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E1
Thermo Top Evo Parking Heater 00 0258
Installation Documentation
VW Golf VII
Validity
Manufacturer Model Type EG BE No. / ABE
VW Golf VII AU e1 * 2007 / 46 * 0623 * ...
SG = manual transmission
DSG = direct gear transmission
Table of Contents
Validity 1 Digital Timer 10
Necessary Components 2 Remote Option (Telestart) 10
Installation Overview 2 Preparing Installation Location 11
Information on Total Installation Time 2 Preparing Heater 11
Information on Operating and Installation Instructions 3 Installing Heater 14
Information on Validity 4 Fuel 16
Technical Information 4 Coolant Circuit of TSI 21
Explanatory Notes on Document 4 Coolant Circuit of TDI 25
Preliminary Work 5 Final Work 29
Heater Installation Location 5 Operating Instructions for End Customer 30
Preparing Electrical System 6
Electrical System 7
Fan Controller 8
Necessary Components
• Basic delivery scope of Thermo Top Evo in accordance with price list
• Installation kit for VW Golf VII 2013 Petrol and diesel: 1319108A
• Heater control in accordance with price list and upon consultation with end customer
• In case of Telestart, indicator lamp in accordance with price list and in consultation with end
customer
Installation Overview
1
6
Legend:
1. Heater
2. Engine compartment fuse
holder 5
3. LIN- Gateway
4. Circulating pump 2 3
5. Digital timer
6. Metering pump
Only use genuine Webasto parts. See the Webasto air and water heat- 2.1.2. Vehicles of category O having liquid fuel heaters are deemed to comply
ers accessories catalogue for this purpose. with the requirements of this Annex.
Do not operate the heater in closed rooms due to the danger of poisoning and suf- 2.2.2. The combustion heater shall not constitute a risk of fire, even in the case
focation. of overheating. This requirement shall be deemed to be fulfilled if the in-
stallation ensures an adequate distance to all parts and suitable ventila-
Always switch off the heater before refuelling. tion, by the use of fire resistant materials or by the use of heat shields.
The heater may only be used with the prescribed fuel Diesel (DIN EN 590) or pet- 2.2.3. In the case of M2 and M3 vehicles, the heater must not be positioned in
rol (DIN EN 227). the passenger compartment. However, an installation in an effectively
sealed envelope which also complies with the conditions in paragraph
The heater may not be cleaned with a high-pressure cleaner. 2.2.2 may be used.
1.3 Please note 2.2.4. The label referred to in paragraph 1.4 or a duplicate, must be positioned
so that it can be easily read when the heater is installed in the vehicle.
ALWAYS follow all Webasto installation and operating instructions and observe all
warnings. 2.2.5. Every reasonable precaution should be taken in positioning the heater
to minimise the risk of injury and damage to personal property.
To become familiar with and understand all functions and properties of the heater,
the operating instructions must be read carefully and observed at all times. 2.3. Fuel supply
For proper, safe installation and repair work, the installation instructions with all 2.3.1. The fuel filler must not be situated in the passenger compartment and
warnings and safety information must be carefully read and observed at all times. must be provided with an effective cap to prevent fuel spillage.
Please always contact a workshop authorised by Webasto for all installation and
repair work. 2.3.2. In the case of liquid fuel heaters, where a supply separate to that of the
vehicle is provided, the type of fuel and its filler point must be clearly la-
Important belled.
Webasto shall assume no liability for defects, damage and injuries resulting 2.3.3. A notice, indicating that the heater must be shut down before refuelling,
from a failure to observe the installation, repair and operating instructions must be affixed to the fuelling point. In addition a suitable instruction
of the information contained in them. must be included in the manufacturer's operating manual.
