Water heater Additional heater Thermo Top / Thermo Top T marks ~ ~ ~ S 238 / ~ ~ ~ S 239 Inst allation Manual (Mandatory

installation instructions) TT9804/11B VW Golf IV 1 2 3 4 5 all the equipment for left hand drive type 1J validity shown on page 2 a vehicle , engine type and configuration options that are not included in these installat ion instructions were not examined. An installation according to these installat ion instructions may also be possible. In any case, the admission rules to be fo llowed on page 3! Legend to Figure 1 a heater Thermo Top - B / D 2 fuse holder and fan timer relay 3 4 5 Exhaust air intake line Pinch special torque wrench for 2.0 - 10 Nm Contents VW Golf IV heater / installation kit validity Foreword General Information prepa ratory work of installation and installation location fuse holder and fan relay mounted fan control without Climatronic blower control with Climatronic timer an d option summer / winter mounting plate fanfare air intake line a 2 2 3 3 4 4 5 5 6 8 9 11 11 Heater Premount heater installed wiring harness to the heater moun ted involvement in the water cycle water integration TDi and SDi water integrati on 1.4 l/1.6l/1, 8l petrol water integration V5 petrol water integration V6 petr ol fuel extraction and bypass fuel integration TDi / SDi Fuel connection put pet rol Aussentemperatursensor Final work 11 12 12 13 13 15 17 19 21 21 23 25 26 Identification number. 656 05D Printed in Germany 05/00 Pressure: Steffen © Webasto Thermo Systems GmbH Germany Thermo Top Heater / installation kit Quantity 1 Description Water heater Thermo Top (Type BW50) with delivery or a wa ter heater Thermo Top (Type DW50) with delivery or a water heater Thermo Top T ( Type BW50) with delivery or a water heater Thermo Top T (Type DW50) with deliver y VW Golf IV Order no. 313 95B 313 96B 313 97B 313 98B Additionally required parts: 1 1 Mounting Kit VW Golf IV Thermo Top / Thermo Top T line spacer (original VW part) 893 81B OZ1133687A For V6: 2m hose insulation 330 49A

Validity Manufacturer Volkswagen AG, Wolfsburg engine indicator AKL AKQ AGN AGZ AQP AGP A HF type 1J trade name Golf IV power in kW 55 74 92 110 150 50 81 EG-BE-N r. e1 * 96/79 * 0071 *.. Displacement in cm3 1390 1595 1781 2327 2792 1896 1896 Engine type Otto / Otto 4 / 4 Otto / 4 Otto / Otto 5 / 6 Diesel / Diesel 4 / 4 2 VW Golf IV Thermo Top Manufacturer Volkswagen AG, Wolfsburg engine indicator AQP AQY AGR ALH Type 1J Trade name Golf IV power in kW 150 85 66 85 EC-BE-Nr. e1 * 98/14 * 0071 *.. Engine type Otto / Otto 6 / 4 Diesel Diesel Displacement in cm3 2792 1984 1896 1896 Preface This binding instructions apply for car VW Golf IV - see front validity - model year 1998 and later, when technical changes do not affect the installation on th e vehicle to the exclusion of any liability. Depending on the version and featur es of the vehicle may change to the installation of these installation instructi ons are necessary. The relevant codes of practice are observed during installati on. NOTE: The licensing requirements must be observed! In the Federal Republic o f Germany, the retrofitting of the auxiliary heater Thermo Top T is not accordin g to these installation instructions to scrutineering, since this is a special s upplement of the ABG. Exempting from the requirement of installation registratio n according to § 19 StVZO applies only if this installation is in all of the fol lowing requirements, mandatory installation instructions. When deviations from t hese installation instructions must be an installation inspection in accordance with § 19 StVZO (see installation instructions Thermo Top T). In addition to the se installation instructions, the provisions of the operating instructions and i nstallation instructions. The ABG and these installation instructions supplied w ith the operating instructions / installation instructions are kept in the vehic le. 3 Thermo Top General Notes - Bare body parts, for example bear on holes with corrosion protection - secure hoses, cables and cable trees with cable ties and labeled on chafing with protec tive hose - Sharp edges with edge protection (sliced fuel hose) provided VW Golf IV Legislative history - Remove the inaccurate date on the duplicate plate - duplicate plate (nameplate ) at a suitable location visible disconnect mount WARNING: Battery and expand! Interior

