Webasto Thermo Top E Operator's manual

Water Heater
Installation documentation
Ident. No.: 1314084D_EN Fee Euro 10.00 © Webasto AG
Skoda Superb
Diesel - Common Rail with direct shifting transmission (DSG)
from Model Year 2008
Left-hand drive vehicle
Saloon and Estate car
Adjustment of the sensitivity of passenger compartment monitoring was not checked
from model year 2010!
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.
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.
Thermo Top E Parking Heater
e1
00 0003
Thermo Top C Parking Heater
e1
00 0002
Thermo Top P Parking Heater
e1
00 0104

Skoda Superb
1314084D_EN 2
Table of Contents
Validity
Vehicle and engine types, equipment variants and national specifications not listed in these installation
instructions have not been tested. However, installation according to this installation documentation
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
Skoda Superb 3T e11 * 2001/116 * 0326 * ...
Engine type Engine model Output in kW Displacement in cm³
CBBB Diesel/Common Rail 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
Electrical system 6
Preparing fuse holder and K3 relay 7
Climatic fan controller 8
Climatronic fan controller 10
Remote option Telestart 12
Premounting heater 13
Premounting combustion air pipe 13
Premounting exhaust pipe 14
Premounting coolant hoses 15
Coolant circuit 18
Preparing hose routing 19
Hose routing 21
Preparing installation location 24
Installing heater 24
Fuel 27
Exhaust gas 30
Final Work 31
Adjusting the sensitivity of the
passenger compartment monitoring 31
Operating Instructions for End Customer 32

Skoda Superb
1314084D_EN 3
Heater / Installation Kit
To be ordered extra:
Also required for 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 Skoda Superb Diesel - Common Rail with direct shifting
transmission (DSG) vehicles - for validity, see page 2 - from model year 2008 and later, assuming tech-
nical 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 this "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. Insulate loose wires and tie back.
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).
Check or adjust the corresponding settings before installing an IPCU!
Special Tools
- Torque wrench for 2.0 - 10 Nm
- Hose clamping pliers
- Hole saw 42mm dia.
Quantity Description Order No.:
1 Retail accessories with desired heater control See price list
1 Installation kit for Skoda Superb Diesel - Common Rail with
direct shifting transmission (DSG) 1314083B
Quantity Description Order No.:
1 Additional bracket Skoda No.: 1Z0 810 679
2 Bolt Skoda No.: N90 749 003
1 Quick-release coupling VAG No.: 3B0 122 291 B
Quantity Description Order No.:
1 IPCU Kit for Climatronic 9013645A
Vehicle Heater
Compact car Thermo Top E
Mid-size car, estate car Thermo Top C
Full-size car, van, Offroader Thermo Top P

Skoda Superb
1314084D_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.
ReferencetogeneralinstallationinstructionsofWebas-
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
Software
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.

Skoda Superb
1314084D_EN 5
Preliminary Work
WARNING!
- Open the fuel tank cap, ventilate the tank.
- Close the fuel tank cap again.
- Disconnect the battery "earth" or "ground" 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.
- Remove the engine cover.
- Remove the charge-air hose.
- Remove the air filter together with the intake hose
- Completely remove the battery together with the carrier.
- Remove the cover of the fuse and relay box in the engine compartment.
- Remove the front left wheel.
- Remove the left-hand wheel well trim.
- 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 left-hand instrument panel trim.
- Remove the lower instrument panel trim on the front passenger side (only with Climatronic).
- Remove the lower instrument panel trim from the centre console (only with Climatronic).
- Provide Skoda additional bracket with corrosion protection according to VAG repair manual
Remove page 32 "Operating Instructions for End Customer" and add to the vehicle operating instruc-
tions.
Heater installation location
1Heater
Installa-
tion loca-
tion
11

Skoda Superb
1314084D_EN 6
Electrical system
Wiring routing
Route wiring harness of metering pump and fuel
line 1behind insulation mat to right-hand vehicle
side.
Digital timer and summer/winter switch op-
tion
1Digital timer
2Summer/winter switch, drilled hole 12 mm dia.
Wiring har-
ness rout-
ing
diagram
Wiring harness routing
Route wiring harnesses in original vehicle cable
duct 1.
Wiring harness pass through
1Protective rubber plug
2Wiring harnesses of fan controller and heater
control
2
11
3
1
2
Do not install the metering pump
wiring harness until later togeth-
er with fuel pipe along the origi-
nal vehicle fuel lines on the
underbody
4
1
5
2
1

