Webasto Thermo Top E Installation Documentation

Fee Euro 10.00 © Webasto AG Audi A3 1.2 and 1.4 TFSI from model year 2008 Left-hand drive vehicle 1.2 TFSI automatic transmission not checked! Feel the drive 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. The initial startup is to be executed with the Webasto Thermo Test Diagnosis. See sec- tion "Final Work". Webasto does not accept any liability for defects and damage that are attributable to installa- tion by untrained staff. Thermo Top E Parking Heater e1 00 0003 Thermo Top C Parking Heater e1 00 0002

Validity Vehicle and engine types, equipment variants and national specifications not listed in this installation documentation have not been tested. However, installation according to this installation documentation 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 Audi A3 8P e1 * 2001/116 * 0217 * ... Engine type Engine model Output in kW Displacement in cm³ CBZB Petrol TFSI 77 1197 CAXC Petrol TFSI 92 1390 Validity 2 Heater/Installation Kit 3 Foreword 3 General Instructions 3 Special Tools 3 Explanatory Notes on Document 4 Preliminary Work 5 Heater installation location 5 Electrical system 6 Fuse holder and K3 relay 7 Climatronic fan control 8 Climatic fan control 9 Digital timer 10 Summer/winter switch option 10 Remote option (Telestart) 10 Premounting heater 11 Preparing installation location 12 Installing heater 13 Fuel Connection 15 Coolant circuit 18 1.2 manual transmission 19 1.4 manual transmission 21 1.4 Automatic transmission 24 Exhaust gas 29 Final Work 30 Operating Instructions for End Customer 31

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 This installation documentation applies to Audi A3 1.2 and 1.4 TFSI vehicles - for validity, see page 2 - from model year 2008 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, the stipulations in the "installation documentation", the "operating instructions" and "installa- tion instructions" for the Thermo Top C/E must always be observed. The corresponding rules of technology and any information from the vehicle manufacturer should be observed during the installation work. When installing an IPCU, the appropriate settings must be checked and set prior to the installation. 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 rub protection (split-open fuel 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 - Unlocking tool Quantity Description Order No.: 1 Retail accessories for Thermo Top E / C See price list 1 Installation kit for Audi A3 1.2 and 1.4 TFSI 1313621B 1 Heater control See price list Vehicle Heater Compact car Thermo Top E Mid-size car, estate car Thermo Top C Full-size car, van, offroader Thermo Top P

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. Reference to general installation instructions of Webas- to components or to the manufacturer's vehicle-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 Coolant circuit Fuel Exhaust gas Combustion air Explanatory Notes on Document You will find an identification mark on the outside top right corner of the page in question to provide you with a quick overview of the individual working steps.

- Close the fuel tank cap again. - Depressurise 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. - Disconnect the battery "earth" or "ground" connection. - Remove the air filter box - Remove the battery - Remove the battery carrier. - Remove the left front wheel - Remove the front section of the left front wheel well trim - Remove the underride protection. - Remove the right-hand underbody trim - Remove the rear bench seat - Open the right-hand tank-fitting service lid. - Remove the footwell trim on the driver's side - Remove the lower instrument panel trim on the driver's side - Only with Climatronic: remove the A/C control panel. Remove page 31 "Operating Instructions for End Customer" and add to the vehicle operating instruc- tions. Heater installation location 1 Heater Installa- tion loca- tion 1 1

Route excess lengths from wiring harness of heater 1 in cable duct below battery and secure with cable ties. Wiring harness pass through in engine com- partment 1 Original vehicle wiring harness pass through Wiring har- ness rout- ing diagram Fuse holder, K3 relay Description of installation for K3 relay 1 and fuse carrier 2 on Page 7 Wiring harness pass through of passenger compartment 1 Original vehicle wiring harness pass through 2 1 1 3 1 5 Do not install the metering pump wiring harness until later togeth- er with fuel pipe along the origi- nal vehicle fuel lines on the underbody 4 2 1 5 1

