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 needed 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
an installation by untrained staff.
Feel the drive
Audi A4 1.9 + 2.0 TDI
Diesel
From model year 2006
For left-hand drive vehicles only
Also for vehicles without diesel particle filters
Ident. No.: 9015522A €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
Audi A4 1.9 + 2.0 TDI
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
Audi A4 8E e1 * 2001 / 116 * 0151 * ...
Engine type Engine Power in kW Engine capacity in cm³
BKE Diesel 85 1896
BRB Diesel 85 1896
AWX Diesel 96 1896
BLB Diesel 103 1968
BPW Diesel 103 1968
BRE Diesel 103 1968
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
Blower Control 7
Remote Start Option 8
Preparing the Installation Location 9
Preparing the Heater Unit 9
Installing the Heater Unit 10
Water Connection 11
Combustion Air 15
Fuel Connection 16
Exhaust System 19
Final Work 21
Operating instructions for the end customer 22
Fastening Strap Template 23
Tank Extracting Device Template 24
Table of Contents

33
Audi A4 1.9 + 2.0 TDI
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 vehicles Audi A4 1.9 + 2.0 TDI with Diesel 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 for example bore holes, with anti-corrosion wax (Tectyl 100K,
Order No. 111329)!
Special Tools
- Torque spanner for 2.0 - 10 Nm
- Vise-grip wrench
- Riveting nut tool
Amount Description Order no.:
1 Commercial supply of required control See price list
1 Installation kit for Audi A4 1.9 + 2.0 TDI Diesel 9015441A
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.
Audi A4 1.9 + 2.0 TDI
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
Audi A4 1.9 + 2.0 TDI
Heater Unit Installation Location
1Heater unit
Installation
location
11
Preliminary Work
WARNING!
- 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 cooling water reservoir cover
- Completely remove the battery.
- Completely remove the air filter with intake hose.
- Loosen the engine control unit in the cooling water reservoir.
- Open the tank cap, ventilate the tank.
- Close the tank cap again.
- Remove the underride protection
- Remove the right underbody panel.
- Remove the trunk cover (sedans only)
- Completely remove the lower plastic panel for the trunk floor (Avant only)
- Open the tank mounting service lid
- Remove tank mounting according to manufacturer's instructions.
- Remove air conditioning control according to manufacturer's instructions.
- Remove the dashboard panel on the driver’s side.

6
Audi A4 1.9 + 2.0 TDI
Electrical Connections
Fuse holder, K3 relay
2K3 relay
3Fuse holder retaining plate
1M5x12 bolt, washer, M5 nut
4Fuse holder
Positive and ground wire
Run the positive wire 1through the protective
rubber sleeve to the battery.
3Ground wire
2Original vehicle cable harness
Cable
harness
installation
diagram
Cable harness installation
Run the cable harnesses for the time switch and
blower control 1 through the protective rubber
sleeve 2in the control box and down under the
engine control unit into the passenger
compartment.
Time switch and summer / winter switch
option
1Time switch
2Summer / winter switch, bore hole Ø 12 mm.
2
42
1
33
2
13
br
sw
rt
br
bl
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
1
2
15
1
2

7
Audi A4 1.9 + 2.0 TDI
Blower Control
Connection the air conditioning control
connector D
(use enclosed micro timer).
Connect according to the circuit diagram.
1Connector D
2Insulate the red (rt) wire to K3/87a and tie
back
3Black (sw) wire from K3/30
4Green/white (gn/sw) wire to connector D
pin 10
Connec-
ting the air
conditio-
ning
control
Automatic
air condi-
tioning
circuit
diagram
Webasto components Components Audi A4 1.9 + 2.0 TDI Colors and symbols
Legend
HG Heater unit TT-C/E Fx Fuse rt red
X1 6-pin heater unit connector KB Air conditioning control ws white
F3 Fuse D Connector KB sw black
K3 Blower relay br brown
gn green
Insulate and tie
back wire ends
XSplitting point
Cable colors may vary.
6
1
4
2
3
Webasto
31
30
15
Audi
F3
5A
HG
4
X1
86
85 30
87a87
K3
gn/ws rt
sw
!
D
10
KB
F
br
rt
gn/ws
i

