Webasto Thermo Top E User 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, 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 suc-
cessfully 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 installa-
tion by untrained staff.
Water Heater Unit
Installation Instructions
Ident. No.:1313475D_EN Fee Euro 10.00 © Webasto AG
VW Tiguan
Gasoline and Diesel
from Model Year 2008
Left-hand drive vehicle
Climatronic
Feel the drive
Thermo Top E Additional Heater e1
00 0003
Thermo Top C Additional Heater e1
00 0002
Thermo Top P Additional Heater e1
00 0104

VW Tiguan
1313475D_EN 2
Table of Contents
Validity
Vehicle and engine types, equipment variants and national specifications not listed in these installation
instructionshavenotbeentested.However,installation according to these installationinstructions 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 Tiguan 5N e1 * 2001/116 * 0450
Engine type Engine model Output in kW Displacement in cm³
BWK Gasoline 110 1390
CAWA Gasoline 125 1984
CAWB Gasoline 147 1984
CBAB Diesel 103 1986
CAHB Diesel 125 1986
Validity 2
Heater Unit/Installation Kit 3
Foreword 3
General Instructions 3
Special Tools 3
Explanatory Notes on Document 4
Preliminary Work 5
Heater unit installation location 5
Preparing electrical system 6
Electrical system 7
Fuse holder and relay K3 8
Fan controller 9
Digital timer 11
Remote option (Telestart) 11
Preparing bracket 12
Premounting heater unit 12
Installing heater unit 14
Coolant on 1.4 liter and 2.0 liter TSI 16
Coolant on 2.0 liter TDI 21
Fuel Connection 25
Exhaust gas 29
Final Work 30
Operating Instructions for End Customer 31

VW Tiguan
1313475D_EN 3
Heater Unit/Installation Kit
Other required parts
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 VW Tiguan Gasoline and Diesel vehicles - 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, modifica-
tions may be necessary during installation with respect to these installation instructions.
However,thestipulations in the "installationinstructions"and"operating and maintenanceinstructions"
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 must be provided with rub protection (cut-open fuel 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
Quantity Description Order No.:
1 Retail accessories with desired heater control See price list
1 Installation kit for VW Tiguan Gasoline and Diesel 1313473B
Quantity Description VW Order No.:
1 Plate washer 191 411 331
Quantity Description Order No.:
1 Kit for Climatronic VW Tiguan 1313474A
Vehicle Heater Unit
Compact car Thermo Top E
Mid-size car, station wagon Thermo Top C
Full-size car, van, offroader Thermo Top P

VW Tiguan
1313475D_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
Fuel
Exhaust gas
Combustion air
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.

VW Tiguan
1313475D_EN 5
Preliminary Work
WARNING!
- Open the fuel tank cap and vent the fuel 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.
- Remove the battery
- Remove the battery carrier
- Remove the engine cover
- Remove the air filter (only on 2.0 TSI).
- Remove the right-hand charge-air tube.
- Remove the charge-air tube completely (only on 2.0 TSI).
- Remover the front right wheel well trim and detach on the left.
- Remove the bumper
- Remove the underride protection
- Remove the right-hand underbody trim
- Remove right rear single 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
- Remove the footwell trim on the front passenger side
Remove page 31 "Operating Instructions for End Customer" and add to the vehicle operating instruc-
tions.
Heater unit installation location
1Heater unit
Installa-
tion loca-
tion
11

VW Tiguan
1313475D_EN 6
Preparing electrical system
Lines for
IPCU
Install lines according to wiring diagram.
Preparing
IPCU
3
500
br
0,75²
2
500
sw
0,75²
1
500
rt
0,75²
2
86 85
A
E
15
IPCU
1
2
3
A
15
86 85
E
3

VW Tiguan
1313475D_EN 7
Electrical system
Wiring harness pass through
1Original vehicle wiring harness pass through
Wiring harness pass through
1Original vehicle wiring harness pass through
Wiring har-
ness in-
stallation
diagram
Routing wiring harness
1Wiring harness of heater unit and wiring har-
ness of metering pump in corrugated tube
2Adhesive base [2x]
Fuse holder, K3 relay
Description of installation for K3 relay 1and fuse
carrier 2on Page 7
4
1
5
1
Do not installthe metering pump
cableharnessuntillatertogether
with fuel pipe along the original
vehicle fuel lines on the under-
body
6
2
2
1
7
2
1

