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
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 to carry out correct installation and repairs.
ALWAYS follow all Webasto installation and repair instructions and observe all
warning instructions.
Webasto does not accept any liability for defects and damage that are attributable to
installation by untrained staff.
Feel the drive
VW Fox
Gasoline
From model year 2006
For left-hand drive vehicles only
Ident. No.: 9015968A €10 fee © Webasto AG
Water Heater Unit
Thermo Top E Auxiliary Heating
Thermo Top C Auxiliary Heating
Thermo Top P Auxiliary Heating
Installation Instructions
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22
VW Fox
Validity
Vehicle and engine types, equipment variants as well as national specifications, which are not listed in
these installation instructions, have not been tested. Installation according to these installation
instructions may, however, be possible.
The installation location of a time switch and summer / winter switch should be confirmed with the end
customer before installation.
Manufacturer Model Type EG-BE No. / ABE
VW Fox 5Z e1 * 2001 / 116 * 0301 * ...
Engine type Engine Power in kW Engine capacity in cm³
BMD Gasoline 40 1198
BKR Gasoline 55 1390
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
Electrical Connections 6
Climatic blower control 7
Remote Start Option 8
Thermo Call Option 9
Preparing the Heater Unit 10
Preparing the Installation Location 11
Installing the Heater Unit 11
Combustion Air 13
Exhaust System 14
Water Connection 15
Fuel Connection 19
Final Work 21
Final Work 21
Operating instructions for the end customer 22
Tank Extracting Device Template 23
Table of Contents

3
VW Fox
Heater Unit / Installation Kit
Recommended heater unit for the relevant vehicle class:
Select the heater unit based on the size of the vehicle passenger compartment and the customer's
comfort requirements.
Foreword
These installation instructions apply to vehiclesVW Fox with Gasoline engines – re. validity, see page
2 – from model year 2006 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, the stipulations in the "installation instructions" and "operating and maintenance instructions"
for the Thermo Top C/P/E are to be observed in any event.
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 cable harnesses to original vehicle lines and cable
harnesses using cable clips.
Sharp edges should be fitted with edge protectors (split open plastic hose).
Spray unfinished body areas, such as bore holes, with anti-corrosion wax (Tectyl 100K, Order no.
111329).
Special Tools
- Torque wrench
- Vise-grip wrench
Amount Description Order no.:
1 Commercial supply of required control See price list
1 Installation kit for VW Polo / Fox Gasoline 9015515B
Vehicle Heater unit
Compact car Thermo Top E
Mid-class, station wagon Thermo Top C
Luxury, van, off-roader Thermo Top P

44
Special features are highlighted using the following symbols:
Mechanics
Electrics
Water connection
Fuel connection
Exhaust system
Combustion air
The arrow in the vehicle icon indicates the position on
the vehicle and the viewing angle.
VW Fox
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 the 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
VW Fox
Heater Unit Installation Location
1Heater unit
Installation
location
11
Preliminary Work
WARNING!
- Disconnect the battery.
- Let off pressure in 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 engine cover.
- Remove the windshield wiper arms.
- Remove the wiper assembly.
- Remove the cooling water reservoir cover
- Remove the motor controller unit mounting
- Remove the silencer mat from the engine compartment separating wall.
- Remove the water reservoir separating panel to the engine compartment.
- Open the tank cap, ventilate the tank.
- Close the tank cap again.
- Loosen the right and left wheel-house panel.
- Remove the underride protection.
- Remove the bumper.
- Remove the right underbody panel.
- Lift up the rear seat bench.
- Open the tank mounting service lid
- Remove tank mounting according to manufacturer's instructions.
- Remove the glove compartment (only for Thermo Call).
- Remove the lower dashboard panel on the driver’s side.
- Loosen the central electrics.
- Remove air conditioning control according to the manufacturer's instructions (only for Climatronic
systems).
- Please remove page 25 “Operating instructions for the end customer” and add this to the operating
instructions.

6
VW Fox
Electrical Connections
Cable harness feed-through
1Bowden cable rubber sleeve
Time switch
1Time switch
Cable
harness
installation
diagram
Fuse holder, K3 relay
2Fastening strap with holes, with 90° bend
1M5x20 bolt, body washer, M5 flanged nut
5K3 relay, M5x12 bolt, washer, flanged nut
4Fuse holder
3M5x12 bolt, washer, M5 flanged nut
Summer / winter switch option
1Summer / winter switch, bore hole Ø 12 mm.
2
1
1
3
11
br
bl
sw
rt
Wait to install the metering pump
cable harness until later,
together with fuel pipe along the
original vehicle fuel lines on the
underbody.
i
4
4
1
5
32
5
1

