Installation documentation Audi A6 / A6- Avant / Audi A7 ...автоотопитель.рф/manual/AUDI/A6 A7... · This installation documentation applies to Audi A6 / A6- Avant

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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.

Webasto does not accept any liability for defects and damage that are attributable to installa-tion by untrained staff.

Water Heater

Installation documentation

Ident. No.: 1317500C_EN Fee Euro 10.00 © Webasto AG

Audi A6 / A6- Avant /Audi A7 Sportback

2.0 and 3.0 TDI quattro

from model year 2011

Left-hand drive vehicle

Automatic transmission

Climatronic

Thermo Top Evo Parking Heatere1

00 0258

Audi A6 / A6- Avant / Audi A7 Sportback

Table of Contents

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 the digital timer should be confirmed with the end customer before installa-tion.

Manufacturer Model Type EG-BE No./ABEAudi A6 4G e1 * 2007 / 46 * 0436 * ...Audi A6 Avant 4G e1 * 2007 / 46 * 0436 * ...Audi A7 Sportback 4G e1 * 2007 / 46 * 0436 * ...

Engine type Engine model Output in kW Displacement in cm³CGLC Diesel / quattro 130 1968CDUC Diesel / quattro 180 2967

Validity 2Heater/Installation Kit 3Foreword 3General Instructions 3Special Tools 3Explanatory Notes on Document 4Preliminary Work 5Heater installation location 5Preparing electrical system 6Electrical system 8Fan controller 9Digital timer 11Remote option (Telestart) 11

Preparing installation location 12Preparing heater 12Installing heater 16Coolant circuit 2.0 TDII 17Coolant circuit 3.0 TDII 21Fuel 25Exhaust gas 29Final Work 30Adaptation of Climatronic J255 control unit 30Operating Instructions for End Customer 31

1317500C_EN 2


Heater/Installation Kit

2.0 TDI additionally requires

ForewordThis installation documentation applies to Audi A6 / A6- Avant / Audi A7 Sportback / 2.0 and 3.0 TDI quattro vehicles - for validity, see page 2 - from model year 2011 and later, assuming technical modi-fications 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 this instal-lation documentation.

However, the stipulations in this "installation documentation", the "operating and installation instruc-tions" for the Thermo Top Evo must always be observed.The corresponding rules of technology and any information from the vehicle manufacturer should be observed during the installation work.

General InstructionsInstallation 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. Insulate loose wires and tie back!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).When installing an IPCU, the appropriate settings must be checked and set prior to the installation.

Special Tools- Torque wrench for 2.0 - 10 Nm- Hose clamping pliers- 25mm dia. punching tool- Metric thread-setter kit

Quantity Description Order No.:1 Basic delivery scope Thermo Top Evo See price list1 Audi A6 / A7 installation kit 2011 2.0 and 3.0 TDI quattro 1317499A1 Heater control See price list

Quantity Description Order No.:1 Add-on kit for Audi A6 / A6- Avant / A7 2011 2.0 TDI 1318098A

1317500C_EN 3


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.

1317500C_EN 4

Special features are highlighted using the following symbols:

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.

Mechanical system

Electrical system

Coolant circuit

Fuel

Exhaust gas

Combustion air

Software

All dimensions are in mm!Tightening torque of 5x13 heater bolts = 8Nm!Tightening torque of 5x15 bolt of water connection piece retaining plate = 7Nm!


Preliminary Work

WARNING!

- Open the fuel tank cap, ventilate the tank.- 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 (luggage compartment).- Remove the engine design cover.- Remove the air filter together with the intake hose.- Remove the right-hand front wheel.- Remove the right-hand front wheel well trim.- Remove the right-hand underride protection.- Remove the front underride protection, located in the centre.- Remove the rear bench seat.- Remove the fuel-tank sending unit in accordance with the manufacturer's instructions.- Remove the lower instrument panel trim on the front passenger's side.- Remove the glove compartment.- Remove the A-pillar trim on the front passenger's side.- Remove the A/C control panel in accordance with the manufacturer's instructions.

Remove page 31 "Operating Instructions for End Customer" and add to the vehicle operating instruc-tions.

