Water Heater Unit

Feel the drive

e1
Thermo Top E Additional Heater 00 0003

e1
Thermo Top C Additional Heater 00 0002

e1
Thermo Top P Additional Heater 00 0104

Installation Instructions

VW Golf V, Golf Plus, Touran

Gasoline
from Model Year 2006
Left-hand drive vehicle

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.:1312760A_EN Fee Euro 10.00 © Webasto AG

VW Golf V, Golf Plus, Touran

Table of Contents
Validity 2 Premounting heater unit 17
Heater Unit/Installation Kit 3 Installing heater unit 19
Foreword 3 Fuel Connection 21
General Instructions 3 Coolant on 1.4 TSI 25
Special Tools 3 Coolant on 1.6 FSI 29
Explanatory Notes on Document 4 Final Work 34
Preliminary Work 5 Operating Instructions for End Customer 35
Heater unit installation location 5
Electrical system 6
Fuse holder and relay K3 7
Climatic fan controller 8
Climatronic fan controller 10
Digital timer, summer/winter switch option 14
Remote option (Telestart) 14

Validity
Manufacturer Model Type EG-BE No./ABE
VW Golf V 1K e1 * 2001/116 * 0242 * ...
VW Golf Plus 1KP e1 * 2001/116 * 0304 * ...
VW Touran 1T e1 * 2001/116 * 0211 * ...

VW Golf V and Golf Plus

Engine type Engine model Output in kW Displacement in cm³

BMY Gasoline/TSI 103 1390
BLG Gasoline/TSI 125 1390

VW Touran

Engine type Engine model Output in kW Displacement in cm³

BMY Gasoline/TSI 103 1390
BLG Gasoline/TSI 125 1390
BLF Gasoline/FSI 85 1598

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.

1312760A_EN 2
VW Golf V, Golf Plus, Touran

Heater Unit/Installation Kit

Quantity Description Order No.:
1 Retail accessories with desired heater control See price list
1 Installation kit for VW Golf V, Golf Plus, Touran Gasoline 1312759A

Also required with Climatronic

Quantity Description Order No.:

1 IPCU Kit for Climatronic 9013645A

Heater unit recommended for the respective vehicle class:

Vehicle Heater unit

Compact car Thermo Top E
Mid-size car, station wagon Thermo Top C
Full-size car, van, offroader 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 V, Golf Plus, Touran Gasoline vehicles - for 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 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
- Metric thread-setter kit

1312760A_EN 3
VW Golf V, Golf Plus, Touran

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

Water

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!

1312760A_EN 4
VW Golf V, Golf Plus, Touran

Preliminary Work
WARNING!
- Open the fuel tank cap, ventilate the 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.
- Remove the battery
- Remove the battery carrier.
- Remove the engine cover
- 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
- Golf only: Remove the rear bench seat
- Golf Plus only: Remove the right rear 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 35 "Operating Instructions for End Customer" and add to the vehicle operating
instructions.

1 Heater unit installation location

1 Heater unit

Installation
location

1312760A_EN 5
VW Golf V, Golf Plus, Touran

Electrical system
Wiring harness pass through

1 Original vehicle wiring harness pass through

Wiring
Do not install the metering pump harness
cable harness until later together installation
with fuel pipe along the original diagram
vehicle fuel lines on the
underbody

1 1

3 4

Fuse holder, relay K3 Wiring harness pass through

Description of installation for K3 relay 1 and fuse 1 Original vehicle wiring harness pass through
carrier 2 on Page 7

1312760A_EN 6
VW Golf V, Golf Plus, Touran

1 2 Fuse holder and relay K3

Countersink holes 3 from behind for M5
countersunk head screws.
9 9 1 Cover of fuse/relay carrier in engine Holes in
20 compartment cover
2 Cut away bar in shaded area
3 5.0 mm dia. hole [2x]
40

3 3 5

1 1 1 M5x12 countersunk head screw [2x]

Installing
fuse holder
and K3
relay

1 2 On vehicles with Climatronic, replace 25 A

fuse F3 7 with 3 A fuse provided.

