Water Heater Unit

Feel the drive

Thermo Top E Additional Heater

Thermo Top C Additional Heater
Thermo Top P Additional Heater

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Installation Instructions
VW Golf VI
2.0 TDI Common Rail
from Model Year 2008
Left-hand drive vehicle
Adjustment of sensitivity of passenger compartment monitoring not checked!

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.

Ident. No.:1314423A_EN

Fee Euro 10.00

Webasto AG

VW Golf VI

Table of Contents
Validity
Heater Unit/Installation Kit
Foreword
General Instructions
Special Tools
Explanatory Notes on Document
Preliminary Work
Heater unit installation location
Electrical system
Fuse holder and relay K3
Climatic fan controller
Climatronic fan controller
Digital timer, summer/winter switch option
Remote option (Telestart)

2
3
3
3
3
4
5
5
6
7
8
10
12
12

Premount heater unit

Preparing exhaust system
Preparing coolant
Installing heater unit
Fuel Connection
Coolant
Exhaust gas
Final Work
Operating Instructions for End Customer

13
14
15
17
18
21
26
27
28

Validity
Manufacturer
VW

Model
Golf VI

Type
1K

EG-BE No./ABE
e1 * 2001/116 * 0242 * ...

Engine type
CBAB

Engine model
Diesel

Output in kW
103

Displacement in cm
1968

Vehicle and engine types, equipment variants and national specifications not listed in these installation
instructions have not been tested. However, installation according to these installation instructions may
be possible.
The installation location of a digital timer and summer/winter switch should be confirmed with the end
customer before installation.

1314423A_EN

VW Golf VI

Heater Unit/Installation Kit

Quantity
1
1

Description
Retail accessories with desired heater control
Installation Kit for VW Golf VI 2.0 TDI Common Rail

Order No.:
See price list
1314422A

Also required with Climatronic

Quantity
1

Description
IPCU Kit for Climatronic

Order No.:
9013645A

Heater unit recommended for the respective vehicle class:

Vehicle
Compact car
Mid-size car, station wagon
Full-size car, van, offroader

Heater Unit
Thermo Top E
Thermo Top C
Thermo Top P

The selection of the heater unit 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 Golf VI 2.0 TDI Common Rail vehicles - for validity, see
page 2 - from model year 2008 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 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
- Torque wrench for 2.0 - 10 Nm
- Hose clamping pliers

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VW Golf VI

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.

Mechanical system
Electrical system
Coolant
Fuel
Exhaust gas
Combustion air
Special features are highlighted using the following symbols:
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.

The arrow in the vehicle icon indicates the position on

the vehicle and the viewing angle.

All dimensions are in mm!

Tightening torque of hose clamps = 2.0 + 0.5 Nm!
Tightening torque of Ejot screws, Ejot studs = 10 Nm!
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VW Golf VI

Preliminary Work
WARNING!
- Open fuel tank cap, ventilate tank.
- Close the tank cap again.
- Depressurize 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.
- Completely remove the battery with the battery carrier.
- Remove the engine cover.
- Detach the coolant reservoir cap.
- Remove the left front wheel.
- Remove the front section of the left front wheel well trim.
- Remove the left-hand front fog light or, on vehicles without front fog lights, the left-hand cover.
- Remove the underride protection.
- Remove the right-hand underbody trim.
- Remove the rear bench seat.
- Open the right-hand fuel sender service lid.
- Remove the footwell trim on the driver's side
- Remove the lower instrument panel trim on the driver's side
- Only vehicles with Climatronic: Remove the footwell trim on the front passenger side
Remove page 28 "Operating Instructions for End Customer" and add to the vehicle operating instructions.

Heater unit installation location

1 Heater unit

Installation location

1
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VW Golf VI

Electrical system
Wiring harness routing

Wiring harness pass through

Route excess lengths from wiring harness 1 in

cable duct 2 below battery and secure with cable
ties.

1 Original vehicle wiring harness pass through

Wiring harness installation

diagram

Do not install the metering pump

cable harness until later together
with fuel pipe along the original
vehicle fuel lines on the underbody

Fuse holder, relay K3

Wiring harness pass through

Installation of K3 relay 1 and fuse carrier 2 on

Page 7

1 Original vehicle wiring harness pass through

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VW Golf VI

Fuse holder and relay K3

Countersink holes 3 from behind for M5 countersunk head screws.

1 Cover of fuse/relay carrier in engine compartment

2 Cut away bar in shaded area
3 5 mm dia. hole [2x]

20

Holes in
cover

40

3
1

1 M5x12 countersunk head screw [2x]

Installing
fuse holder
and K3 relay

7
1

On vehicles with Climatronic, replace 25 A

fuse F3 7 with 3 A fuse provided.

3
4
5

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 relay

8
1

Route brown (br) ground wire to original vehicle ground support point below headlight and
connect.