This liability exclusion particularly applies to improper installations and re- 2.4. Exhaust system
pairs, installations and repairs by untrained persons or in the case of a fail-
ure to use genuine spare parts. 2.4.1. The exhaust outlet must be located so as to prevent emissions from en-
tering the vehicle through ventilators, heated air inlets or opening win-
The liability due to culpable disregard to life, limb or health and due to dam- dows.
age or injuries caused by a wilful or reckless breach of duty remain unaf-
fected, as does the obligatory product liability. 2.5. Combustion air inlet
Installation should be carried out according to the general, standard rules 2.5.1. The air for the combustion chamber of the heater must not be drawn
of technology. Unless specified otherwise, fasten hoses, lines and wiring from the passenger compartment of the vehicle.
harnesses to original vehicle lines and wiring harnesses using cable ties.
Insulate loose wire ends and tie back. 2.5.2. The air inlet must be so positioned or guarded that blocking by rubbish
or luggage is unlikely.
Sharp edges should be fitted with rub protection (split-open fuel hose)!
Spray unfinished body areas, e.g. drilled holes, with anti-corrosion wax 2.6. Heating air inlet
(Tectyl 100K, Order No. 111329).
2.6.1. The heating air supply may be fresh or recirculated air and must be
Observe the instructions and guidelines of the respective vehicle manufac- drawn from a clean area not likely to be contaminated by exhaust fumes
turer for demounting and mounting vehicle specific components! emitted either by the propulsion engine, the combustion heater or any
other vehicle source.
The initial startup is to be executed with the Webasto Thermo Test Diagno-
sis. 2.6.2. The inlet duct must be protected by mesh or other suitable means.
When installing an IPCU, the corresponding settings must be checked or 2.7. Heating air outlet
adjusted before the installation.
2.7.1. Any ducting used to route the hot air through the vehicle must be so po-
2 Statutory regulations governing installation sitioned or protected that no injury or damage could be caused if it were
to be touched.
Guidelines Thermo Top Evo
2.7.2. The air outlet must be so positioned or guarded that blocking by rubbish
Heating Directive ECE R122 E1 00 0258 or luggage is unlikely.
EMC Directive ECE R10 E1 03 5627 End of excerpt.
Note In multilingual versions the German language is binding.
The regulations of these guidelines are binding in the scope of the Directive
70/156/EEC and/or 2007/46/EC (for new vehicle models from 29/04/2009) and
should also be observed in countries in which there are no special regulations.
Important
Failure to follow the installation instructions will result in the invalidation of the type
approval for the heater and therefore invalidation of the general homologation of
the vehicle.
Note
For vehicles with an EU permit, no entry in accordance with § 19 Sub-Section 4
of Annex VIII b to the Road Traffic Act is required.
2.1 Excerpt from the directive 2001/56/EC Appendix VII for the
installation of the heater
Information on Validity
This installation documentation applies to VW Golf VII Petrol and diesel vehicles - for validity, see page 1 - from model
year 2013 and later, assuming technical modifications to the vehicle do not affect installation, any liability claims ex-
cluded. Depending on the vehicle version and equipment, modifications may be necessary during installation with re-
spect to this installation documentation.
Vehicle and engine types, equipment variants and other specifications not listed in this installation documentation
have not been tested. However, installation according to this installation documentation may be possible.
Technical Information
Special tools
• Hose clamp pliers for self-clamping hose clamps
• Hose clamp pliers for Clic hose clamps of type W
• Automatic wire stripper 0.2 - 6mm²
• Crimping pliers for cable lug / tab connector 0.5 - 6mm²
• Torque wrench for 2.0 - 10 Nm
• Hose clamping pliers
• Metric thread-setter kit
• Webasto Thermo Test Diagnosis with current software
Dimensions
• All dimensions are in mm.
Tightening torque values
• Tightening torque values of 5x13 heater bolts and 5x11 heater stud bolts = 8Nm.
• Tightening torque values of 5x15 retaining plate of water connection piece bolts = 7Nm.
• Tighten other bolt connections in accordance with manufacturer's instructions or in accordance with state-of-the-
art-technology.
Software
Preliminary Work
Vehicle
Heater
• Remove years that do not apply from the type and duplicate label.
• Attach the duplicate label (type label) in the appropriate place in the engine compartment.
Note:
The installation steps are nearly identical for both TSI and TDI. Deviations have been documented, otherwise all im-
ages show a 1.6 TDI.