Countersink holes 3 from behind for M5 coun- tersunk head screws. 1 Cover of fuse/relay carrier in engine com- partment 2 Cut away bar in shaded area 3 5.0 mm dia. hole [2x] Holes for fuse holder and K3 re- lay 1 M5x12 countersunk head screw [2x] Installing fuse holder and K3 re- lay On vehicles with Climatronic, replace 25 A fuse F3 7 with 5 A fuse provided. 1 M5 flanged nut 2 Large diameter washer (between cover and retaining plate) 3 Retaining plate 4 M5 flanged nut 5 Relay K3 6 Fuse holder Installing fuse holder and K3 re- lay Route brown (br) earth wire to original vehicle earth support point below headlight and con- nect. 1 Fuse/relay carrier 2 Original main vehicle fuse 3 Red (rt) positive wire Connect- ing posi- tive and earth wire 1 6 40 9 9 3 20 2 3 7 1 1 6 2 3 8 7 4 5 1 2 1 3 9

Produce connection as shown in wiring dia- gram. 1 Black (sw) wire from K3/30 2 Beige connector T16e 3 Green/white (gn/ws) wire Connect- ing air-con- ditioning control panel Climatron- ic Wiring Diagram Webasto components Components of Audi A3 Colours and symbols Legend HG Heater TT-C/E J255 Control unit of A/C control panel rt red X1 6-pin connector T16e Connector, beige ws white F3 Replace 25 A fuse F3 with 5 A fuse. sw black br brown K3 Fan relay gn green Insulate wire ends and tie back Wiring colours may vary. 1 2 3 10 Webasto 31 30 15 Audi F3 HG 4 X1 86 85 30 87a 87 K3 sw ! T16e 16 J255 F rt gn/ws

Detach vehicle fuse carrier 4 and unlock con- tact lock. Unlock and remove black/yellow (sw/ge) 4² wire 1 on fuse carrier. Produce connection as shown in wiring diagram - cut- ting point . 2 Red (rt) wire from K3/87a 3 Black (sw) wire from K3/30 For vehicles from model year 2008, cut black/yellow (sw/ge) 4² wire from relay J59 of connector T10a and connect red (rt) 4² K3/87a wire and black (sw) K3/30 wire (see Wiring Diagram dashed - cutting point ). Alternative cutting point on connector T5d. Fan motor connection Climatic Wiring Dia- gram Webasto components Components of Audi A3 Colours and symbols Legend HG Heater TT-C/E J65 Control unit of A/C control panel rt red X1 6-pin connector N24 Resistor group ws white F3 25 A fuse F3 SC40 Fuse 40A sw black K3 Fan relay SC22* 40A fuse from Model Year 2008 br brown J59* Release relay gn green T.... Connector ge yellow * from Model Year 2008 T10a 10-pin connector behind glove compartment Wiring colours may vary. 2 11 3 1 4 Webasto 31 30 15 Audi sw/ge br rt/sw rt/ws sw/ge F3 HG 4 X1 86 85 30 87a 87 K3 sw rt SC40 + - V2 M 5 T5d 3 T5d 1 2 4 J65 3 T4m 4 2 1 N24 T10a 30 87 J59* 1 2 sw/ge SC22* rt sw/ge rt/bl