1 Fuse/relay carrier
2 Original main vehicle fuse
3 Red (rt) positive wire
3

Connecting positive and

ground
wire

9
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VW Golf VI

Climatic fan controller

Webasto

VW
30
15

HG
X1

SC22
(SC40)

F3

Climatic
wiring diagram

T10k
rt/ge

rt/ws

rt
4

86

87

J301

87a

K3
85

T5

30

rt/
sw

ge

rt/
ge

sw/
ws

rt/sw

sw
4

T5

rt/
sw

1
M

V2

T4f

N24
br

31
Webasto components
HG
Heater unit TT-C/E
X1
6-pin heater unit connector
F3
25 A fuse
K3
Fan relay

Vehicle components
GM
Fan motor
SC22 40 A fan fuse
(SC 40) (depending on respective
fuse assignment)

Colors and symbols

rt
red
ge
yellow
sw

black
Legend

J301
T5
N24
T4f
T10k

Control unit of air conditioning

5-pin connector J301
Resistor group
4-pin connector N24
Connector
Wiring colors may vary.

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VW Golf VI

Connection on fuse carrier 2 (instrument panel at upper left). Remove red/yellow (rt/ge) 4
wire 1 on fuse output of fan SC 22 or SC40
(depending on respective vehicle equipment).

Connection to fuse
carrier

10
Red (rt) wire from K3/87a 4 with crimped-on
standard power timer engaged in fuse output
SC 22 or SC40.
Produce connections as shown in wiring diagram.

1 Red/yellow (rt/ge) wire of fuse SC22 or

SC40
2 AMP housing
3 Black (sw) wire to K3/30

Connecting wires

3
4

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VW Golf VI

Climatronic fan controller

Webasto

VW
30
15

HG
X1

Climatronic wiring
diagram

rt

F3

J255

4
16

15

rt

sw/
ws

bl/
ws

0,35

0,35

SC22
(SC40)

T16d

rt/
ge
4

86

87

87a
rt

K3
85

0,75

30

sw/ws
0,75

sw

IPCU

T10k

A
86

rt/ws

85

sw/
ws

br

0,35

gn/ws

V2

br

1
M

T6t

J126
31

Webasto components
HG
Heater unit TT-C/E
X1
6-pin heater unit connector
K3
Fan relay
F3
Replace 25 A fuse
with 3 A fuse
IPCU Pulse width modulator
IPCU adjustment values
Voltage: 8 V
Frequency: 400 Hz
Duty cycle: 30 %
Function: High-side

1314423A_EN

Vehicle components
Colors and symbols
SC22 40 A fan fuse
rt
red
(SC 40) (depending on respective fuse ws white
assignment)
T10k
J255
T16d
J126
V2
T6t

Plug connections
Climatronic control unit
16-pin connector J255
Fan controller
Fan motor
6-pin connector J126

sw
br
gn
ge

black
brown
green
yellow

bl

blue

Insulate wire end

and tie back
Cutting point

Legend

10

VW Golf VI

Produce connections as shown in wiring diagram.

Position of free sockets dependent on vehicle
equipment.
1 IPCU socket

12

1
1

Installing
IPCU socket

Insulate red (rt) wire K3/87a 1 and tie back.

Produce connections as shown in wiring diagram.

2
3

2 AMP connector
3 Brown (br) wire of IPCU/85, original vehicle
ground support point
4 Green/white (gn/ws) wire of IPCU/86
5 Connect IPCU
6 Black (sw) wire from K3/30

Connecting IPCU

13
Route wiring harness of IPCU 1 to center console.

Routing
wiring harness from
IPCU

14
2

2
5

4
1314423A_EN

Route wiring harness of IPCU 1 to fan unit.

Connection on connector of fan unit 1.
2 Black/white (sw/ws) wire of connector
T6t/2
3 Black/white (sw/ws) wire of IPCU/A
4 Red (rt) wire of IPCU/E
5 Black/white (sw/ws) wire of A/C control
panel

Connection to fan
unit

15

11

VW Golf VI
Digital timer, summer/winter
switch option

1 Digital timer
2 12 mm dia. hole; summer/winter switch
Digital timer

16

Remote option (Telestart)

Drill out bracket 3 to 6.5 mm dia. at position 1.

1 Existing hole, M6x20 bolt, flanged nut
2 Receiver
3

Installing
receiver

17

1 Antenna

Installing
antenna

18

Temperature sensor HTM 100

Fasten temperature sensor 1 with double-sided adhesive tape.

Installing
temperature sensor

19
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VW Golf VI
Premount heater unit

1 Ejot stud

Premounting heater
unit

20
1 Combustion air pipe
a = 250

Discard section X
Cutting
combustion air
pipe to
length
a

X
1

Insert one washer each between heater unit

and bracket at positions 2.