8
Audi A4 1.9 + 2.0 TDI
Remote Start Option
1Receiver
2Double-sided Velcro tape (self adhesive)
Assem-
bling the
receiver
1Antenna
Assem-
bling the
antenna
Temperature sensor for HTM100 only
1Temperature sensor
2Double-sided Velcro tape (self adhesive)
Assem-
bling the
tempera-
ture sensor
1
2
7
i
1
8
1
9
2

9
Audi A4 1.9 + 2.0 TDI
Preparing the Installation Location
Remove the original vehicle bolt at position 1
and 3(will be used here again). Drill hole at
position 2.
2Ø 9.1mm bore hole, insert rivet nut
Inserting
rivet nut
2Servo hose
1Rubberised tube clamp, plastic nut on
existing stay bolt
Tie back
servo hose
Preparing the Heater Unit
Remove the enclosed bracket for the
mounting, this will be replaced with the
fastening strap.
Bend the fastening strap 1to 90°according to
the template and loosely pre-assemble.
2M6x20 bolt, flanged nut
Loosely
fitting the
fastening
strap on
the bracket
Insert two washers between the heater unit
and the bracket 3in position 2.
Ejot screw bolts tightening torque 10 Nm!
1Ejot screw bolt [2x]
2Ejot screw bolt, washer [2x]
Assem-
bling the
bracket
10
321
11
2
1
12
1
2
13
1
3
2
1

10
Audi A4 1.9 + 2.0 TDI
1Mecanyl fuel line
2Hose section, Ø 10 mm hose clamps [2x]
Pre-
assem-
bling the
fuel line
Installing the Heater Unit
Insert the bracket 3with the heater unit as
shown in the figure.
Tighten bolt in position 4.
1Original vehicle nuts [4x] on the pre-
assembled bolts
2M6x20 bolt, spring washer on pre-
assembled rivet nut
Assem-
bling the
heater unit
14
1
2
15
1
1
4
3
2

11
Audi A4 1.9 + 2.0 TDI
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 hose clamps Ø 20-27 mm. Connecting pipe = Ø 20x20.
Position 1= black rubber profile. Position 2= Original vehicle spring band clamp.
Motor
1
B
Wärme-
tauscher
2
A
1
Heat
exchanger

12
Audi A4 1.9 + 2.0 TDI
a = 270 mm
b = 530 mm
Dispose of sections X
Cutting
water
hoses into
sections
Remove the original vehicle engine outlet
hose to the heat exchanger inlet 2(spring
band clamp 1will be used again).
Removing
the water
hose
Cut off the protective hose 2in the splitting
point area.
2Engine outlet hose section
1Dispose of hose section
Separate
the water
hose
1Slide on the black (sw) rubber profile [2x]
2Engine outlet hose section
Preparing
the hoses
ab
A X B
XX
1
2
16
1
217
18
A 1
1B

13
Audi A4 1.9 + 2.0 TDI
Connec-
ting the
heater unit
inlet
Fasten the hose Ato the engine outlet.
Refasten the hose Ato the stay bolt 2with
original vehicle hose clamps.
3Align the black (sw) rubber profile on the
cable harness. Connec-
ting the
heater unit
inlet
Connec-
ting the
heater unit
outlet
Run the hose Bthrough the original vehicle
rubber sleeve 2into the cooling water
reservoir.
Before connecting, fill the water hoses with
coolant.
1Original vehicle spring band clamp. Connec-
ting the
heat
exchanger
inlet
19
A
20
A 321
21
B
22
B
1
2

14
Audi A4 1.9 + 2.0 TDI
1Align the black (sw) rubber profile
according to the figure.
Connec-
ting the
heater unit
outlet
Run the hose Bthrough the original vehicle
rubber sleeve 2into the cooling water
reservoir.
Before connecting, fill the water hoses with
coolant.
1Original vehicle spring band clamp. Connec-
ting the
heat
exchanger
inlet
1Spacer bracket
Inserting
spacer
bracket
23
B
1
A
24
B
1
2
25
1
B
A

