Webasto Thermo Top E Installation Documentation

Brand: Webasto

Model: Thermo Top E

Type: Installation Documentation

This manual is also suitable for

Thermo Top C

Feel the drive

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 Fee Euro 10.00 © Webasto AG

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

Water Heater

Thermo Top E Parking Heater

Thermo Top C Parking Heater

Installation documentation

00 0003

00 0002

Citroen C1 / Peugeot 107 / Toyota Aygo

Validity

Vehicle and engine types as well as equipment variants not listed in this installation documentation

have not been tested. However, installation according to this installation documentation may be possi-

ble.

The installation location of a digital timer and summer/winter switch should be confirmed with the end

customer before installation.

Manufacturer Model Type EG-BE No./ABE

Citroen C1 P e11 * 2001 / 116 * 0238

Peugeot 107 P e11 * 2001 / 116 * 0237

Toyota Aygo AB1 e11 * 2001 / 116 * 0236

Engine type Engine model Output in kW Displacement in cm³

1KR-FE Petrol 50 998

1KR-(CFA) Petrol 50 998

Validity 2

Heater/Installation Kit 3

Foreword 3

General Instructions 3

Special Tools 3

Explanatory notes on document 4

Preliminary Work 5

Heater installation location 5

Electrical system 6

Fan control 7

Remote option (Telestart) 8

Preparing installation location 9

Installing heater 10

Coolant circuit 11

Combustion air 18

Fuel 19

Exhaust gas 22

Final Work 24

Template for fuel standpipe 25

Template for fuel-tank sending unit 25

Operating Instructions for End Customer 26

Table of Contents

Citroen C1 / Peugeot 107 / Toyota Aygo

Heater/Installation Kit

Heater recommended for the respective vehicle class:

The selection of the heater is based on the passenger compartment size of the vehicle and the level of

comfort required by the customer.

Foreword

This installation documentation applies to Citroen C1 / Peugeot 107 / Toyota Aygo vehicles with Petrol

engine - for validity, see page 2 - from model year 2005 and later, assuming technical modifications to

the vehicle do not affect installation, any liability claims excluded. Depending on the vehicle version

and equipment, modifications may be necessary during installation with respect to this installation doc-

umentation.

However, the stipulations in this "installation documentation", the "operating instructions" and "installa-

tion instructions" for the Thermo Top C/E must always be observed.

The corresponding rules of technology and any information from the vehicle manufacturer should be

observed during the installation work.

General Instructions

Installation should be carried out according to the general, standard rules of technology. Unless spec-

ified otherwise, fasten hoses, lines and wiring harnesses to original vehicle lines and wiring harnesses

using cable ties.

Sharp edges should be fitted with rub protection (split-open fuel hose).

Spray unfinished body areas, e.g. drilled holes, with anti-corrosion wax (Tectyl 100K, Order No. 111329).

Special Tools

- Torque wrench for 2.0 - 10 Nm

- Hose clamping pliers

- Metric thread-setter kit

Quantity Designation Order No.:

1 Thermo Top E / C retail accessories See price list

1 Installation kit for Citroen C1 / Peugeot 107 / Toyota Aygo

Petrol 1310257B

1 Heater control See price list

Vehicle Heater

Compact car Thermo Top E

Mid-size car, estate car Thermo Top C

Special features are highlighted using the following symbols:

The arrow in the vehicle icon indicates the position on

the vehicle and the viewing angle.

Citroen C1 / Peugeot 107 / Toyota Aygo

Specific risk of injury or fatal accidents.

Specific risk of damage to components.

Specific risk of fire or explosion.

Reference to general installation instructions of Webas-

to components or to the manufacturer's vehicle-specific

documents.

Reference to a special technical feature.

Mechanical system

Electrical system

Coolant circuit

Fuel

Exhaust gas

Combustion air

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.

Citroen C1 / Peugeot 107 / Toyota Aygo

Heater installation location

1Heater

Installa-

tion loca-

tion

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.

