Water Heater

Upgrade documentation

Ident. No.: 9024029B_EN Fee Euro 10.00 © Webasto AG

VW Touran / Sharan

TDI

from Model Year 2011

Left-hand drive vehicle

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.

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

Thermo Top VEVO Parking Heatere1

00 0277

Thermo Top V Parking Heatere1

00 0018

VW Touran / Sharan

Table of Contents

Validity

Vehicle and engine types, equipment variants and national specifications not listed in this upgrade doc-umentation have not been tested. However, installation according to this upgrade documentation may be possible.

Manufacturer Model Type EG-BE No./ABEVW Touran 1T e1 * 2001/116 * 0211 * ...VW Sharan 7N e1 * 2007 / 46 * 0401 * ...

Engine type Engine model Output in kW Displacement in cm³CAYC Diesel 77 1598CFFB Diesel 103 1968

Validity 2Upgrade kit 3Foreword 3General Instructions 3Special Tools 3Explanatory Notes on Document 4Preliminary Work 5Electrical system 6Fan control for manual air conditioning 7Automatic air-conditioning fan control 9

Connecting wiring harness 11Connecting LED 14Remote option (Telestart) 14Install upgrade 16Installing digital timer 17Install LED 17Final Work 18Adjusting passenger compartment monitoring 18Operating Instructions for End Customer 19

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VW Touran / Sharan

Upgrade kit

ForewordThis upgrade documentation applies to the VW Touran / Sharan TDI vehicles - for validity, see page 2 - from model year 2011 and later with factory-instaled auxiliary heaters, assuming technical modifica-tions 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 upgrade documentation.

However, the stipulations in the "upgrade documentation" and "operating instructions" and the "instal-lation instructions" for the heater 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.Sharp edges should be fitted with rub protection (split-open plastic hose).Spray unfinished body areas, e.g. drilled holes, with anti-corrosion wax (Tectyl 100K, Order No. 111329).When installing an IPCU, check or adjust the corresponding settings before installation.

Special Tools- Insertion aid

Quantity Description Order No.:1 Upgrade kit VW Touran / Sharan without serial Climatronic 9013728For1 Upgrade kit VW Touran / Sharan serial Climatronic 9013729Gor1 Upgrade kit VW Touran / Sharan without USB Climatronic 9015993Dor1 Upgrade kit VW Touran / Sharan USB Climatronic 9015994Dand1 Heater control See Price list

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VW Touran / Sharan

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.

9024029B_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

Software

VW Touran / Sharan

Preliminary Work

WARNING!

- Open the fuel tank cap, ventilate the tank.- Close the fuel tank cap again.- Disconnect the battery "earth" or "ground" connection.- 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.- Remove windscreen wiper- Remove the coolant reservoir cap.- Detach left and right wheel well trim, remove bumper (for a better installation of the Touran con-

nector X1 HG wire pin2)- Detach intake silencer of the heater, remove intake manifold (Touran only)- Remove the glove compartment.- Remove the lower instrument panel trim on the front passenger side.- Remove the left air outlet nozzle (only for better fitting in the Sharan)- Remove driver's side instrument panel trim (Touran only)- Remove lower A-pillar trim on the driver's side- Detach the central electrical box.- Remove upper A-pillar trim on the driver's side (only for Telestart)

Remove page 19 "Operating Instructions for End Customer" and add to the vehicle operating instruc-tions.

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VW Touran / Sharan

Wiring har-ness rout-ing diagram

Electrical system

Installation location of auxiliary heater

1 Heater

Wiring harness routing in engine compartmentInstall yellow (ge) wire in the original vehicle cor-rugated tube 3 to the heater.1 Original vehicle protective rubber plug in pas-

senger compartment2 Original vehicle protective rubber plug in en-

gine compartment

Wiring harness routing in passenger compartment

1 Yellow (ge) wire

Digital timer

1 Digital timer

11 2

2

1

3

3

1

2 4

1

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VW Touran / Sharan

Wiring dia-gram

Legend

Fan control for manual air conditioning

Webasto components Vehicle components Colours and symbolsHG TT-V heater GM Fan motor V2 rt redX1 8-pin heater connector GS Fan switch J301 ws whiteF1 1A fuse T5 Connector J301 sw blackF2 25 A fuse WG Resistor group N24 br brownK3 Fan relay F33 40 A fan fuse ge yellowVWU Digital timerTele Telestart receiverLED* LED diode as single

heater control only for Telestart * Only for digital timer and

Telestart.

Insulate wire ends and tie back

X Cutting pointWiring colours may vary.

