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 equ...
2 2 vw polo validity 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 summe...
3 3 vw polo heater/installation kit also required with climatronic: heater recommended for the respective vehicle class: the selection of the heater is based on the passenger compartment size of the vehicle and the level of comfort required by the customer! Foreword these installation instructions a...
4 4 mechanical system electrical system coolant circuit fuel exhaust gas combustion air vw polo 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 explo...
5 vw polo heater installation location 1 heater installa- tion loca- tion 1 1 preliminary work warning! - disconnect the battery "earth" or "ground" connection. - depressurize the cooling system. - copy the factory number from the original type label to the duplicate type label. - remove years that ...
6 vw polo preparing electrical system only with climatronic produce connections as shown in wiring dia- gram. Fasten wire section 1 with insulating tape on the fan wiring harness. Preparing exhaust pipe connect the included lines to ipcu. Crimp 8mm dia. Cable lug on brown (br) wire. The following ip...
7 vw polo electrical system wiring harness pass through 1 protective rubber plug of bowden cable digital timer 1 digital timer wiring har- ness in- stallation diagram fuse holder, k3 relay 1 m6x20 bolt, large diameter washer, m6 flang- ed nut 2 perforated bracket 3 m5x12 bolt, washer, fuse holder, k...
8 vw polo climatic fan controller climatic wiring dia- gram webasto components components of vw polo colours and symbols legend hg heater gm fan motor - v2 rt red x1 6-pin heater connector sb36 25 a fuse ws white f3 25 a fuse n24 resistor group sw black k3 fan relay e9 switch unit br brown t... Conn...
9 vw polo climatronic fan controller climatron- ic wiring diagram webasto components components of vw polo colours and symbols legend hg heater j127 fan unit rt red x1 6-pin heater connector j255 a/c control panel ws white f3 25 a fuse sb36 25 a fuse sw black k3 fan relay t... Connector br brown ipc...
10 vw polo insert ipcu base in free socket. Produce connections as shown in wiring dia- gram. 1 ipcu connec- tion to re- lay carrier connection on connector t12g 3, pin 3 of a/c control panel 4. Produce connections as shown in wiring dia- gram. 1 black/white (sw/ws) wire of ipcu/a 2 black (sw) wire ...
11 vw polo remote option (telestart) 1 receiver 2 4 mm dia. Hole [2x], 4.8x13 self-tapping screw [2x] 3 bracket installing receiver 1 antenna installing antenna temperature sensor for htm100 only 1 cable tie 2 temperature sensor installing tempera- ture sensor 1 3 2 10 2 i 1 11 1 12 2.
12 vw polo remote option (thermo call) mount tc receiver on a-pillar as shown; mounting materials not included in delivery scope! 1 receiver 2 m5x16 bolt, large diameter washer, m5 flanged nut installing receiver copy hole pattern 2 of tc receiver 1 to right- hand a-pillar as shown. Fasten receiver ...
13 vw polo preparing heater only on vehicles with engine code letters: amf! Discard section x cut heat protection hose in half, compress and push onto hose b and e. B = 1050mm c = 210mm e = 730mm d = 40mm cutting coolant hose to length discard section x a = 210mm cutting coolant hose to length vehic...
14 vw polo hose d with engine code letters: amf! Hose c with engine code letters: bnv and bnm! 1 27 mm dia. Spring clip from water pump 2 20x20 connecting pipe 3 27 mm dia. Spring clip from water pump installing coolant hose on heater ejot screw, tightening torque 10 nm! 1 strut 2 loosely mount ejot...
15 vw polo preparing installation location discard original vehicle bolts from engine mount and replace with included double bolts. Observe tightening torque according to manufacturer. 1 double bolt [2x] preparing installa- tion loca- tion 1 right-hand frame side member. 2 m8 rivet nut installing ri...
16 vw polo installing heater before installing heater, tighten fastening bolts of bracket. Tighten ejot screws to 10 nm! Insert two 6 mm dia. Washers between heater and bracket at position 2. 1 ejot screw 2 ejot screw, washer [2x] installing heater tighten strut on heater following installation. Tig...
17 vw polo coolant circuit with engine code letters: amf 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! Wh...