1 Digital timer 2 12 mm dia. hole, summer/winter switch Installing digital tim- er Remote option (Telestart) If M6 bolt 2 is not present, then use suitable M6 bolt with spring lockwasher. Drill out upper hole of bracket to 6.5 mm dia. 1 Receiver 2 M6 bolt in existing threaded hole 3 Bracket Installing receiver 1 Antenna Installing antenna Temperature sensor HTM100 1 Fasten temperature sensor with adhesive tape Installing tempera- ture sensor 1 12 2 2 13 1 3 1 14 1 15

a = 250 Discard section X Cutting combus- tion air pipe to length Ejot stud, tightening torque 10 Nm. 1 Ejot stud Premount- ing heater Insert one washer each between heater and bracket at positions 2 1 M6x30 spacer nut 2 Washer, Ejot screw [2x] 3 27 mm dia. clamp 4 Prepared combustion air pipe (slotted side on heater) 5 Bracket Premount- ing heater 1 Hose section, 10 mm dia. clamp [2x] 2 Strut 3 Ejot screw [2x] 4 Combustion-air intake silencer 5 Retaining clip in hole of heater 6 Combustion air pipe 7 Fuel line Premount- ing heater a 1 X 16 1 17 1 5 2 3 2 4 18 2 5 4 3 3 6 7 1

a = 190 2 Exhaust end section b = 240 Discard section X Cutting ex- haust pipe to length 1 M6x16 bolt, spring lockwasher 2 Hose clamp [2x] 3 Red (rt) rubber isolator, without groove 4 Exhaust pipe with insulation 5 Silencer Premount- ing ex- haust system 1 Hose clamp 2 Red rubber isolator, without groove 3 Exhaust end section Premount- ing ex- haust system Preparing installation location Secure large diameter washer against falling with putty etc. 1 Large diameter washer on original vehicle stud bolt [3x] 2 Edge protection section Preparing installa- tion loca- tion a b 1 2 X 19 5 2 1 4 2 3 20 3 1 2 21 1 1 1 2

clip from original vehicle wiring harness 2 on position 3 and reinsert from the top. 1 Cable tie Routing wiring har- ness Installing heater 1 Large diameter washer, flanged nut M8 [3x] Installing heater The wiring harnesses 1 in vehicles must be at- tached with cable ties as shown. Ensure freedom of movement of exhaust pipe 3 relative to original vehicle components and lines. 2 Horn Aligning exhaust system Align the exhaust pipe 1 in vehicles as shown. Ensure freedom of movement of original vehi- cle component and lines. Aligning exhaust system 22 2 3 1 23 1 1 1 24 2 1 3 1 25 1

tem relative to original vehicle component and lines. Position rubber isolator 2. 1 Headlight washer system 3 Horn 4 Horn bracket Aligning exhaust system Punch through the perforation in the centre heater cover at position 2. 1 Wiring harness of heater 2 Insert clip-type cable tie 3 Cable tie Mounting and rout- ing wiring harness 26 4 1 3 2 27 1 2 3

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 as shown in the wiring harness rout- ing diagram. 1 Fuel line Routing to firewall Route Mecanyl line and wiring harness of me- tering pump 2 in coolant reservoir to right and fasten on original vehicle lines with cable ties. Pay particular attention to freedom of move- ment of wiper linkage. Route Mecanyl line and wiring harness of me- tering pump to underbody in wiring duct. 2 Existing pass through [2x] Routing in coolant reservoir Route fuel line and wiring harness of meter- ing pump along original vehicle fuel lines 2 to fuel tank. 1 Line duct Routing fuel line and wiring harness of metering pump 28 1 1 1 29 1 1 2 2 1 1 1 2 30

flanged nut 2 Remove sealing plug Installing silent block 1 Wiring harness of metering pump, connec- tor mounted 2 Secure rubber-coated p-clamp on silent block with flanged nut 3 Metering pump 4 Plug remounted 5 Hose section, 10 mm dia. clamp [2x] 6 Fuel line Mounting metering pump and connect- ing pres- sure side 1 Standpipe 2 Moulded hose Cutting standpipe and mould- ed hose to length 10 mm dia. Caillau clamp 2 in centre between beads on end of standpipe. 1 Standpipe 3 Moulded hose Premount- ing stand- pipe and moulded hose 31 1 2 32 1 6 5 2 3 4 1 2 33 235 10 dia. 4.5 mm dia. 7.5 mm 34 1 2 3 dia. 7.5 mm dia. 4.5 mm