1314423A_EN

M6x30 spacer nut

Ejot screw, washer [2x each]
27 mm dia. hose clamp
Combustion air pipe
Bracket

1
2
3
4
5
6
7

Strut
Ejot screw [2x]
Muffler
Retaining clip in hole
Combustion air pipe
Hose section, 10 mm dia. hose clamp [2x]
Fuel line

Premounting heater
unit

21

1
2
3
4
5

Premounting heater
unit

22

13

VW Golf VI

Preparing exhaust system

1 Exhaust pipe
a = 190
2 Exhaust end section
b = 240
Discard section X

Cutting exhaust pipe

to length

X
Slide insulation 2 onto exhaust pipe.

1 Hose clamp [2x]

Preassembling exhaust pipe

2
1

23
1 Hose clamp
2 Muffler
3 M6x16 bolt, spring lockwasher on spacer
nut
4 Exhaust end section
5 Red (rt) rubber isolator

Premounting muffler
and exhaust end
section

24
1 Exhaust end section

Aligning
exhaust
end section

25
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VW Golf VI
Preparing coolant
A

Hose D = 180 elbow

Discard section X

a = 920
b = 100
c = 910
X

Cutting
coolant
hoses to
length

Push braided protection hoses onto hose A

and C and cut to length.
Cut heat shrink plastic tubing to length.

1
A

1 25 mm long heat shrink plastic tubing [4x]

Preparing
coolant
hoses

26

1
1

1
2
3
4

27 mm dia. spring clip

Cable tie [2x]
27 mm dia. hose clamp
20x20 mm connecting pipe
Installing
hose B

2
3

27

2
D

1 20x20 mm connecting pipe, 27 mm dia.

spring clip [2x]

Preparing
hose C and
D

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28

15

VW Golf VI

Pull hose off engine outlet 1. Spring clip 2 will

be reused.
Remove coupling from heat exchanger
inlet 3.

Cutting
point

29
1 Original vehicle spring clip
2 Coupling of heat exchanger inlet

Premounting hose C
and D

2
C

30

1 27 mm dia. spring clip

2 27 mm dia. hose clamp

Premounting hoses

2
1

31

Preparing installation location

Secure large diameter washer against falling

with putty etc.
1 Large diameter washer on original vehicle
stud bolt [3x]
2 100 mm edge protection
1

Preparing
installation location

32
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VW Golf VI
Installing heater unit

1 Large diameter washer, flanged nut M8

[3x]
Installing
heater unit

33
Ensure freedom of movement of exhaust system relative to original vehicle component
and lines.

2
2

1 Exhaust pipe
2 Original vehicle wiring harnesses (secured
with cable ties)
3 Horn

Aligning
exhaust
system

34
Punch through perforation of heater unit lid at
position 2. Mount clip cable tie and fasten wiring harness of heater unit 1.

Connecting wiring
harness

35
Combustion air muffler tied back for demonstration purposes.

1 Cable tie
2 Wiring harness of heater unit
3 Edge protection 50
2

Fastening
wiring harness

36
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17

VW Golf VI
Fuel Connection
CAUTION!
Open the vehicle's fuel tank cap, ventilate the tank and then re-close the tank lock.
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. Unless 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 in as shown in the wiring harness
routing diagram.

1 Fuel line

Installing
fuel line

37
1

Route fuel line and wiring harness of metering pump 2 in coolant reservoir to right and
fasten on original vehicle lines with cable ties.
Pay particular attention to freedom of movement of wiper linkage.
Route fuel line and wiring harness of metering pump to underbody in line duct.

1 Existing pass through [2x]

Installing
lines

38
Route fuel line and wiring harness of metering pump along original vehicle fuel lines 2 to
fuel tank.

1 Line duct
Installing
lines

2
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39

18

VW Golf VI

Remove sealing plug 3 for installation. Remove bracket of handbrake cable at position
2 and install at position 1.

Offsetting
bracket

40

1 Noise isolation mounts, large diameter

washer, flanged nut

Installing
silent
block

2
1

41
Following installation, remount sealing plug at
position 4.

1 Wiring harness of metering pump, connector mounted

2 Rubber-coated p-clamp, flanged nut, silent
block
3 Metering pump
5 Fuel line, hose section, 10 mm dia. hose
clamp [2x]

42
1 Standpipe
2 Molded hose

2
10

Installing
metering
pump

7.5 mm dia.

4.5 mm dia.

Cutting
standpipe
and molded hose to
length

235
43
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19

VW Golf VI

10 mm dia. Caillau clamp 2 in center between

beads on end of standpipe.
1 Standpipe
3 Molded hose
Premounting standpipe and
molded
hose

7.5 mm dia.

4.5 mm dia.

44
1

Cut 3 mm off blind plug 1.