1 M5 flanged nut
2 Large diameter washer (between cover
7 3 and retaining plate) Installing
4 3 Retaining plate fuse holder
4 M5 flanged nut and K3
5 5 Relay K3
6 relay
6 Fuse holder

1 2 Route brown (br) ground wire to original

vehicle ground support point below headlight
and connect.

1 Fuse/relay carrier
2 Original main vehicle fuse Con-
3 Red (rt) positive wire necting
3 positive
and
ground
wire

1312760A_EN 7
VW Golf V, Golf Plus, Touran

2 Climatic fan controller

Golf V
Detach original vehicle fuse carrier 1
(instrument panel at upper left) and unlock Un-
contact lock 2. crimping
1 Uncrimp 4² black/yellow (sw/ge) wire 3 on wire
fuse output SC40
3

1 2 Produce connections as shown in wiring

diagram.

1 AMP housing
3 Red (rt) wire from K3/87a with crimped-on
standard power timer engaged in fuse Con-
output SC40 necting
3 2 Black/yellow (sw/ge) wire with original wires
5 standard power timer
4 Black (sw) wire K3/30 with crimped-on tab
connector
5 AMP housing

4 10 Lock contact lock again.

1 Golf Plus and Touran

Fuse socket dependent on vehicle equipment
SC33 or SC 35; wire color black (sw) or
black/yellow (sw/ge)
Detach original vehicle fuse carrier 1 Un-
(instrument panel at lower left) and unlock crimping
contact lock 2. wire
Uncrimp 4² black (sw) or black/yellow (sw/ge)
2 wire 3 on fuse output SC33 or SC35

3 11
Produce connections as shown in wiring
diagram.

1 Red (rt) wire from K3/87a with crimped-on

standard power timer engaged in fuse
1 output SC33 or SC35
5 Con-
2 AMP housing necting
3 AMP housing wires
4 4 Black (sw) or black/yellow (sw/ge) wire
11/3 with original standard power timer
5 Black (sw) wire K3/30 with crimped-on tab
connector

3 2 12 Lock contact lock again.

1312760A_EN 8
VW Golf V, Golf Plus, Touran

Webasto VW
30
15 Wiring
diagram

HG
F3 F1
X1 4

sw T10k
4² (sw/ge)

rt 4²
5 T5

86 87 87a KB
K3
4 1 2 3 T5
85 30
sw 4²

+
1 4 2 3 T4r
M GM
-
WG

31

Webasto components Vehicle components Colors and symbols

HG Heater unit TT-C/E GM Fan motor rt red
X1 6-pin heater unit F1 Fuse SC33 or SC35 with 40 ws white
connector A
F3 Fuse, 25 A sw black
K3 Fan relay KB Air-conditioning control unit br brown Legend
or heater switch E16 gn green
WG Resistor group N24 bl blue
T10k Connector ge yellow
Insulate wire ends and
tie back
X Cutting point
Wiring colors may vary.

1312760A_EN 9
VW Golf V, Golf Plus, Touran

1 Climatronic fan controller

Golf V
2
Produce connections as shown in wiring
3 diagram. Installing
Position of free sockets dependent on vehicle wiring
equipment. harness of
Clima-
1 IPCU socket tronic
2 Red (rt) and black/white (sw/ws) wires from
IPCU
3 Green/white (gn/ws) wire to IPCU/86 with
AMP connector
13

1 Brown (br) wire from IPCU/85 to original

vehicle ground point.
Insulate and tie back red (rt) wire from
K3/87a.
Connect black (sw) wire from K3/30 to
green/white (gn/ws) wire (AMP connector) 2. Con-
necting
2 1 IPCU wires

14

1 Route wiring harness IPCU 1 along cross

member 2 to center console

Routing
1 wiring
harness
from IPCU

2 15

1 Golf Plus
Produce connections as shown in wiring
diagram.
Position of free sockets dependent on vehicle
2 equipment. Installing
wiring
1 IPCU socket harness of
3 2 Green/white (gn/ws) wire to IPCU/86 with Clima-
AMP connector tronic
3 Red (rt) and black/white (sw/ws) wires from
IPCU

16

1312760A_EN 10
VW Golf V, Golf Plus, Touran

1 Brown (br) wire from IPCU/85 to original

vehicle ground point.
Insulate and tie back red (rt) wire from
K3/87a.
Connect black (sw) wire from K3/30 3 to
green/white (gn/ws) wire (AMP connector) 2. Con-
necting
1 IPCU wires

3 2 17
Route wiring harness IPCU 2 along cross
member 1 to center console.