- Remove Remove Remove outer and inner dash panel in the driver's foot space - f use box - If the vehicle with Climatronic control unit Engine Drain the cooling system pressure from the air induction ports to expand fully e xtend cable channel (facing left) clip on battery holder Vehicle exterior - Open the gas cap, tank vent, close gas cap - Remove bumper - Remove fanfare Vehicle underside (only TDi) - Reduce underrun Installation and mounting position The heater (2 / 1) in the left direction installed behind the bumper. The instal lation position is vertical 1 2 4 VW Golf IV Fuse holder and fan relay - Transfer hole picture blower relay K3 (3 / 1), the mounting plate of the fuse holder (3 / 2) and the minus-base (3 / 3) according to the position in Figure 3 on the splash wall CAUTION: When drilling, not behind it cable! - Drill a hole f or mounting plate ø 2,5 mm - holes ø 4 mm for fan relay and minus base drill - m ounting plate of the fuse holder (3 / 2) with countersunk head tapping screw 3.5 x13 - blower relay K3 (3 / 1) and minus-base ( 3 / 3) with sheet metal screw 5, 5 x9, 5 - Mount the fuse holder (3 / 2) mounting plate to attach NOTE: Be carefu l in all cable penetrations on aprons! - Lay the wiring harness for timer and fa n control through existing cable entry in the firewall in the interior - wiring harness to the heater and plus cable in the manhole leading into the engine comp artment (Fig. 4) - Plus-line into red on battery-Plus - Cable harness for heater to the installation move the heater 1 1 2 3 Thermo Top 3 4 Fan control without Climatronic Figure 5 and Figure 6 - Remove the fuse box - separate Black / Blue 4.0 mm 2 50 mm after the vehicle fuse 30A - Crimp the flat and flat plug, connector housing (5 / 1, 2) complete 2 - compounds of the circuit diagram to produce Figure 6 - Red 2.5 mm2 from the blower relay K3/87a black line / connect blue 4 mm2 for vehicle backup - Black 2 .5 mm2 from the blower relay K3/30 line with the black / blue 4 mm2 blower switc hes connect 5 F25 30A 6

5 Thermo Top Blower control with Climatronic - Operating and display unit 87 E (7 / 1 increase) for a Climatronic VW Golf IV 7 - Remove the fuse box (Fig. 8) - Black / Blue 4.0 mm2 50 mm after the vehicle fuse 30A - separate crimp flat plug and receptacles, plug housing (8 / 1, 2) com plete produce - compounds according to wiring diagram Figure 10 - Line red, 2.5 mm2 from the blower relay K3/87a black line / connect blue 4 mm2 for vehicle bac kup - Black 2.5 mm 2 from the blower relay K3/30 with Black / blue 4 mm 2 to the fan switch to connect a 2 - Additional line gn / ws 1.0 mm2 (9 / 1) to control and display unit for Clim atronic E 87 - D connector (9 / 2) black (16-pin pull off) and open according to the manufacturer gn - Additional Management / ws 1.0 mm2 (9 / 1) to the termina l D1 (free slot) connect - fix cables with cable ties 8 1 2 9 6 VW Golf IV Thermo Top 30 15 X 31 15 X 31 30 30 6.0 ro A32 75x G21 15 10.0 sw / ge 225 4.0 S225 30A 225a sw / bi 1.0 gn / ws K J 268 J168 K F 25 2.5 rt 1.0 gn / ws A50 A60 A19

A45 C2 D16 C13 A11 A5 C5 C6 D1 Rt 2.5 rt 2.5 F 3 Webasto 87a 87 86 1.0 gn / ws SG 1570 30 85 K C16 C11 C14 D14 D15 D9 A65 D6 A4 A10 K3 2.5 sw 1 + M 1 1 M 2 2 K J125 3 2 2 21 G56 0.35 1 br / ws 38 A65 A69 135 135 135

