Webasto Thermo Top E Installation Instructions Manual
Parking heater for citroen c4 from 2004
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- Installation documentation (41 pages) ,
- Installation instructions manual (36 pages) ,
- Manual (31 pages)
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Installation instructions
Citroen C4
Gasoline and Diesel
from Model Year 2004
Left-hand drive vehicle
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.
Webasto does not accept any liability for defects and damage that are attributable to installa-
tion by untrained staff.
Ident. No.: 1303571D_EN
e1
00 0003
e1
00 0002
e1
00 0104
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.
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Page 2: Table Of Contents
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 summer/winter switch should be confirmed with the end customer before installation. 1303571D_EN https://webasto-russia.ru... -
Page 3: Heater/Installation Kit
Citroen C4 Heater/Installation Kit Quantity Description Order No.: Retail accessories Thermo Top E / C / P See price list Heater control See price list Installation kit for Citroen C4 Gasoline and Diesel 1303584B Manual air conditioning Installation kit for Citroen C4 Gasoline and Diesel... -
Page 4: Explanatory Notes On Document
Citroen C4 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 Fuel Exhaust gas Combustion air... -
Page 5: Preliminary Work
Citroen C4 Preliminary Work WARNING! - Open the fuel tank cap and vent the fuel tank. - Close the tank cap again. - 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 do not apply from the duplicate label. -
Page 6: Preparing Electrical System
Citroen C4 Preparing electrical system Automatic air-conditioning gn/ws Pull 2000 mm long green/white (gn/ws) wire into the attached insulation hose. Preparing K3 relay Connect wires to IPCU. IPCU view on contact side! IPCU Preassem- bling IPCU 1303571D_EN... -
Page 7: Electrical System
Citroen C4 Electrical system Positive wire Wiring harness pass through Route wiring harnesses (digital timer, fan control 1 Red (rt) wire and red (rt) wire in the insulation hose of the au- 2 Original vehicle positive support point tomatic A/C) just behind the rubber plug 1 in the direction of the upper vehicle centre! Do not install the metering pump cable harness until later together... -
Page 8: Fan Controller For Manual Air Conditioning
Citroen C4 Fan controller for manual air conditioning Webasto Citroen Wiring dia- gram IC26 St 01 Webasto components Vehicle components Colours and symbols TT-C/E/P heater Fan motor 6-pin heater connector Fan relay black Fuse Fan switch 8025 Fan relay St 01... -
Page 9: Automatic Air-Conditioning Fan Controller
10V NR IC26 br/ge gn/ws St 03 St 02 IPCU gn/ge St 04 St 05 Webasto components Vehicle components Colours and symbols TT-C/EP heater Fan motor 8050 6-pin heater connector Fan controller 8045 white Fuse St 02 4-pin connector GR... - Page 10 Citroen C4 Connection to 6-pin connector 5 from IC 26. Produce connections as shown in wiring dia- gram. 1 Red (rt) wire from K3/87a 2 Black (sw) wire from K3/30 Connect- 3 Red (rt) wire of fan switch ing fan-mo- 4 Red (rt) wire for 6-pin connector IC 26 Pin 3 Before installing, connect green/white ...
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Page 11: Digital Timer, Summer/Winter Switch Option
Citroen C4 Digital timer, summer/winter switch option The installation location according to this or the following figure is only a recommenda- tion. Agree upon with final customer before Installing installing. digital tim- Variant 1 1 Digital timer 2 Summer/winter switch, drilled hole 12 mm dia. -
Page 12: Remote Option Thermo Call
Citroen C4 Remote option Thermo Call Secure the receiver of Thermo Call 1 on the bracket 2 with adhesive tape. Installing receiver 1 Antenna Installing antenna 1 Pushbutton Installing push but- 1303571D_EN... -
Page 13: Preparing Heater
Citroen C4 Preparing heater Hose B = 90° elbow Discard section X A = 1240 mm Cutting coolant hoses to length Hose C = 90° elbow Discard section X D = 1240 mm Cutting coolant hoses to length Push braided protection hoses onto hose A and D and cut to length. -
Page 14: Preparing Installation Location
Citroen C4 Preparing installation location Hole at the centre of the bumper. 1 Drill 9.1 mm dia. hole; rivet nut Mounting rivet nut Hole at the centre of the bumper. 1 Drill 9.1 mm dia. hole; rivet nut Mounting rivet nut Rectangular recess at Position 4 , recess for oblong hole at Position 3 ! 1 7 mm dia. -
Page 15: Installing Bracket
Citroen C4 2.0l gasoline Cut away edge 1 at marking and discard. Cutting away edge on radiator cross member Cut consecutive 500 mm ends from edge pro- tection provided and install. 1 50 mm edge protection 2 70 mm edge protection 3 130 mm edge protection Installing 4 60 mm edge protection... -
Page 16: Installing Heater
Citroen C4 1 M6x20 bolt, spring lockwasher 2 Strut 3 Ejot screw, washer [2x], pin lock Installing strut 1 M6x20 bolt, spring lockwasher 2 Strut Fastening strut Installing heater Mount wiring harness of heater before instal- lation. 1 Ejot screw [3x] Installing heater 1 Strut... -
Page 17: Coolant Circuit
Citroen C4 Coolant circuit WARNING! Any coolant running off should be collected using an appropriate container! Route coolant hoses kink- free! Unless specified otherwise, always fasten using cable ties. Position clamps so that no other hose can be damaged! When installing the hoses, the heater must be filled with coolant. The connection should be "inline"... - Page 18 Citroen C4 Turn perforated bracket 2 by approx. 75° on longitudinal axis. 1 M6x20 bolt, flanged nut 2 Perforated bracket 3 Rubber-coated pipe clamp Preparing perforated bracket Sliding on heat protection hoses. Route hos- es A and D through pass-through in the cool- er at the left of the heater.
