Webasto Thermo Top P 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, specialised tools and equipment are
required to install and repair Webasto heating and cooling systems.
Only original Webasto parts must be used. For this, also see the catalog of air and water heat-
er accessories from Webasto.
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.
Webasto does not accept any liability for defects and damage that are attributable to installa-
tion by untrained staff.
Feel the drive
Ident. No.: 9015699D_EN Fee Euro 10.00 © Webasto AG
VW Polo
Diesel
from Model Year 2006
For left-hand drive vehicles only
Water Heater
Thermo Top Parking Heater E
Thermo Top Parking Heater C
Thermo Top Parking Heater P
Installation Instructions
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22
VW Polo
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 Polo 9N e1 * 2001/116 * 0174 * ...
Engine type Engine model Output in kW Displacement in cm³
AMF Diesel 55 1422
BNM Diesel 51 1422
BNV Diesel 59 1422
Validity 2
Heater/Installation Kit 3
Foreword 3
General Instructions 3
Special Tool 3
Explanatory Notes on Document 4
Preliminary Work 5
Heater installation location 5
Electrical system 7
Climatic fan controller 8
Climatronic fan controller 9
Remote option (Telestart) 11
Remote option (Thermo Call) 12
Preparing heater 13
Preparing installation location 15
Installing heater 16
Coolant circuit with engine code letters: AMF 17
Coolant circuit with engine code letters: BNV and BNM 21
Combustion air 26
Fuel 27
Exhaust gas 30
Final Work 31
Template for Fuel Standpipe and Fuel-Tank Sending Unit 32
Operating Instructions for End Customer 33
Table of Contents

33
VW Polo
Heater/Installation Kit
Also required with Climatronic:
Heater recommended for the respective vehicle class:
The selection of the heater 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 Polo vehicles with a Diesel engine - for validity, see page 2
- from model year 2006 and later, assuming technical modifications to the vehicle do not affect instal-
lation, any liability claims excluded. Depending on the vehicle version and equipment, modifications
may be necessary during installation with respect to this installation documentation.
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 Tool
- Torque wrench
- Hose clamping pliers
- M8 metric thread-setter kit
Quantity Description Order No.:
1 Retail accessories Thermo Top E / C / P See price list
1 Installation kit for VW Polo Diesel 9015698A
1 Heater control See Price list
Quantity Description Order No.:
1 Climatronic kit 9013645A
Vehicle Heater
Compact car Thermo Top E
Mid-size car, station wagon Thermo Top C
Full-size car, van, offroader Thermo Top P

44
Mechanical system
Electrical system
Coolant circuit
Fuel
Exhaust gas
Combustion air
VW Polo
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.
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.

5
VW Polo
Heater installation location
1Heater
Installa-
tion loca-
tion
11
Preliminary Work
WARNING!
- 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.
- Remove the air filter together with the intake hose.
- Remove the wiper arms.
- Remove the coolant reservoir cap.
- Remove the coolant reservoir.
- Open the fuel tank cap, ventilate the tank.
- Close the tank cap again.
- Open the right-hand fuel sender service lid.
- Remove the fuel-tank sending unit in accordance with the manufacturers specifications.
- Remove the underride protection
- Remove the fuse box of the central electrical box.
- Take off the cover of the relay box for the central electrical box (only with Climatronic).
- Remove the A/C control panel according to the manufacturer's instructions (only with Climatronic).
Please remove page 33 of the “Operating instructionsfor the end customer” and add this to the vehicle
operating instructions.

6
VW Polo
Preparing electrical system
Only with Climatronic
Produce connections as shown in wiring dia-
gram. Fasten wire section 1with insulating
tape on the fan wiring harness. Preparing
exhaust
pipe
Connect the included lines to IPCU. Crimp
8mm dia. cable lug on brown (br) wire. The
following IPCU adjustment values should be
verified or adjusted before installation:
Duty cycle: 100%
Frequency:14 KHz
Voltage: 3,3 - 3.7V
Function: High side active
The voltage value (the rotation speed of the
fanmotor)shouldbe verified or adjustedafter
the function check.
Preassem-
bling IPCU
1Perforated bracket
Angling
down per-
forated
bracket
gn/ws rt
rt/ws
br
1
sw
86
85 30
87a87
K3
gn/ws
86 85
A
E
IPCU
sw
rt
br
A
15
86 85
E
90°
80
1