2 Fuel-tank sending unit 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. 1 Premounted moulded hose with standpipe 2 10 mm dia. clamp 3 Fuel line 4 13.5 mm dia. clamp Connec- tion to fuel- tank send- ing unit 1 Hose section, 10 mm dia. clamp [2x] 2 Fuel line from fuel-tank sending unit Connect- ing intake side of me- tering pump 1 35 2 36 4 3 2 1 37 2 1

are kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that other hoses cannot be damaged. The heater must be filled with coolant when installing the hoses. The connection should be "inline" based on the following diagram: Hose in- stallation diagram All spring clips without a specific designation = 27 mm dia. 1 = Original vehicle spring clip . All hose clamps = 20-27 mm dia. All connecting pipes = 20x20 mm dia. 2 = Black (sw) rubber isolator (only for 1.2 manual transmission and 1.4 automatic transmission). 3 = Black (sw) rubber isolator (only for 1.4 manual transmission). A B C 1 2 3

Discard section X. A = 750 B = 120 C = 900 Cutting hoses to length Push braided protection hoses onto hose A and C, cut to length and shrink. 1 Heat shrink plastic tubing [4x] Premount- ing hoses Turn clamp lock 1 toward engine [2x]. Turning clamps Disconnect hose to engine outlet/heat ex- changer inlet 2 at connection piece of engine outlet. Spring clip 1 will be reused. Cutting point C A B X 10 B C A 1 1 1 38 1 39 1 1 40 1 2

piece with a 180° elbow. 1 Original vehicle spring clip Connect- ing engine outlet Routing in engine compart- ment Combustion air silencer tied off for demon- stration purposes. Connect- ing heater Routing in engine compart- ment 41 1 A 42 A 43 C B 44 C C

necting point. 1 Hose on heat exchanger inlet Connect- ing heat exchanger inlet Align black (sw) rubber isolator 2 on the gear change bracket. Align hoses and attach to the original vehicle hose with cable tie 3. Observe a sufficient distance to the adjacent compo- nents, especially to the gear change. Adjust, if necessary. 1 Cable tie Fastening hoses Align hoses and attach to the original vehicle hose with cable tie 1. Fastening hoses 1.4 manual transmission Discard section X. A = 780 B = 120 C = 1000 Cutting hoses to length 45 1 C 2 46 1 A 2 C 3 47 1 A C C A B X

and C, cut to length and shrink. 1 Heat shrink plastic tubing [4x] Premount- ing hoses Turn clamp lock 1 toward engine [4x]. Turning clamps Disconnect hose to engine outlet/heat ex- changer inlet 2 at connection piece of engine outlet. Spring clip 1 will be reused. Cutting point Install hose A on engine outlet connection piece with a 180° elbow. 1 Original vehicle spring clip Connect- ing engine outlet B C A 1 1 1 48 1 49 1 1 1 1 50 1 2 51 1 A

stration purposes. Connect- ing heater Routing in engine compart- ment 1 Hose on heat exchanger inlet 2 Original vehicle spring clip Connect- ing heat exchanger inlet 52 A 53 B C 54 C C 55 1 C

change bracket. Attach hose A and C to the original vehicle hose with cable tie 2. Routing in engine compart- ment Align hoses and attach to the original vehicle hose with cable tie 2. Observe sufficient dis- tance to connector 1 , adjust if necessary. Fastening hoses 1 Cable tie [2x] Fastening hoses 1.4 Automatic transmission Discard section X. A = 670 B = 120 C = 700 Cutting hoses to length 56 A 1 C 2 57 A 2 1 58 1 1 B D C A B X

and C, cut to length and shrink. 1 Heat shrink plastic tubing [4x] Premount- ing hoses 1 50 mm narrow edge protection 2 Straighten earth cable Installing edge pro- tection Disconnect hose to engine outlet/heat ex- changer inlet 1 at connection piece of engine outlet. Spring clip 2 will be reused. Cutting point 1 Hose on heat exchanger inlet 2 Black (sw) rubber isolator Connect- ing heat exchanger inlet B C A 1 1 1 59 1 60 1 2 61 1 2 62 C 1 2

stration purposes. Connect- ing heater Routing in engine compart- ment Install hose A on engine outlet connection piece with a 180° elbow. 1 Original vehicle spring clip Connect- ing engine outlet 63 C 64 C B 65 A 66 A 1 C