2 Fuel-tank sending unit

Cutting off
blind plug

45
Ensure sufficient distance to adjacent components, especially to fuel gauge!

1
2
3
4

13.5 mm dia. Caillau clamp

Fuel line
10 mm dia. Caillau clamp
Molded hose with standpipe

Connection to fueltank sending unit

46

2
1

1 Hose section, 10 mm dia. hose clamp [2x]

2 Fuel line

Connecting metering pump

47
1314423A_EN

20

VW Golf VI
Coolant
WARNING!
Tighten all hose clamps to 2.0 + 0.5 Nm.
Any cold water running off should be collected using an appropriate container!
Install coolant hoses kink-free. Unless specified otherwise, always fasten using cable ties. Position
hose clamps and spring band clamps so that no other hose can be damaged.
The connection should be "inline" based on the following diagram:

Coolant
routing diagram

A
B

All spring clips

= 27 mm dia.! 1 = Original vehicle spring clip
.
All connecting pipes
= 20x20 mm dia. All hose clamps
= 20-27 mm dia.

1314423A_EN

21

VW Golf VI

Align original vehicle hose clamps 1 [2x] as

shown (turn to right).

Aligning
clamps

48
Drill 6 mm dia. hole at position 1. When drilling, Watch lines located behind when drilling.
Mount clip-type cable ties 1.

2 50 mm edge protection
Installing
clip-type
cable tie
2

49
Insert clip-type cable tie 1 [2x] in holes of
bracket for coolant hoses 2.

3 M6x20 bolt, flanged nut, existing hole

Installing
bracket
2
3

50
Close clip-type cable tie 1 [3x].

1
Routing in
engine
compartment

a
1

C
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51

22

VW Golf VI

1 Hose of engine outlet

Connecting engine
outlet

52
1 90 connection on heat exchanger inlet
2 Original vehicle spring clip
3 Spacer bracket

Connecting heat
exchanger
inlet

53

1 Lockable spacer bracket

Installing
spacer
bracket

C
a

54
Fix hose A and C in place with cable tie.

Aligning
hoses

55
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VW Golf VI

Fix hose A and C in place with cable tie. Ensure sufficient distance to neighboring components.

Aligning
hoses

56
1

Position of drain pipe may vary!

Glue rub protection 2 [2x] onto air filter box 1
as shown.

Preparing
air filter
box

57
Version 1:

If drain pipe 1 present as shown, then route

parallel to water hose C.
Installing
air cleaner
housing

58
If drain pipe 2 is present as shown, then fasten on strut with cable tie 1.

2
Fastening
drain pipe
on air filter
box

59
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24

VW Golf VI

Version 2:

If drain pipe 1 is present as shown, then route

between coolant hoses A and C.
Installing
air cleaner
housing

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60

25

VW Golf VI
Exhaust gas
1

Align exhaust end section 2 and rubber isolator 1 as shown.

Ensure sufficient distance of exhaust end
section from wheel well trim.

Installing
wheel well
trim

61
Remove insulation at position 2 if present.

1 Underride protection
2 42 mm dia. hole
Hole in underride
protection
2

62
Align exhaust end section 3 flush on red rubber isolator 2.

1 Underride protection
Mounting
rubber isolator
2

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63

26

VW Golf VI
Final Work
WARNING!
Reassemble the disassembled components in reverse order.
Check all hoses, spring and Caillau clamps, as well as all electrical connections for firm seating.
Secure all loose cables using cable ties.
Spray heater unit components with anti-corrosion wax (Tectyl 100K, Order No. 111 329).
-

Connect the battery.

Fill and bleed the coolant circuit according to the vehicle manufacturers specifications.
Set the digital timer.
Adjust vehicle heater in accordance with "Operating Instructions for End Customer".
Check the proper operation of the additional heater, see the operating instructions/installation instructions.
- File included vehicle-specific "Operating Instructions for End Customer in vehicle logbook.
- Attach the "Switch off additional heater before refueling" sticker to the left-hand B-pillar.

Feel the drive

Webasto AG
Postfach 80 - 82132 Stockdorf
Hotline 01805 / 932278 - Hotfax 0395 / 5592-353
http://www.webasto.de

1314423A_EN

Printed in Germany

02/2009

Printing: Steffen

VW Golf VI
Operating Instructions for End Customer
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, this must be switched in accordance with the
time of year. The heater unit will then only switch on the vehicle fan to ventilate the vehicle interior in
the position Winter
heat and in the position Summer .
WARNING:
The passenger compartment monitoring must be deactivated for the duration of the heater operation!

Before parking the vehicle, make the following settings:

3

1 Air outlet to windshield

2 Set temperature to "max."
3 Set fan to level "1", or possibly "2"

Climatic

64

1 Air outlet to windshield

2 Set temperature on both sides to "HI".

Climatronic

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28