Webasto

31

3015

VW

F1

rt/sw0,5²

ge0,5²

br

VWU

21 4 3

HG

X1 2

ge

br

sw0,5²

sw

sw

rt/sw

F2

rt/sw

rt/ge4,0²

rt4,0²

sw4,0²

sw 4,0²

F33

+

-

GM M WG

sw 4,0²

GS

5T5

T5 4 1 2 3

86

85 30

87a87

K3

Option Einstelluhr Option Telestart

Tele

21 6 3

br

br1,5²

ge

LED*

br

sw

sw

!

!*

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VW Touran / Sharan

Installing socket K3 relay

Connect-ing K3 re-lay

Connec-tion to fuse carrier

Connec-tion to fuse carrier

Insert socket K3 relay 1 into free slot and se-cure it with two cable ties 2 on the relay carrier.

1 K3 relay

Connection to fuse carrier 3.Produce connections as shown in wiring dia-gram.

1 Black (sw) wire on fan motor2 Black (sw) wire of F33 fuse4 Red (rt) wire K3/87a5 Black (sw) wire from K3/30

Connection to fuse carrier 3.Produce connections as shown in wiring dia-gram.Insert fuse F1 1A and F2 25A.A bridge must be created from base 4 for the slot for F1, F2, if no free socket is available for terminal 30.

1 Insert red/black (rt/sw) into free socket of terminal 30

2 Insert red/yellow (rt/ge) into free socket of terminal 30

52

1

2

6

1

7

1

5

4

2 3

8

1 2 3

4

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VW Touran / Sharan

Wiring dia-gram

Legend

Automatic air-conditioning fan control

Webasto components Vehicle components Colours and symbolsHG TT-V heater GM Fan motor rt redX1 8-pin heater connector GRs Fan relay ws whiteF1 1A fuse GRr Fan controller sw blackF2 1A fuse KB A/C control panel br brownK3 Fan relay Fx Fuse gn greenVWU Digital timer bl blueTele Telestart receiver ge yellowLED* LED diode as single

heater control only for Telestart

IPCU Pulse width modulator * Only for digital timer and Telestart.IPCU adjustment values:

Duty cycle: 30% Insulate wire ends and tie backFrequency: 400Hz

Voltage: 8V X Cutting pointFunction: High side Wiring colours may vary.

Webasto

31

3015

VW

F1

86

85 30

87a87

K3

rt/sw0,5²

ge0,5²

br

VWU

21 4 3

HG

X1 2

ge

Tele

21 6 3

br

br

br1,5²

sw0,5²

sw

swrt/sw

ge

F2

rt/sw

bl0,5²

86 85

A

EIPCU

br0,5²

sw/bl0,5²

rt0,5²

sw0,5²

KB

T16f 15

sw/ws0,35²

sw/ws0,35²

GR

T6t 2

Option TelestartOption Einstelluhr

LED*

br

sw

sw

!

!*

9024029B_EN 9

VW Touran / Sharan

Installing socket K3 relay

Connect-ing K3 re-lay and IPCU

Connec-tion to fuse carrier

Connect-ing A/C control panel

Insert socket K3 relay 1 and socket IPCU 2 into free slots and fasten on the relay carrier with two cable ties 3 each.

1 K3 relay2 IPCU

Connection to fuse carrier 2.Produce connections as shown in wiring dia-gram.Insert fuse F1 1A and F2 1A.Proceed as in the manual air conditioning system, if free slots are not available.

1 Insert red/black (rt/sw) into free socket of terminal 30

3 Insert blue (bl) wire into free socket of ter-minal 15

Connection on connector T16f 5 A/C control panel. Produce connections as shown in wir-ing diagram.

1 Black/white (sw/ws) wire from fan controller2 Black (sw) wire of IPCU/A3 Red (rt) wire of IPCU/E4 Black/white (sw/ws) wire from connector T16f

Pin 15

9

1

3

2

333

10

1 2

11

1

3

2

12

1

3

2

45

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VW Touran / Sharan

Earth con-nection

Earth con-nection

Routing yellow (ge) wire

Routing yellow (ge) wire

Connecting wiring harness

Earth wire

Figure shows Touran.Produce connections as shown in wiring dia-gram.

1 Brown (br) earth wire2 M5x16 bolt, flanged nut, existing hole

Figure shows Sharan.Produce connections as shown in wiring dia-gram.

1 M6x20 bolt, flanged nut, existing hole2 Brown (br) earth wire

Route yellow (ge) wire to the heater

Install yellow (ge) wire to the heater with the aid of an insertion aid.

1 Yellow (ge) wire

1 Yellow (ge) wire

13

1

2

142

1

15

1

1

16

1

1

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VW Touran / Sharan

Routing yellow (ge) wire

Routing yellow (ge) wire

Routing yellow (ge) wire

Routing yellow (ge) wire

1 Yellow (ge) wire

Route yellow (ge) wire 2 through original ve-hicle protective rubber plug 1 in the coolant reservoir, use insertion aid.