Installa-tion loca-tion

Heater installation location

1 Heater

1

1

1317500C_EN 5


Cutting wiring har-ness of metering pump to length

Preparing additional lines

Preparing time-delay relay

Preparing perforated bracket

Preparing electrical system

Wire sections retain their numbering through-out the whole document.

Cut metering pump connector with blue and brown (bl/br) 100mm wires to length (connec-tor will later be remounted with the butt con-nector). Blue and brown wires (br/bl), 1000mm each, will be needed to connect the time-delay relay!

Produce connections as shown in wiring dia-gram.

1 Turn perforated bracket about 90° in it's longitudinal axis

7

1000

bl

100

br8

1

1000

gn/ws0,5²

6

150

rt0,75²

15

31

87

ZR30

ta

87z

87a

8

76

1

1317500C_EN 6


Installing perforated bracket

Preparing positive support point

1 Perforated bracket2 M6x20 bolt, flanged nut, existing hole

Cut thread of M6 in existing hole 2 of positive support point 1 (check depth, about 8mm)!

22 1

3

1

2

1317500C_EN 7


Wiring har-ness rout-ing diagram

Electrical system

Positive and earth wire

Shorten M6x20 bolt to 10mm!

1 M6x10 bolt, toothed washer, cable lug, posi-tive wire on positive support point

2 Earth wire on original vehicle earth support point

Wiring harness pass through

1 Protective rubber plug (hidden)2 Wiring harness of heater and heater control

Fuse holder engine compartment

Observe sufficient distance to positive support point 4. If necessary, bend perforated bracket 3 again!

1 M5x16 bolt, washer [2x], nut2 F1-2 fuses (replace F2 with 1A)

Wiring harness routing

Cut edge protection in middle!

1 Wiring harness of heater and heater control2 50 mm edge protection

4

1

2

1

5

1

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

6

1 2

3

4

7

1

2

1

1

1317500C_EN 8


Wiring dia-gram

Legend

Fan controller

Webasto components Vehicle components Colours and symbolsHG Heater TT-Evo J126 Fan unit rt redX1 6-pin heater connector T4cb 4-pin J126 connector sw blackX2 2-pin heater connector J255 Control unit of A/C control

panelge yellow

X10 4-pin connectorHeater control

gn greenT20c 20-pin connector J255 or orange

F1 Fuse 20A SC1 Fuse ws whiteF2 Replace 30A with 1 A

fuse.SC2 Fuse br brownHSF Switch glove-

compartment lightinggr grey

ZR Time-delay relayST A 2-pin HSF connector * Wiring harness of glove

compartment lighting

X Cutting pointWiring colours may vary.

Webasto

31

3015

Audi

HG

X2 1 2 X152

F2 F1

ge0,5²

rt/sw0,5²

rt4²

X10

br0,5²

br0,5² gn/ws

0,75²1

5

4

3

2

SC1 SC2

HSF

St A 2 1

J255

T20c 10 20 191

6

15

31

87

ZR30

ta

87z

87a

rt0,75²

gn/ws0,75²

bl

br

gr

J126 M

T4cb 4 3 1

* *gr

br

br

7

8

1317500C_EN 9


Connec-tion of time-delay relay

Mounting time-delay relay sock-et

Glove com-partment lighting connection

Connec-tion of A/C control unit

1 ZR socket2 Soldering end connector3 Wiring harness of heater

Green/white (gn/ws) wire of ZR/15 - J255 T20c/10Green/white (gn/ws) wire of ZR/15 - X1/5 heaterRed/black (rt/sw) wire of X10 heater con-trolRed (rt) wire of F2 fuseBrown (br) wire of ZR/31 - heater earth wireRed (rt) wire of ZR/30

4.5 mm dia. hole at position 1. Route ZR wir-ing harness 3 to glove compartment lighting connector!

1 5.5x13 self-tapping screw2 ZR socket

Connection to 2-pin connector 4 of glove compartment lighting. Produce connections as shown in wiring diagram.

