Webasto Thermo Top E Operator's manual

Water Heater
Installation documentation
Ident. No.: 1314421C_EN Fee Euro 10.00 © Webasto AG
VW Golf VI, Golf Plus, Golf Variant
1.2 and 1.4 TSI
from Model Year 2008
Left-hand drive vehicle
Feel the drive
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.
Webasto does not accept any liability for defects and damage that are attributable to installa-
tion by untrained staff.
Thermo Top E Parking Heater
e1
00 0003
Thermo Top C Parking Heater
e1
00 0002
Thermo Top P Parking Heater
e1
00 0104

VW Golf VI, Golf Plus, Golf Variant
1314421C_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 a digital timer and summer/winter switch should be confirmed with the end
customer before installation.
Manufacturer Model Type EG-BE No./ABE
VW Golf VI 1K e1 * 2001/116 * 0242 * ...
VW Golf Plus 1KP e1 * 2001/116 * 0304 * ...
VW Golf Variant 1KM e1 * 2001 / 116 * 0328 * ...
Engine type Engine model Output in kW Displacement in cm³
CBZA Petrol/TSI 63 1197
CBZB Petrol/TSI 77 1197
CAXA Petrol/TSI 90 1390
CAVD Petrol/TSI 118 1390
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
Electrical system 6
Fuse holder and K3 relay 7
Climatic fan control 8
Climatronic fan control 10
Digital timer, summer/winter switch option 13
Remote option (Telestart) 13
Premounting heater 15
Preparing exhaust system 16
Installing heater 17
Fuel 18
Coolant circuit 21
1.2 Manual transmission 22
1.4 90kW manual transmission 24
1.4 90kW DSG 27
1.4 118 kW manual transmission 31
All vehicles 35
Exhaust gas 36
Final Work 37
Reduce sensitivity of passenger compartment
monitoring 37
Operating Instructions for End Customer 38

VW Golf VI, Golf Plus, Golf Variant
1314421C_EN 3
Heater/Installation Kit
Also required with Climatronic:
Heater recommended for the respective vehicle class:
The selection of the heater is based on the passenger compartment size of the vehicle and the level of
comfort required by the customer.
Foreword
This installation documentation applies to the vehicles VW Golf VI, Golf Plus, Golf Variant 1.2 and 1.4
TSI - for validity, see page 2 - from model year 2008 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 docu-
mentation.
However, the stipulations in the "installation documentation", the "operating instructions" and the "in-
stallation 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 technology. Unless spec-
ified otherwise, fasten hoses, lines and wiring harnesses to original vehicle lines and wiring harnesses
using cable ties.
Sharp edges should be fitted with rub protection (split-open plastic 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
- Metric thread-setter kit
Quantity Description Order No.:
1 Retail accessories Thermo Top E / C / P See price list
1 Installation kit for VW Golf VI, Golf Plus, Golf Variant 1.2 and
1.4 TSI 1314420B
1 Heater control See Price list
Quantity Description Order No.:
1 IPCU Kit for Climatronic 9013645A
Vehicle Heater
Compact car Thermo Top E
Mid-size car, station wagon Thermo Top C
Full-size car, van, offroader Thermo Top P

VW Golf VI, Golf Plus, Golf Variant
1314421C_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.
All dimensions are in mm!
Tightening torque of hose clamps = 2.0 + 0.5 Nm!
Tightening torque of Ejot screws, Ejot studs = 10 Nm!
Mechanical system
Electrical system
Coolant circuit
Fuel
Exhaust gas
Combustion air
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 Golf VI, Golf Plus, Golf Variant
1314421C_EN 5
Preliminary Work
WARNING!
- Open the fuel tank cap, ventilate the tank.
- Close the fuel tank cap again.
- Depressurise 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.
- Completely remove the battery with the battery carrier.
- Remove the engine cover.
- Detach the coolant reservoir cap.
- Remove the left front wheel.
- Remove the front section of the left front wheel well trim.
- Remove the left-hand front fog light or, on vehicles without front fog lights, the left-hand cover.
- Remove the underride protection
- Remove the right-hand underbody trim.
- Remove the rear bench seat.
- Open the right-hand tank-fitting 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
Remove page 38 "Operating Instructions for End Customer" and add to the vehicle operating instruc-
tions.
Heater installation location
1Heater
Installa-
tion loca-
tion
1
1