18 vw polo 1 original vehicle bolt 2 angle bracket with long leg under bolt 3 m6x16 bolt, m6 flanged nut 4 circulating pump 5 rubber-coated pipe clamp, 48 mm dia. Fastening circulating pump 1 circulating pump connec- tion to heater and circulating pump before producing electrical connection, cut con...
19 vw polo install hose b with 90° elbow on circulating pump 1. Connec- tion to cir- culating pump 1 spacer bracket routing in engine compart- ment 1 spacer bracket [2x] routing in engine compart- ment install individual spacer bracket 3 with brack- et for air intake silencer 1. Dispose of mount- in...
20 vw polo 1 charge-air tube 2 premounted spacer bracket routing in engine compart- ment remove and dispose of original vehicle cool- ant hose 1. The spring clips will be reused. Removing coolant hose 1 heat exchanger inlet 2 heat protection hose connec- tion to heat exchanger inlet fasten hose a on...
21 vw polo coolant circuit with engine code letters: bnv and bnm 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 dam...
22 vw polo 1 original vehicle bolt 2 angle bracket with long leg under bolt 3 m6x16 bolt, m6 flanged nut 4 circulating pump 5 rubber-coated pipe clamp, 48 mm dia. Fastening circulating pump 1 circulating pump connec- tion to heater and circulating pump before producing electrical connection, cut con...
23 vw polo install hose a with 90° elbow on circulating pump 1. Connec- tion to cir- culating pump 1 spacer bracket routing in engine compart- ment 1 spacer bracket [2x] routing in engine compart- ment install individual spacer bracket 3 with brack- et for air intake silencer 1. Dispose of mount- in...
24 vw polo 1 charge-air intake pipe 2 premounted spacer bracket routing in engine compart- ment pull original vehicle coolant hose 1 off con- nection piece and turn toward right-hand side of vehicle. Spring clip 2 will be reused. Preparing coolant before installing, push black (sw) rubber iso- lator...
25 vw polo 1 spacer bracket installing spacer bracket 49 d 1 a.
26 vw polo combustion air 1 flexible tube 2 20-27 mm dia. Hose clamp installing intake pipe 1 combustion-air intake pipe 2 intake silencer 3 48 mm dia. Clamp, flanged nut on pre- mounted m6x16 bolt installing silencer 50 1 2 i 51 2 3 1.
27 vw polo 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, a...
28 vw polo remove stoneguard in area of hole. 1 silent block, m6 flanged nut in existing hole installing metering pump 1 metering pump 2 rubber-coated p-clamp, m6 flanged nut on silent block 3 hose section 4 hose section from heater, 10 mm dia. Hose clamp [2x] installing metering pump 1 fuel sender ...
29 vw polo install fuel-tank sending unit according to manufacturer's specifications. Shorten moulded hose by 10 mm on 3.5 mm dia. Side and mount on fuel standpipe. 1 moulded hose, 3.5 mm dia. 4.5 mm 2 fuel line 3 10mm dia. Caillau clamp 4 8mm dia. Caillau clamp connect- ing fuel line connect fuel l...
30 vw polo exhaust gas exhaust pipe a = 380 mm exhaust end section b = 320 mm discard section preparing exhaust pipe 1 perforated bracket angling down per- forated bracket 1 original vehicle nut 2 angled-down perforated bracket 3 m6x12 bolt, flanged nut m6 4 exhaust silencer 5 exhaust pipe 6 red rub...
Vw polo printed in germany 16.03.2011 printing: steffen 31 feel the drive webasto ag postfach 80 d-82132 stockdorf / germany national hotline: 01805 93 22 78 (14 cent aus dem deutschen festnetz) hotfax: 0395 5592 353 hotmail: hotline@webasto.De http://www.Webasto.De final work warning! Reassemble th...
32 vw polo template for fuel standpipe and fuel-tank sending unit no. Description 1 fuel hose 2 90° moulded hose 3 standpipe 4 fuel standpipe 5 single-lug clamp, 8.0mm dia. 6 single-lug clamp, 6.6mm dia. 7 caillau clamp, 9.0mm dia. 8 caillau clamp, 10.0mm dia. 9 fuel line 10 cut to length slantwise.
33 vw polo 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 excee...