VW Tiguan
1313475D_EN 8
Fuse holder and relay K3
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
35.0 mm dia. hole [2x]
Holes in
cover
1
M5x12 countersunk head screw [2x]
Installing
fuseholder
and K3 re-
lay
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 K3 re-
lay
Route brown (br) ground wire to original vehi-
cle ground support point below headlight and
connect.
1Fuse/relay carrier
2Original main vehicle fuse
3Red (rt) positive wire Connect-
ing posi-
tive and
ground
wire
1
8
40
99
3
20
2
3
9
11
6
2
3
10
74
5
1
21
3
11

VW Tiguan
1313475D_EN 9
Fan controller
Wiring dia-
gram
Webasto components Vehicle components Colors and symbols
Legend
HG Heater unit TT-C/E F1 Fuse SC22 or SC56 with 40 A rt red
X1 6-pin heater unit con-
nector ws white
K3 Fan relay KB Climatronic control unit - J255 sw black
F3 Fuse (25 A replaced
with 3 A!) T10k Plug connections br brown
ge Fan control unit - J126 and fan
motor - V2 gn green
IPCU Pulse width modulator ge yellow
IPCU adjustment values bl blue
Voltage: 8 V Insulate wire ends
and tie back
Frequency: 400 Hz
Duty cycle: 30 %
Function: High-side XCutting point
31
30
15
VW
br
sw/
ws rt/
ge
T10k
rt/ws
bl/
ws
Webasto
rt
sw
br
sw
86 85
A
E
IPCU
HG
4
X1 F3
86
85 30
87a87
K3
GE
T6t
31 42
M
KB
T16f
15 16 F1
sw/
ws
0,75²
0,75²
0,75²
0,75²
rt
!

VW Tiguan
1313475D_EN 10
1Original vehicle bolt
2IPCU socket
Installing
IPCU
1Original vehicle bolt
2Brown (br) wire of IPCU/85
Connec-
tion to
ground of
IPCU
1Black (sw) wire of IPCU/A
2Black/white (sw/ws) wire of connector
T6t/2
3Connector T6t
4Black/white (sw/ws) wire of Climatronic
connector T6t/15
5Red (rt) wire of IPCU/E Connect-
ing wires
12
1
2
13
1
2
3
14
4
5
1 2

VW Tiguan
1313475D_EN 11
Digital timer
112 mm dia. hole, summer/winter switch
2Digital timer
Installing
digital tim-
er
Remote option (Telestart)
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
Installing
receiver
1Antenna
Installing
antenna
1
15
2
16
1
2
3
1
17

1313475D_EN 12
VW Tiguan
Preparing bracket
16 mm dia. hole in bracket 1at position 2.
Hole in
bracket
Premounting heater unit
1Combustion air pipe
a = 270
Discard section XCutting
combus-
tion air
pipe to
length
1.4 and 2.0 TSI
b = 70
c = 160
e = 70
Discard section XCutting 20
mm dia.
coolant
hose to
length
2.0 TDI
b = 70
c = 160
e = 70
Discard section XCutting 20
mm dia.
coolant
hose to
length
87,5 7,5
21
a
1
X
C
BE
X
X
C
BEX

1313475D_EN 13
VW Tiguan
All vehicles
115x20 connecting pipe
2Hose clamp [3x]
3Black (sw) rubber isolator
4Angle bracket
5Ejot screw Premount-
ing heater
unit
1Bracket
2Combustion air pipe, 10 mm dia. hose
clamp
315x20 connecting pipe
410 mm dia. hose clamp
5Ejot stud, flanged nut
6Ejot screw [2x] Premount-
ing heater
unit
Preparing installation location
Remove horn 1and bend lug 2by 180°
Preparing
installa-
tion loca-
tion
1Glue on sponge rubber as rub protection
2Original vehicle bolt
3Remove clip from hole
Installing
horn
18
b
2
1 2
4
3
5
2
C
19
1
6
6 5
3 42
20
2
1
21
2
1
3