VW Golf VI, Golf Plus, Golf Variant
1314421C_EN 6
Electrical system
Wiring harness routing
Route excess lengths from wiring harness 1in
cable duct 2below battery and secure with cable
ties.
Wiring harness pass through
1Original vehicle wiring harness pass through
Wiring har-
ness rout-
ing
diagram
Fuse holder, K3 relay
Description of installation for K3 relay 1and fuse
carrier 2on Page 7
Wiring harness pass through
1Original vehicle wiring harness pass through
2
1
22
3
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
4
2
1
5
1

VW Golf VI, Golf Plus, Golf Variant
1314421C_EN 7
Fuse holder and K3 relay
Countersink holes 3from behind for M5 coun-
tersunk head screws.
1Cover of fuse/relay carrier in engine com-
partment
2Cut away bar in shaded area
35 mm dia. hole [2x]
Holes in
cover
1M5x12 countersunk head screw [2x]
Installing
fuseholder
and relay
K3
On vehicles with Climatronic, replace 25 A
fuse F3 7with 3 A fuse provided.
1M5 flanged nut
2Large diameter washer (between cover
and retaining plate)
3Retaining plate
4M5 flanged nut
5Relay K3
6Fuse holder
Installing
fuseholder
and relay
K3
Route brown (br)earthwireto original vehicle
earth support point below headlight and con-
nect.
1Fuse/relay carrier
2Original main vehicle fuse
3Red (rt) positive wire Connect-
ing posi-
tive and
earth wire
1
6
3
2
3
20
40
9
9
7
11
6
2
3
8
74
5
1
21
3
9

VW Golf VI, Golf Plus, Golf Variant
1314421C_EN 8
Climatic fan control
Climatic
wiring dia-
gram
Webasto components Vehicle components Colours and symbols
Legend
HG Heater TT-C/P/E GM Fan motor rt red
X1 6-pin heater connector F1*Fuse 40A (depending on respec-
tive fuse assignment)
Golf VI = SC22 or SC40
Golf Plus = SC33
ge yellow
F3 25 A fuse sw black
K3 Fan relay ** Wire depends on
the respective vehi-
cle equipment
Golf VI = red/yellow
(rt/ge)
Golf Plus = red yel-
low (rt/ge) or
black/yellow (sw/ge)
J301 Control unit of air conditioning
T5 5-pin connector J301
N24 Resistor group
T4f 4-pin connector N24
T10k Connector
XCutting point
Wiring colours may vary.
sw
Webasto
31
30
15
VW
rt
HG
4
X1 F3 F1
86
85 30
87a87
K3
4²
4²
3241 T4f
N24
J301
5T5
3214 T5
1
2V2
M
br
rt/sw
rt/
sw
ge rt/
ge sw/
ws
rt/
sw
4²
rt/ws
rt/ge 4² T10k
2
**
*SC22/SC40
(SC33)
(sw/ge) 4²

VW Golf VI, Golf Plus, Golf Variant
1314421C_EN 9
Golf VI and Variant
Connection on fuse carrier 2(instrument pan-
el at upper left). Remove red/yellow (rt/ge) 4²
wire 1on fuse output SC 22 or SC40 (de-
pending on respective vehicle equipment). Connec-
tion to fuse
carrier
Red (rt) wire 4from K3/87a with crimped-on
standard power timer interlocked in fuse out-
put SC 22 or SC40.
Produce connections as shown in wiring dia-
gram.
1Red/yellow (rt/ge) wire of fuse SC22 or
SC40
2AMP housing
3Black (sw) wire to K3/30
Connect-
ing wires
Golf Plus
Connection on fuse carrier 1(instrument pan-
elatbottomleft).Removered/yellow(rt/ge)4²
wire 2on fuse output SC33 (depending on re-
spective vehicle equipment). Connec-
tion to fuse
carrier
Red (rt) wire 1from K3/87a with crimped-on
standard power timer interlocked in fuse out-
put SC33.
Produce connections as shown in wiring dia-
gram.
2AMP connector
3Red/yellow (rt/ge) wire from fuse S33
4Black (sw) wire to K3/30
Connect-
ing wires
10
2
1
11
1
2
4
3
1
12
2
13
1
3
2
4

