Webasto Thermo Top E User manual

WARNING!
Hazard warning:
The 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.
To install and repair Webasto heating and cooling systems you need to have completed a
special company training course and have the appropriate technical documentation, special
tools and special equipment.
Only use genuine Webasto parts. See the Webasto air and water heaters accessories cata-
logue for this purpose.
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
Audi A4 / A5
2.7 and 3.0 TDI
Model year 2008 up to 2011
Left-hand drive vehicle
Automatic transmission
Automatic air-conditioning
Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE
Thermo Top E Parking Heater
e1
00 0002
Thermo Top C Parking Heater
e1
00 0003

Audi A4 / A5
Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE
Table of Contents
Validity
Vehicle and engine types, equipment variants and national specifications not listed in this installation
documentationhavenotbeentested.However,installationaccordingtothisinstallationdocumentation
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
Audi A4 B8 e1 * 2001 / 116 * 0430 * ...
Audi A5 B8 e1 * 2001 / 116 * 0430 * ...
Engine type Engine model Output in kW Displacement in cm³
CAMA Diesel 140 2698
CLAB Diesel 150 2967
CAPA Diesel 176 2967
CDUC Diesel 180 2967
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
Fan Controller 7
Digital Timer, Summer/Winter Switch Option 9
Remote Option (Telestart) 9
Preparing Heater 10
Preparing Installation Location 11
Installing Heater 12
Combustion Air 13
Coolant Circuit 3.0l 150KW / 180KW 14
Coolant Circuit 2.7l 140KW / 3.0l 176KW 17
Fuel 20
Exhaust Gas 24
Final Work 25
Adaptation of Climatronic J255 Control Unit 25
Operating Instructions for End Customer 26

Audi A4 / A5
Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE
Heater/Installation Kit
Foreword
This installation documentation applies to the vehicles Audi A4 / A5 2.7 and 3.0 TDI - for validity, see
page 2 - model year 2008 up to 2011 and later, assuming technical modifications to the vehicle do not
affect installation, any liability claims excluded. Depending on the vehicle version and equipment, mod-
ifications may be necessary during installation with respect to this installation documentation.
However, the stipulations in the "installation documentation", the "operating instructions" and "installa-
tion instructions" for the Thermo Top E / C 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, the appropriate settings must be checked and set prior to the installation.
Special Tools
- Torque wrench for 2.0 - 10 Nm
- Hose clamping pliers
- Metric thread-setter kit
- VAS tester (adjustment of Climatronic control unit)
Quantity Description Order No.:
1 Basic delivery scope for Thermo Top E / C See price list
1 Installation Kit for Audi A4 / A5 2.7 / 3.0 TDI with Automatic
Transmission 1313526B
1 Heater control See price list

Audi A4 / A5
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.
Mechanical system
Electrical system
Coolant circuit
Fuel
Exhaust gas
Combustion air
Software
All dimensions are in mm!
Tightening torque of hose clamps = 2.0 + 0.5 Nm!
Tightening torque of Ejot screws, Ejot studs = 10 Nm!
Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE 4
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.

Audi A4 / A5
Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE 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.
- 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.
- Remove the air filter together with the intake hose.
- Remove the coolant reservoir cap.
- Removing the filler neck of the washer fluid reservoir.
- Remove the cover of the fuse and relay box.
- Pull out the control unit and lay it aside.
- Detach the wheel well trim on the right and left.
- Remove the bumper.
- Remove the right-hand underride protection.
- Remove the 3-piece underbody cover.
- Remove the rear bench seat.
- Open the right-hand tank-fitting service lid.
- Remove the A/C control panel in accordance with the manufacturer's instructions.
- Remove the lower instrument panel trim on the driver's side.
Remove page 26 "Operating Instructions for End Customer" and add to the vehicle operating instruc-
tions.
Heater Installation Location
1Heater
Installa-
tion loca-
tion
1
1