1 Green (gr) wire of glove compartment lighting wiring harness

2 Brown (br) wire of glove compartment lighting wiring harness

3 Brown (br) wire of 2-pin connector pin 1 5 Green (gr) wire of 2-pin connector pin 2

Blue (bl) wire of ZR/87Brown (br) wire of ZR/87z

Connection to 20-pin T20c connector 1 Pin10 A/C control unit. Microtimer on green/white (gn/ws) wire Crimp and insert into free pin 10 socket. Produce connection as shown in wiring diagram.

1 T20c connector dismantled

8

1

46 3

2

1

5

2

3

1

2

3

4

5

6

9

1

23

104

7

3

5

8

1

2

7

8

111

1

1

1317500C_EN 10


Installing digital tim-er

Installing receiver

Installing antenna

Installing tempera-ture sensor

Digital timer

1 Digital timer

Remote option (Telestart)

1 Receiver2 Original vehicle bolt3 Bracket

1 Antenna

Temperature sensor T100 HTM

Fasten temperature sensor 1 with adhesive tape.

1 12

1

2 133

1

14

1

15

1317500C_EN 11


Installing rivet nut

Installing edge pro-tection

Routing wiring har-ness of heater

Assem-bling wa-ter connec-tion piece

Preparing installation location

1 Existing hole, install rivet nut [4x]

1 Fuel hose on original vehicle stud bolt2 50 mm edge protection

1 Wiring harness of heater

Preparing heater

1 Water connection piece, sealing ring [2x each]

2 Self-tapping bolt 5x15, retaining plate, water connection piece

16

1 1

1 1

17

1 2

181

1

191

1

2

1317500C_EN 12


Premount-ing clamp

Installing bracket

Preparing exhaust pipe

Preparing silencer

1 Bracket part A2 Mount M5x16 bolt, self-locking nut, loosely3 51mm dia. clamp

1 Bracket part A2 Self-tapping bolt 5x13 [3x]

Discard section X.

1 Exhaust pipea = 230

Lightly bend exhaust end section 2 at the end as shown (threaded insert points to the right).

1 Silencer

20

3

1 2

21

2 2

2

1

a

1

X

22

2

1

1317500C_EN 13


Premount-ing ex-haust pipe and silenc-er

Cutting hoses to length

Cutting hoses to length

Preparing hoses

1 Hose clamp [2x]2 Exhaust pipe3 M6x16 bolt, spring lockwasher4 Locking tab of bracket part A (twist pro-

tection)5 Silencer

2.0 TDI

Discard section X.

A = 800B = 100C = 150D = 80E = 90F = 60G = 230H = 700

3.0 TDI

Discard section X.

A = 590B = 80C = 150D = 80E = 90F = 60G = 210H = 740

All vehicles

Push braided protection hoses onto hoses A and H and cut to length (3.0 TDI only). Heat shrink plastic tubing on position 1, 3.0 TDI on-ly.

1 50 mm long heat shrink plastic tubing [4x]2 150 mm long heat shrink plastic tubing

23

2

1

4

3

1

5

A

B XC D E F G H

A B XC D E F G H

H

A

G

1 1

1 1

2

1317500C_EN 14


Mounting circulating pump

Premount-ing hoses

Premount-ing hoses

Premount-ing com-bustion air silencer

Push circulating pump mount 2 onto bracket part A at position 4!

1 Attach wiring harness of circulating pump [2x]3 Circulating pump

All connecting pipes = 90° 18x18mm dia. [3x], all spring clips = 25mm dia. [8x]!

All connecting pipes = 90° 18x18mm dia., all spring clips = 25mm dia. [2x]!

Tighten bolt of 51mm dia. clamp.

1 Combustion air pipe2 25 mm dia. clamp3 Combustion air silencer

2

1

3

24

1

4

CE

25

F

D

26

G

27

2

1

3

1317500C_EN 15


Premount-ing fuel hose on heater

Installing heater

Installing heater

Mounting wiring har-ness of heater

1 10 mm dia. clamp2 90° moulded hose

Installing heater

1 M8x20 bolt, spring lockwasher [2x each]

1 Bracket part B2 Self-tapping bolt 5x13 [3x]3 M8x20 bolt, spring lockwasher [2x]

1 Wiring harness of heater [2x]

28

1

2

29

1

1

30

1 2

2

3

3

2

311

1317500C_EN 16


Hose in-stallation diagram

Coolant circuit 2.0 TDII

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 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:

All spring clips without a specific designation = 25 mm dia.2 = Original vehicle spring clip .1= Original vehicle circulating pump.All connecting pipes and = 18x18 mm dia.