7
VW Fox
Climatic blower control
Connection to the central electrics 2.
Connect according to the circuit diagram.
3Red/black (rt/sw) wire from fuse SB42 25A.
1Black/red (sw/rt) wire to the switch unit.
5Black (sw) wire from K3/30
4Red (rt) wire to K3/87a
Connec-
ting the
central
electronics
Manual air
conditio-
ning circuit
diagram
Webasto components Components VW Fox Colors and symbols
Legend
HG Heater unit TT-C/E/P V2 Blower motor rt red
X1 6-pin connector SB42 Fuse, 25A ws white
F3 Fuse, 25A N24 Resistor group sw black
K3 Blower relay E9 Switch unit br brown
T... connector gn green
ge yellow
XSplitting point
Cable colors may vary.
6
1
4
3
5
2
1
sw
br
Webasto
31
30
15
VW Fox ohne Klimaanlage/
mit Climatic
rt
sw/rt
br
rt
5
E9
4
23T5h
T5h
rt/sw
sw/ge
gn/ws
rt/
ws
T10c/1
HG
4
X1
86
85 30
87a87
K3
F3
+
-
V2
M
SB42
T4e
2
13
N24
4
VW FOX without air conditioning/ with
Climatic
i

8
VW Fox
Remote Start Option
Drill bracket at position 1to Ø 6.5 mm.
2Receiver
1M6x20 bolt, bracket on existing threaded
bore hole
Assem-
bling the
receiver
1Antenna
Assem-
bling the
antenna
Temperature sensor for HTM100 only
Fasten temperature sensor 1correctly as
shown in the figure.
Assem-
bling the
tempera-
ture sensor
1
27
i
1
8
9
1

9
VW Fox
Thermo Call Option
Fasten the TC receiver 1on the A-pillar as
shown in the image, the fastening material is
not a component of delivery.
Assem-
bling the
receiver
1Antenna
Assem-
bling the
antenna
1Tip switch
Assem-
bling the
tip switch
110
i
1
11
i
112
i

10
VW Fox
Preparing the Heater Unit
1Exhaust pipe
a = 370mm
2Exhaust end section
b = 110mm
Dispose of section XPreparing
the
exhaust
pipe
Ejot screw bolts tightening torque 10 Nm!
1Ejot screw bolts [3x]
3Combustion air intake pipe
4Intake silencer
2Ø 27 mm hose clamp
Preassem-
bling the
heater unit
Ejot screw bolts tightening torque 10 Nm!
Insert two washers between the heater unit
and the bracket in position 4.
The flanged nut M6 1will be screwed later.
3bracket
2M6 flanged nuts [2x]
Preassem-
bling the
heater unit
Assemble the exhaust lines according to the
illustration and shape.
1Exhaust silencer
3Exhaust pipe
2Hose clamps [3x]
4Red (rt) rubber profile
5Bracket, M6x20 bolt, flanged nut M6
6Exhaust end section
7Red (rt) rubber profile with groove
Preassem-
bling the
exhaust
pipe
a b
1 2
X
2 43
11
1
13
14
1 2
2
3
4
4
2
2
3
5
2
6
7
1
15

11
VW Fox
Preparing the Installation Location
Remove original vehicle bolt 1, this will be
used again.
Preparing
the
Installation
Location
Drill a Ø 6mm bore hole 1according to the
figure for the air intake silencer bracket.
Check first for any wires!
Preparing
the
Installation
Location
Installing the Heater Unit
Insert 5mm spacer sleeve [2x] between the
bracket and the body at position 1.
3Preassembled Heater Unit
1M6 flanged nuts [2x]
2M8x30 bolt, spring washer on the original
vehicle threaded bore hole (secure from
above with the M8 nut)
Assem-
bling the
heater unit
Ejot screw bolts tightening torque 10 Nm!
2Strut
1Ejot screw bolt [2x]
3Original vehicle bolt
Assem-
bling the
heater unit
16
1
17
1
20mm
65mm
18
1
3
2
1
19
3
1
1
2

12
VW Fox
1Edge protection 200 mm long
2Edge protection 100mm long
Inserting
edge
protection
20
1
2

13
VW Fox
Combustion Air
Insert retaining clip 1in the Ø 6mm bore hole
according to the figure.
Inserting
retaining
clip
Fasten the combustion air intake silencer 1to
the hole in the strut 3with cable ties2.
Assem-
bling the
vacuum
line
Insert intake silencer 2in the preassembled
retaining clip 1.
Assem-
bling the
silencer
21
1
22
3
2
1
i
23
1
2
i

14
VW Fox
Exhaust System
Ensure sufficient distance from adjacent
components.
1Pre-assembled exhaust pipe
2Tighten the hose clamp
3Bracket, M6 bolt on pre-assembled Ejot
stay bolt
4Exhaust silencer
Assem-
bling the
exhaust
pipe
Ensure sufficient distance from adjacent
components.
Drill a Ø 42mm bore hole according to the
figure.
1Exhaust end section
2Ø 42mm bore hole, red rubber profile with
nut
3Right wheel-house panel
Inserting
rubber
profile
Align the red (rt) rubber profile according to
the figure.
3Wheel-house panel
1Red (rt) rubber profile with groove
2Exhaust end section
Inserting
rubber
profile
2
4
1
24
3
1
2
325
26
2
1
3