31 10 11 12 13 14 15 16 17 18 19 20 X 10 = Disconnect Only vehicles with interior monitoring - Place the connector pin 4 of the control of the interior surveillance in mass (Fig. 11) - 1.0 mm2 cable with wire from terminal 30 of relay K3 and connect to the control of the interior monitoring embarrassed - 1.0 mm2 cable with pin 14 o f the control of Interior Monitoring connect (Figure 11) Webasto K 3 / 30 mass II 14 I 4 J 347 11 7 Thermo Top Timer option and summer / winter WARNING: Do not press when installing the timer on the LCDDisplay VW Golf IV NOTE: The illustrated installation location of the timer (12 / 1) and the summer / winter (12 / 2) is a recommendation! Before installation, please coordinate t he installation with your customers - stick template for timer (12 / 1) with ima ge 12 on the dash panel - Drill two holes using the template - remove template fixing case with steel screw assemble NOTE: Pay attention to the direction of t he locking teeth (See installation instructions )! Be careful in laying the wiri ng harness for chafing protection! - Place the timer - hole picture summer / win ter (12 / 2) transferred to the desired location and drill hole ø 12 mm - summer / winter with toothed washer and nut 1 - Creating the dashboard panel and trans fer holes for harness timer on dashboard - Bore ø 12 mm (13 / 1 drill) in-dash lead wire harness of the timer (13 / 2) through hole 25 1 2 45 12 2 represented 13 - brown and purple lines in Figure 14 at the switch connect (lowe r contact) - Plug the wiring harness plug on the timer with timer - mounted dash board panel 14 8 VW Golf IV Mounting plate Angle bend in the sketch image 15 Thermo Top

15 - exhaust pipe and exhaust pipe end piece as shown in Figure 16 Cut the exhau st pipe Leaf with an exhaust pipe section AbgasleitungEndstück 300 1000 100 16 - leaf (17 / 3) as shown in Figure 17 in retaining plate (use 17 / 1) (exhaus t side right) - leaf (17 / 3) with two countersunk screws (17 / 2) - Fix side pl ate (17 / 4) with two screws M6x20 and washers loosely mounted on the plate 1 2 2 3 4 17 - Holding plate (18 / 2) and curved angle (19 / 2) with four screws M6x16, la rge washer (the angle), spring washers and nuts as shown in Figure 18 and Figure 19 on the holder (18 / 1) - Fix brace (18 / 3 ) with two M6x16 screws, lock was hers and nuts as shown in Figure 18 loose at the plate (18 / 2) onto a 2 3 18 9 Thermo Top - Exhaust silencers (19 / 1) secure with screw M6x20, spring washer and nut on t he angle (19 / 2) VW Golf IV 2 1 - Distance rubber red (20 / 6) to exhaust gas line (20 / 5) in position - exha ust line shape (20 / 5) as shown in Figure 20, the exhaust silencer (Attach 20 / 4) and secure with hose clamp - Distance rubber red (20 / 6 ) orient as shown i n Figure 20 - Exhaust pipe end piece (20 / 3) with a hose clamp on the exhaust m uffler (20 / 4 fixed) and fit according to the illustration in Figure 20 forms air intake line (20 / 1) to branches on the leaf and secure with hose clamp - e nd cap (20 / 2) on air intake line (20 / 1) onto a 19 2 3 6 5 Figure 21: View from below! - Remove the existing screw (21 / 2) - Mount (22 / 1) to existing bore (21 / 1) and Einschweißmutter Assemble (21 / 2) - Mount (22 / 1) and support (22 / 2) as shown in Figure 22 and align holes for drilling (2 1 / 3) transfer - reduce operator back CAUTION: When drilling to ground cable an d harness! - Bore (11 / 3) Ø 7 mm drill 3 NOTE: large washers between the bracke t and attach to body sheet! 2 - holder / plate (22 / 1) with screw M6x20, large washer and lock washer existing Einschweißmutter (21 / 2) - Mount holder / plate (22 / 1) with two screws M6x20, four large washers, lock washers and nuts on th e holes ( 21 / 1, 21 / 3) - Fix support (22 / 2) with screw M6x20, spring washer and nut to fasten the existing hole in the side rails - Loose screws tighten 1