VW Golf VI, Golf Plus, Golf Variant
1314421C_EN 10
Climatronic fan control
Climatron-
ic wiring
diagram
Webasto components Vehicle components Colours and symbols
Legend
HG Heater TT-C/P/E F1*Fuse 40A (depending on re-
spective fuse assignment) of
SC22 or SC56
rt red
X1 6-pinheater connector ws white
K3 Fan relay sw black
F3 Replace 25 A fuse
with 3 A fuse T10k Plug connections br brown
J255 Climatronic control unit gn green
IPCU Pulse width modulator T16d 16-pin connector J255 ge yellow
J126 Fan controller
IPCU adjustment values: V2 Fan motor bl blue
Duty cycle: 30% T6t 6-pin connector J126 Insulate wire ends and
tie back
Frequency: 400Hz
Voltage: 8V XCutting point
Function: High side Wiring colours may vary.
Webasto
31
30
15
VW
F3
86
85 30
87a87
K3
HG
X1 4
!
rt
4²
J126
M
T6t
3412
V2
br
J255
T16d
1516
sw/
ws bl/ ws
0,35² 0,35²
86 85
A
E
IPCU
sw
4²
gn/ws
br
2T10k
F1
sw/
ws
0,35²
rt
sw/ws
rt/ws
4²
rt/
ge
4²
rt
0,75²
0,75²
SC22/
SC56
*

VW Golf VI, Golf Plus, Golf Variant
1314421C_EN 11
Golf VI and Variant
Produce connections as shown in wiring dia-
gram.
Position of free sockets depends on respec-
tive vehicle equipment.
Note:
Attach IPCU socket 1with cable ties for new
shape of the fuse carrier.
1IPCU socket
Installing
IPCU sock-
et
Insulate red (rt) wire K3/87a 1and tie back.
Produce connections as shown in wiring dia-
gram.
2AMP connector
3Brown(br)wireofIPCU/85,originalvehicle
earth support point
4Green/white (gn/ws) wire of IPCU/86
5IPCU mounted
6Black (sw) wire from K3/30
Connect-
ing IPCU
Golf Plus
Insulate red (rt) wire K3/87a 2and tie back.
Produce connections as shown in wiring dia-
gram.
Position of free sockets depends on respec-
tive vehicle equipment.
Note:
Attach IPCU socket 1with cable ties for new
shape of the fuse carrier.
1IPCU socket
3Black (sw) wire from K3/30
4Green/white (gn/ws) IPCU/86
Installing
wiring har-
ness of Cli-
matronic
Brown (br) wire from IPCU/85 to original vehi-
cle earth point.
1IPCU mounted
2Wiring harness of IPCU Connect-
ing wires
14
1
1
15
3
2
5
6
4
16
1
4
3 2
17
1
2

VW Golf VI, Golf Plus, Golf Variant
1314421C_EN 12
Route wiring harness IPCU 2along cross
member 1to centre console.
Routing
wiring har-
ness from
IPCU
All vehicles
Route wiring harnessof IPCU 1tocentre con-
sole.
Routing
wiring har-
ness from
IPCU
2Route wiring harness of IPCU 1to fan unit.
Connection on connector of fan unit 1.
2Black/white (sw/ws) wire of connector
T6t/2
3Black/white (sw/ws) wire of IPCU/A
4Red (rt) wire of IPCU/E
5Black/white (sw/ws) wire of A/C control
panel
Connect-
ing fan unit
18
2
1
2
1
19
1
1
20
2
5
43

VW Golf VI, Golf Plus, Golf Variant
1314421C_EN 13
Digital timer, summer/winter
switch option
Golf VI and Variant
1Digital timer
212 mm dia. hole; summer/winter switch Digital tim-
er
Golf Plus
1Digital timer
212 mm dia. hole; summer/winter switch
Digital tim-
er
Remote option (Telestart)
Golf VI and Variant
Drill out bracket 3to 6.5 mm dia. at position 1.
1Existing hole, M6x20 bolt, flanged nut
2Receiver
Installing
receiver
1Antenna
Installing
antenna
1
21
2
1
22
2
23
1
3
2
124

VW Golf VI, Golf Plus, Golf Variant
1314421C_EN 14
Golf Plus
Bend down lower tab of bracket by 90° and
drill out hole to 6.5 mm dia. as shown.
1Receiver
2Bracket
3M6 bolt, large diameter washer (between
bracket instrument carrier), large diameter
washer (from outside), flanged nut
4Instrument carrier, existing hole
Installing
receiver
1Antenna
Installing
antenna
Temperature sensor T100 HTM
Figure shows Golf VI.
Fasten temperature sensor 1with double-sid-
ed adhesive tape. Installing
tempera-
ture sensor
25
1
2
3
4
1
26
27
1

