Webasto Thermo Top V User manual

Water Heater Unit
Upgrading Auxiliary Heater
Thermo Top V
Installation Instructions
e1
00 0018
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
warnings.
Webasto does not accept any liability for defects and damage that are attributable to
installation by untrained staff.
Feel the drive
VW Passat
Diesel
from Model Year 2005
For left-hand drive vehicles only
Ident. No.: 9013730G_EN Fee Euro 10 © Webasto AG

2
VW Passat
Validity
Vehicle and engine types, equipment variants and national specifications not listed in these installation
instructionshavenotbeentested.However, installationaccordingtotheseinstallationinstructionsmay
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
Volkswagen VW Passat 3C e1 * 2001/116 * 0307 * ...
Engine type Engine model Output in kW Displacement in cm³
BKC Diesel 77 1896
BKP Diesel 103 1968
BMP 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
Climatic Fan Controller 7
Climatronic Fan Controller 10
Remote Option (Telestart) 11
Final Work 13
Operating Instructions for End Customer 14
Table of Contents

3
VW Passat
Heater Unit/Installation Kit
Also required:
and/or
Other required tools:
Attention
No heater control is included in the delivery scope. The desired heater control must be ordered
separately.
Foreword
These installation instructions apply to VW Passat Diesel vehicles with an auxiliary heater installed as
standard equipment
- For the 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"operatingandmaintenanceinstructions"
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
specified 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
- Computer with MS Windows operating system
- Webasto diagnosis adapter
Quantity Description Order No.:
1 Upgrade kit for VW Passat Climatronic 9013729E
1 Upgrade kit for VW Passat Climatic 9013728D
1 Digital timer kit 1301122C
1 Telestart T80 advanced kit 9007098A
Vehicle Heater unit
PC USB diagnosis 9009064C
Upgrade kit for Touran 9008996A

44
Special features are highlighted using the following symbols:
Mechanical work
Electrical system
The arrow in the vehicle icon indicates the position on
the vehicle and the viewing angle.
VW Passat
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 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 Passat
Heater unit installation location
1Heater unit
Installation
location
1
1
Preliminary Work
WARNING!
- Disconnect the battery "earth" or "ground" connection.
- Completely remove the battery.
- Remove the battery carrier.
- 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 fuse and relay carrier.
- Remove the bumper.
- With Climatronic, remove the radio or navigation system cover.
- With Climatronic, remove the A/C control panel.
Please remove page 15 “Operating instructions for the end customer” and add this to the operating
instructions.

6
VW Passat
Electrical Connections
Wiring harness pass through
1Protective rubber plug
Wiring routing
Wiring
harness
installation
diagram
Ground connection
1Original vehicle bolt
2Ground wire
Digital timer
1Digital timer
2
1
3
+
-
i
4
1
2
5
1

7
VW Passat
Climatic fan controller
Produce connections as shown in wiring
diagram.
Position of free sockets dependent on
equipment variant.
1Relay K3 Installing
K3 relay
Produce connections as shown in wiring
diagram.
2Red/black (rt/sw) wire from fuse slot 41
6Red/black (rt/sw) wire to A/C control panel
1Connector with red (rt) wire from K3/87a
7Connector with black (sw) wire to K3/30
5Mount red/yellow (rt/ge) wire in socket 36
orfreesocket(terminal30)if necessary,40
A fuse
4Black/red (sw/rt) wire in socket 35 or free
socket (terminal 30) if necessary
3Mount fuse carrier, 1 A fuse
Con-
necting
fuse carrier
Screw on ground cable between fuse carrier
and instrument panel bracket with original
vehicle bolt.
1Original vehicle bolt
2Ground wire
Ground
connection
2Remove sealing plug (chamber 2)
1Yellow (ge) wire
38-pin connector to heater unit
Control of
heater unit
6
1
7
2
1
3
7
6
5
4
8
1
2
9
1
3
2

8
VW Passat
Climatic
wiring
diagram
Webasto components VW Passat components Colors and symbols
Legend
HG TT-V heater unit SC41 40 A fan fuse rt red
X1 6-pin connector KB Control unit for air conditioning -
J301 ws white
F1 1 A fuse WG Resistor group - N24 sw black
F2 Fuse 40A GM Fan motor - V2 br brown
K3 Fan relay T.... Plug connections ge yellow
VWU Digital timer
XCutting point
sw
br
rt/ge
Webasto
31
30
15
VW Passat Climatic
rt
br
rt/sw
WG
rt/sw
rt/sw
ge
HG
2X1
+
-GM
M
F2 SC41
86
85 30
87a87
K3
T5
31 24
T4r
34 21
KB
5T5
VWU
sw
F1
rt/sw
rt/sw
br
i