Skoda Superb
1314084D_EN 7
Preparing fuse holder and K3 relay
Countersink 5.5 mm dia. hole [2x] 2from be-
hind.
1Cover of fuse and relay carrier Holes in
fuse carrier
Insulate wiring harness under the fuses with
PVC tape. Insert large diameter washer be-
tween cover and retaining plate 2.
1M5x12 countersunk head screw, large di-
ameter washer, flanged nut
3M5x12 countersunk head screw, flanged
nut
4K3 relay
5Fuses pushed on
Installing
fuseholder
and K3 re-
lay
1Original vehicle positive support point
2Positive wire
Positive
connection
1Earth wire
2Original vehicle earth support point
Earth con-
nection
6
1
9
9
9
9
2
2
40
7
3
4
5
21
1
2
8
2
1
9
2
1

Skoda Superb
1314084D_EN 8
Climatic fan controller
Wiring dia-
gram
Webasto components Vehicle components Colours and symbols
Legend
HG Heater TT-C/E V2 Fan motor rt red
X1 6-pin heater connector N24 Resistor group ws white
F3 Fuse, 25 A J301 A/C control panel sw black
K3 Fan relay T... Plug connections br brown
SC40 Fuse, 40A gn green
Detach wire end from
SC40
XCutting point
Wiring colours may vary.
Webasto
31
30
75
Skoda
F3
86
85 30
87a87
K3
HG
X1 4
SC
40
gn/ws rt/ws
br
4²
rt
sw/rt
sw/rt
J301
T5h
3214
5T5h
rt/ws
4²
sw
N24
3241 T4ac
12
V2
Mrt/sw
br
rt/
sw
rt/
sw
br
2
T10j
1
4²
4²
!

Skoda Superb
1314084D_EN 9
Detach fuse carrier 2and unlock contact lock.
Detach black/red (sw/rt) 4 mm² wire 1on fuse
output SC40.
Connect-
ing central
electrical
box
Mount red (rt) wire 4 K3/87a in fuse output SC40.
Produce connections as shown in wiring dia-
gram.
1Black (sw) wire from K3/30
2AMP housing
3Black/red (sw/rt) wire of fuse SC40 Connect-
ing central
electrical
box
10
2
1
11
1
4
32

Skoda Superb
1314084D_EN 10
Climatronic fan controller
Wiring dia-
gram
Webasto components Vehicle components Colours and symbols
Legend
HG Heater TT-C/E SC22 40 A fan fuse rt red
X1 6-pin heater connector T... Plug connections ws white
F3 Replace 25A fuse with
3A fuse. J126 Fan controller sw black
J255 A/C control panel br brown
K3 Fan relay V2 Fan motor gn green
IPCU Pulse width modulator bl blue
IPCU adjustment values:
Duty cycle: 30% Insulate wire end and tie
back
Frequency: 400Hz
Voltage: 8V XCutting point
Function: High-side active Wiring colours may vary.
Webasto
31
30
15
Skoda
F3
86
85 30
87a87
K3
HG
X1 4
gn/
ws !
br
rt
4²
sw
4²
86 85
A
E
IPCU
rt/ws
gn/
ws
br
SC
22
J126
T6ad 2 1 4
br
sw/rt
sw sw/ws
sw/
ws
rt
rt
sw/ws
3
bl/ws
J255
T16l 15 16
1 2
V2 M
2
T10j
1
rt/ws
br
sw/
rt

Skoda Superb
1314084D_EN 11
Produce connections as shown in wiring diagram.
Insert IPCU socket 1in free slot. Position of
freesocketsdependenton respectivevehicle
equipment.
Note:
If the shape of the IPCU socket fuse carrier 1
is new, fasten with cable ties.
2Black (sw) wire of IPCU/A
3Brown (br) wire of IPCU/85, cable lug
4Red (rt) wire of IPCU/E
5Green/white(gn/ws)wireofIPCU/86,AMP
connector
Installing
IPCU
1Original vehicle bolt
2Brown (br) wire of IPCU/85
Earth con-
nection of
IPCU
Insulate red (rt) wire of K3/87a 5and tie back.
Replace 25 A fuse F3 with 3 A fuse.
Produce connections as shown in wiring dia-
gram.
1Green/white (gn/ws) wire IPCU/86
2AMP connector
3Connect IPCU
4Black (sw) wire from K3/30
Connect-
ing IPCU
1Wiring harness of fan controller
Wiring
routing
12
1
4
5
3
2
13
2
1
14
1
5
4
32
1
1
1
15

Skoda Superb
1314084D_EN 12
Connection on 6-pin connector 1T6ad, Pin 2
from fan controller.
Produce connections as shown in wiring dia-
gram.
2Black/white (sw/ws) wire of 6-pin connec-
tor T6ad, Pin 2
3Black/white (sw/ws) wire from IPCU/A
4Red (rt) wire of IPCU/E
5Black/white (sw/ws) wire of A/C control
panel
Connect-
ing fan
controller
Remote option Telestart
1Apply double-sided adhesive tape
Fastening
receiver
Fastenreceiver 1withdouble-sidedadhesive
tape, secure with cable tie, if necessary.
Installing
receiver
1Antenna
Installing
antenna
16
1
4
2
5
3
117
18
1
1
19