G

B

DE

F

C

A

12

H

1317500C_EN 17


Routing in engine compart-ment

Removing protective rubber plug

Cutting point

Preparing protective rubber plug

1 Protective rubber plug

Cut off hose of original vehicle circulating pump / engine outlet at marking. Turn original vehicle hose section on circulating pump inlet 2 about 180° forward.

1 Original vehicle circulating pump3 Engine outlet hose section

1 Punch in 25 mm dia. hole [2x]2 Protective rubber plug

32

B

G

C

33

1

3423

1

35

1

43

80

301

2

1317500C_EN 18


Installing p-clamps

Premount-ing hose A and H


Connect-ing hoses

Remove and discard original vehicle bolts at position 2.

1 Air filter box2 5.5x13 self-tapping screw [2x each]3 48 mm dia. rubber-coated p-clamp [2x]

Cut heat protection hose in middle. Push one end each onto hoses A and H and route using rubber-coated p-clamps 1. Push protective rubber plug 2 onto both hoses.

Mount air filter box 2. Route hoses A and H (below hose A, hidden) through the original vehicle pass through into the coolant reser-voir!

36

3

2

3

1 2

37

A

2

1

1

H

38

2

1

A

39

A

G

B

H

1317500C_EN 19


Connec-tion of heat exchanger inlet

Connect-ing engine outlet

Aligning hoses

1 Hose on circulating pump inlet

1 Hose of engine outlet2 Spacer bracket

Ensure sufficient distance to neighbouring components, adjust, if necessary.

401

H

41

1 A 2

42H

A

1317500C_EN 20


Hose in-stallation diagram

Coolant circuit 3.0 TDII

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 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:

All spring clips without a specific designation = 25 mm dia.2 = Original vehicle spring clip .1= Original vehicle circulating pump.All connecting pipes and = 18x18 mm dia.

G

H

B

DE

F

C

A

12

1317500C_EN 21


Installing p-clamp

Connect-ing heater outlet


Cutting point

1 38 mm dia. rubber-coated p-clamp2 M6x20 bolt, existing threaded hole

Route hose H through rubber-coated p-clamp 1.

1 Insert hose bracket2 Original vehicle hose

Remove hose 1 from engine outlet/original vehicle circulating pump. Spring clip on circu-lating pump will be reused.

43

1

2

44

H

G

1

45

2

H

1

46

1

1317500C_EN 22


Cutting point

Connec-tion of heat exchanger inlet

Connect-ing heater inlet


Protective hose removed. Cut off hose at markings.

1 Engine outlet hose section2 Discard hose section3 Original vehicle circulating pump hose

section

1 Original vehicle circulating pump2 Hose on heat exchanger inlet3 Original vehicle hose4 Original vehicle spring clip

Route hose A through rubber-coated p-clamp 1.

1 Insert hose bracket

47

1

23

48H

2

4

1

3

49

A

B

1

C

50

1 A

H

1317500C_EN 23


Connect-ing engine outlet

Aligning hoses

1 Hose of engine outlet

Ensure sufficient distance to neighbouring components, adjust, if necessary.

51

1

A

52

HA

1317500C_EN 24


Connect-ing heater

Installing lines

Installing lines

Fuel

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. 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.

Pull fuel line 2 and wiring harness of metering pump 1 into corrugated tube!

3 10 mm dia. clamp

Route fuel line and wiring harness of meter-ing pump in corrugated tube 1 in the right-hand wheel well to the line duct!

Route fuel line and wiring harness of meter-ing pump in corrugated tube 1 through origi-nal vehicle cable duct 2 to the underbody!