7
VW Polo
Electrical system
Wiring harness pass through
1Protective rubber plug of Bowden cable
Digital timer
1Digital timer
Wiring har-
ness in-
stallation
diagram
Fuse holder, K3 relay
1M6x20 bolt, large diameter washer, M6 flang-
ed nut
2Perforated bracket
3M5x12 bolt, washer, fuse holder, K3 relay, M5
flanged nut
4Original vehicle bracket, drill out hole to 6 mm
dia.
Summer/winter switch option
1Summer/winter switch, drilled hole 12 mm dia.
2
11
3
1
sw
rt
br
bl
Do not install the metering pump
cableharnessuntillatertogether
with fuel pipe along the original
vehicle fuel lines on the under-
body
i
4
2
3
1
4
5
1

8
VW Polo
Climatic fan controller
Climatic
wiring dia-
gram
Webasto components Components of VW Polo Colours and symbols
Legend
HG Heater GM Fan motor - V2 rt red
X1 6-pin heater connector SB36 25 A fuse ws white
F3 25 A fuse N24 Resistor group sw black
K3 Fan relay E9 Switch unit br brown
T... Connector gn green
bl blue
XCutting point
Wiring colours may vary.
Connection on central electrical box 5to fan
module.
Produce connections as shown in wiring dia-
gram.
1Black/red (sw/rt) wire from fuse SB36, 25 A
2Black (sw) wire from K3/30
4Black/red (sw/rt) wire to connector T6ac
3Red (rt) wire K3/87a
Connec-
tion to cen-
tral
electrical
box
1
sw
br
Webasto
31
30
15
VW Polo
rt
sw/rt
br
rt
5
E9
4
23T5h
T5h
sw/rt
rt/sw
gn/ws
rt/
ws
T10c/1
HG
4
X1
86
85 30
87a87
K3
F3
+
-GM
M
SB36
T4e
21 3
N24
4
i
6
2
4
3
5
1

9
VW Polo
Climatronic fan controller
Climatron-
ic wiring
diagram
Webasto components Components of VW Polo Colours and symbols
Legend
HG Heater J127 Fan unit rt red
X1 6-pin heater connector J255 A/C control panel ws white
F3 25 A fuse SB36 25 A fuse sw black
K3 Fan relay T... Connector br brown
IPCU Pulse width modulator gn green
IPCU adjustment values:
Duty cycle 100%
Frequency 14 kHz
Function High side active XCutting point
Voltage 3,3 - 3.7V Wiring colours may vary.
Connection on central electrical box 5to fan
module.
Produce connections as shown in wiring dia-
gram.
1Black/red (sw/rt) wire from fuse SB36, 25A
2Black (sw) wire from K3/30
4Black/red (sw/rt) wire to connector T6ac
3Red (rt) wire K3/87a
Connec-
tion to cen-
tral
electrical
box
Webasto
31
30
15
VW Polo
86 85
E
A
IPCU
sw
sw
sw/
rt
gn/
ws
rt
rt/ws
rt
sw/ws
rt
sw
br
br
HG
4
X1
gn/ws
F3
T12g
3
J255
SB36
T6ac
26
J127
M
sw/
rt
86
85 30
87a87
K3
i
7
2
4
3
5
1

10
VW Polo
Insert IPCU base in free socket.
Produce connections as shown in wiring dia-
gram.
1IPCU
Connec-
tion to re-
lay carrier
ConnectiononconnectorT12g3,Pin3ofA/C
control panel 4.
Produce connections as shown in wiring dia-
gram.
1Black/white (sw/ws) wire of IPCU/A
2Black (sw) wire from fan unit
5Black (sw) wire of connector T12g
6Red (rt) wire of IPCU/E
Connect-
ing air-con-
ditioning
control ele-
ment
8
1
9
1
5
4
6
2
3

11
VW Polo
Remote option (Telestart)
1Receiver
24 mm dia. hole [2x], 4.8x13 self-tapping
screw [2x]
3Bracket
Installing
receiver
1Antenna
Installing
antenna
Temperature sensor for HTM100 only
1Cable tie
2Temperature sensor
Installing
tempera-
ture sensor
1
3
2
10
2
i
1
11
1
12
2

12
VW Polo
Remote option (Thermo Call)
Mount TC receiver on A-pillar as shown;
mounting materials not included in delivery
scope!
1Receiver
2M5x16 bolt, large diameter washer, M5
flanged nut Installing
receiver
Copy hole pattern 2 of TC receiver 1to right-
hand A-pillar as shown.
Fasten receiver with self-tapping screws.
Installing
receiver
1Antenna
Installing
antenna
1Push button
Installing
push but-
ton
1
213
i
1
14
2
2
1
15
i
1
16
i