1314084D_EN 13
Skoda Superb
Premounting heater
1Ejot screw [3x]
2Bracket
Premount-
ingbracket
on heater
Insert one washer each between heater and
strut 1at position 2.
2Ejot screw, washer
3Ejot stud Premount-
ingstruton
heater
Insert retaining clip 1 in existing hole of heater.
2Hose section, 10 mm dia. clamp [2x]
3Fuel line
Premount-
ing heater
Premounting combustion air pipe
1Combustion air pipe
a = 250
Discard section XCutting
combus-
tion air
pipe to
length
20
1
1
2
1
21
1
3 2
22
3
1 2
a
1
X

1314084D_EN 14
Skoda Superb
1Intake silencer
2Combustion air pipe
327 mm dia. clamp
Premount-
ing com-
bustion air
pipe
Premounting exhaust pipe
1Exhaust pipe
a = 365
2Exhaust end section
b = 125
Discard section X
Preparing
exhaust
pipe
1Exhaust silencer
2M6x20 bolt, large diameter washer, M6
flanged nut
3Angle bracket
Premount-
ing ex-
haust
silencer
1M6 flanged nut
Premount-
ing ex-
haust
system
23
1 2
3
a b
1 2
X
1
24
23
25
1

1314084D_EN 15
Skoda Superb
1Hose clamp [2x]
2Red (rt) rubber isolator
3Exhaust pipe
Premount-
ing ex-
haust
system
Punch through perforation at position 3.
1Exhaust end section
2Hose clamp
3Clip-type cable tie Premount-
ing ex-
haust
system
Premounting coolant hoses
Discard section X
B= 180
D= 170
E= 210 Cutting
hoses to
length
Hose A= 90° moulded hose, 15 mm dia.
Hose F= 90° moulded hose, 15 mm dia.
Hose C= 180° moulded hose, 20 mm dia.
Hose G= 30° moulded hose, 20 mm dia.
Preparing
hoses
26
1 2
1
3
27
1 2
3
BX D
XX
E
X
C
G
A
F

1314084D_EN 16
Skoda Superb
Push braided protection hoses onto hose A
and F.
Cut heat shrink plastic tubing to length.
150 mm long heat shrink plastic tubing [4x] Preparing
15mm dia.
hoses
115x20 connecting pipe
227 mm dia. spring clip [3x]
320x20 connecting pipe
Premount-
ingcoolant
hoses
115x20 connecting pipe
227 mm dia. spring clip [3x]
320x20 connecting pipe
Premount-
ingcoolant
hoses
127 mm dia. spring clip
Premount-
ing heater
A
F
11
1 1
C
2 2
1
2
3 B 28
D
E
1
2
2 23 29
30
D
1

1314084D_EN 17
Skoda Superb
= 400
= 1800
= 600
Cutting
fabric pro-
tective
hose to
length
Install and align coolant hoses.
Slide fabric protective hose onto fuel line.
127 mm dia. spring clip
Premount-
ing heater
120x20 mm hose bracket
25x20 mm hose bracket
Premount-
ing heater


B
31
C
ED
1

32
1
2

Skoda Superb
1314084D_EN 18
Coolant circuit
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 rout-
ing dia-
gram
All connecting pipes without a specific designation = dia. 20x20 mm. 1 =Original vehicle spring clip .
All spring clips without a specific designation = 27 mm dia.
2 = Black (sw) rubber isolator [2x]!
3 = 22 mm dia. spring clip
G1
Ø 15x20
Ø 15x20
F
A
B
C
D
E
3
3
22
Ø 15x20
Ø 15x20
3
3

Skoda Superb
1314084D_EN 19
Preparing hose routing
1Clip bracket 
2Hose bracket
Installing
hose
bracket
1Clip bracket 
2Hose bracket
Installing
hose
bracket
1Clip bracket 
2Hose bracket
Installing
hose
bracket
1Original vehicle nut
2Clip bracket 
Installing
clip brack-
et 
33
1
20
20
34
1
2
25¬
35
1
2
36
1
1

Skoda Superb
1314084D_EN 20
Precut thread of plastic nut 1on original vehi-
cle stud bolt.
Preparing
plastic nut
Remove bracket 1for connector 2and dis-
card. Fasten connector on original vehicle
wiring harness with cable tie.
Premount-
ingcoolant
hoses
Insert 10mm shim and 5mm shim between
body and angle bracket 3. Use M6x40 bolt 1
on threaded hole (if available), otherwise use
flanged nut.
1M6x40 bolt, spring lock washer, large di-
ameter washer, 10mm shim, 5mm shim,
flanged nut
2M6x30 bolt, pin lock
Premount-
ing angle
bracket
Remove coupling piece from heat exchanger
inlet 3and discard. Spring clip 2will be re-
used.
1Engine outlet hose section Cutting
point
37
1
21
38
2
1
39
3
40
1
3
2