Routing
wiring
harness
1 from IPCU

2 2 18

1 Touran
Produce connections as shown in wiring
diagram.
Position of free sockets dependent on vehicle
equipment. Installing
2 wiring
1 IPCU socket harness of
2 Green/white (gn/ws) wire to IPCU/86 with Clima-
AMP connector tronic
3 Red (rt) and black/white (sw/ws) wires from
3 IPCU

19

1 Fasten brown (br) wire from IPCU/85 to

original vehicle ground point 2.
Insulate and tie back red (rt) wire from
K3/87a.
Connect black (sw) wire from K3/30 to
green/white (gn/ws) wire (AMP connector) 3. Con-
necting
1 IPCU wires

3 20

1312760A_EN 11
VW Golf V, Golf Plus, Touran

Route wiring harness from IPCU 1 to fan unit.

Routing
wiring
harness
from IPCU

21

1 2 Golf V, Golf Plus, Touran

1 Wiring harness with red (rt) wire from
IPCU/E and black/white (sw/ws) wire from
IPCU/A
2 Fan unit Routing
wiring
harness
from IPCU

22

1 2 3 4 Position of connector T6t is dependent on

vehicle. If necessary, disconnect fan unit in
accordance with manufacturer's instructions.
Produce connections as shown in wiring
diagram.
Con-
1 Wiring harness from IPCU necting
2 Black/white (sw/ws) wire from IPCU/A wires
3 Red (rt) wire from IPCU/E
5 4 Black/white (sw/ws) wire from Climatronic
control unit
5 Connector T6t
6 Black/white (sw/ws) wire to connector
T6t/2
6 23

1 2 Picture shows version without having to

disconnect fan unit.

1 Black/white (sw/ws) wire from IPCU/A

2 Black/white (sw/ws) wire to connector
T6t/2 Con-
3 3 Connector T6t necting
6 4 Black/white (sw/ws) wire from Climatronic wires
4 control unit
5 Red (rt) wire from IPCU/E
6 Wiring harness from IPCU

5 24

1312760A_EN 12
VW Golf V, Golf Plus, Touran

1 2 If previously removed, reinstall fan unit.

Fasten wiring harness on original vehicle
wires with cable ties.

1 Wiring harness from IPCU

2 Fan unit Installing
fan unit

25

Kabelbaum Kabelbaum VW
Hg Climatronic
30
Wiring
15 diagram

HG KB
X1 4 F3 15 16
F1
T16f
sw/ bl/ rt/
ws ws ge
0,75²

! IPCU E rt 0,75²
rt T10k
A
sw/ws 0,75²

86 87 87a
86 85
sw/ rt/ws
K3 gn/ ws
85 30 0,75²
ws

2 1 4 3 T6t
sw
M
GE
br br

31
Webasto components Vehicle components Colors and symbols
HG Heater unit TT-C/E F1 Fuse SC22 or SC56 with 40 A rt red
X1 6-pin heater unit connector ws white
K3 Fan relay KB Climatronic control unit - J255 sw black
F3 Fuse (25 A replaced T10k Plug connections br brown
with 3 A!) ge Fan control unit - J126 and fan gn green
IPCU Pulse width modulator motor - V2 ge yellow Legend

IPCU adjustment values bl blue

Voltage: 8 V
Frequency: 400 Hz Insulate wire end
Duty cycle: 30 % and tie back
Function: High-side X Cutting point

1312760A_EN 13
VW Golf V, Golf Plus, Touran

1 Digital timer, summer/winter

switch option
Golf V
Do not press on display! Digital
timer
2 1 Digital timer
2 Summer/winter switch

26

1 Golf Plus

Do not press on display!