Installation
location
Preparing
2 perforated
bracket
90°
115°
Premount-
ing the fuse
2 holder of
the engine
compart-
ment
3 2
Installing
rivet nut
Electrical System
Wiring harness routing Fuse holder of engine compartment
Route wiring harness of heater below the cover 1 M6x20 bolt, large diameter washer
along the marking to the installation location of the 2 Perforated bracket
heater and fasten using retaining clamp 1 [3x]. 3 Fuses F1-2
1 1 1 2
1
3
5 6
Wiring har-
ness rout-
Do not install the metering pump ing
wiring harness until later togeth- diagram
er with fuel pipe along the origi-
nal vehicle fuel line on the
underbody
3 7 1 8
Fan Controller
Webasto VW
30
15
HG Wiring dia-
X2 1 2 2 5 X1 gram
F2 F1
ge 2
0,5²
rt KB
3 4²
gn/ws
0,75²
T20c 16
rt/sw
0,5²
vi/bl
br 4 1 0,35²
0,5²
gn/ws rt
0,5² 0,5²
sw/ws
X10 SH 0,5²
vi/bl
IN 0,35²
LIN 7
OUT T4dc
8 4
GND M GM
! br
0,5²
br
0,5²
5 6
31
Webasto components Vehicle components Colours and symbols
HG TT-Evo heater GM Fan motor rt red
X1 6-pin heater connector T4dc 4-pin connector GM sw black
X2 2-pin heater connector KB A/C control unit ge yellow
X10 4-pin connector T20c 20-pin connector KB gn green
Heater control Legend
vi violet
K1 Fan relay ws white
F1 20A fuse br brown
F2 Replace 30A fuse with bl blue
1A fuse
LIN LIN- Gateway Insulate wire end and tie
back
X Cutting point
Wiring colours may vary.
6 9
1 10
7 11
1 Digital Timer
1 Digital timer
Installing
digital tim-
er
12
13
1 1 Antenna
Mounting
antenna
14
Installing
tempera-
ture sensor
15
1 16
1 Preparing Heater
1 Water connection piece, sealing ring [2x
each]
2 5x15mm self-tapping bolt, retaining plate
of water connection piece Mounting
water con-
nection
pieces
2
1 17
1 2 1 Bracket
2 5x13 self-tapping bolt [3x]
Mounting
bracket
2 2 18
TSI
Discard section X.
A F C D
A = 1070
B = 110 Cutting
C = 60 hoses to
D = 80 length
E = 110
B E X F = 990
2 C 19
Premount-
ing hoses
E
D 20
TDI
Discard section X.
B G D E X Hose A = 18x20 mm dia., straight moulded
hose
Cutting
B = 1020 hoses to
C = 110 length
D = 80
C F X E = 60
A F = 110
G = 980
2 D 21
Premount-
ing hoses
F
E 22
1 All vehicles
1 Cable tie
2 Wiring harness of circulating pump
Connect-
ing wiring
harness
2 2 23
1 2 Discard section X.
1 Exhaust pipe
a = 195
2 Exhaust end section
b = 100 Preparing
exhaust
pipe
a b
X
1 1 Exhaust end section
2 M6x16 bolt, spring lockwasher
3 Silencer
4 Hose clamp
4
Installing
silencer
and end
section
3
2 24
1 1 Exhaust pipe
2 Hose clamp [2x]
Mounting
2 exhaust
2
pipe
25
1 Combustion air pipe
2 Cable tie
3 Fuel line
4 90° short moulded hose, 10 mm dia.
clamp [2x]
Premount-
1 ing com-
bustion air
2 pipe and
fuel line
4 3 26
Premount-
2 ing com-
bustion air
4 silencer
3 27
1 Installing Heater
Insert one 5 mm shim each between bracket 3
and frame side member. Route original vehicle
wiring harness 1 in front of the bracket as
shown. Mounting
2 heater
2 Original vehicle stud bolt, 5mm shim, M8
flanged nut [2x each]
3
3 2 28
Mounting
heater
29
Aligning
exhaust
pipe
30
Fuel
CAUTION!