1314421C_EN 15
VW Golf VI, Golf Plus, Golf Variant
Premounting heater
1Ejot stud
Premount-
ing heater
1Combustion air pipe
a = 250
Discard section X
Cutting
combus-
tion air
pipe to
length
Insert one washer each between heater and
bracket at positions 2.
1M6x30 spacer nut
2Ejot screw, washer [2x each]
327 mm dia. hose clamp
4Combustion air pipe
5Bracket
Premount-
ing heater
1Strut
2Ejot screw [2x]
3Silencer
4Retaining clip in hole
5Combustion air pipe
6Hose section, 10 mm dia. hose clamp [2x]
7Fuel line Premount-
ing heater
28
1
a
1
X
29
1
5
2 3
2
4
30
1
3
2 2
4567

VW Golf VI, Golf Plus, Golf Variant
1314421C_EN 16
Preparing exhaust system
1Exhaust pipe
a = 190
2Exhaust end section
b = 240
Discard section X
Cutting ex-
haust pipe
to size
Slide insulation 2onto exhaust pipe.
1Hose clamp [2x]
Premount-
ing ex-
haust pipe
1Hose clamp
2Silencer
3M6x16 bolt, spring lockwasher on spacer
nut
4Exhaust end section
5Red (rt) protective rubber isolator Premount-
ing silenc-
er and
exhaust
end sec-
tion
1Exhaust end section
Aligning
exhaust
end sec-
tion
a b
1 2
X
31
1
2
1
32
4
5
321
33
1

1314421C_EN 17
VW Golf VI, Golf Plus, Golf Variant
Preparing installation location
Preventlarge diameterwasherfromfallingby
securing with putty etc.
1Large diameter washer on original vehicle
stud bolt [3x]
2100 mm edge protection
Preparing
installa-
tion loca-
tion
Installing heater
1Large diameter washer, flanged nut M8
[3x]
Installing
heater
Ensure freedom of movement of exhaust sys-
tem in relation to original vehicle components
and lines.
1Exhaust pipe
2Originalvehicle wiring harnesses(secured
with cable ties)
3Horn
Aligning
exhaust
system
Punch through perforation of heater cover at
position 2. Mount clip cable tie 2and fasten
wiring harness of heater 1.
3Cable tie
450 mm edge protection Connect-
ing wiring
harness
34
1
1
12
35
1
1
1
36
2
2
3
1
37
1
2
4
3

VW Golf VI, Golf Plus, Golf Variant
1314421C_EN 18
Fuel
CAUTION!
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.
Install fuel line and metering pump wiring harness so that they are protected against 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 as shown in the wiring harness rout-
ing diagram.
1Fuel line
Installing
fuel line
Route fuel line and wiring harness of meter-
ing pump 2in coolant reservoir to right and
fasten on original vehicle lines with cable ties.
Pay particular attention to freedom of move-
ment of wiper linkage.
Route fuel line and wiring harness of meter-
ing pump to underbody in wiring duct.
2Existing pass through [2x]
Installing
lines
Route fuel line and wiring harness of meter-
ing pump along original vehicle fuel lines 2to
fuel tank.
1Line duct Installing
lines
38
1 1 1
39
11
22
1
1
12
40

VW Golf VI, Golf Plus, Golf Variant
1314421C_EN 19
1Silent block, large diameter washer, M6
flanged nut
2Sealing plug removed
Installing
silent
block
1Wiring harness of metering pump, connec-
tor mounted
2Secure rubber-coated p-clamp on silent
block with flanged nut
3Metering pump
4Plug remounted
5Hose section, 10 mm dia. hose clamp [2x]
6Fuel line
Installing
metering
pump
1Standpipe
2Moulded hose
Cutting
standpipe
and mould-
ed hose to
length
10 mm dia.Caillau clamp 2incentre between
beads on end of standpipe.
1Standpipe
3Moulded hose Premount-
ing stand-
pipe and
moulded
hose
41
1
2
42
1
5
6
2 3
4
1 2
43
235
10
4.5mm dia.
7.5mm dia.
44
123
7.5mm dia.
4.5mm dia.

VW Golf VI, Golf Plus, Golf Variant
1314421C_EN 20
Cut 3 mm off blind plug 1.
2Fuel-tank sending unit
Cutting off
blind plug
Ensuresufficientdistance fromadjacent com-
ponents, especially from fuel gauge.
113.5mm dia. Caillau clamp
2Fuel line
310 mm dia. Caillau clamp
4Moulded hose with standpipe Connect-
ing fuel-
tank send-
ing unit
1Hose section, 10mm dia. hose clamp [2x]
2Fuel line
Connect-
ing meter-
ing pump
1
45
2
46
1
2
4
3
47
2
1