Webasto Thermo Top E Installation Documentation
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Also See for Thermo Top E:
- Installation documentation (41 pages) ,
- Installation instructions manual (36 pages) ,
- Manual (31 pages)
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Water Heater
Thermo Top E Parking Heater
Thermo Top C Parking Heater
Installation documentation
Citroen C1 / Peugeot 107 / Toyota Aygo
Petrol
from Model Year 2005
For left-hand drive vehicles only
Manual air conditioning
5-gear manual transmission
5-gear MultiMode transmission
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 equipment are
required to install and repair Webasto heating and cooling systems.
Only original Webasto parts must be used. For this, also see the catalog of air and water heat-
er accessories from Webasto.
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 warnings.
The initial startup is to be executed with the Webasto Thermo Test Diagnosis.
Webasto does not accept any liability for defects and damage that are attributable to installa-
tion by untrained staff.
Ident. No.: 1310261B_EN
e1
00 0003
e1
00 0002
Fee Euro 10.00
Feel the drive
© Webasto AG
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Table of Contents
Related Manuals for Webasto Thermo Top E
Summary of Contents for Webasto Thermo Top E
- Page 1 Specialist company training, technical documentation, specialised tools and equipment are required to install and repair Webasto heating and cooling systems. Only original Webasto parts must be used. For this, also see the catalog of air and water heat- er accessories from Webasto.
-
Page 2: Table Of Contents
Citroen C1 / Peugeot 107 / Toyota Aygo Table of Contents Validity Preparing installation location Heater/Installation Kit Installing heater Foreword Coolant circuit General Instructions Combustion air Special Tools Fuel Explanatory notes on document Exhaust gas Preliminary Work Final Work Heater installation location Template for fuel standpipe Electrical system Template for fuel-tank sending unit... -
Page 3: Heater/Installation Kit
Citroen C1 / Peugeot 107 / Toyota Aygo Heater/Installation Kit Quantity Designation Order No.: Thermo Top E / C retail accessories See price list Installation kit for Citroen C1 / Peugeot 107 / Toyota Aygo 1310257B Petrol Heater control See price list... -
Page 4: Explanatory Notes On Document
Citroen C1 / Peugeot 107 / Toyota Aygo Explanatory notes on document To provide you with a quick overview of the individual working steps, you will find an identification mark on the outside top right corner of the page in question. Mechanical system Electrical system Coolant circuit... -
Page 5: Preliminary Work
Citroen C1 / Peugeot 107 / Toyota Aygo Preliminary Work WARNING! - Disconnect the battery - Depressurise 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 duplicate label. - Attach the duplicate label (type label) in the appropriate place. -
Page 6: Electrical System
Citroen C1 / Peugeot 107 / Toyota Aygo Electrical system Wiring harness pass through Digital timer, summer/winter switch option 1 Protective rubber plug 1 Digital timer 2 Summer/winter switch, 12 mm dia. drilled hole Do not install the metering pump wiring harness until later togeth- er with fuel pipe along the origi- nal vehicle fuel lines on the... -
Page 7: Fan Control
2 Instrument cluster (view from rear.) Webasto C1 / 107 / Aygo rt/ws gr/ws Wiring dia- gram for manual air condition- Webasto components C1 / 107 / Aygo components Colours and symbols Heater TT-C/E Fan relay 25 A fuse Instrument cluster white Fan relay... -
Page 8: Remote Option (Telestart)
Citroen C1 / Peugeot 107 / Toyota Aygo Remote option (Telestart) Fasten receiver 2 with adhesive tape. 1 Upper centre console Installing receiver 1 Antenna Installing antenna Only with Telestart T100 HTM Fasten temperature sensor 2 with adhesive tape. 1 Upper centre console Installing tempera- ture sensor... -
Page 9: Preparing Installation Location
Citroen C1 / Peugeot 107 / Toyota Aygo Preparing installation location 1 Detach retaining clip [3x] 2 Original vehicle wiring harness [2x] Detaching wiring har- ness Detach original vehicle bolt at Position 3 . Re- move earth cable at Position 2 , discard bolt and fasten at Position 1 . -
Page 10: Installing Heater
Citroen C1 / Peugeot 107 / Toyota Aygo Installing heater Mount wiring harness on heater before in- stalling. Tighten Ejot screws to 10 Nm. 1 Bracket 2 Ejot screw [2x] Installing heater Tighten Ejot screws to 10 Nm. 1 Ejot screw [2x] 2 Bracket Installing heater... -
Page 11: Coolant Circuit
Citroen C1 / Peugeot 107 / Toyota Aygo Coolant circuit With throttle valve heating WARNING! Any coolant running off should be collected in an appropriate container. Route coolant hoses kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that other hoses cannot be damaged. - Page 12 Citroen C1 / Peugeot 107 / Toyota Aygo Discard section X . Hose B with long 90° elbow. Hose C =90° elbow A = 460 mm B = 550 mm Cutting hoses to length Coolant reservoir cap removed for demon- stration purposes.