Open the vehicle's fuel tank cap, ventilate the tank and then re-close the tank lock.
Route 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 Connector housing
2 Lock
3 Blue / brown (bl / br) wires Disman-
4 Coding tling con-
5 5 Timer lock nector
5
31
32
Routing
lines
1
1 33
Routing
lines
34
Preparing
installation
location of
metering
pump
2 35
Insert M6x20 bolt 1 through opening 2 into
hole.
Preparing
installation
location of
metering
pump
2 1 36
5 4 37
3 M6 flanged nut
4 Cover cap inserted
Mounting
metering
pump
5 4 3 38
4 3 39
40
Inserting
retaining
clamp
41
1 Standpipe A
2 Discard section
b a TSI TDI
Cutting
a = 120 145 standpipes
b = 130 140 to length
3 2 1 42
1 4.5x10.5mm dia., 90° moulded hose
2 Discard section
Cutting
1
10 moulded
hose to
length
2 43
1 2 1 Standpipe A
2 10 mm dia. clamp
3 4.5x10.5mm dia., 90° moulded hose
Premount-
ing mould-
3 ed hose
44
1 13.5 mm dia. clamp
2 Standpipe A
Installing
standpipe A
2
1 45
1 4 46
1 4 47
1 Fuel line
2 Cable tie
3 10 mm dia. clamp Connect-
ing fuel line
4 3 48
3 2 49
Hose in-
stallation
diagram
2 1
F
1
2
A
E
All spring clips without a specific designation = 25mm dia. 2 = Original vehicle spring clip .
1 = Original vehicle hose. All connecting pipes and = 18x18mm dia.
Mounting
perforated
bracket
2 50
Mounting
spacer nut
51
Cutting
point
52
Cutting
point
40
3 53
2 Connec-
tion of heat
exchanger
inlet
F 54
Connect-
1 ing engine
outlet
55
1 Spacer bracket
2 Spacer bracket, twistable
3 Hose for heat exchanger outlet Routing on
firewall
F 3 56
Fastening
to firewall
2 F 57
2 A 58
Connec-
tion of
heater inlet
B 59
Connec-
tion of
heater out-
let
F
E 60
F 2 B 61
Hose in-
stallation
diagram
Ø 18x20
2
Ø 27
3
Ø 18x18
A
G 2
E B
All spring clips without a specific designation = 25mm dia. 2 = Original vehicle spring clip .
1 = EGR. 3 = Original vehicle hose.
All connecting pipes = 18x18 mm dia..
Mounting
perforated
bracket
2 62
1 M6x30 spacer nut, original vehicle stud
bolt
Mounting
spacer nut
1 63
Remove hose from engine outlet/EGR inlet 2.
Spring clips 1 will be reused!
1 Cutting
point
2 1 64
Slide 600mm long heat protection hose 3
onto hose B.
3 B A 2 65
1 Pipe of EGR
2
2 Original vehicle spring clip
3 Original vehicle hose Connec-
tion of heat
exchanger
inlet
3
4 G 66
Fastening
to firewall
G 2 67
G Routing on
frame side
member
3 2 68
Align hoses. Ensure sufficient distance to cat-
alytic converter at position 1, correct if neces-
sary.
Routing in
engine
compart-
ment
1 69
Connec-
tion of
2
heater inlet
C 70
Connec-
tion of
heater out-
let
F 71
Final Work
WARNING!
Mount removed parts in reverse order. Check all hoses, clamps and all electrical connections for firm
seating. Insulate and tie back all loose lines.
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 digital timer, teach Telestart transmitter.
• Make settings on A/C control panel according to the "Operating Instructions for End Cus-
tomer".
• Place the "Switch off parking heater before refuelling" signboard near the filler neck.
• See installation instructions for initial start-up and function test.
3 2 72
Passenger compartment monitoring unit, if installed, must be deactivated in addition to vehicle settings
for the heating operation.
For instructions on deactivation, please refer to the operating instructions of the vehicle.
A/C control
panel
73
Fuses of
engine
compart-
ment
2 74