2 Angle bracket 3 29 mm dia. rubber-coated p-clamp [2x] Fastening hoses 1 6 mm dia. hole 2 Battery carrier Preparing battery car- rier Install battery carrier 2. Loosely install clip- type cable tie 1 around hose A and C. Fastening hoses Shift clip-type cable tie under the battery car- rier, insert in hole on position 1 and tighten. 2 Cable tie Fastening hoses 67 1 A 3 3 C 1 68 10 10 2 69 A C 1 2 70 2 1

to hose A. Align angle bracket at position 2 on original vehicle hole. Fastening hoses Install battery. Ensure sufficient distance to neighbouring components. 1 Angle bracket 2 Original vehicle bolt Fastening hoses 71 A C 72 3 C 2 1 A 73 1 2 2

Ensure sufficient spacing of exhaust end sec- tion to transmission and to wheel well trim. (The figure shows the vehicle with automatic transmission) 1 Wheel well trim Installing wheel well trim 1 Underride protection 2 42 mm dia. hole Hole in un- derride protection Align exhaust end section 3 flush on red rub- ber isolator 2. 1 Underride protection Mounting rubber iso- lator 1 74 75 1 2 2 3 76 1

04/2012 Printing: Steffen 30 Feel the drive Webasto AG Postfach 80 D-82132 Stockdorf / Germany National Hotline: 01805 93 22 78 (14 Cent aus dem deutschen Festnetz) Hotfax: 0395 5592 353 Hotmail: [email protected] http://www.webasto.com Final Work WARNING! Reassemble the disassembled components in reverse order. Check all hoses, clamps and all electrical connections for firm seating. Secure all loose lines using cable ties. Only use manufacturer-approved coolant. Spray the heater components with anti-corrosion wax (Tectyl 100K, Order No. 111329). - Connect the battery - Fill and bleed the coolant circuit according to the vehicle manufacturer’s specifications. - Set the digital timer. - Make settings on A/C control panel according to the "Operating Instructions for End Cus- tomer". - Place the "Switch off parking heater before refueling" signboard in the area of the filler neck - Check the proper function of the parking heater, see the operating instructions/installation instructions. - Proceed with the Webasto Thermo Test Diagnostics as follows at the initial start-up: Pump up fuel for heater under the pipeline filling button CO2- Check setting, adjustment values are listed in the General Installation Instructions During the test run, check all water and fuel connections for leaks and firm seating Conduct troubleshooting in case of any malfunctions Adjust the sensitivity of the passenger compartment monitoring WARNING! Pass through can only be carried out at an authorized workshop. Observe the applicable repair manual of the respective vehicle. - Connect the VAS 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.

Please remove page and add to the vehicle operating instructions. Note: We recommend matching the heating time to the driving time. Heating time = driving time Example: For a driving time of approx. 20 min. (in one direction), we recommend not exceeding a switch-on time of 20 min. If the summer/winter switch option has been installed, it must be switched in accordance with the time of year. The heater will then heat in the position Winter and in the position Summer it will only switch on the vehicle fan to ventilate the vehicle interior. Before parking the vehicle, make the following settings: 1 Set temperature to "max." 2 Air outlet to windscreen 3 Set fan to level "1", or possibly "2" Climatic 1 Set temperature on both sides to "HI". Climatron- ic 77 1 2 3 78 1 1