Webasto Air Top 2000 S D Installationshandbuch

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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, specialized tools and equip-
ment 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 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.
Feel the drive
VW T5
Gasoline and Diesel
from Model Year 2004
For left-hand drive vehicles only
Ident. No.: 9014157C_EN Fee Euro 10 © Webasto AG
Air Heater Unit
Air Top 2000 ST B Additional Heater
Air Top 2000 ST D Additional Heater
Installation Instructions
e1
*2001/56*0022
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1 2 3 4 5 6 ... 29 30

Inhaltsverzeichnis

Seite 1 - Installation Instructions

WARNING!Hazard warning:Incorrect installation or repair of Webasto heating systems may cause a fire or result in the emission of carbon monoxide, whic

Seite 2 - Table of Contents

10VW T5Combustion airShape combustion-air intake pipe as shown in picture.2 Combustion-air intake pipe1 Cable tieInstalling intake pipe111 211i

Seite 3 - Special tools

11VW T5Fuel ConnectionCAUTION!Open the vehicle's fuel tank cap, ventilate the tank and then re-close the tank lock.Catch any fuel running off wit

Seite 4 - Explanatory Notes on Document

12VW T5Metering pumpCut Mecanyl fuel line to length at installation location of metering pump.2 Metering pump5 Rubber-coated pipe clamp1 Silentblock,

Seite 5 - General Installation Diagram

13VW T5Fuel Removal on Vehicles without Additional or Auxiliary HeaterRemove fuel tank according to manufactur-er's specifications. Remove fuel-t

Seite 6 - Preliminary Work

14VW T5Fuel Removal on Vehicles with Additional or Auxiliary HeaterCut off fuel line to additional or auxiliary heat-er as shown.Mount fuel standpipe

Seite 7

15VW T5Exhaust systemAlign exhaust pipe as shown.Drill 2 mm dia. condensed-water drain hole at lowest point in exhaust pipe.Ensure sufficient distance

Seite 8 - Preparing heater unit

16VW T5Optional Hot Air SystemWARNING!The routing of the air ducting parts shown is an application example on the van with a partition wall. Should ot

Seite 9 - Installing heater unit

17VW T5Optional Hot Air SystemFold back cover under front passenger seat. Lay on dia. 55x60 adapter as shown.2 Dia. 55x60 mm adapter1 Copy hole patter

Seite 10 - Combustion air

18VW T5Cut 55 mm dia. flexible tube 1 to length as shown and mount on adapter 3.1 55 mm dia. flexible tube3 50-70 mm dia. hose clamp2 Bracket with hos

Seite 11 - Fuel Connection

19VW T5Optional Recirculating AirNo underride protection is required for the op-tion recirculating air mode!1 Underride protectionUnderride protection

Seite 12 - Metering pump

22VW T5ValidityForewordThese installation instructions apply to VW T5 vehicles with a Gasoline and Diesel engine (van with partition wall) from model

Seite 13

20VW T5Electrical Connections4 Fuse holder retaining plate, M4x12 bolt, washer, M4 nut1 Wiring harness of power supply for heater unit2 Ground wire on

Seite 14

21VW T5Remote option (Telestart)Connect receiver for Telestart as shown in wiring diagram.1 M5x16 bolt, flanged nut on existing hole2 Telestart3 Teles

Seite 15 - Optional Exhaust Muffler

22VW T5System wiring dia-gram with heater con-trol and ve-hicle fanS41411575 6121310112X612 3X13MM1brrtbr2EX2gegebr21ϑϑB1B2br98X6X521X412X3B3ϑblblA1A2

Seite 16 - Optional Hot Air System

23VW T5System wiring dia-gram with combina-tion timer, Telestart and vehicle fanX1212963X2/X3/X4/X512X10X11X6X112X8212112S41411575 6131210112X612 3X13

Seite 17

24VW T5With positive wire from terminal (15/75) to connection 10:Continuous operation with immediate heating as long as ignition is switched onWithout

Seite 18

25VW T5Pos. Name RemarksLegend for Wiring Dia-gramsA1 Heater unit Air Top 2000 STA2 Control unitB1 Flame detector Only on gasoline unitB2 Temperature

Seite 19 - Optional Recirculating Air

26VW T5Shut-down on faultFaults in individual heater unit components and malfunctions during the entire operation are recog-nized in the control unit.

Seite 20 - External temperature sensor

VW T5Webasto AGPostfach 80 - 82132 Stockdorf, Germany - Hotline +49-(0)1805-932278Hotfax +49-(0)395-5592-353 - http://www.webasto.deFeel the driveFina

Seite 21 - Remote option (Telestart)

2828VW T5Operating Instructions for End CustomerPlease remove page and add to the vehicle operating instructions.Only for vehicles with standard heate

Seite 22

29VW T5Template for Fuel sender0100 mm100 mmScale 1:1Compare the size of the printed version with dimension lines.Permitted tolerance a maximum of 2%.

Seite 23

33VW T5Heater Units/Installation KitThe installation kit contains the bracket with fastening parts.The required air ducting parts must be ordered as a

Seite 24

30VW T5Template for Fuel Standpipe0100 mm100 mmScale 1:1Compare the size of the printed version with dimension lines.Permitted tolerance a maximum of

Seite 25

44Special features are highlighted using the following symbols:Mechanical systemElectrical systemHot air systemFuel connectionExhaust systemCombustion

Seite 26 - Fault code output:

55VW T5General Installation DiagramInstalla-tion dia-gram for AT 2000 STConnec-tion dia-gram for comfort digital tim-erDigital timer:comfort accessory

Seite 27 - Feel the drive

6VW T5Heater unit installation location1 Heater unitInstalla-tion loca-tion11Preliminary WorkWARNING!- Disconnect the battery "earth" or &qu

Seite 28

7VW T5Preparing installation location1 Rivet nut (2x) in existing holesInstalling rivet nuts2 Bracket1 M6x20 bolt, large diameter washer on rivet nuts

Seite 29 - Template for Fuel sender

8VW T5Preparing heater unitWith fresh-air mode, an underride protection as shown in Figure 33 must be installed if not present!1 Heater unit2 Mount ba

Seite 30 - Template for Fuel Standpipe

9VW T5Installing heater unit2 Preassembled heater unit1 M6x20 bolt, spring lockwasher, flanged nut [2x each]Installing heater unit1 Preassembled heate

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