15
VW Fox
Water Connection
WARNING!
Tighten all hose clamps with 2.0 + 0.5 Nm.
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 clips.
Position hose clamps and spring band clamps so that no other hose can be damaged.
The connection should be "inline" based on the following diagram:
Water
installation
diagram
All undesignated clamps are Ø 20-27 mm hose clamps.
All connecting pipes = Ø 20x20.
Wärme-
tauscher
Motor
Ø 20x20
Ø 20x20
Heat
exchanger

16
VW Fox
a = 1,010mm
b = 820mm
Dispose of section X
Cutting
water hose
into
sections
Prepare the water hoses according to the
illustration
1Black (sw) rubber profile [2x]
2Hose bracket
Preparing
the water
hoses
Assemble the bracket 1and 2according to
the illustration.
(see also illustration 27)
1Bracket, rubber tube shaft Ø 29mm [2x],
M6x20 bolt, flanged nut
2Bracket, rubber tube shaft Ø 29mm [2x],
M6x20 bolt, flanged nut Preparing
the water
hoses
Turn the heat exchanger inlet hose section to
the right after separating it.
1Hose section to the heat exchanger inlet
2Hose section from engine outlet
Splitting
point
b a
X
B A
X
A
B
1
2 1 27
28
2
1
B
A
515mm
135mm
29
1 2

17
VW Fox
Connec-
ting to the
heater unit
1Cable clip
2Position the black (sw) rubber profile
Placement
in the
engine
compart-
ment
Align the pre-assembled bracket 1according
to the illustration.
Note the manufactures recommendations for
the torque to screw on the on the engine
bearing bracket.
Check that these rotate freely.
2Original vehicle bolt, engine bearing
bracket.
Installing
in the
engine
compart-
ment
Align the pre-assembled bracket 1according
to the illustration.
Note the manufactures recommendations for
the torque to screw on the on the engine
bearing bracket.
Check that these rotate freely.
2Original vehicle bolt, engine bearing
bracket.
Installing
in the
engine
compart-
ment
30
A
B
31
2
1AB
32
A1
2B
33
B1
2

18
VW Fox
Insert the hose bracket 1as shown in the
figure.
2Engine exhaust hose section
Connec-
ting to the
engine
outlet
Before connecting, fill the water hoses with
coolant.
Align the black (sw) rubber profile 1according
to the illustration.
2Heat exchanger inlet hose section
3Cable clips Connec-
ting to the
heat
exchanger
inlet
Check that these rotate freely.
Align the hose bracket 1as shown in the
illustration.
Inserting
the hose
bracket
34
1A 2
35
1 2
3
B
36
A
1 B

19
VW Fox
Fuel Connection
CAUTION!
Open the vehicle's tank-cap lock, 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 cable harness so that they are protected against stone impact.
Unless specified otherwise, always fasten using cable clips.
Fit the fuel line and cable harness with edge protectors around sharp edges.
WARNING!
The fuel line and cable harness to the metering pump should be installed based on the cable harness
installation diagram.
1Mecanyl fuel line
2Ø 10mm hose clamps [2x]
3Hose section
Connec-
ting to the
heater unit
Assemble the silent block 1according to the
illustration.
1Silent block, original vehicle hole, body
washer, M6 flanged nut
Metering
pump
installation
location
Note the installation position of the metering
pump, see the Installation Instructions.
Fuel line from the heater unit on the pressure
side of the metering pump [side with
connector].
1Metering pump cable harness
2Fuel line from the heater unit
3Hose section, Ø 10 mm hose clamps [2x]
4Metering pump; rubberized tube clamp;
flanged nut
Metering
pump
installation
location
37
2
1
2
3
38
1
39
1 2 3 4
i

20
VW Fox
Remove the tank mounting1according to the
manufacturer's instructions.
1Tank mounting
2Body washer Ø 6 mm
3Copy the hole image, Ø 6mm bore hole
Fuel take-
off
Cut the tank extracting device 1into sections
and insert according to the template, see the
Installation Instructions.
Assem-
bling the
tank
extracting
device
Assemble tank mounting according to
manufacturer's instructions.
4Tank extracting device
190° moulded hose
3Residual section of Mecanyl fuel line to the
metering pump
2Ø 10mm universal clips [2x] Connec-
ting to the
metering
pump
Fuel line from the tank extracting device 1on
the intake side of the metering pump 4[side
without connector].
Check the position of the components; adjust
if necessary. Check that these rotate freely.
3180°-moulded hose
2Ø 10mm hose clamps [2x]
Fuel take-
off
40
3
1
2
41
1
i
42
1
2
2 3
4
43
2
2
3
4
1