1 Summer/winter switch Digital

2 2 Digital timer timer

27

1 2 Touran
1 Digital timer
2 Summer/winter switch

Summer/
winter
switch
option

28

1 2 Remote option (Telestart)

Golf V
If M6 screw 2 is not present, then use suitable
M6 screw with spring lockwasher. Installing
Drill out upper hole of bracket to 6.5 mm dia. receiver
3
1 Receiver
2 M6 bolt
3 Bracket

29

1312760A_EN 14
VW Golf V, Golf Plus, Touran

1 1 Antenna

Installing
antenna

30

1 Golf Plus
Bend down lower tab of bracket by 90° and
drill out hole to 6.5 mm dia. as shown.

1 Receiver Installing
2 Bracket receiver
2 3 M6 bolt, large diameter washer (between
bracket instrument carrier), large diameter
washer (from outside), flanged nut
4 Instrument carrier, existing hole
3
4

31

1 1 Antenna

Installing
antenna

32

1 Touran
1 Instrument carrier
2 Existing hole, M6x20 bolt, large diameter
washer, flanged nut
3 Bracket, drill out hole to 6.5 mm dia. Installing
4 Receiver receiver

4 3 2 33

1312760A_EN 15
VW Golf V, Golf Plus, Touran

1 1 Antenna

Installing
antenna

34

1312760A_EN 16
VW Golf V, Golf Plus, Touran

1 Premounting heater unit

1 Combustion air pipe
a = 250

Discard section X Cutting

com-
bustion air
pipe to
length
a

X
1 Ejot stud, tightening torque 10 Nm.

1 Ejot stud

Pre-
mounting
heater unit

35

1 2 3 4 Insert one washer each between heater unit

and bracket at positions 2

1 M6x30 spacer nut

2 Washer, Ejot screw [2x]
3 Hose clamp Pre-
4 Prepared combustion air pipe (slotted side mounting
5
on heater unit) heater unit
5 Bracket

2 36

1 2 3 3 1 Hose section
2 Strut
3 Ejot screw [2x]
4 Combustion-air intake muffler
5 Retaining clip in hole of heater unit
6 Combustion air pipe
7 10 mm dia. hose clamp [2x] Pre-
8 Mecanyl line mounting
heater unit
4

8 7 7 6 5 37

1312760A_EN 17
VW Golf V, Golf Plus, Touran

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

Discard section X Cutting

exhaust
pipe to
length

a b

X
1 2 1 M6x16 bolt, spring lockwasher
2 Hose clamp [2x]
3 Red (rt) rubber isolator, without groove
2 4 Exhaust pipe with insulation
5 Muffler
Pre-
mounting
exhaust
system

5 4 3 38

1 1 Hose clamp
2 Red (rt) rubber isolator, without groove
3 Exhaust end section

2 Pre-
mounting
exhaust
3 system

39

1 2 1 Preparing installation location

Secure large diameter washer against falling
with putty etc.

1 Large diameter washer on original vehicle Preparing

stud bolt [3x] installation
2 Edge protection section location
1

40

1312760A_EN 18
VW Golf V, Golf Plus, Touran

1 Installing heater unit

1 Large diameter washer, flanged nut M8
[3x]
1
Installing
heater unit
1

41
Ensure freedom of movement of exhaust
system relative to original vehicle component
1 and lines.

1 Original vehicle wiring harnesses (secured

3 1 with cable ties) Aligning
2 Horn exhaust
3 Exhaust pipe system

42
Ensure freedom of movement of exhaust
system relative to original vehicle component
and lines.
1 Position rubber isolator 2 as shown.
(Picture shows Golf Plus with headlight
washer system) Aligning
exhaust
1 Headlight washer system (Golf Plus) system
4 2 3 Horn
4 Horn bracket

43

1 Watch routing of wiring harness. Danger of

rubbing!

1 Wiring harness of heater unit

3 2 Clip cable tie in pre-perforated hole of
heater unit cover Mounting
2 3 Cable tie and
routing
wiring
harness

44

1312760A_EN 19
VW Golf V, Golf Plus, Touran

1 Watch routing of wiring harness. Danger of

rubbing!