2 4 20 21 1 22 10 VW Golf IV Fanfare fit NOTE: Make sure when installing the fanfare that they can swing freely! - Holder of the upper Fanfare (23 / 1) and fasten fanfare in Figure 23 on the holder - f anfare fit WARNING: fanfare harness wegbinden. Ensure sufficient distance from t he exhaust! 1 Thermo Top 23 Air intake line - Lay the air intake line (24 / 2) as shown in Figure 24 - Angle (24 / 1) with e xisting screw (fanfare fixing fix) - air intake line (24 / 2) with a pipe clamp (24 / 3), screw M6x20 and nut on the angle (24 / 1) - Fix water drain hole 4 mm in diameter at the lowest point of the air intake install 1 3 2 24 Heater Premount - Cut from the included water hose a piece of tubing as shown in Figure 25: 60 m m + 90 ° arc (25 / 1) 1 60 25 - Kevlar fuel lines (26 / 3) subject to the darts attach to the heater and secure with hose clamps - fuel lines (fuel inlet / fuel outlet) mark - insulati on tube 400 mm long on both fuel lines slide NOTE: Install hose clamp (26 / 4) s o that does not hesitate to lock the strut! - Water hose (26 / 2 attach) on the heater, entering water and use with hose clamp (26 / 4) secure - Pipe 18/18 (26 / 1) in water hose and secure with hose clamp 1 2 3 4 26 11 Thermo Top Heater Mount - Socket (exhaust gasket) (27 / 1) if not available, place them in the exhaust o utlet on the heater

VW Golf IV 27 Only for V6 - deflector (28 / 1) as shown in Figure 28 forms a 28 For all vehicles: - deflector (29 / 1) loose on side panel (installed 17 / 4) - Fuel Hoses (29 / 2) lead up into the engine and heater as shown in Figure 29 used in the retaining plate and side plate (17 / 4) Clamp 1 2 29 Harness on heater installed - 2-pin connector X15 (30 / 3) and 6-pin connector X14 (30 / 4) of the cable har ness plug into the controller - 2-pin connector X20 (30 / 1) of the solenoid val ve and the plug (30 / 2) on wiring harness to connect NOTE: The strain relief of the three connectors must contact the clearly audible click! 1 2 3 4 30 12 VW Golf IV Involvement in the water cycle NOTE: All hose clamps with a 2.0 + 0.5 Nm! Leaking cooling water must be collect ed with a suitable container! The following is an integration of the heater "in series" (inline) is described in the cooling circuit of the vehicle (Figure 31) Thermo Top Legend for Figure 31: a reservoir Kühlerthermostat 2 3 4 heater motor vehicle he ater core 5 (vehicle) six cooler θ 31 Water and integration TDi SDi (Cut the image shown 32 to Figure 36) - water hoses as in Figure 32: Water hose (32 / 1) is already on the heater 1 x 1100 mm pre-mounted straight (32 / 2) heat er-water outlet 1 x 500 mm, straight (32 / 3) Heater Water inlet 1 2 3 Section 1100 500 32 - Heat protection tube 600 mm long (33 / 1) water hose 1100 mm long (33 / 2) pus h and position as shown in Figure 33 - Water Hose 1100 mm long (Attach 33 / 2) o n the heater water outlet, secure with hose clamp and run in the engine compartm ent - water hose and wiring harness using cable ties 1 2

33 13 Thermo Top - Separate on-board water hose (34 / 1) from the outlet to the vehicle heat exch anger (on the fire wall in left direction) as shown in Figure 34 VW Golf IV A separation point 34 - Water Hose (35 / 1) connect 500 mm long with pre-fitted water hose to the h eater water inlet and secure with hose clamp - run water hoses to the battery ho lder according to Figure 35 on the left side of the engine - Loosen hose clamp o n the outlet, tube sheets (35 / 3) in accordance with Figure 35 forward and fast en hose clamp again - water hose (35 / 1) connect to the heater water inlet conn ecting pipe 20/18 with water hose (35 / 3) from the motor outlet and secure with hose clamp - chafer (35 / 2), water hose (35 / 4 ) affix a 2 4 - Water Hose (36 / 2) connect the heater water outlet connecting pipe 20/18 wi th water hose (36 / 1) for vehicle heat exchangers and secure with hose clamps Position chafer (35 / 2) as shown in Figure 35 - Attach the water hoses with ca ble ties - Battery Holder Mount 3 35 1 2 36 14 VW Golf IV 1.4 Integration of water l/1.6l/1, 8l petrol (Cut shown Figure 37 to Figure 43) 1 - water hoses, as in Figure 37: Water hose (37 / 1) is already on the heater 1 x 1200 mm assembled straight (37 / 2) heater -water outlet 1 x 700 mm + 180-degree arc ( 37 / 3)-water heater inlet 2 Thermo Top 3 Section 1200 700 37 - Heat protection tube 600 mm long (38 / 1) water hose 1200 mm long (38 / 2) pus h and position as shown in Figure 38 - Water Hose 1200 mm long (38 / 2) on the h eater water outlet attach, fasten with hose clamp and run in the engine compartm ent - water hose and wiring harness using cable ties 1 2