- Page 19 Citroen C4 Fasten perforated bracket on transmission block. 1 Prepared perforated bracket 2 Original vehicle bolt Installing perforated bracket Gasoline Route hose A and D through rubber-coated p-clamps. 1 Rubber-coated p-clamp [2x] Routing to cutting point 1.4 and 1.6l Gasoline Remove braided protection hose in area of cutting point.
- Page 20 Citroen C4 2.0l gasoline Disconnect hose from engine outlet to heat exchanger inlet with hose clamping pliers. 1 Engine-outlet hose section Cutting 2 Hose section of heat exchanger inlet point Before installation, push black (sw) rubber isolator 1 onto hose D . 2 Engine-outlet hose section 3 Hose section of heat exchanger inlet Connect-...
- Page 21 Citroen C4 1.6l diesel Route hose A and D through rubber-coated p-clamps. 1 Rubber-coated p-clamp [2x] Routing to 2 100 mm edge protection cutting point Disconnect hose from engine outlet to heat exchanger inlet with hose clamping pliers. 1 Engine-outlet hose section 2 Hose section of heat exchanger inlet Cutting point...
- Page 22 Citroen C4 Check the position of the components; adjust if necessary. Check that they have free clear- ance. 1 50 mm edge protection Position- ing hose A and D 2.0l diesel Remove braided protection hose in area of cutting point. 1 Engine-outlet hose section Cutting 2 Hose section of heat exchanger inlet...
- Page 23 Citroen C4 Check the position of the components; adjust if necessary. Check that they have free clear- ance. 1 50 mm edge protection Position- ing hose A and D 1303571D_EN...
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Page 24: Fuel
Citroen C4 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, always fasten using cable ties. - Page 25 Citroen C4 Secure angle bracket 4 with oblong hole and large diameter washer on the stud bolt of the tank suspension 3 . 1 Metering pump 2 Rubber-coated p-clamp, silent block, Installing flanged nut [2x] on angle bracket metering pump 1 Wiring harness of metering pump, connec- tor mounted 2 Fuel line from heater...
- Page 26 Citroen C4 Install fuel-tank sending unit according to manufacturer's specifications. Replace seal- ing ring! 1 clamp of 10 mm dia 2 Fuel line Connect- ing fuel line Variant 2 Remove fuel-tank sending unit 1 in accord- ance with manufacturer's specifications. 2 M6 flanged nut 3 Copy hole pattern, 6 mm dia.
- Page 27 Citroen C4 Check the position of the components; adjust if necessary. Check that they have free clear- ance. 1 Fuel line 2 Hose section, 10 mm dia. clamp [2x] Connect- ing meter- ing pump Diesel Remove fuel-tank sending unit 1 in accord- ance with manufacturer's specifications.
- Page 28 Citroen C4 Install fuel-tank sending unit according to manufacturer's specifications. Replace seal- ing ring! 1 Fuel line 2 clamp of 10 mm dia Connect- ing fuel line Check the position of the components; adjust if necessary. Check that they have free clear- ance.
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Page 29: Combustion Air
Citroen C4 Combustion air Discard section X . 1 Combustion air pipe a = 250 Cutting combus- tion air pipe to length Drill hole in side member from rear at Position 1 . 1 6.2 mm dia. hole (centered from bar) Hole for muffler 1 Combustion air pipe... -
Page 30: Exhaust Gas
Citroen C4 Exhaust gas Discard section X 1 Exhaust pipe a = 120 Preparing 2 Exhaust end section exhaust b = 110 pipe Route red (rt) rubber isolator 1 at Position 5 . Paste base with cable tie 3 [3x]. Fasten origi- nal vehicle wiring harness 4 . - Page 31 Citroen C4 Ensure sufficient distance to neighbouring components. 1 Hose clamp on exhaust manifold 2 M6x20 bolt, flanged nut Installing exhaust system Install underride protection 1 . Insert red rub- ber isolator 2 in underride protection 1 . Align exhaust end section 3 flush on red rubber iso- lator 2 .
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Page 32: Final Work
Citroen C4 Final Work WARNING! Mount removed parts in reverse order. Check all hoses, clamps and all electrical connections for firm seating. Secure all loose cables using cable ties. Only use manufacturer-approved coolant. Spray heater components with anti-corrosion wax (Tectyl 100K, Order No. 111329). - Connect the battery. -
Page 33: Gasoline Fuel Standpipe
Citroen C4 Gasoline fuel standpipe 100 mm 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 “minimise margins” and 100% of the normal size. 100 mm 1303571D_EN... -
Page 34: Diesel Fuel Standpipe
Citroen C4 Diesel fuel standpipe 100 mm 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 “minimise margins” and 100% of the normal size. 100 mm 1303571D_EN... -
Page 35: Operating Instructions For End Customer
Citroen C4 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 exceeding a switch-on time of 20 min.