9
VW Passat
Climatronic fan controller
Produce connections as shown in wiring
diagram.
1Relay IPCU
2K3 relay Installing
IPCU
module,K3
relay
Integrating on fuse holder.
Produce connections as shown in wiring
diagram.
1Fuse holder
2Mountred/black(rt/sw)wireinsocket 35 or
free socket (terminal 30) if necessary, 1 A
fuse
3Mount blue (bl) wire in socket 25 or free
socket (terminal 15) if necessary, 1 A fuse
Con-
necting
fuse carrier
Fasten ground wire 2between fuse carrier
and instrument panel bracket with original
vehicle bolt 1.
Con-
necting
ground
wire
Integrating on connector T16f from A/C
control panel 2.
Produce connections as shown in wiring
diagram.
1Black/white (sw/ws) wire to fan unit
3Black/white (sw/ws) wire to connector T16f
5Connector with black (sw) wire from
IPCU/A
4Connector with red (rt) wire to IPCU/E
Con-
necting air-
con-
ditioning
control
element
10
21
11
1
2
3
12
1
2
13
1
3 2
5
4

10
VW Passat
2Remove sealing plug (chamber 2)
1Yellow (ge) wire
38-pin connector to heater unit
Control of
heater unit
Clima-
tronic
wiring
diagram
Webasto components VW Passat components Colors and symbols
Legend
HG TT-V heater unit SC56 Fuse 40A rt red
X1 6-pin connector KB Climatronic control unit -
J255 ws white
F1 1 A fuse sw black
F2 1 A fuse T... Plug connections br brown
K3 Fan relay ge Fan control unit - J126 and
fan motor - V2 gn green
VWU Digital timer bl blue
ge yellow
XCutting point
14
1
3
2
31
30
15
VW Passat Climatronic
br
sw/
ws bl/
ws
rt
br
sw/bl 86 85
A
E
IPCU
GE
T6t
31 42
M
KB
T16f
15 16 SC56
sw/
ws
sw
br
bl
Webasto
ge
HG
2X1 F2
86
8530
87a 87
K3
VWU
sw
F1
rt/sw
rt/sw
br
i

11
VW Passat
Remote option (Telestart)
Route antenna cable to duct behind relay
carrier.
1Antenna on windshield
Installing
antenna
Position bracket of receiver 2over fuse
holder and fasten with original vehicle bolt 3.
1Receiver
Installing
receiver
1Receiver of radio remote control
Position-
ing
receiver
Connect antenna cable to receiver of radio
remote control.
When simultaneously integrating digital timer
1533, black (sw) wire, 0.5 mm², on socket,
Pin 3, must be cut off and insulated approx.
50 mm before connector of Telestart.
Connect wiring harness on receiver of radio
remote control. Installing
receiver
1
15
i
1
16
2 3
1
17
Telestart
1
2
3
18

12
VW Passat
To establish communication to heater control
unit, an unassigned serial or USB port must
be used.
1Dongle
2Laptop
3,5 Diagnosis adapter (serial version shown)
4Plug adapter Installing
software
1Connector of wiring harness of digital timer
2Plug adapter
Con-
necting
connector
Read Readme file carefully before upgrading!
Starting from Windows Explorer.
- Start upgrade program with
- "Upgrade.exe"
- Select language
- Follow menus
Starting with CD.
-InsertCD
- Select language
- Follow menus
Disconnect connection after message
"Upgrade successful".
Installing
upgrade
When installing the software, the fuel level in
the tank must be above the "Reserve“ level.
If the radio remote control option is not
installed, the following message may appear
during future diagnosis:
"W-bus communication: faulty"
This message can be ignored! Note on
software
update
1
19
5
3
2
4
1
20
2
21

VW Passat
Webasto AG
Postfach 80 - 82132 Stockdorf, Germany - Hotline +49-
(0)1805-932278
Hotfax [phone] - http://www.webasto.de
Feel the drive
Final Work
WARNING!
Apply the warranty sticker in an easily visible location on the relay carrier bracket.
Reassemble the disassembled components in reverse order.
Check all electrical connections for firm seating.
Secure all loose cables using cable ties.
- Connect the battery.
- Set the digital timer and/or teach Telestart.
- Adjust the vehicle heater with Climatronic or Climatic according to "OperatingInstructions for End
Customer".
- Check the proper operation of the additional heater, see the operating instructions/installation
instructions.
- Attach the "Switch off additional heater before refueling" sticker to the left-hand B-pillar.
Adjustment of passenger compartment monitoring with VAG5052 Tester.
The following steps must be carried out with the VAG Tester :
- Connect the VAG tester.
- Open Item 46 (Central Module of Comfort System)
- Go to Item 10 (Adjustment)
- Follow the request for the code entry and enter the code 15
- Reduce the sensitivity of the passenger compartment monitoring to 50 %
- Save this setting
The adjustment of the sensitivity of the passenger compartment monitoring is completed.
i
Printed in Germany 03/07Printed by: Steffen

1414
VW Passat
Operating Instructions for End Customer
Please remove page and add to the vehicle operating instructions.
To ensure proper operation of the additional heater, the fuel level in the tank must be above the
"Reserve" level.
The sensitivity of the passenger compartment monitoring has been reduced.
Before parking the vehicle, make the following settings:
1Set temperature to "max."
2Air outlet to windshield
3Set fan to level "1", or possibly "2"
Climatic
1Air outlet to windshield
2Set temperature to "max."
Clima-
tronic
22
1 2
3
23
1 22