Route excess lengths from wiring harness 1

in cable duct 2 below battery and secure with
cable ties. Routing
wiring
1 Wiring harness from heater unit harness
2 Cable duct

2 2 45

1312760A_EN 20
VW Golf V, Golf Plus, Touran

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 1 1 1 Mecanyl line

Routing
mecanyl
line to
firewall

46

1 2 1 Coolant reservoir cap detached

2 Existing pass through
3 Mecanyl line and wiring harness of
metering pump

Routing
3 mecanyl
line and
wiring
harness of
metering
pump into
coolant
reservoir
47

1 1 Fasten mecanyl line and wiring harness of

metering pump 1 in coolant reservoir on
original vehicle lines with cable tie.
Pay particular attention to freedom of
movement of wiper linkage.
Routing
mecanyl
line and
wiring
harness of
metering
pump to
right
48

1312760A_EN 21
VW Golf V, Golf Plus, Touran

1 2 1 Metering pump wiring harness

2 Existing pass through
3 Mecanyl line

Routing
3 mecanyl
line and
wiring
harness of
metering
pump

49

1 2 Route mecanyl line and wiring harness of

metering pump along original vehicle fuel
lines 2 to fuel tank.

1 Line duct
Routing
mecanyl
line and
wiring
harness of
metering
pump

50
1 Silentblock, large diameter washer, M6
flanged nut
2 Remove sealing plug

Installing
noise
1 isolation
mount

2 51

1 2 3 4 1 Metering pump wiring harness

2 Connector housing, single-wire seals,
plug-in contacts
3 Secure rubber-coated p-clamp on silent
block with flanged nut
4 Metering pump
5 Plug remounted
8 6 10 mm dia. hose clamp [2x] Mounting
7 Hose section metering
8 Mecanyl line pump and
6 connecting
pressure
side

7 6 5 52

1312760A_EN 22
VW Golf V, Golf Plus, Touran

1 2 1 Standpipe
2 Molded hose

10
Cutting
standpipe
7.5 mm dia. 4.5 mm dia. and
molded
hose to
235 length

53

1 2 3 Caillau clamp 2 in center between beads on

end of standpipe.

1 Standpipe
2 10 mm dia. Caillau clamp
3 Molded hose Pre-
7.5 mm dia. mounting
standpipe
and
molded
4.5 mm dia. hose

54

1 2 Cut 3 mm off blind plug.

1 Tip cut off blind plug

2 Fuel sender

Cutting off
blind plug

55

1 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.
Con-
1 13.5 mm dia. Caillau clamp nection to
2 Preassembled molded hose with fuel-tank
2
standpipe sending
3 10 mm dia. Caillau clamp unit
3 4 Remaining piece of mecanyl line

4 56

1312760A_EN 23
VW Golf V, Golf Plus, Touran

1 1 Hose section
2 Mecanyl line from fuel-tank sending unit
3 10 mm dia. hose clamp [2x]

Con-
necting
2 intake side
of metering
pump

3 3 57

1312760A_EN 24
VW Golf V, Golf Plus, Touran

Coolant on 1.4 TSI

WARNING!
Any coolant running off should be collected using an appropriate container. Install hoses so that they
are kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that no
other hose can be damaged! When installing the coolant hose, the heater unit must be filled with
coolant.
The connection should be "inline" based on the following diagram:

Coolant
routing
diagram

C
A

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 dia..

1312760A_EN 25
VW Golf V, Golf Plus, Touran

a = 600
b = 50
c = 770

Discard section X
A C X B
Cutting
coolant
hoses to
length

1 C 1 Push braided protection hoses onto hose A

and C, cut to length and shrink.

1 Heat shrink plastic tubing [4x]

Pre-
mounting
coolant
hoses

B 1 A 58

1 1 1 Cable ties with clip [2x]

2 Bracket for coolant hoses

Preparing
bracket for
coolant
hoses

2 59

1 2 Loosen original vehicle bolt 2 and position

bracket for coolant hoses 5 between battery
carrier 1 and body 3.

4 M6x20 bolt, original vehicle hole, flanged

nut Installing
bracket for
coolant
5 hoses

4 3

1312760A_EN 26
VW Golf V, Golf Plus, Touran

1 1 Pull hose off heat exchanger inlet

2 Original spring clip will be reused

Cutting
point

2 60

1 Ensure sufficient distance to neighboring

components.

