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.:9013722D_EN Fee Euro 10.00 © Webasto AG
VW Caddy
1.6 Liter Gasoline and 2.0 Liter Gasoline Eco Fuel; 2.0 Liter SDI
from Model Year 2005
Left-hand drive vehicle
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 Caddy
9013722D_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 Caddy 2KN L 320
VW Caddy 2K150 e1*2001/116*0252*...
Engine type Engine model Output in kW Displacement in cm³
BSE Gasoline 75 1595
BSX Gasoline [Eco Fuel] 80 1984
BDJ Diesel 51 1968
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
Electrical system 6
Fuse holder and relay K3 7
Climatic fan controller 8
Climatronic fan controller 10
Remote option (Telestart) 12
Preparing heater unit 13
Preparing installation location 13
Installing heater unit 14
Fuel 16
Coolant for gasoline engine 21
Coolant for diesel engine 25
Combustion air 29
Exhaust gas 30
Final Work 31
Operating Instructions for End Customer 32

VW Caddy
9013722D_EN 3
Heater Unit/Installation Kit
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 Caddy 1.6 Liter Gasoline and 2.0 Liter Gasoline Eco Fuel;
2.0 Liter SDI vehicles - for validity, see page 2 - from model year 2005 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,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 should be fitted with edge protectors (split-open plastic 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
- Metric thread-setter kit
Quantity Description Order No.:
1 Retail accessories with desired heater control See price list
1 Installation kit for VW Caddy 1.6 Liter Gasoline and 2.0 Liter
Gasoline Eco Fuel; 2.0 Liter SDI 9013723B
Quantity Description Order No.:
1 IPCU Kit for Climatronic 9013645A
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 Caddy
9013722D_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
Water
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 Caddy
9013722D_EN 5
Preliminary Work
WARNING!
- Open fuel tank cap, ventilate tank.
- Close the tank cap again.
- Disconnect the battery "earth" or "ground" connection.
-Depressurizethe 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.
- Completely remove the battery.
- Remove the battery carrier.
- Remove the engine cover.
- Remove the air filter together with the intake hose.
- Remove the right front wheel.
- Remove the front section of the right front wheel well trim.
- Remove the underride protection (if present).
- Remove the bumper.
- Remove the washer reservoir.
- Remove the right-hand underbody trim
- Remove the footwell trim on the driver's side and front passenger side
- Remove the lower instrument panel trim on the driver's side
- Remove the fuel-tank sending unit according to the manufacturer's instructions (with gasoline
only).
Remove page 32 "Operating Instructions for End Customer" and add to the vehicle operating instruc-
tions.
Heater unit installation location
1Heater unit
Installa-
tion loca-
tion
1
1

VW Caddy
9013722D_EN 6
Electrical system
Wiring harness of heater unit
Guide wiring harness of heater unit 2in front of
radiator at position 1and route to right along up-
per edge of radiator. Then route into engine com-
partment again at position 3. Fastening is not
carried out until after heater unit is installed!
Fuse holder, relay K3
For information on installing fuse holder and K3
relay, see page 7.
1Relay K3
2Fuse holder
Wiring har-
ness in-
stallation
diagram
Wiring harness pass through
1Original vehicle wiring harness pass through
2Wiring harnesses for fan controller and heater
control
Digital timer, summer/winter switch option
1Digital timer
2Summer/winter switch, drilled hole 12 mm dia.
2
2
1
2
3
3
1
2
Do not installthe metering pump
cableharnessuntillatertogether
with fuel pipe along the original
vehicle fuel lines on the under-
body
4
1
2
5
2
1

VW Caddy
9013722D_EN 7
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 for
fuseholder
and K3 re-
lay
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
6
40
99
3
20
2
3
7
11
6
2
3
8
74
5
1
21
3
9

VW Caddy
9013722D_EN 8
Climatic fan controller
Fusesocketdependentonvehicleequipment
SC33 or SC35; wire color black (sw) or
black/yellow (sw/ge).
Detach original vehicle fuse carrier 2(instru-
ment panel at lower left) and unlock contact
lock 3.
Uncrimp black (sw) or black/yellow (sw/ge)
wire 1on fuse output SC33 or SC35.
Uncrimp-
ing wire
Produce connection as shown in wiring dia-
gram.
1Black (sw) or black/yellow (sw/ge) wire
with original standard power timer
2AMP housing [2x]
3Contact lock locked
4Black (sw) wire to K3/30
5Red (rt) wire from K3/87a with standard
power timer engaged in fuse output SC33
or SC35
Installing
wiring har-
ness
10
3
21
11
3 3
1
2
45
2