532

1

3

54

1 1 1

1

55

1

2

1

1317500C_EN 25


Installing lines

Angling down per-forated bracket

Preparing perforated bracket

Premount-ing meter-ing pump

Route fuel line and wiring harness of meter-ing pump in corrugated tube 1 on original ve-hicle fuel lines to the installation location of the metering pump.

1 Perforated bracket

1 Discard section2 Perforated bracket

1 Metering pump mount2 Metering pump3 Perforated bracket (angled at 90°)4 Perforated bracket (angled at 65°)5 M6x25 bolt, flanged nut

56

1

1

57

76

65°

1

45

90°

20

1

2

57

1 2

35

4

1317500C_EN 26


Premount-ing meter-ing pump

Installing metering pump

Connect-ing meter-ing pump

Fuel ex-traction

1 180° moulded hose2 10 mm dia. clamp [2x]3 90° moulded hose

1 M6x20 bolt, large diameter washer, flanged nut, existing hole

2 Perforated bracket

Connect wiring harness of metering pump and blue/brown wires (bl/br) (each 100mm long) 2 from metering pump connector 1 with butt connector so that the wires of the same colour are connected.

1 Connector attached3 Fuel line4 10 mm dia. clamp

Remove fuel-tank sending unit 1 according to manufacturer's instructions. Drill out connec-tion piece 2 to 2.5 mm dia.

58

13

22

592 1

60

1

3

4

2

61

1

2

1317500C_EN 27


Cutting fuel stand-pipe to length

Installing fuel stand-pipe

Connect-ing fuel line

Connect-ing meter-ing pump

Cut off standpipe 1 at end at an angle.

1 10 mm dia. hose clamp2 Hose section3 10 mm dia. Caillau clamp4 Standpipe

Install fuel-tank sending unit 1 in accordance with manufacturer's instructions.

2 Fuel line3 10 mm dia. Caillau clamp4 3.5x4.5 mm dia. moulded hose5 8 mm dia. Caillau clamp6 Coupling piece

Check the position of the components; adjust if necessary. Check that they have freedom of movement.

1 10 mm dia. clamp2 Fuel line in corrugated tube

621

135

63

2

4

31

64

1

24

6

3

5

652 1

1317500C_EN 28


Removing covering cap

Aligning exhaust end sec-tion

Aligning si-lencer

Exhaust gas

Remove covering cap 2 at position 3!

1 Underride protection

Centrally position exhaust end section 2 in hole!

1 Underride protection mounted

Ensure sufficient distance to neighbouring components (especially to the exhaust silenc-er at position 1), take corrective measures if necessary.

66

2

1

3

2

1

67

1 68

1317500C_EN 29


Aligning time-delay relay sock-et

Final Work

WARNING!Reassemble the disassembled components 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 refueling" signboard in the area of the filler

neck- For initial start-up and function check, see installation instructions

Adaptation of Climatronic J255 control unitwith VAS-VCDS

Function:- Control unit selection- 08 AC-heater electronics- Adaptation > „activate retrofit parking heater without CAN“

Save

Align relay socket 2 with glove compartment trim and glove compartment cap lever 3!

1 Time-delay relay mounted

69

1

2

3

Printed in Germany 06/2012 Printing: Steffen 301317500C_EN

Feel the driveWebasto AGPostfach 80D-82132 Stockdorf / GermanyNational Hotline: 01805 93 22 78(14 Cent aus dem deutschen Festnetz)Hotfax: 0395 5592 353Hotmail: [email protected]://www.webasto.com


Climatron-ic

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 timeExample:For a driving time of approx. 20 min. (in one direction), we recommend not exceeding a switch-on time of 20 min.

Passenger compartment monitoring, if installed, must be de-activated in addition to the vehicle settings for the heating cycle.Please refer to the Operating Manual of the vehicle for instructions concerning the de-activation.

Before parking the vehicle, make the following settings:

1 Set temperature on both sides to "HI".2 Air outlet to windscreen

70

1

2

1

1317500C_EN 31

Installation documentation Audi A6 / A6- Avant / Audi A7 ...автоотопитель.рф/manual/AUDI/A6 A7... · This installation documentation applies to Audi A6 / A6- Avant

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