Beruflich Dokumente
Kultur Dokumente
Installation Instructions
VW T5
Gasoline and Diesel
from Model Year 2004
For left-hand drive vehicles only
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.
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 warn-
ings.
Webasto does not accept any liability for defects and damage that are attributable to
installation by untrained staff.
Table of Contents
Validity 2 Fuel Removal on Vehicles
Heater Units 3 with Additional or Auxiliary Heater 14
Foreword 3 Exhaust System 15
General Instructions 3 Optional Exhaust Muffler 15
Special tools 3 Optional Hot Air System 16
Explanatory Notes on the Document 4 Optional Recirculating Air 19
General Installation Diagram 5 Electrical Connections 20
Preliminary Work 6 Optional Combination Timer 20
Heater Unit Installation Location 6 External Temperature Sensor 20
Preparing Installation Location 7 Remote Option (Telestart) 21
Preparing Heater Unit 8 Fault Code Deactivation 26
Installing Heater Unit 9 Final Work 27
Combustion Air 10 Operating Instructions for End Customer 28
Fuel Connection 11 Template for Fuel Sender 29
Metering Pump 12 Template for Fuel Standpipe 30
Fuel Removal on Vehicles
without Additional or Auxiliary Heater 13
Validity
Manufacturer Model Type EG-BE No./ABE
Volkswagen Transporter T5 L148
Foreword
These installation instructions apply to VW T5 vehicles with a Gasoline and Diesel engine (van with
partition wall) from model year 2004 and later, assuming technical modifications to the vehicle do not
affect installation, any liability claims excluded.
Vehicles and equipment variants, which are not listed in these installation instructions, have not been
tested. However, installation according to these installation instructions may be possible. Depending
on the version and the equipment variants of the vehicle, changes may be necessary relative to these
"installation instructions" during installation and must be adjusted accordingly.
However, where this is the case the stipulations in the "installation instructions" and "operating and
maintenance instructions" for the Air Top 2000 ST should be observed.
The installation location of heater controls and the routing of the air ducting parts must be coordinated
with the final customer prior to installation!
WARNING!
Original load-bearing components of the vehicle and/or component used for crash safety may not be
modified for the hot air and recirculating air ducting!
General Instructions
Installation 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 edge protectors (split-open plastic hose).
Spray unfinished body areas, e.g. drilled holes, with anti-corrosion wax (Tectyl 100K, Order No.
111329).
2
VW T5
The materials used for this application example - in accordance with validity on page 2 - are contained
in the following list. In case of deviations in accordance with the customer order, the materials actually
required can be ordered from the currently valid Webasto Accessories Catalog.
Special tools
- Torque wrench for 2.0 - 10 Nm
- Metric thread-setter kit
- Blind rivet tool
3
VW T5
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
Fuel connection
Exhaust system
Combustion air
4
VW T5
Digital timer:
comfort accessory
Installa-
tion dia-
gram for
AT 2000 ST
Fuel filter:
option
Terminal 15
Jumper
0.75 mm²
0.75 mm²
sw Terminal 30
br
Terminal 58 1.0 mm²
0.75 mm² rt
gr
Terminal 31
1.0 mm²
br
Connec-
tion dia-
gram for
0.5 mm² comfort
sw
digital tim-
0.5 mm² er
bl
0.5 mm²
rt
0.5 mm²
ws
5
VW T5
Preliminary Work
WARNING!
1 Heater unit
Installa-
tion loca-
tion
1
6
VW T5
Installing
rivet nuts
1 2 1 2 Bracket
1 M6x20 bolt, large diameter washer on rivet
nuts
Loosely
mount
bracket
Copying
hole pat-
tern
2
7
VW T5
3 1 Heater unit
2 Mount base seal Preparing
3 Protective grill heater unit
2
3 Heater unit
4 Wiring harness
1 60 mm dia. flexible pipe, 360 mm long
2 50-70 mm dia. hose clamp
Premount-
ing heater
unit
5 7
5 4 8
8
VW T5
Installing
heater unit
Installing
heater unit
10
9
VW T5
1 2 1 Combustion air
i
Shape combustion-air intake pipe as shown
in picture.
1 11
10
VW T5
Fuel Connection
CAUTION!
Open the vehicle's fuel tank cap, ventilate the tank and then re-close the tank lock.
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 in as shown in the wiring harness
routing diagram.
12
13
3 14
11
VW T5
1 2 3 4 Metering pump
5 15
4 16
3 17
12
VW T5
18
1 Installing
fuel stand-
2 pipe
19
1 Fuel tank
2 Fuel-tank sending unit
5 Fuel standpipe
3 Remaining end of Mecanyl fuel line
5 4 Hose section, 10 mm dia. Caillau clamp Connect-
[2x] ing fuel
line
3
4 20
1 Fuel tank
3 Remaining end of Mecanyl fuel line
2 Fastening points [3x]
Installing
fuel line
2 2 3 2 21
13
VW T5
14
VW T5
1 2 Exhaust system
23
1 Exhaust pipe
2 Underride protection Exhaust
muffler
2 24
1 Exhaust pipe
2 P-clamp
Removing
p-clamp
2 1 25
1 Exhaust pipe
5 Angle bracket, M6x20 bolt, flanged nut on
bracket
3 Exhaust muffler, M6x20 bolt, flanged nut
on angle bracket Installing
2 Hose clamp [2x] muffler
4 1 26
15
VW T5
WARNING!