VW Caddy
9013722D_EN 9
Climatic fan controller
Wiring dia-
gram
Webasto components Vehicle components Colors and symbols
Legend
HG Heater unit TT-C/E SC33 Fan fuse rt red
X1 6-pin heater unit connec-
tor SC35 Fan fuse ws white
F3 25 A fuse J301 Control unit of air condi-
tioning sw black
K3 Fan relay E16 Heater switch br brown
N24 Resistor group ge yellow
V2 Fan motor
T... Plug connections
4
sw
Webasto
31
30
15
VW Caddy
rt
sw oder
sw/ge
br
rt/sw
T4r
5
J301 oder E16
312 T5
342
N24
T5
rt/ws
1
T10k
K3
87a8786
85 30
4
HG X1 F3 SC33
oder
SC35
sw oder
sw/ge
M
+
-
V2
4²
4²
4²
4²

VW Caddy
9013722D_EN 10
Climatronic fan controller
Produce connections as shown in wiring dia-
gram.
Positionof freesocketsdependentonvehicle
equipment.
Connect black (sw) wire from K3/30 3to
green/white (gn/ws) wire 2(AMP connector).
Insulate red (rt) wires K3/87a 4and tie back.
1IPCU socket
Installing
wiring har-
ness of Cli-
matronic
Fasten brown (br) wire IPCU/85 2on original
vehicle ground point.
1IPCU
Installing
ground
wire
Route wiring harness from IPCU 1to original
vehicle wires to fan unit.
Routing
wiring har-
ness of
IPCU
1Connector T6t
2Black/white (sw/ws) wire to connector
T6t/2
3Black/white (sw/ws) wire from IPCU/A
4Red (rt) wire from IPCU/E
5Black/white (sw/ws) wire from Climatronic
control unit
6Wiring harness from IPCU
Connect-
ing wires
12
1
2
3
4
13
2
1
1
14
1
63
15
4
2
1
5

VW Caddy
9013722D_EN 11
Climatronic fan controller
Wiring dia-
gram
Webasto components Vehicle components Colors and symbols
Legend
HG Heater unit TT-C/E SC52 Fan fuse rt red
X1 6-pin heater unit connec-
tor KB Air-conditioning control panel ws white
F3 Replace 25 A fuse F3
with 3 A fuse. ge Fan controller sw black
T... Plug connections br brown
K3 Fan relay gn green
IPCU Pulse width modulator bl blue
IPCU adjustment values: ge yellow
Duty cycle: 30 % Insulate wire ends and
tie back
Frequency: 400 Hz
Voltage: 8 V XCutting point
Function: High-side
rt
Kabelbaum
Climatronic
31
30
15
VW Caddy
br
sw/
ws rt/
ge
T10k
rt/ws
bl/
ws
Kabelbaum
Hg
rt
sw
br
sw/ws
gn/
ws
86 85
A
E
IPCU
HG
4
X1 F3
86
85 30
87a87
K3
GE
T6t
31 42
M
KB
T16f
15 16 SC52
sw/
ws
!
4²
4²
0,75²
0,75²
0,75²
0,75² 0,75²
0,75²

VW Caddy
9013722D_EN 12
Remote option (Telestart)
Drill out upper hole of bracket to 6.5 mm dia.
1Receiver
2Mount M6x12 bolt, large diameter washer,
flanged nut in existing hole
3Bracket
Installing
receiver
1Antenna
Installing
antenna
16
3
1
2
17
1

9013722D_EN 13
VW Caddy
Preparing heater unit
1Replace circulating pump cover with cover
with straight inlet
Convert-
ing circu-
lating
pump
Preparing installation location
1Washer reservoir
2Drill 6.5 mm dia. hole
Preparing
washer
reservoir
Install washer reservoir and copy hole pat-
tern.
1Hole pattern, 9.1 mm dia. hole
2Washer reservoir Copying
hole pat-
tern
1M6 rivet nut
Installing
rivet nut
1
2
1
18
19
21
1
20

9013722D_EN 14
VW Caddy
Position rivet nut in center between A/C lines.
1Edge protection 50
29.1 mm dia. hole; M6 rivet nut
Installing
rivet nut
Installing heater unit
Loosely mounting strut
1Strut
2M6x35 bolt, spring lockwasher, large diam-
eter washer, 5 mm shim, 20 mm shim Installing
strut
Connect connector on heater unit.
Loosely mount heater unit on strut.
1Strut
2Ejot screw Installing
heater unit
Inserttwo washers between heaterunit2and
bracket 1at position 3.
Tighten all screw connectionsbetween brack-
et, strut, heater unit and body.
4Ejot screw [2x]
5Original vehicle stud bolt, M6x30 spacer
nut [2x]
Installing
heater unit
21
2
1
30
22
1
2
23
2
1
24
3
1
2
5
5
4
4

9013722D_EN 15
VW Caddy
1M6x60 bolt, spring lockwasher, washer,
30 mm spacer, existing threaded hole
2M6x60 bolt, spring lockwasher, large diam-
eter washer, 30 mm spacer, large diameter
washer, rivet nut
3Washer reservoir Installing
washer
reservoir
1Washer reservoir
2M6x25 bolt, spring lockwasher, large diam-
eter washer [2x each], premount spacer
nuts
Installing
washer
reservoir
25
1
2
3
26
1
2
2