Audi A4 / A5
Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE 6
Electrical System
Wiring harness routing
1Original vehicle line duct
2Wiring harnesses of heater, metering pump in
corrugated tube
3Cut open original vehicle protective rubber
plug
Fuse holder, K3 relay
1Positive wire on positive support point
2Angle bracket
3Mount M6x20 bolt, large diameter washer,
flanged nut in existing hole
4M5x16 bolt, retaining plate for fuse holder, K3
relay, washer, flanged nut on angle bracket
5Wiring harness of heater and metering pump
Wiring har-
ness rout-
ing
diagram
Wiring harness pass through
1Control unit pulled out
2Wiring harness of fan controller, digital timer
3Earth wire on earth support point
Wiring harness pass through
1Control unit mounted again
2Wiring harness of digital timer
3Wiring harness of fan controller
2
3
2 1
3
2
5
3
4
1
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
2
21
3
5
3
2
1

Audi A4 / A5
Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE 7
Fan Controller
Wiring dia-
gram
Webasto components Vehicle components Colours and symbols
Legend
HG Heater TT-C/E J255 Air-conditioning control
panel rt red
X1 6-pin heater connector T20e 20-pin connector J255 ws white
F3 Replace 25 A with 1 A
fuse sw black
gn green
K3 Fan relay
Insulate wire ends and
tie back
XCutting point
Wiring colours may vary.
Webasto
31
30
15
Audi
F3
86
85 30
87a87
K3
HG
X1 4
!J255
3
T20e
sw
4² gn/ws 0,75²
rt
4²

Audi A4 / A5
Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE 8
Produce connections as shown in wiring dia-
gram.
1Black (sw) wire from K3/30
2Green/white (gn/ws) additional wire in pro-
tective sleeving
3Insulate red (rt) wire K3/87a and tie back Preparing
fan wiring
harness
Connection to 20-pin connector T20e 1from
A/C control panel.
Produce connections as shown in wiring dia-
gram.
1Remove connector T20e of A/C control
panel
2Free socket, PIN 3
3Green/white (gn/ws) additional line
Connec-
tion of air-
condition-
ing con-
trols
1Complete 20-pin connector of A/C control
panel
Reinsert-
ing con-
nector
6
1
3
2
7
1
3
2
8
1

Audi A4 / A5
Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE 9
Digital Timer, Summer/Winter
Switch Option
1Summer/winter switch, drilled hole 12 mm
dia.
2Digital timer Installing
digital tim-
er
Remote Option (Telestart)
Drill out bracket 3to 6.5mm dia. at position 1.
1M6x16 bolt in existing threaded hole
2Receiver Installing
receiver
1Antenna
Installing
antenna
Temperature sensor only in case of T100
HTM
1Fasten temperature sensor with adhesive
tape Installing
tempera-
ture sensor
1
29
310
1 2
11
1
1
12

Audi A4 / A5
Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE 10
Preparing Heater
Discard section X
1Combustion air pipe
a = 350 Cutting
combus-
tion air
pipe to
length
1Combustion air pipe
2Clamp
Premount-
ing com-
bustion air
pipe
190° moulded hose, 10 mm dia. clamp [2x]
2Fuel line
Premount-
ing fuel
line
a
1
X
13
1
2
14
2
1

Audi A4 / A5
Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE 11
3.0l 150KW / 180 KW
Hose F= 90°, 20x20 mm dia. moulded hose
Discard section X
A= 380
B= 90° elbow
C= 115
D= 105
E= 250
Cutting
hoses to
length
2.7l 140KW / 3.0l 176 KW
Hose A= 90° moulded hose, 15x18 mm
Discard section X
B= 100
C= 115
D= 105
E= 250
Cutting
hoses to
length
All vehicles
127 mm dia. spring clip [2x]
220x20 connecting pipe
Premount-
ing hose
Preparing Installation Location
17 mm dia. hole [2x]
Drilling
hole in
cross
member
C
X
EX
D
X
F
B
A
B
X
EXD
X
C
X
A
D
15
1
1
2
16
1
155
180
37
1