38 - Onboard water hose (39 / 1) separate from the motor outlet to the vehicle h eat exchanger (on the splash wall and towards the front left) as shown in Figure 39 and Figure 40 - Connection pipe 20/18 used in separate water hose and hose c lamps secure separation point 1 39 - chafer (40 / 1) at 180 degree arc of the water hose (40 / 2) in position 70 0 mm long - water hose (40 / 2) to the heater water inlet water hose (40 / 3) co nnect the motor outlet and secure with hose clamp - chafer (40 / 1) as shown in Figure 40 positioned at the brake booster 1 3 2 40 15 Thermo Top - The water hose 700 mm long lay on the left side of the engine to the heater an d connect with the straight side with pre-fitted water hose to the heater water inlet and secure with hose clamp (Figure 41) - chafer (43 / 3, 4) pre-assembled water tube (41 / 1) from the heater water outlet install - water hose (41 / 1) t o be installed in accordance with Figure 41 VW Golf IV 1 41 - Water Hose (42 / 1) connect the heater water outlet with hose (42 / 2) for vehicle heat exchangers and secure with a hose clamp 2 42 32 - Battery Holder - Mount chafer (43 / 3, 4) position as shown in Figure 43 - Adjustable (43 / 5) as shown in Figure 43 slightly bending WARNING: Ensure th at sufficient clearance mass balance shift linkage! - Adjustable (43 / 5 pre-ass embled) for securing the water hoses with two rubber pipe clamps (43 / 1), screw M6x20, spring washer and nut on the water hoses (43 / 2, 6) - water hoses with cable ties NOTE: Hole Band (43 / 5 ) coupled during the assembly of the air filt er with the original screw (Figure 43) 1 2 3 4 65 43 34 16 VW Golf IV Water involvement V5 petrol (Cut the illustrated image 44 1 to image 50) - water hoses, as in Figure 44: Wat er hose (44 / 1) is already on the heater 1 x 1120 mm pre-mounted straight (44 / 2) heater-water outlet 1 x 850 mm + 180-degree arc ( 44 / 3)-water heater inlet 2 Thermo Top 3 Section 1120

850 44 - Heat protection tube 600 mm long (45 / 1) water hose 1120 mm long (45 / 2) pus h and position as shown in Figure 44 - Water Hose 1120 mm long (Attach 45 / 2) o n the heater water outlet, secure with hose clamp and run in the engine compartm ent - water hose and wiring harness using cable ties 1 2 45 - Onboard water hose (46 / 1) separate from the motor outlet to the vehicle h eat exchanger (on the fire wall in left direction) as shown in Figure 46 - 20/18 connecting tubes used in separate water hose and secure with hose clamps 1 Separation point 46 1 - Chafer (47 / 1) at 180 degree arc of the water hose (47 / 2) in position 850 m m long - water hose (47 / 2) to the heater water inlet water hose (47 / 1) conne ct from the motor outlet and secure with hose clamp - chafer (position 47 / 3) a s shown in Figure 47 on the brake booster 2 3 47 17 Thermo Top - The water hose 850 mm long (48 / 4) to be installed on the left side of the en gine to the heater and connect with the straight side with pre-fitted water hose to the heater water inlet and secure with hose clamp - chafer (48 / 1, 3) pre-a ssembled water tube (48 / 2 ) from the heater water outlet and attach as shown i n Figure 48 position - water hose (48 / 1) in accordance with Figure 48 transfer 1 2 VW Golf IV 4 - Water Hose (49 / 2) connect the heater water outlet with hose (49 / 1) for v ehicle heat exchangers and secure with hose clamp 3 48 1 2 49 1 - battery holder mount - Adjustable (50 / 1) as shown in Figure 50 slightly bending WARNING: Ensure that sufficient clearance mass balance shift linkage! Adjustable (50 / 1 pre-assembled) for securing the water hoses with two rubber pipe clamps (50 / 3), screw M6x20, spring washer and nut on the water hoses (50 / 2, 4) - water hoses with cable ties NOTE: Hole Band (50 / 1 ) coupled during t he assembly of the air filter with original screw 4 3 2