VW Caddy
9013722D_EN 16
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 in as shown in the wiring harness
routing diagram.
Route wiring harness of metering pump in
coolant reservoir to right and secure on origi-
nal vehicle lines with cable ties.
Pay particular attention to freedom of move-
ment of wiper linkage.
1Coolant reservoir cap
2Metering pump wiring harness
Installing
wiring har-
ness of
metering
pump
115 mm dia. rubber-coated p-clamp, plastic
nut on original vehicle stud bolt
2Hose section, 10 mm dia. clamp [2x]
3Fuel line
4Cloth protective hose cut to 1,100 mm
length Connec-
tion to
heater unit
Guide fuel line 1and wiring harness of meter-
ing 2intooriginal vehicle line duct 3androute
to underbody.
1Fuel line in protective hose Installing
lines
27
2
1
2
28
4
3 2
1
29
2
3
1

VW Caddy
9013722D_EN 17
Route fuel line and wiring harness of meter-
ing pump along originalvehicle fuel lines 2to
rear.
1Line duct Installing
lines
Metering pump of 1.6 liter gasoline and
diesel engine
1Rubber-coated p-clamp, silent block,
flanged nut [2x]
2Metering pump
3Perforated bracket
4Mount M6x20 bolt, large diameter washer,
M6 flanged nut in existing hole
Installing
metering
pump
1Fuel line
2Hose section, 10 mm dia. hose clamp [2x]
3Wiring harness of metering pump, connec-
tor mounted
Connect-
ing meter-
ing pump
30
1 2
31
3
4
21
32
21
3

VW Caddy
9013722D_EN 18
Preparing fuel standpipe
1Standpipe
2Molded hose
Cutting
standpipe
and mold-
ed hose to
length
10 mm dia. Caillauclamp 2in centerbetween
beads on end of standpipe.
1Standpipe
3Molded hose Premount-
ing stand-
pipe and
molded
hose
Fuel removal on diesel engines
Lower fuel tank in accordance with manufac-
turer's specifications.
Cut 3 mm off blind plug.
1Fuel sender
2Tip cut off blind plug
Cutting off
blind plug
Should the standpipe be slightly curved on
delivery, then it must be aligned so that the
end points toward the rear right.
Otherwise there is a danger of the fuel gauge
being impaired.
1Remaining section of fuel line
210 mm dia. Caillau clamp
3Preassembled molded hose with stand-
pipe
413.5 mm dia. Caillau clamp
Connect-
ing fuel-
tank send-
ing unit
33
1 2
235
10
4.5 mm dia.
7.5 mm dia.
34
123
7.5 mm dia.
4.5 mm dia.
35
1 2
36
1
4
3
2

VW Caddy
9013722D_EN 19
Check the position of the components; adjust
if necessary. Check that they have free clear-
ance.
1Fuel line from fuel-tank sending unit
2Hose section, 10 mm dia. hose clamp [2x] Connect-
ing meter-
ing pump
Metering pump of Eco Fuel
Angle down perforated bracket 3by 90°.
1Rubber-coated p-clamp, silent block,
flanged nut [2x]
2Metering pump Premount-
ing meter-
ing pump
1Original vehicle stud bolt from fuel tank
Installing
metering
pump
1Fuel line
2Hose section, 10 mm dia. hose clamp [2x]
3Wiring harness of metering pump, connec-
tor mounted
Connect-
ing meter-
ing pump
37
2
1
38
3
21
80
3
39
1
40
21
3

VW Caddy
9013722D_EN 20
Fuel standpipe of 1.6liter gasoline and 2.0
liter Eco Fuel
Remove the fuel tank according to the manu-
facturer's instructions.
Cut 3 mm off blind plug.
1Fuel sender
2Tip cut off blind plug
Cutting off
blind plug
Position guide clip 1for standpipe.
Reinstall fuel tank in accordance with manu-
facturer's instructions.
213.5 mm dia. Caillau clamp
3Preassembled molded hose with stand-
pipe
410 mm dia. Caillau clamp
5Remaining section of fuel line
Connect-
ing fuel-
tank send-
ing unit
1.6 liter gasoline
Check the position of the components; adjust
if necessary. Check that they have free clear-
ance.
1Fuel line from fuel-tank sending unit
2Hose section, 10 mm dia. hose clamp [2x]
Connect-
ing meter-
ing pump
2.0 liter Eco Fuel
Check the position of the components; adjust
if necessary. Check that they have free clear-
ance.
1Fuel line from fuel-tank sending unit
2Hose section, 10 mm dia. hose clamp [2x]
Connect-
ing meter-
ing pump
41
1
2
42
2
5
4
3
1
43
2
1
44
2
1