Audi A4 / A5
Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE 12
1Cut away tab at marking
2Cut away bar at marking
3Remove original vehicle bolt (will be re-
used)
Preparing
installa-
tion loca-
tion
Installing Heater
Insert two washers between bracket 2and
heater at position 4.
1Ejot screw [2x]
3Original vehicle bolt
4Ejot screw, washer [2x]
Installing
heater
Insert two 5 mm shims between heater and
cross member 1at position 3.
2Mount wiring harness of heater
3Ejot screw, 5 mm shim [2x each] Installing
heater
17
3
1 2
18
1 1
4
2
3
19
1 2
3 3

Audi A4 / A5
Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE 13
Combustion Air
1Retaining clip in hole of bracket
2Silencer
Installing
silencer
20
1
2

Audi A4 / A5
Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE 14
Coolant Circuit 3.0l 150KW / 180KW
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 other
hoses cannot be damaged. The heater must be filled with coolant when installing the hoses.
The connection should be "inline" based on the following diagram:
Hose in-
stallation
diagram
Allspring clipswithout a specific designation = 27mmdia. All connecting pipes = 20x20mm dia.
1 = Original vehicle spring clip .
1
B
D
E
1
C
A
F

Audi A4 / A5
Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE 15
Remove hose section on heat exchanger out-
let 2and discard. Spring clip 1will be reinsert-
ed. Hose section of engine inlet 3and spring
clip 4will be remounted.
Cutting
point
Installhosesectionofengineinlet 3 with16mm
dia. onto pipe of heat exchanger outlet
1 .
2Original vehicle spring clip [2x]
Connect-
ing to en-
gine inlet
and heat
exchanger
outlet
Insert insulation protection strips 1between
hoses and frame side member.
Routing in
engine
compart-
ment
Connect-
ing heater
outlet
21
42 3
80
1
22
23 F2
A
1
E
23
E1 A
24
D
E

Audi A4 / A5
Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE 16
Connect-
ing heater
inlet
Align hoses. Ensure sufficient distance to
neighbouring components, adjust, if neces-
sary.
Routing in
engine
compart-
ment
25
B
C
26
B
E
A

Audi A4 / A5
Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE 17
Coolant Circuit 2.7l 140KW / 3.0l 176KW
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 other
hoses cannot be damaged. The heater must be filled with coolant when installing the hoses.
The connection should be "inline" based on the following diagram:
Hose in-
stallation
diagram
All spring clips without a specific designation = 27 mm dia. 1= original vehicle spring clip
2 = Coupling piece on engine inlet! All connecting pipes without a specific designation = dia. 20x20 mm.
1
A
B
D
E
2
Ø 20x18
Ø 25
C

Audi A4 / A5
Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE 18
Remove hose on heat exchanger outlet/en-
gineinlet
2 .Spacerbracket 1 and spring clip 3
will be remounted.
Cutting
point
Donotdamagecouplingpiece3whencutting
open clamp 2!
1Discard hose section with protective hose
Removing
coupling
piece
1Coupling piece on engine inlet
Preparing
hose E
Connect-
ing heater
outlet
27
3 12
28
1 2 3
29
1E
30
D
E

Audi A4 / A5
Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE 19
Preparing
hoses A, B
and C
Connect-
ing heater
inlet
Align hoses. Ensure sufficient distance to
neighbouring components, adjust, if neces-
sary.
1Coupling piece on engine inlet
2Spacer bracket
3Original vehicle spring clip Connect-
ing to en-
gine inlet
and heat
exchanger
outlet
31
C
A
B
32
B
C
33
E
1
3 A 2

Audi A4 / A5
Ident. No.: 1313525D_EN Status: 25.09.2012 © Webasto Thermo & Comfort SE 20
Fuel
CAUTION!
Open the vehicle's fuel tank cap, ventilate the tank and then re-close the tank lock.
Catch any fuel running off with 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.
1Wiring harness of metering pump and fuel
line in corrugated tube
Installing
lines
1Wiring harness of metering pump and fuel
line in corrugated tube
Installing
lines
1Clamping bracket [3x]
2Fuel line, wiring harness of metering pump
Installing
lines
34
1
1
1
35
1
1
36
1 1 1
2