1 Hose on heat exchanger inlet

Con-
necting
heat
exchanger
inlet
C

61

Routing in
engine
compart-
ment

C 62

B C
Con-
nection to
heater unit

63

1312760A_EN 27
VW Golf V, Golf Plus, Touran

A Install hose A with 180° elbow on connection

piece of engine outlet.

Con-
necting
engine
outlet

64

1 2 3 Drill out perforated bracket 2 to 8.5 mm dia. at

position 3.

1 M6x20 bolt, flanged nut

A 3 Original vehicle bolt
4 29 mm dia. rubber-coated p-clamp [2x] Fastening
hoses
4

4 C 65
Ensure sufficient distance to neighboring
components.

Aligning
hoses
C

A 66

C 1 1 Fix hose A and C in place with clip-type cable

ties 1 [2x].

Fastening
A hoses

67

1312760A_EN 28
VW Golf V, Golf Plus, Touran

Coolant on 1.6 FSI

WARNING!
Any coolant running off should be collected using an appropriate container. Install hoses so that they
are kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that no
other hose can be damaged! When installing the coolant hose, the heater unit must be filled with
coolant.
The connection should be "inline" based on the following diagram:

Coolant
routing
diagram

All spring clips without a specific designation = 27 mm dia. 1 = Original vehicle spring clip .
All hose clamps = 20-27 mm dia.! Connecting pipe = 20x20 dia.
2 = Black (sw) rubber isolator .

1312760A_EN 29
VW Golf V, Golf Plus, Touran

a = 1000
b = 1050

Discard section X
A B
Cutting
coolant
hoses to
length

1 B 1 Push braided protection hoses onto hose A

and B, cut to length and shrink.

1 Heat shrink plastic tubing [4x]

Pre-
mounting
coolant
hoses

1 2 A 1 68

1 2 Pull off hose on engine outlet to heat

exchanger inlet 3 on connection piece of heat
exchanger inlet 2. Spring clip 1 will be reused.
Install battery carrier.

Cutting
point
3

69

1 1 Connection piece of heat exchanger inlet

Con-
B necting
heat
exchanger
inlet

70

1312760A_EN 30
VW Golf V, Golf Plus, Touran

Routing in
engine
compart-
ment

71

B C
Con-
nection to
heater unit

72

Routing in
engine
compart-
ment
A

73

1 1 Engine-outlet hose section

2 Align rubber profile

Con-
necting
engine
outlet
A 2

74

1312760A_EN 31
VW Golf V, Golf Plus, Touran

1 B 1 M6x20 screw, spring lockwasher on

existing thread
2 29 mm dia. rubber-coated p-clamp [2x]
2
2
Fastening
hoses

A 75

1312760A_EN 32
VW Golf V, Golf Plus, Touran

Exhaust gas
Align exhaust end section and rubber isolator
as shown.
Ensure sufficient spacing of exhaust end
1 section to transmission and to wheel well Installing
trim. wheel well
(Picture shows vehicle with direct shift trim
transmission)

1 Wheel well trim

76

1 1 Underride protection
2 42 mm dia. hole

Hole in
underride
protection

77

1 2 Picture shows Golf V!

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

3 Underride protection
Mounting
rubber
isolator
3

78

1 2 1 Cut off section

2 Front fog light trim piece (depending on
equipment)

Cutting
front fog
light trim
piece to
size

79

1312760A_EN 33
VW Golf V, Golf Plus, Touran

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 manufacturer’s 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.

Adjust the sensitivity of the passenger compartment monitoring

WARNING!
This 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.

Feel the drive

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

1312760A_EN Printed in Germany 09/2007 Printing:

Steffen
VW Golf V, Golf Plus, Touran

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 .

Before parking the vehicle, make the following settings:

1 2 1 Set temperature to "max."

2 Air outlet to windshield
3 Set fan to level "1", or possibly "2"

Climatic

3 80

1 2 1 1 Set temperature to "HI“ [2x]

2 Air outlet faces upward

Clima-
tronic

81

1312760A_EN 35