1313475D_EN 14
VW Tiguan
Installing heater unit
Connect wiring harness of heater unit prior to
installation. Insert plate washer (VW Order
No. 191 411 331) at position 1.
1Originalvehicle studbolt,platewasher, M8
nut
2M10x30 bolt with locking pawl in existing
thread
Installing
heater unit
Beforeinstallation,gluespongerubber2onto
strut 3.
1M6x20 bolt, large diameter washer [2x],
M6 flanged nut
4M6x20 bolt, M6 flanged nut Installing
strut
22
1 2
23
3
1
4
2

VW Tiguan
1313475D_EN 15
1Intake muffler
2M5x16 bolt, large diameter washer, M5
flanged nut
351 mm dia. p-clamp
Installing
intake muf-
fler
24
3
1
2

VW Tiguan
1313475D_EN 16
Coolant on 1.4 liter and 2.0 liter TSI
WARNING!
Any coolant running off should be collected using an appropriate container! Route coolant hoses kink-
free! Unless specified otherwise, always fasten using cable ties. Position clamps so that no other hose
can be damaged! When installing the coolant hose, the heater unit must be filled with coolant.
The connection should be "inline" based on the following diagram:
Coolant
routing di-
agram
All hose clamps = 20-27 mm dia.! 1 = Black (sw) rubber profile . 2= Original vehicle spring
clip . All connecting pipes without a specific designation = dia. 15x20.
B
C
1
A
DE2

VW Tiguan
1313475D_EN 17
a = 1200
d = 1200
Discard section X
Cutting 15
mm dia.
coolant
hose to
length
Push braided protection hoses onto hose A
and D, cut to length and shrink.
1Heat shrink plastic tubing [4x]
Premount-
ingcoolant
hoses
125 mm dia. rubber-coated p-clamp [2x]
2M6x40 bolt, spring lockwasher, 20 mm, ex-
isting threaded hole
Preparing
installa-
tion of
coolant
hoses
Detach plastic duct 2and dispose of original
vehicle nut.
1M6x20 spacer nut, M6x12 bolt, spring lock-
washer, large diameter washer Preparing
installa-
tion of
coolant
hoses
AD
D
A
1
1 1
1
21
125
1
226

VW Tiguan
1313475D_EN 18
Position 10 mm shim 2between 34 mm dia.
rubber-coated p-clamp 4.
1M6x20 bolt, spring lockwasher
3M6x40 spacer nut on existing thread Preparing
installa-
tion of
coolant
hoses
Connec-
tion to
heater unit
Routing in
engine
compart-
ment
Push through hoses Aand Dbetween body
and plastic duct at position 1.
Routing in
engine
compart-
ment
2
3
1
27
4
28
C
aD
b
29
a
D
30
1

VW Tiguan
1313475D_EN 19
Routing in
engine
compart-
ment
1.4 TSI
Dispose of hose section 1.
Original vehicle clamp will be reused.
2Cutting point Cutting
point
Ensure sufficient distance to neighboring
components.
1Hose of engine outlet
Connect-
ing engine
outlet
1Cable tie
2Original vehicle spring clip
Connect-
ing heat
exchanger
inlet
31
D
a
32
12
33
1
a
34
D
E
1 2

VW Tiguan
1313475D_EN 20
2.0 TSI
Remove trim of heat exchanger inlet/output 1
and discard.
Cutting
point
Slide back heat shield on hose on heat ex-
changer inlet/engine outlet.
Dispose of hose section 2.
Original vehicle clamp 1will be reused.
3Cutting point Cutting
point
Slide heat shield on hose on engine outlet 2
forward again. Ensure sufficient distance to
neighboring components.
1Original vehicle spring clip
3Cable tie Connec-
tion on en-
gine outlet
and heat
exchanger
inlet
35
1
36
1 2
3
37
E
D
2a
1
3