- Page 13 Citroen C1 / Peugeot 107 / Toyota Aygo Pull out hose of engine outlet 3 from T-piece. Spring clip 2 will be reused. Remove hose of heat exchanger inlet 1 with supply line of throttle valve. Cutting point Dismantle supply line of throttle valve 4 at po- sition 1 , shorten by 20 mm and reinstall.
- Page 14 Citroen C1 / Peugeot 107 / Toyota Aygo Before connecting, fill the coolant hoses with coolant. Aligning hoses. Ensure sufficient distance from neighbouring components. 1 Install hose bracket (on 2 and hose C ) 2 Hose of engine outlet Connect- ing engine outlet...
- Page 15 Citroen C1 / Peugeot 107 / Toyota Aygo Coolant circuit Without throttle valve heating WARNING! Any coolant running off should be collected in an appropriate container. Route coolant hoses kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that other hoses cannot be damaged.
- Page 16 Citroen C1 / Peugeot 107 / Toyota Aygo Discard section X . Hose B with long 90° elbow. A = 460 mm B = 550 mm Cutting hoses to length Coolant reservoir removed for better display. Figure shows vehicle with throttle valve pre- heating.
- Page 17 Citroen C1 / Peugeot 107 / Toyota Aygo 1 Hose of engine outlet 2 Hose on heat exchanger inlet Cutting point 1 Hose of heat exchanger inlet turned up- ward by approx. 30° Connect- ing heat exchanger inlet Before connecting, fill the coolant hoses with coolant.
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Page 18: Combustion Air
Citroen C1 / Peugeot 107 / Toyota Aygo Combustion air 1 Combustion air pipe a = 310mm Cutting Discard section X combus- tion air pipe to length 1 Combustion air pipe 2 27 mm dia. hose clamp 3 Cable tie Installing combus- tion air... -
Page 19: Fuel
Citroen C1 / Peugeot 107 / Toyota Aygo Fuel CAUTION! Open the vehicle's fuel tank cap, ventilate the tank and then re-close the tank lock. Catch any fuel running off in an appropriate container. Install fuel line and metering pump wiring harness so that they are protected against stone impact. Un- less specified otherwise, always fasten using cable ties. - Page 20 Citroen C1 / Peugeot 107 / Toyota Aygo Route Mecanyl fuel line and wiring harness of metering pump in corrugated tube 1 to origi- nal vehicle fuel lines at installation location of metering pump. Installing lines Ensure proper installation position of meter- ing pump 4 , see "Installation Instructions“.
- Page 21 Citroen C1 / Peugeot 107 / Toyota Aygo Shape fuel standpipe 2 according to tem- plate, cut to length and install, see "installa- tion instructions". 1 Fuel-tank sending unit Installing fuel stand- pipe Install fuel-tank sending unit according to manufacturer's specifications. Shorten 3.5mm dia.
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Page 22: Exhaust Gas
Citroen C1 / Peugeot 107 / Toyota Aygo Exhaust gas 1 Exhaust pipe a = 430mm 2 Exhaust end section b = 430mm Preparing exhaust Discard section X pipe 1 M6 rivet nut, existing hole Installing rivet nut 1 M6x50 bolt, spring lockwasher, 30 mm shim 2 Exhaust silencer Mounting silencer... - Page 23 Citroen C1 / Peugeot 107 / Toyota Aygo 1 Exhaust pipe 2 Hose clamp Installing exhaust pipe Ensure sufficient distance from neighbouring components. 1 Exhaust end section 2 Hose clamp Installing exhaust end sec- tion 1 Red (rt) rubber isolator [2x] 2 P-clamp 3 Exhaust end section 4 M6x20 bolt, large diameter washer, flang-...
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Page 24: Final Work
- Place signboard "Switch off parking heater before refuelling" in the area of the filler neck - See installation instructions for initial start-up and function test Feel the drive Webasto AG Postfach 80 D-82132 Stockdorf / Germany National Hotline: 01805 93 22 78... -
Page 25: Template For Fuel Standpipe
Citroen C1 / Peugeot 107 / Toyota Aygo Template for fuel-tank sending unit Template for fuel standpipe 100 mm Scale 1:1 Compare the size of the printed version with dimension lines. Permitted tolerance a maximum of 2%. Correct major differences in the printer settings or request an original printout. -
Page 26: Operating Instructions For End Customer
Citroen C1 / Peugeot 107 / Toyota Aygo 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.