50 18 VW Golf IV Water involvement V6 petrol (Cut shown Figure 51 to Figure 55) 1 - water hoses, as in Figure 51: Water hose (51 / 1) is already on the heater 1 x 1150 mm assembled straight (51 / 2) from t he vehicle's own tube of the heat exchanger to the heater water outlet 1 x 780 m m + 180 ° arc (51 / 3) from the vehicle 'water hose outlet to the water pre-heat er hose on a water inlet 1 x 90-degree arc (51 / 4) between the heat exchanger t ube and water tube 3 2 Thermo Top 3 4 1150 780 51 - Thermal Cut the hose to 750mm and 1100mm - insulation tube 750 mm long push on hose length 780 mm - 1100 mm long tube heat onto water hose 1150 mm long - Separate on-board water hose (52 / 1,2,3) is shown from the motor outlet to th e vehicle heat exchangers such as in Figure 52 and dispose of hose (52 / 2) - Pi pe 20/18 in vehicle own piece of hose of the engine outlet (52 / 3) and tighten with hose clamp A separation point 3 - water hose 780mm long (53 / 2) plugged with 180-degree arc to connect pipe t o the outlet (52 / 1), align as shown in Figure 53 and secure with a hose clamp 2 2 52 53 19 Thermo Top - Water hose (54 / 2) as shown in Figure 54 to the heater embarrassed to connect with a connecting tube of the pre-heater water hose from water entry and fix it with a hose clamp 2 VW Golf IV 54 - connecting pipe 20/18 in vehicle own piece of tubing of the heat exchanger (55 / 2) and secure with hose clamp - attach a 90 ° arc (55 / 3) to connect pipe , align it as shown in Figure 55 and secure with hose clamp - water hose 1150mm long (55 / 1) connect via connecting tube 18 / 18 with 90-degree arc (55 / 3) an d secure with hose clamp - water hose (54 / 1) in accordance with Figure 54 move to the heater, connect the heater water outlet with hose clamp WARNING: Fix is free running mass balance shift linkage eighth! - Position All heat pipes and wa ter hoses with cable ties 1

2 3 55 20 VW Golf IV Fuel extraction and bypass WARNING: field outlet ends with a suitable fuel tank! Fuel lines kink! Thermo Top Fuel connection TDi / SDi Figure 56 to Figure 59 - Thermal insulation hose (56 / 6) in Fig 56 position - l ay fuel lines as shown in Figure 56 and Figure 57 - chafer (56 / 4) and (56 / 5) Put on fuel lines and as shown in Figure 56 - Position hole Ø 6,5 mm at the dri ll in Figure 56 position shown in the cable channel and use cable ties with Spre itzniet (56 / 3) - mount cover for the manhole again - fuel lines with cable tie s (56 / 3) - Fix line spacer (56 / 2) (VW original parts ) attach to fuel lines - chafer (56 / 1) Put on fuel lines and as shown in Figure 56 position 1 2 3 4 5 6 56 - Attach fuel line to the spray wall with cable ties to existing lines (Figure 5 7) 57 21 Thermo Top Cut - round enclosed by Kevlar hose 7.5 x13 - 0.5 m - 2 pieces of tubing as show n in Figure 58: 1 x 50 mm long (58 / 1) 1 x 230 mm (58 / 3) Take Note: On flow o f the check valve! - Non-return valve (58 / 2) as shown in Figure 58 in the tube pieces (58 / 1) and (use 58 / 3) and secure with hose clamps - fuel pickup stra ight (58 / 4) in a tubular piece (58 / 3) and use with hose clamp - Fix fuel pic kup 90 (58 / 5) of hose (58 / 1) and secure with hose clamp 1 2 3 VW Golf IV 4 5 58 - On-board fuel-return line (59 / 6) (from the injection system coming) off the

