Webasto Thermo Top E Installation Documentation
Citroen berlingo/peugeot partner 2008- parking water heater
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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
Thermo Top P Parking Heater
Installation documentation
Citroen Berlingo / Peugeot Partner
Petrol
from Model Year 2008
Left-hand drive vehicle
Manual 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.: 1314460B_EN
e1
00 0003
e1
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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
Citroen Berlingo / Peugeot Partner Table of Contents Validity Preparing bracket Heater/Installation Kit Installing bracket Foreword Installing heater General Instructions Fuel Special Tools Exhaust gas Explanatory Notes on Document Combustion air Preliminary Work Final Work Heater installation location Template for Fuel Standpipe Preparing electrical system Operating Instructions for End Customer Electrical system... -
Page 3: Heater/Installation Kit
However, the stipulations in this "installation documentation", the "operating instructions" and "installa- tion instructions" for the Thermo Top E/C/P must always be observed. The corresponding rules of technology and any information from the vehicle manufacturer should be observed during the installation work. -
Page 4: Explanatory Notes On Document
Citroen Berlingo / Peugeot Partner 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... -
Page 5: Preliminary Work
Citroen Berlingo / Peugeot Partner Preliminary Work WARNING! - 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. - Attach the duplicate label (type label) in the appropriate place. -
Page 6: Preparing Electrical System
Citroen Berlingo / Peugeot Partner Preparing electrical system Manual air conditioning Cut one end of 0.75² brown (br) wire, to ap- prox. 80 mm. Preparing Produce connections as shown in wiring dia- additional gram. relay K3.1 K3.1 1 Red (rt) wire, 0.75² - 1000 2 Black (sw) wire, 4²... -
Page 7: Electrical System
Citroen Berlingo / Peugeot Partner Electrical system Connecting positive wire Wiring harness pass through Before installing, crimp 8 mm dia. cable lug onto Route wiring harnesses (digital timer, fan control- positive wire. ler and red (rt) wire in protective sleeving) on original vehicle wiring harness 1 to protective 1 Red (rt) wire rubber plug 2 and route into passenger compart-... -
Page 8: Fan Controller For Manual Air Conditioning
4² 4² 4² gn/ge 0,75² 4² 1,5² 4² 4² K3.1 gn/ge 4² 0,75² Webasto components Vehicle components Colours and symbols Heater TT-C/E Fan motor 6-pin heater connector Fan relay white 25 A fuse Fan switch black Fan relay Resistor group... - Page 9 Citroen Berlingo / Peugeot Partner Connection to 5-pin connector 2 from resistor group. Produce connections as shown in wiring dia- gram. 1 Blue (bl) wire of fan switch Connect- 3 Blue (bl) wire of connector, Pin 1, discon- ing resistor nected group 4 Blue (bl) wire to K3.1/87a...
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Page 10: Automatic Air-Conditioning Fan Controller
6² sw/ws 4² 4² 4² ge/gr 0,5² IPCU 0,75² ge/gr 0,75² 0,5² Webasto components Vehicle components Colours and symbols Heater TT-C/E A/C control unit 6-pin heater connector GR Fan relay white 25 A fuse Fan module black Fan relay 2-pin connector GM... - Page 11 Citroen Berlingo / Peugeot Partner Before installing, connect red (rt) wire 2 from K3/86 to socket of IPCU terminal 86. 1 IPCU covered (installed behind original ve- hicle strut) 3 M5x16 bolt, large diameter washer, flang- Installing ed nut IPCU 1 Original vehicle bolt 2 Brown (br) wire of IPCU/85, cable lug Connect-...