15
Audi A4 1.9 + 2.0 TDI
Combustion Air
1Combustion air pipe
a = 250 mm
Dispose of section XCutting the
combus-
tion air
pipe into
sections
Punch out the perforation in the header unit
cover at position 1and insert the retaining
clip.
Inserting
retaining
clip
1Combustion air intake pipe
2Ø 27 mm hose clamp
Assem-
bling the
vacuum
line
Place the cable harness 4on the heater unit.
1Combustion air intake pipe
3Combustion air intake silencer
2Retaining clip in bore hole
Assem-
bling the
silencer
a
1
X
26
1
27
2
1
28
2
3
1
4
i

16
Audi A4 1.9 + 2.0 TDI
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.
Run the metering pump cable harness 2and
the Mecanyl fuel line 3through the protective
rubber sleeve 1in the cooling water reservoir
to the right side of the vehicle.
Installing
lines
Run the metering pump cable harness 3and
the Mecanyl fuel line 1from the cooling water
reservoir through the protective rubber sleeve
2along the original vehicle fuel lines to the
underbody.
Installing
lines
Run the metering pump cable harness 2and
the Mecanyl fuel pipe 1along the original
vehicle fuel lines to the metering pump
installation location.
Installing
lines
29
1 32
30
3
1 2
31
2
1

17
Audi A4 1.9 + 2.0 TDI
Note the installation position of the metering
pump 4, see the “Installation Instructions”.
Installation location is to the right next to the
vehicle tank.
2Angle bracket
1Original vehicle bolt
5Rubberized tube clamp
3Silentblock, flanged nut [2x] on the angle
bracket
Metering
pump
installation
location
Fuel line from the heater unit 4on the
pressure side of the metering pump [side with
connector].
390°moulded hose, hose clamps
Ø 10 mm [2x]
2Ø 10mm hose clamps [2x]
1Metering pump cable harness, wire seals,
flat connector, connector housing
Connec-
ting the
metering
pump
Remove the tank mounting1according to the
manufacturer's instructions.
Drill Ø 6mm bore hole at position 2in the
middle of the cutout.
Fuel take-
off
1Tank extracting device
Inserting
tank
extracting
device
32
4
1
5
32
i
33
2
4
32
1 1
34
1
2
35
1

18
Audi A4 1.9 + 2.0 TDI
Cut the tank extracting device to size
according to the template.
1Tank extracting device
Inserting
tank
extracting
device
Install the tank mounting according to
manufacturer's instructions. Check that the
fuel injector can be freely accessed.
1Tank extracting device
3Additional Mecanyl pipe
2Hose section, Ø 10 mm hose clamps [2x] Connec-
ting the
fuel line
Fuel line from the tank extracting device 2on
the intake side of the metering pump [side
without connector].
Check the position of the components; adjust
if necessary. Check that these rotate freely.
1Hose section, Ø 10 mm hose clamps [2x] Connec-
ting to the
metering
pump
1
36
1
2
3
37
1
2

19
Audi A4 1.9 + 2.0 TDI
Exhaust System
1Exhaust pipe
a = 380 mm
2Exhaust end section
b = 140 mm
Dispose of section X
Preparing
the
exhaust
pipe
The illustration shows a standard gear shift
vehicle.
1Exhaust pipe
2Hose clamp
Assem-
bling the
exhaust
pipe
The illustration shows a standard gear shift
vehicle.
2Angle bracket
1Original vehicle bolt
Assem-
bling the
angle
bracket
The illustration shows a standard gear shift
vehicle.
2Exhaust pipe
1Exhaust silencer
2Hose clamp
4M6x20 bolt, body washer, flanged nut on
bracket Assem-
bling the
silencer
a b
1 2
X
38
1 2
2
1
39
1
40
2 3
4

20
Audi A4 1.9 + 2.0 TDI
The illustration shows a standard gear shift
vehicle.
3Exhaust silencer
2Exhaust end section
4Hose clamp
1Red (rt) rubber profile Assem-
bling the
exhaust
end
section
Informative illustration shows a vehicle with
an automatic transmission.
2Exhaust silencer
5M6x20 bolt, flanged nut on bracket
3Exhaust pipe
1Exhaust end section
4Hose clamp [2x]
6Slide on the red (rt) rubber profile
Assem-
bling the
exhaust
system
Assembling the underride protection 1.
2Position red (rt) rubber profile
Assem-
bling the
underride
protection
1
41
2
4
3
2
342
1
5
6
44
2
1
43