13
VW Polo
Preparing heater
Only on vehicles with engine code letters:
AMF!
Discard section X
Cut heat protection hose in half, compress
and push onto hose B and E.
b = 1050mm
c = 210mm
e = 730mm
d = 40mm
Cutting
coolant
hose to
length
Discard section X
a = 210mm
Cutting
coolant
hose to
length
Vehicles BNV and BNM
Discard section X
Compress heat protection hose and push
onto hose D.
a = 930mm
b = 210mm
d = 880 mm
c = 40 mm
Cutting
coolant
hose to
length
All vehicles
Remove heater cover 1and replace cable of
circulating pump with wiring harness exten-
sion. The spring clips will be reused.
2Heater
3Discard hose section
4Circulating pump
5Discard clamp
Removing
circulating
pump
bc e
XCB
F
ED
d
   

X A
a

abd
BA
X
DC
c
 



1
2
3
4
5

14
VW Polo
Hose Dwith engine code letters: AMF!
Hose Cwith engine code letters: BNV and
BNM!
127 mm dia. spring clip from water pump
220x20 connecting pipe
327 mm dia. spring clip from water pump Installing
coolant
hose on
heater
Ejot screw, tightening torque 10 Nm!
1Strut
2Loosely mount Ejot screw
Installing
strut on
heater
1M6x16 bolt, M6 flanged nut
229 mm dia. rubber-coated p-clamp
Installing
p-clamp
1M6x16 bolt, pin lock
2M6x12 bolt, pin lock
Preparing
bracket
2
3
1
17
D/C
18
1
2
2
1
19
1 2
20

15
VW Polo
Preparing installation location
Discard original vehicle bolts from engine
mount and replace with included double
bolts. Observe tightening torque according to
manufacturer.
1Double bolt [2x] Preparing
installa-
tion loca-
tion
1Right-hand frame side member.
2M8 rivet nut
Installing
rivet nut
1Loosely mount bracket
2M8 flanged nut [2x]
Installing
bracket
Loosen clamp at position 2and twist hose
from turbocharger 3as shown. (Distance to
heater)
1Bracket
4M8x30 Torx screw
5Frame side member Installing
bracket
21
1 1
22
2
1
23
21 2
24
4
1
5
2
3

16
VW Polo
Installing heater
Before installing heater, tighten fastening
bolts of bracket. Tighten Ejot screws to 10
Nm! Insert two 6 mm dia. washers between
heater and bracket at position 2.
1Ejot screw
2Ejot screw, washer [2x] Installing
heater
Tighten strut on heater following installation.
Tighten Ejot screws to 10 Nm!
1Strut
2M6 flanged nut
Installing
heater
25
2
11
26
2
1

17
VW Polo
Coolant circuit with engine code letters: AMF
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 no
other hose can be damaged! When installing the hoses, the heater must be filled with coolant!
The connection should be "inline" based on the following diagram:
Hose in-
stallation
diagram
All spring clips = 27 mm dia.!
Al connecting pipes = 20x20 mm
C
E
B
B
F
A

18
VW Polo
1Original vehicle bolt
2Angle bracket with long leg under bolt
3M6x16 bolt, M6 flanged nut
4Circulating pump
5Rubber-coated pipe clamp, 48 mm dia.
Fastening
circulating
pump
1Circulating pump
Connec-
tion to
heater and
circulating
pump
Before producing electrical connection, cut
connector off cable of circulating pump and
cut wiring harness extension to length.
1Wiring harness extension
2Cable of circulating pump
3Connector [2x] Electrical
connec-
tion to cir-
culating
pump
Beforeinstallingcoolanthoses,connectwiring
harness to heater. Guide coolant hose
E
through premounted rubber-coated p-clamp
1 .
Connec-
tion to
heater out-
let
27
5
12
3
4
28
1
C
29
3
1 2
30
1
E

19
VW Polo
Install hose Bwith 90° elbow on circulating
pump 1.
Connec-
tion to cir-
culating
pump
1Spacer bracket
Routing in
engine
compart-
ment
1Spacer bracket [2x]
Routing in
engine
compart-
ment
Install individual spacer bracket 3with brack-
et for air intake silencer 1. Dispose of mount-
ing clip 2.
Premount-
ing spacer
bracket
31
B1
32
1
B
D
E
33
1
1
B
E
1
3 2

20
VW Polo
1Charge-air tube
2Premounted spacer bracket
Routing in
engine
compart-
ment
Remove and dispose of original vehicle cool-
ant hose 1. The spring clips will be reused.
Removing
coolant
hose
1Heat exchanger inlet
2Heat protection hose
Connec-
tiontoheat
exchanger
inlet
Fasten hose Aon connection piece of engine
outlet with original spring clip
1Heat protection hose
2Spacer bracket
Connec-
tion to en-
gine outlet
34
2
1 2
B
E
35
1
36
1
2
EF
37
B
A
1
2