The routing of the air ducting parts shown is an application example on the van with a partition wall. Should
other versions and equipment variants be used, then the appropriate adjustments must be made.
Before installation, the routing of the air ducting parts must be coordinated with the end customer!
Install flexible tubes so that they are kink-free. Unless specified otherwise, always fasten using brack-
ets and cable ties.
The hot air ducting on this version example is executed as shown in the following diagram:
6
4
5
2
3
Diagram
for hot air
8 ducting
1
1 = Heater unit 3 = Dia. 55x60 mm adapter 5 = Air distributor 7 = Flexible tube, 60mm dia.
2 = Flexible tube, 60 mm dia. 4 = Flexible tube, 55 mm dia.6 = Air outlet 8 = Air outlet
16
VW T5
27
Gluing in
adapter
28
4 3 29
1 Partition wall
2 Air outlet
Hole in par-
tition wall
2 30
17
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31
5 4 3 32
18
VW T5
1 Underride protection
Underride
protection
1 33
34
60 mm dia.
hole in en-
trance
35
1 2 3 Electrical Connections
37
1 1 Thermostat
i
Installing
heater con-
trol
38
Installing
combina-
tion timer
39
40
20
VW T5
3 41
Installing
switch
2 42
1 1 Antenna
Installing
antenna
43
Installing
tempera-
ture sensor
44
21
30 30 X1
15 15
sw/rt
T80 F1
5 3
F3 7
2 X2/X3/X4/X5
rt S6 1 X11
F2 rt
rt
br
sw
br
2
gn/ws
X6 86 87 87a
X9 S9 2
1 14 15 7 5 6
S1 1
3 13
rt K X6
A2
4 85 30
4 12
sw
3 9
10
bl 16 4
H1 1 11
ws ϑ 17 X8
B2
2 0 3
1 2
2 X1 X2 X5 X6 X4 X3 X6
1 2 3 3 2 2 1 9 8 2 1 1 2 2 1
br ge X9
br bl
M1 4 1
rt br ge br M
M ϑ bl ϑ
ge
sw
sw
M3
sw/bl
A1 E B1 B3
3 2
X10
X8 2 1 X10 1 2
ws/rt
ws/sw
br br bl
R1
1 2
X8 2 1
S5 S4
8 X11
Y1
ϑ
B4
2 1
VW T5
31 31
i
System
22
hicle fan
gram with
wiring dia-
F2 T80 5 3
F1 F3 7 X2/X3/X4/X5
S6 1 2 X11
rt
br
rt
2
gn/ws
gr
br
86 87 87a
sw
1 10 11
X6
2
1 14 15 7 5 6 1
2 12
sw X6
A2 K
4 85 30
8 13
rt
3 9
H4
H3 10
bl 16 4
H5 X8
6 11
ws ϑ 17
B2
P 9 0 3
1 2
12 7 4 2 X1 X2 X5 X6 X4 X3 X6
2
1
X12 1 2 3 3 2 2 1 9 8 2 1 1 2 X10
br ge br bl 1 2
M1
rt br ge br M
M ϑ bl ϑ
ge
sw
sw M3
sw/bl
A1 E B1 B3
1 2
X11
X8 2 1 X10
ws/rt
ws/sw
S7 br bl
br R1 2 1
X12
X8 2 1
S5 S4
8
Y1
ϑ 3
6
B4 9
12
VW T5
31 31
fan
i
System
23
Telestart
combina-
gram with
tion timer,
wiring dia-
and vehicle
VW T5
24
VW T5
25
VW T5
Shut-down on fault
Faults in individual heater unit components and malfunctions during the entire operation are recog-
nized in the control unit.
- No or faulty start-up
- Temperature sensor defective
- Open or short circuit in overheating sensor
- Overheating sensor mounted incorrectly
- Break or short circuit in glow element
- Fan motor overloaded, blocked, short circuit or open circuit
- Fault in metering pump circuit or overheating protection (only during start-up phase)
- Undervoltage < 10.5 V or overvoltage >16 V and longer than 20 sec. (on heater unit with 12 V)
- Undervoltage < 21 V or overvoltage >32 V and longer than 20 sec. (on heater unit with 24 V)
- Control unit defective
- Overheating
- Flame detector (only on gasoline heater units)
In case of overheating, the fuel feed is interrupted. A run-on is carried out as with manual shut-down.
Following the run-on, the heater unit is in the fault lock-out mode. The overheating is indicated by the
operation indicator flashing 10 times.
For fault release, briefly switch the heater unit off and then on again (at least 2 sec.).
If serious malfunctions, such as overheating, or no start-up occurs increasingly frequently, then the
heater unit is permanently locked (F12 or F13) and can only be returned to operation following repairs
by specially trained Webasto experts.
26
VW T5
Final Work
WARNING!
Reassemble the disassembled components in reverse order.
Check all hoses, hose, spring and Caillau clamps, as well as all electrical connections for firm seating.
Secure all loose cables using cable ties.
Spray the heater unit components with anti-corrosion wax (Tectyl 100K, Order No. 111329).
On vehicles with additional heater or auxiliary heater from factory, the fuel level may
not be below 1/4 of a tank for proper operation of the Air Top 2000 ST air heater!
Version A:
Switching
on heater
with Tele-
start
2 45
Version B:
Switching
on heater
with heat-
er control
2 46
28
VW T5
100 mm
Scale 1:1
100 mm
0
29
VW T5
100 mm
Scale 1:1
100 mm
0
30