connector WG Resistor group ws white
F3 25 A fuse F1 Fuse 40A sw black
K3 Fan relay GM Fan motor br brown
gn green
XCutting point
Wiring colors may vary.
sw
br
rt/ws
Webasto
31
30
15
Seat Leon
rt
sw
br
rt/sw
WG
rt/ws
sw
gn/ws
rt/ws
T10c/2
HG
4
X1
+
-GM
M
F3 F1
86
85 30
87a87
K3 T5
31 24
T4r
34 21
KB
5T5
i

10
Seat Leon
Climatronic fan controller
Positionoffreesockets dependentonvehicle
equipment!
1IPCU socket
2Red (rt) and black (sw) wire from IPCU
3Green/white (gn/ws) wire of IPCU/86 with
connector IPCU
socket
Brown (br) wire from IPCU/85 to original
vehiclegroundpoint.Produceconnectionsas
shown in wiring diagram.
1IPCU
Connect-
ing wires
1Air duct
2IPCU wiring harness
Routing
wiring
harness
forIPCUto
right
1IPCU wiring harness
2Fan unit
Routing
wiring
harness to
fan unit
12
1
3
2
13
1
14
1
2
15
1 2

11
Seat Leon
If necessary, disconnect fan unit in
accordance with manufacturer's instructions.
Produce connections as shown in wiring
diagram.
1Wiring harness from IPCU
2Black/white (sw/ws) wire from IPCU/A
3Red (rt) wire from IPCU/E
4Black/white (sw/ws) wire from Climatronic
control unit
5Black/white (sw/ws) wire to connector Connect-
ing wires
Picture shows version without having to
disconnect fan unit.
1Black/white (sw/ws) wire from IPCU/A
2Black/white (sw/ws) wire to connector
3Black/white (sw/ws) wire from Climatronic
control unit
4Red (rt) wire from IPCU/E
5Wiring harness from IPCU Connect-
ing wires
3 42
16
1
5
i
17
3
5
4
1 2

12
Seat Leon
Climatron-
ic wiring
diagram
Webasto components Vehicle components Colors and symbols
Legend
HG Heater unit TT-C/E KB Climatronic control unit rt red
X1 6-pin heater unit
connector ge Fan unit ws white
K3 Fan relay F1 Fuse 40A sw black
F3 Fuse (25 A replaced
with 3 A) br brown
gn green
IPCU Pulse width modulator ge yellow
bl blue
IPCU adjustment values
Voltage: 8 V
Frequency: 400 Hz Insulate wire end
and tie back
Duty cycle: 30 %
Function: High-side XCutting point
HG
X1 4F3
86
85 30
87a87
K3
rt/ws
gn/
ws
F1
Webasto
31
30
15
Seat Leon
!
86 85
A
E
IPCU
GE M
1 4 32
KB
15 16
rt/ws
rt/ge
br
sw/ws
sw/
ws
sw/ws
rt
sw gn/ws
bl/
ws
i

13
Seat Leon
Remote option (Telestart)
1M6x20 bolt, large diameter washer,
flanged nut
2Telestartbracket,holedrilledoutto6.5 mm
dia.
3Antenna connector
Installing
receiver
1Antenna
Installing
antenna
Temperature sensor only with HTM 100
1Fasten temperature sensor with suitable
means
Installing
tempera-
ture sensor
1
3 2 18
i
1
19
i
1
20
i

14
Seat Leon
Remote option (Thermo Call)
1Fasten receiver with suitable means
Installing
receiver
1Antenna
Installing
antenna
1
21
22
1

15
Seat Leon
Preassembling heater unit
Ejot stud, tightening torque 10 Nm.
1Adapter wiring harness connected
2Long Ejot screw
3Short Ejot screw
4Replace circulating pump cover with cover
with straight inlet Premount-
ing heater
unit
1Bracket
2M6x30 spacer nut, M6x16 bolt, spring
lockwasher
Preassem-
bling
bracket
Ejot screw bolt, tightening torque 10 Nm!
1Strut
2Flanged nut, loosely mounted
3Ejot screw, washer between heater unit
and bracket
Preassem-
bling heat-
er unit
Preassemble exhaust system
1Exhaust pipe
a = 520 mm
2Exhaust end section
b = 90 mm
Discard section XPreparing
exhaust
pipe
1
3
4
2
23
24
2
1
25
3
2 1
a B
1 2
X

16
Seat Leon
Shape exhaust pipe as shown in picture 26
and 27
1Red (rt) rubber profile [2x]
2Exhaust pipe
3Hose clamp [3x]
4Exhaust end section
5M6x16 bolt, spring lockwasher
6Exhaust muffler
Preassem-
ble ex-
haust
system
1M6x20 bolt, flanged nut
2P-clamp
Premount-
ing ex-
haust
system
Combustion air
1Combustion air pipe
a = 650 mm
Discard section XCutting
combus-
tion air
pipe to
length
Shape combustion air pipe as shown in
picture. Align strut 2in accordance with hole
pattern position 3.
1Hose clamp
4P-clamp, M6 flanged nut Preassem-
bling com-
bustion air
pipe and
strut
26
1
3
6
3
1
4
2
5
3
27
2
1
a
1
X
28
31 2
4

17
Seat Leon
Preparing installation location
Existing screws and nut will be reused!
1Cross member
Removing
washer
reservoir
and cross
member
Insert rivet nut 2only loosely, but do not rivet
in.
1Holes drilled out to 9 mm dia., M6 rivet nut
[2x]
2M6 rivet nut centered in oblong hole
Installing
rivet nuts
Drill out large diameter washer from inside
7 mm dia. to 9 mm.
130/2rivet nut, riveted in
2Large diameter washer, drilled out
Installing
rivet nut
Disconnect wiring harnesses 1for washer
reservoir, horn and front fog lights and wrap
individually with insulating tape.
Installing
wiring
harnesses
29
1
30
2
11
31
1
2
32
1

18
Seat Leon
Installing heater unit
Position replacement washer reservoir 2as
shown. Cut away cable duct 1at marking.
Installing
washer
reservoir
Loosely mount bolt 2and nuts 3!
15 mm shim
2M6x30 bolt, spring lockwasher
3Original vehicle nut [2x]
Installing
heater unit
Loosely mount original vehicle bolt 1.
Installing
heater unit
Loosely mount bolts at position 1.
1M6x20 bolt, large diameter washer,
flanged nut [2x each]
2Washer reservoir inserted in bracket
3Washer reservoir inserted in strut
4Combustion air pipe, p-clamp Installing
washer
reservoir
33
2
1
34
2
3
3
1
35
1
36
3
2
1
4
1

19
Seat Leon
1Drill out nut to 7 mm dia. [2x]
Preparing
cross
member
1Original vehicle bolts [2x]
2M6x20 bolt, spring lockwasher [2x each]
Installing
cross
member
Bracket 1will be reused.
Removing
bracket for
A/C line
19 mm dia. hole, M6 rivet nut
Installing
rivet nut
37
1 1
38
1 1
2 2
39
1
40
1

20
Seat Leon
16.5 mm dia. hole
Drilling out
bracket
150 mm edge protection
2Bracket laid on loosely
Installing
bracket
Loosely mount bolt 2!
1Strut
2M6x50 bolt, spring lockwasher, large
diameter washer
Installing
strut
Loosely mount Ejot screw 2.
1Strut
2Ejot screw
Installing
strut
41
1
42
2
1
43
2
1
44
21