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 equ...
2 2 audi a4 1.9 + 2.0 tdi validity vehicle and engine types, equipment variants as well as national specifications, which are not listed in these installation instructions, have not been tested. Installation according to these installation instructions may, however, be possible. The installation loc...
3 3 audi a4 1.9 + 2.0 tdi heater unit / installation kit recommended heater unit for the relevant vehicle class: select the heater unit based on the size of the vehicle passenger compartment and the customer's comfort requirements. Foreword these installation instructions apply to vehicles audi a4 1...
4 4 special features are highlighted using the following symbols: mechanics electrics water connection fuel connection exhaust system combustion air the arrow in the vehicle icon indicates the position on the vehicle and the viewing angle. Audi a4 1.9 + 2.0 tdi specific risk of injury or fatal accid...
5 audi a4 1.9 + 2.0 tdi heater unit installation location 1 heater unit installation location 1 1 preliminary work warning! - let off pressure in 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 duplicat...
6 audi a4 1.9 + 2.0 tdi electrical connections fuse holder, k3 relay 2 k3 relay 3 fuse holder retaining plate 1 m5x12 bolt, washer, m5 nut 4 fuse holder positive and ground wire run the positive wire 1 through the protective rubber sleeve to the battery. 3 ground wire 2 original vehicle cable harnes...
7 audi a4 1.9 + 2.0 tdi blower control connection the air conditioning control connector d (use enclosed micro timer). Connect according to the circuit diagram. 1 connector d 2 insulate the red (rt) wire to k3/87a and tie back 3 black (sw) wire from k3/30 4 green/white (gn/sw) wire to connector d pi...
8 audi a4 1.9 + 2.0 tdi remote start option 1 receiver 2 double-sided velcro tape (self adhesive) assem- bling the receiver 1 antenna assem- bling the antenna temperature sensor for htm100 only 1 temperature sensor 2 double-sided velcro tape (self adhesive) assem- bling the tempera- ture sensor 1 2 ...
9 audi a4 1.9 + 2.0 tdi preparing the installation location remove the original vehicle bolt at position 1 and 3 (will be used here again). Drill hole at position 2. 2 Ø 9.1mm bore hole, insert rivet nut inserting rivet nut 2 servo hose 1 rubberised tube clamp, plastic nut on existing stay bolt tie ...
10 audi a4 1.9 + 2.0 tdi 1 mecanyl fuel line 2 hose section, Ø 10 mm hose clamps [2x] pre- assem- bling the fuel line installing the heater unit insert the bracket 3 with the heater unit as shown in the figure. Tighten bolt in position 4. 1 original vehicle nuts [4x] on the pre- assembled bolts 2 m6...
11 audi a4 1.9 + 2.0 tdi water connection warning! Tighten all hose clamps with 2.0 + 0.5 nm. 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 clips. Position hose clamps and sp...
12 audi a4 1.9 + 2.0 tdi a = 270 mm b = 530 mm dispose of sections x cutting water hoses into sections remove the original vehicle engine outlet hose to the heat exchanger inlet 2 (spring band clamp 1 will be used again). Removing the water hose cut off the protective hose 2 in the splitting point a...
13 audi a4 1.9 + 2.0 tdi connec- ting the heater unit inlet fasten the hose a to the engine outlet. Refasten the hose a to the stay bolt 2 with original vehicle hose clamps. 3 align the black (sw) rubber profile on the cable harness. Connec- ting the heater unit inlet connec- ting the heater unit ou...
14 audi a4 1.9 + 2.0 tdi 1 align the black (sw) rubber profile according to the figure. Connec- ting the heater unit outlet run the hose b through the original vehicle rubber sleeve 2 into the cooling water reservoir. Before connecting, fill the water hoses with coolant. 1 original vehicle spring ba...
15 audi a4 1.9 + 2.0 tdi combustion air 1 combustion air pipe a = 250 mm dispose of section x cutting the combus- tion air pipe into sections punch out the perforation in the header unit cover at position 1 and insert the retaining clip. Inserting retaining clip 1 combustion air intake pipe 2 Ø 27 m...
16 audi a4 1.9 + 2.0 tdi fuel connection caution! Open the vehicle's tank-cap lock, 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 cable harness so that they are protected against stone impact. Unless ...
17 audi a4 1.9 + 2.0 tdi note the installation position of the metering pump 4, see the “installation instructions”. Installation location is to the right next to the vehicle tank. 2 angle bracket 1 original vehicle bolt 5 rubberized tube clamp 3 silentblock, flanged nut [2x] on the angle bracket me...
18 audi a4 1.9 + 2.0 tdi cut the tank extracting device to size according to the template. 1 tank extracting device inserting tank extracting device install the tank mounting according to manufacturer's instructions. Check that the fuel injector can be freely accessed. 1 tank extracting device 3 add...
19 audi a4 1.9 + 2.0 tdi exhaust system 1 exhaust pipe a = 380 mm 2 exhaust end section b = 140 mm dispose of section x preparing the exhaust pipe the illustration shows a standard gear shift vehicle. 1 exhaust pipe 2 hose clamp assem- bling the exhaust pipe the illustration shows a standard gear sh...
20 audi a4 1.9 + 2.0 tdi the illustration shows a standard gear shift vehicle. 3 exhaust silencer 2 exhaust end section 4 hose clamp 1 red (rt) rubber profile assem- bling the exhaust end section informative illustration shows a vehicle with an automatic transmission. 2 exhaust silencer 5 m6x20 bolt...
Audi a4 1.9 + 2.0 tdi webasto ag postfach 80 - 82132 stockdorf - hotline 0 18 05 / 93 22 78 hotfax (0395) 55 92-353 - http://www.Webasto.De feel the drive final work warning! Reassemble disassembled components in reverse order. Check that all hose lines, hose, spring band clamps and universal clips,...
Operating instructions for the end customer please remove page and add to the vehicle operating instructions. Before parking the vehicle, make the following settings: 1 temperature to "hi" for vehicles with automatic air conditio- ning 44 1 1.
23 audi a4 1.9 + 2.0 tdi 0 100mm 100mm scale 1:1 compare the size of the printed version with dimension lines. Permitted tolerance a maximum of 2%. Set the printer settings to “no margin” or “minimize margins” and 100% of the normal size. Fastening strap template 50 mm torsion line 90°.
24 audi a4 1.9 + 2.0 tdi 0 100mm 100mm scale 1:1 compare the size of the printed version with dimension lines. Permitted tolerance a maximum of 2%. Set the printer settings to “no margin” or “minimize margins” and 100% of the normal size. Tank extracting device template.