Route yellow (ge) wire 1 through original ve-hicle protective rubber plug 2 in the engine compartment, use insertion aid.

Route yellow (ge) wire2 in the original vehicle corrugated tube 1 to the installation location of the heater.

17

1

18

1

2

19

1 2

20

1

3

2

2

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VW Touran / Sharan

Discon-necting connector

Connect-ing heater

Inserting connector

Connect yellow (ge) wire

Touran only.Remove intake manifold and intake silencer.

1 8-pin connector to heater

Figure shows Sharan.Disconnect 8-pin connector 1 from the heater. Remove sealing plug from pin 2. Pull out lock 2. Insert yellow (ge) wire 3 in socket 2. Close lock.

Figure shows Sharan.Connect 8-pin connector 1 on the heater.

Touran only.Re-install intake manifold and intake silencer.

21

1

221

3

2

23

1

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VW Touran / Sharan

Connect-ing LED

Connect-ing receiv-er

Installing receiver

Installing receiver

Connecting LED

Connection to timer connector 5.Produce connections as shown in wiring dia-gram.

1 Black (sw) wire of timer connector2 Brown (br) wire of timer connector3 Brown (br) wire of LED4 Black (sw) wire of LED

Remote option (Telestart)

When simultaneously installing the digital timer, the black (sw) 0.5 mm 2 wire on socket, pin 3, must be cut off approx. 50 mm before the Tele-start connector and must be insulated on both wire ends.

Touran

Drill out bracket 3 to 6.5 mm dia. at position 1 and angle down by 90°.WARNING!The receiver is not programmed until after the software installation.

1 Flanged nut, existing stud bolt2 Receiver

Sharan

WARNING!The receiver is not programmed until after the software installation.

1 Receiver3 M5x16 bolt, large diameter washer, flang-

ed nut, existing hole

1

4 24

2

5

1

3

2

Telestart

1

23

Black (sw) 0.5 mm2

Pin 3

1

3 25

2

1

3

26

2

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VW Touran / Sharan

Installing antenna

Installing tempera-ture sensor

All vehicles

1 Antenna

Only with Telestart T100 HTM

1 Temperature sensor T100 HTM2 Original vehicle bolt

1

27

2

28

1

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VW Touran / Sharan

Accesso-ries for in-stallation

Creating connection

Install upgrade

- Connect vehicle battery

Use a free interface (serial or USB) for the communication structure for the heater con-trol unit.

1 Serial connecting line2 USB connecting line (here already con-

nected to the diagnostis adapter)3 Positive and earth wire (not used)4 Adapter wiring harness to clock connector5 Dongle for connecting to the laptop (paral-

lel illustration)

Warning:The program of the Webasto diagnostics tool must be closed on your PC.

1 Connector of wiring harness of digital timer2 Adapter connector

Starting from Windows Explorer. Start the CD- Start upgrade program with "Upgrade.exe"- Select language- Follow menus

- - Insert CD- Select language- Follow menus

Disconnect connection after message "Upgrade successful".

1

5

293

4

2

2

30

1

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VW Touran / Sharan

Installing digital tim-er

Installing digital tim-er

Installing LED

Installing LED

Installing digital timer

Touran

1 Digital timer

Sharan

1 Digital timer

Install LED

Touran

1 LED

Sharan

1 LED

1

31

1

32

1

33

1

34

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VW Touran / Sharan

Final Work

WARNING!Mount removed parts in reverse order.Secure all loose cables using cable ties.Spray the heater components with anti-corrosion wax (Tectyl 100K, Order No. 111329).

- Set the digital timer, teach the Telestart- Make settings on A/C control panel according to the "Operating Instructions for End Cus-

tomer".- Place the "Switch off parking heater before refuelling" sticker near the filler neck.

Adjusting passenger compartment monitoring

Adjustment of passenger compartment monitoring with VAG Tester.Reduce the sensitivity of the passenger compartment monitoring to 50% under the menu "Guided func-tions" The adjustment is completed after storing the new setting.

Printed in Germany 08/2011 Printing: Steffen 189024029B_EN

Feel the driveWebasto AGPostfach 80D-82132 Stockdorf / GermanyNational Hotline: 01805 93 22 78(14 Cent aus dem deutschen Festnetz)Hotfax: 0395 5592 353Hotmail: hotline@webasto.dehttp://www.webasto.de

VW Touran / Sharan

Manual air condition-ing

Automatic air-condi-tioning

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.

Before parking the vehicle, make the following settings:

1 Air outlet to windscreen2 Set temperature to "max."3 Set fan to level "1“ or max. "2"

1 Air outlet to windscreen2 Set temperature on both sides to "HI“

35

3 1

2

36

1

2 2

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