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Page 12: Digital Timer, Summer/Winter Switch Option
Citroen Berlingo / Peugeot Partner Digital timer, summer/winter switch option Installation location shown is a recommenda- tion. Agree upon with end customer before in- stalling. Installing digital tim- 1 Digital timer 2 12 mm dia. hole, summer/winter switch Remote option (Telestart) Fasten receiver 1 with double-sided adhesive tape. -
Page 13: Preparing Bracket
Citroen Berlingo / Peugeot Partner Preparing bracket 1 M6x12 bolt, flanged nut [2x each] 2 Bracket A 3 Bracket B Preparing bracket Preparing installation location Dismantle bracket resonator 1 . Original vehi- cle bolts at position 2 will be reused. Disman- tling brack- Install premounted brackets (A and B) 5 to-... -
Page 14: Installing Bracket
Citroen Berlingo / Peugeot Partner Cut off tab 1 from resonator at the marking. Preparing resonator Installing bracket Install premounted brackets (A and B) 5 to- gether with resonator bracket 2 . 1 M6x20 bolt, spring lockwasher, large diam- Installing eter washer bracket 3 Original vehicle bolt [2x]... - Page 15 Citroen Berlingo / Peugeot Partner 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 other hoses cannot be damaged. When installing the hoses, the heater must be filled with coolant. The connection should be "inline"...
- Page 16 Citroen Berlingo / Peugeot Partner Hose A = 180° moulded hose Discard section X . B = 770 C = 620 Cutting hoses to length Cut off original vehicle hose on engine out- let/heat exchanger inlet at marking. Remove original vehicle braided protection hose, if available.
- Page 17 Citroen Berlingo / Peugeot Partner 1 Push black (sw) rubber isolator onto hose C. 2 Hose on heat exchanger inlet Connect- ing heat exchanger inlet 1 Slide on black (sw) rubber isolator Connect- ing engine outlet Align and position black (sw) rubber isolator 1 [2x].
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Page 18: Fuel
Citroen Berlingo / Peugeot Partner 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 19 Citroen Berlingo / Peugeot Partner Lower fuel tank and fuel-tank sending unit 1 according to manufacturer's instructions. 2 Large diameter washer 3 Copy hole pattern, 6 mm dia. hole Removing fuel Shape fuel standpipe 1 according to tem- plate, cut to length and install. Installing fuel stand- pipe...
- Page 20 Citroen Berlingo / Peugeot Partner 1 Metering pump 2 Rubber-coated pipe clamp 3 Silent block, flanged nut [2x] Installing metering pump 1 Hose section [2x], 10mm dia. clamp [4x] 2 Fuel line of Heater 3 Wiring harness of metering pump, connec- tor mounted 4 Fuel line of fuel standpipe Installing...
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Page 21: Exhaust Gas
Citroen Berlingo / Peugeot Partner Exhaust gas 1 Exhaust pipe a = 330 2 Exhaust end section b = 260 Preparing exhaust Discard section X pipe 1 Perforated bracket 2 8.5mm dia. hole Preparing perforated bracket 90° 1 Perforated bracket 2 Original vehicle bolt Installing perforated... - Page 22 Citroen Berlingo / Peugeot Partner Secure original vehicle wiring harness 1 with cable tie. 2 M6x20 bolt, flanged nut 3 Silencer 4 Hose clamp Installing silencer Ensure sufficient distance to neighbouring components. 1 Hose clamp 2 Exhaust end section Installing exhaust end sec- tion...
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Page 23: Combustion Air
Citroen Berlingo / Peugeot Partner Combustion air 1 Combustion air pipe a = 300 Discard section X Cutting combus- tion air pipe to length 1 27 mm dia. clamp 2 Combustion air pipe Installing combus- tion air pipe 1 35mm dia. rubber-coated p-clamp 2 52mm dia. -
Page 24: Final Work
Citroen Berlingo / Peugeot Partner Final Work WARNING! Mount removed parts in reverse order. Check all hoses, clamps and all electrical connections for firm seating. Insulate all loose wires and tie back. Only use manufacturer-approved coolant. Spray heater components with anti-corrosion wax (Tectyl 100K, Order No. -
Page 25: Template For Fuel Standpipe
Citroen Berlingo / Peugeot Partner 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%. Set the printer settings to “no margin” or “minimise mar- gins” and 100% of the normal size. 100 mm 1314460B_EN... -
Page 26: Operating Instructions For End Customer
Manual air condition- No specific settings necessary. Automatic air-condi- tioning Feel the drive Webasto AG Postfach 80 D-82132 Stockdorf / Germany National Hotline: 01805 93 22 78 (14 Cent aus dem deutschen Festnetz) Hotfax: 0395 5592 353 Hotmail: technikcenter@webasto.com http://www.webasto.com...