Self-Study Programme 502 Supplementary heating systems thermo top V and thermo top fleece.pdf

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Service Training
Self-study programme 502
Supplementary heating systems
Thermo Top V and Thermo Top Fleece
Design and function
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Winter driving in the cold, snow and ice is always a challenge for the car as well as the driver. Is there anyone who
would not prefer a pleasantly pre-heated vehicle, which can be started safely and straight away, and where the
windows are clear?
A supplementary heating system in the car is an effective way of achieving that.
A water-based supplementary heating system is integrated into the vehicle's cooling and heating system and heats
the coolant. This in turn flows through the vehicle's heat exchanger and heats up the vehicle interior. Then the
coolant flows into the engine and heats it up as well. A pre-heated engine will reach its operating temperature
more quickly and thereby make a contribution to environmental protection.
The vehicle interior reaches a pleasant temperature and the misted or icy windows are cleared – the journey can
begin.
This self-study program describes the workings and application of water-based supplementary heating systems
Thermo Top V and Thermo Top Fleece produced by Webasto.
The self-study programme shows the
design and function of new
developments.
The contents will not be updated.
For current testing, adjustment and repair
instructions, refer to the relevant service
literature.
Important
Note
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Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Operation of supplementary heating systems . . . . . . . . . . . . . . . . . . . . . . . . . .6
Thermo Top V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Thermo Top Fleece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Fuel supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Coolant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Heating system management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Test your knowledge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
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Introduction
Supplementary heating systems
Depending on the purpose they are used for, supplementary heating systems are classified as supplementary
heating systems or auxiliary heaters.
Supplementary heater
A supplementary heater has the task of increasing the
vehicle's heating output in vehicles with a high degree
of efficiency and consequently a low heat output
(diesel engines).
A supplementary heater heats the coolant while the
engine is running. This allows the engine to reach its
operating temperature more quickly, and also speeds
up the heating of the vehicle interior.
The supplementary heater switches itself on and off
automatically when certain conditions are met.
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Auxiliary heater
Auxiliary heaters have the task of heating the vehicle
interior.
Auxiliary heaters work in connection with the heating/
air conditioning system. Auxiliary heaters can be used
when the vehicle is stationary, to pre-heat the vehicle
interior when the engine is switched off, or during the
journey (e.g. during the engine's warm-up phase). If
the auxiliary heater is switched on while the vehicle is
stationary and the engine is not running, the engine
may also be pre-heated.
Auxiliary heaters heat the coolant, which in turn heats
the air in the heat exchanger. The heated air then
flows into the vehicle interior and heats it.
Unlike supplementary heating systems, auxiliary
heaters do not switch on automatically when the
engine is started.
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For the switch-on and switch-off conditions for
supplementary heating systems and auxiliary
heaters, please see page 46.
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Supplementary heating systems in vehicles from Volkswagen
Passenger Cars
Passenger cars from the Volkswagen Group contain water-based supplementary heating systems.
This booklet describes the water-based supplementary heating systems Thermo Top V and Thermo Top Fleece
produced by Webasto.
Since mid-November 2010, the Thermo Top V supplementary heating system is installed only in vehicles with petrol
engines.
Thermo Top Fleece is a development of Thermo Top V for use in vehicles with diesel engines. It differs from Thermo
Top V only in terms of its combustion principle, and therefore in the structure of the related components.
The supplementary heating system Thermo Top V will be described first. The subsequent description of Thermo Top
Fleece will then describe the specific ways in which Thermo Top Fleece differs from Thermo Top V.
Where in the vehicle are supplementary heating systems installed?
The installation location of supplementary heating systems depends on the vehicle type. The installation location for
the supplementary heating systems described in this booklet, Thermo Top V and Thermo Top Fleece, is on the front
right behind the headlight. Connection to the fuel supply system is by means of a separate line to the fuel tank.
Supplementary heating system
Separate fuel line
Fuel tank
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