blue clutch (return to tank) - On-board fuel-return line (59 / 6) with connectin g pipe 8x8 with the fuel line (59 / 3) to the heater fuel inlet connect and secu re with hose clamps - from the fuel line (59 / 4) from the heater leaking fuel a piece of tubing 100 mm long (cut off 59 / 5) - of hose length 100 mm (59 / 5) A ttach the blue clutch (return to tank) and hose clamp Fix - On-board fuel supply line (59 / 1) at the position shown in Figure 59 separate WARNING: arrow points to the non-return valve to return to the tank! - Fuel pickup 90 according to Fi gure 59 on-board fuel supply line (59 / 1) and secure with hose clamps - Replace fuel pickup just as shown in Figure 59 in the fuel line from the heater fuel ou tlet (59 / 4, 59 / 5) to the tank and secure with hose clamps - non-return valve (59 / 2) position as shown in Figure 59 1 2 3 4 5 6 59 22 VW Golf IV Gasoline Fuel connection Figure 60 to Figure 65 - hole Ø 6.5 mm at the drill position shown in Figure 60 in the conduit and mount cable ties with Spreitzniet (60 / 1) Insert - back cove r for manhole Thermo Top 1 60 - insulation tube (61 / 4) in Fig 61 position - Fuel lines must be laid as sh own in Figure 61 - Attach chafer (61 / 2, 3) fuel lines - Line spacer (61 / 1) ( VW-original part) to place on fuel lines 1 2 3 4 61 - Replace filter - fuel lines as shown in Figure 62 lay behind air filter - f ix fuel lines with cable ties (62 / 2) on the cable channel - chafer (62 / 3, 4) as shown in Figure 62 positioned at the air filter - Line spacer (62 / 1) (VW o riginal parts position) as shown in figure 62 - fuel injection lines to the wall with cable ties to fasten the existing lines 1 2 3 4 62 - On-board hose (63 / 1) coupling between white (63 / 2) and remove clutch (6 3 / 3) activated carbon filter - clutch (63 / 2) and coupling (63 / 3 mine) 1 2 3 63 23 Thermo Top Cut - round enclosed by Kevlar hose 7.5 x13 - 0.5 m - 2 pieces of tubing as show n in Figure 58: 1 x 230 mm (64 / 2) 1 x 90 mm long (64 / 8) - from existing tube

LI-4,Cut two pieces of tubing as shown in Figure 5 58: 1 x 50 mm long (64 / 3) 1 x 120 mm long (64 / 5) Take Note: On flow of the check valve! Non-return valve (64 / 4) as shown in Figure 64 in the tube pieces (64 / 3) 50 mm long and (64 f ifths use) 120 mm long and secure with hose clamps - fuel pickup straight (64 / 6) in tubular piece (64 fifths ) and tighten with hose clamp - fuel pickup 90 ° (64 / 9) into hose (64 / 3) and secure with hose clamp - Connectors (64 / 2) 230 mm long and (64 / 8) 90 mm long on the fuel pickup 90 (Attach 64 / 9) and secur e with hose clamps - jack white (64 / 7) in a tubular piece (64 / 8) set up 90 m m in length and secure with hose clamp - clutch (64 / 1) activated carbon filter in tubular piece (64 / 2) 230 mm long and tighten with hose clamp - On-board fu el-return line (65 / 6) (from the injection system coming) to the blue clutch (r eturn to tank) off and cut as shown in Figure 65 - On-board fuel-return line (65 / 6) with connecting pipe 8x8 Connect fuel line (65 / 5) to the heater fuel inl et and secure with hose clamps - from the fuel line (65 / 2) Turn the heater lea king fuel a piece of tubing 80 mm long (65 / 2) Disconnect - Blue clutch of hose length 80 mm (65 / 2) Attach the blue clutch (return to tank) and hose clamp fi x WARNING: arrow on the valve points to return to the tank! - White fuel pickup straight (65 / 4) as shown in Figure 65 in fuel line from the heater fuel outlet (65 / 3) and hose (use 65 / 2) to the tank and secure with hose clamps - clutch (65 / 8) onto the activated carbon filter - Clutch (Fit 65 / 7) - check valve ( 65 / 1) position as shown in Figure 65 1 2 3 VW Golf IV 4 5 6 9 8 7 64 12 3 4 5 6 8 7 65 24 VW Golf IV Aussentemperatursensor enable - Aussentemperatursensor from bracket (66 / 3) Unclip - car's own wiring harness (66 / 2) as shown in Figure 66 50 mm cut off before the Aussentemperatursensor - enclosed two-wire harness (66 / 1) using butt connectors with vehicle's wiring harness (66 / 2) connect and behind the radiator to the left side of the vehicl e move 1 2 Thermo Top 3 66 NOTE: Coverage is not available in all vehicle kits! - Remove the cover - tha t mounting bracket (67 / 1), with nut M8 on existing screw (67 / 2) Attach a 2

