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

00 0003

00 0002

00 0104

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

Operating instructions for the end customer 22

Tank Extracting Device Template 23

Table of Contents

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

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.

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.

VW Fox

Heater Unit Installation Location

1Heater unit

Installation

location

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.

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.

Wait to install the metering pump

cable harness until later,

together with fuel pipe along the

original vehicle fuel lines on the

underbody.

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.

Webasto

VW Fox ohne Klimaanlage/

mit Climatic

sw/rt

23T5h

T5h

rt/sw

sw/ge

gn/ws

rt/

T10c/1

85 30

87a87

SB42

T4e

N24

VW FOX without air conditioning/ with

Climatic

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

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

112

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

2 43

1 2

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