- Remove upper air filter box

- Open the fuel tank cap and vent the fuel tank.

- Close the fuel tank cap again.

- Remove the rear bench seat in accordance with the manufacturer's instructions.

- Open the tank-fitting service lid in the middle.

- Remove the fuel-tank sending unit in accordance with the manufacturer's instructions.

- Remove instrument cluster in accordance with the manufacturer's instructions.

Remove page 26 "Operating Instructions for End Customer" and add to the vehicle operating instruc-

tions.

Citroen C1 / Peugeot 107 / Toyota Aygo

Electrical system

Wiring harness pass through

1Protective rubber plug

Digital timer, summer/winter switch option

1Digital timer

2Summer/winter switch, 12 mm dia. drilled hole

Wiring har-

ness rout-

ing

diagram

Fuse holder, K3 relay

1Original vehicle bolt

2M5x16 bolt, washers, retaining plate of fuse

holder, perforated bracket (turned by 90°),

K3 relay, M5 flanged nut

Earth support point

If bracket at Position

is not available, route wiring

harnesses into the corrugated tube to the firewall.

1Original vehicle M6 bolt

2Earth wire of heater

rt/sw

Do not install the metering pump

wiring harness until later togeth-

er with fuel pipe along the origi-

nal vehicle fuel lines on the

underbody

Citroen C1 / Peugeot 107 / Toyota Aygo

Fan control

Connection to 4-pin connector 3K from instru-

ment cluster.

Make connections as shown in the wiring dia-

gram with the provided connectors.

14-pin connector 3K

2Instrument cluster (view from rear.) Connect-

ing fan-mo-

tor

Wiring dia-

gram for

manual air

condition-

ing

Webasto components C1 / 107 / Aygo components Colours and symbols

Legend

HG Heater TT-C/E GRs Fan relay rt red

F3 25 A fuse KI Instrument cluster ws white

K3 Fan relay 3K Connector 3K on KI sw black

GM Fan motor br brown

bl blue

XCutting point

Webasto

C1 / 107 / Aygo

87a8786

85 30

GRs

gr/ws

rt/ws sw 3

Citroen C1 / Peugeot 107 / Toyota Aygo

Remote option (Telestart)

Fasten receiver 2 with adhesive tape.

1Upper centre console

Installing

receiver

1Antenna

Installing

antenna

Only with Telestart T100 HTM

Fasten temperature sensor 2 with adhesive

tape.

1Upper centre console

Installing

tempera-

ture sensor

Citroen C1 / Peugeot 107 / Toyota Aygo

Preparing installation location

1Detach retaining clip [3x]

2Original 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.

Moving

earth sup-

port point

1Position heater loosely

Position-

ing heater

1Bracket

2M6x12 bolt, large diameter washer, M6

flanged nut, existing hole [2x each]

3M8x20 bolt, large diameter washer, M8

flanged nut, existing hole

Installing

bracket

1 2

1 2 3

Citroen C1 / Peugeot 107 / Toyota Aygo

Installing heater

Mount wiring harness on heater before in-

stalling.

Tighten Ejot screws to 10 Nm.

1Bracket

2Ejot screw [2x] Installing

heater

Tighten Ejot screws to 10 Nm.

1Ejot screw [2x]

2Bracket

Installing

heater

2 1

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. When installing the hoses, the heater must be filled with coolant.

The connection depends on the equipment, and takes place "inline" based on the following diagram:

Hose rout-

ing dia-

gram

All hose clamps = 20-27 mm dia. All connecting pipes = 20x20 dia.

1 = Throttle valve pre-heating. 2 = Black (sw) rubber isolator.

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.

Connect-

ing heater

inlet

1Slide on black (sw) rubber isolator and

align

Connect-

ing heater

outlet

1M6 flanged nut, original vehicle stud bolt

238 mm dia. rubber-coated p-clamp

Installing

p-clamp

B 1

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.