67 - Aussentemperatursensor (68 / 2) Cut in Halter (68 / 3) Clip - 2-wire harnes s (68 / 1) and using butt connectors with cables to plug (to connect 68 / 4) - W iring harness with cable ties 1 2 3 4 68 25 Thermo Top Final work VW Golf IV Reconnect vehicle battery removed parts in reverse order fit all hoses, hose and pipe clamps and all electrical connections are tight Check all loose wires with cable ties securing heaters components with corrosion protection wax (Tectyl ML , Order no. 111 329) Spray CAUTION: Use only original VW coolant! Coolant G12 ABD according to TL VW 774D! Start the engine, the water cycle bleeding, according to the vehicle manufacture r, cooling water refill car heater to "warm" and the fan set to level 2 at Clima tronic with ignition ON to "DEF". Beam switch set to fan II Webasto heating, see "Operating instructions / installation instructions" 26 VW Golf IV For your notes Thermo Top 27 Thermo Top VW Golf IV Webasto Thermo GmbH Postfach 80 - D-82 132 Stockdorf - Hotline 0 18 05 / 93 22 7 8 Hotfax (0395) 55 92-353 - http://www.webasto.de 28 Material List Mounting Kit Ident-No. 89381B Audi A3 and Golf IV Thermo Top / Thermo Top T Order no. 65677A 28526A 28601A 33047A 175 110 88247B 118971 146714 147249 152560 18137A 19603A 25154A 242 780 242 950 243 744 362 891 387 045 454 737 462 497 48 4 032 45890A 65692A 176 591 242 780 262 363 022 64A 63839A 65691A 492 302? 87190 A 90466A 65691A 65606A 776 812 Name HOLDER 3-PIECE AUDI A 3 B / D BRENNSTOFFL. KEVLAR LG 2000. WAS BRENNSTOFFL cable ties. KEVLAR 500 LG. FLEX. PIPE GA-A28, 1200 LG. BTL.KLEINT.AUDI A3 B / D fuel pickup 6KT MOTHER-ISO 4032-M6-6-A3G 6KT-SCHR. ISO 4017-M6X20-5.6-A3G SPRING RING DIN 128-A6-PHRF RUBBER PROFILE 6KTBLSCHR. DIN 7976-B5, 3x19 A3G-ANGLE PIPE

CLAMP 25 SCHLAUCHSC BRIGHT 20th .27 DISTANCE WASHER PIPE CLAMP 29 RUBBER RING 8 X5X8 fuel pickup cable ties VERBINDUNGSROHR FUEL HOSE 18 X 20 X10 4.5, 5 LG 50. BTL.KLEINTEILE VW GOLF 4 6.3 to 2.5 FL.ST.HUELSE NAEINZ ANGLE MICRO-TIMER CONTAC T HOSE CLAMP PIPE DIN72551 14 .75 GN / WS 1000 LG. "D" VW GOLF 4 EBA DISTANCE MO THER 20 LG. Check valves 2 X 7K KRAFTSTOFFSCHL.4, 5X10, LG 5120.€"D" ABG-EBV THE RMO TOP "D" EBA AUDI A3 "D" MAT-LIST FOR 65605A and 65691A Quantity 1 2 1 1 1 1 1 5 5 6 1 1 1 1 2 1 2 5 1 1 2 1 1 1 1 1 10 1 1 1 1 1 1 1 1 Ident-No. 776 123 ? / 0498 © Webasto Thermo Systems GmbH Germany