2Hose on heat exchanger inlet

3Twist original vehicle spring clips

Preparing

hoses

Turn original vehicle spring clips on T-piece to

Position 3 downwards.

1Supply line of throttle valve

2Hose on heat exchanger inlet

Installing

hose of

heat ex-

changer in-

let

1Slide on black (sw) rubber isolator and

align

Connect-

ing heat

exchanger

inlet

Citroen C1 / Peugeot 107 / Toyota Aygo

Before connecting, fill the coolant hoses with

coolant.

Aligning hoses. Ensure sufficient distance

from neighbouring components.

1Install hose bracket (on 2 and hose C)

2Hose of engine outlet Connect-

ing engine

outlet

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. When installing the hoses, the heater must be filled with coolant.

The connection depends on the equipment, and takes place "inline" based on the following diagram:

Hose rout-

ing dia-

gram

All hose clamps = 20-27 mm dia.

All connecting pipes = 18x20 dia.

1 = Black (sw) rubber isolator.

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.

Connect-

ing heater

inlet

Figure shows vehicle with throttle valve pre-

heating.

1Slide on black (sw) rubber isolator and

align

Connect-

ing heater

outlet

Figure shows vehicle with throttle valve pre-

heating.

1M6 flanged nut, original vehicle stud bolt

238 mm dia. rubber-coated p-clamp

Installing

p-clamp

B 1

Citroen C1 / Peugeot 107 / Toyota Aygo

1Hose of engine outlet

2Hose on heat exchanger inlet

Cutting

point

1Hose of heat exchanger inlet turned up-

ward by approx. 30°

Connect-

ing heat

exchanger

inlet

Before connecting, fill the coolant hoses with

coolant.

Aligning hoses. Ensure sufficient distance

from neighbouring components.

1Install hose bracket (on hose A and B)

2Hose of engine outlet Connect-

ing engine

outlet

A 1

Citroen C1 / Peugeot 107 / Toyota Aygo

Combustion air

1Combustion air pipe

a = 310mm

Discard section XCutting

combus-

tion air

pipe to

length

1Combustion air pipe

227 mm dia. hose clamp

3Cable tie

Installing

combus-

tion air

pipe

1Retaining clip in hole

2Silencer

Mounting

silencer

1 3 2

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.

Mount the fuel line and wiring harness with rub protection on sharp edges.

WARNING!

The fuel line and wiring harness are routed to the metering pump as shown in the wiring harness rout-

ing diagram.

Complete connector of metering pump after

routing. Pin assignment is not relevant.

1Connector housing

2Lock

3Blue/brown (bl/br) wires

4Coding

5Time lock Disman-

tling con-

nector

1Fuel line

2Hose section, 10 mm dia. hose clamp [2x]

Connect-

ing heater

Pull fuel line through attached corrugated

tube 1 and route with heater wiring harness 2

to existing lines. Routewiring harness of me-

tering pump 3 together with fuel line to under-

body.

Installing

lines

1 42 3

1 2 3

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“.

Installation location at left on vehicle fuel tank.

1Angle bracket

2Original vehicle bolt

3Rubber-coated p-clamp, silent block, M6

flanged nut [2x] Installa-

tion loca-

tion of

metering

pump

Check the position of the components; adjust

if necessary. Check that they have freedom of

movement.

1Wiring harness of metering pump, connec-

tor mounted

2Fuel line of Heater

3Hose section, 10 mm dia. hose clamps [2x] Connect-

ing meter-

ing pump

Remove fuel-tank sending unit 1 according to

manufacturer's instructions and remove plas-

tic bar 2 carefully.

2Template, copy hole pattern, 6 mm dia.

hole

Removing

fuel

1 2

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Webasto Thermo Top E Installation Documentation

Brand: Webasto

Model: Thermo Top E

Type: Installation Documentation

This manual is also suitable for

Thermo Top C

Download PDF

report

Webasto Thermo Top E Installation Documentation

This manual is also suitable for

Webasto Thermo Top E Installation Documentation

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