water heater - Продажа webasto evo, air top...

Water Heater

Installation documentation

Ident. No.: 1316733B_EN Fee Euro 10.00 © Webasto AG

Citroen C5 / Peugeot 407

2.7 and 3.0 HDI

from Model Year 2008

Left-hand drive vehicle

Automatic air-conditioning

Automatic transmission

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.

Thermo Top Evo Parking Heatere1

00 0258


Table of Contents

Validity

Vehicle and engine types, equipment variants and national specifications not listed in this installation documentation have not been tested. However, installation according to this installation documentation may be possible.

The installation location of the digital timer should be confirmed with the end customer before installa-tion.

Manufacturer Model Type EG-BE No./ABECitroen C5 R.... e2 * 2001/116 * 0360 *...

Manufacturer Model Type EG-BE No./ABEPeugeot 407 6 e2 * 2001/116 * 0328 * ...

Engine type Engine model Output in kW Displacement in cm³UHZ Diesel 150 2720DT 17TED4 Diesel 177 2992

Validity 2Heater/Installation Kit 3Foreword 3General Instructions 3Special Tools 3Explanatory Notes on Document 4Preliminary Work 5Heater installation location 5Preparing electrical system 6Electrical system 8Fan controller 9Digital timer option 11Remote option (Telestart) 12

Preparing installation location 13Installing heater 13Coolant circuit 14Fuel 17Final Work 20Template for Fuel Standpipe 21Operating Instructions for End Customer 22

1316733B_EN 2


Heater/Installation Kit

ForewordThis installation documentation applies to the vehicles Citroen C5 / Peugeot 407 2.7 and 3.0 HDI - for validity, see page 2 - from model year 2008 and later, assuming technical modifications to the vehicle do not affect installation, any liability claims excluded. Depending on the vehicle version and equip-ment, modifications may be necessary during installation with respect to this installation documenta-tion.

However, the stipulations in this "installation documentation", the "operating instructions" and "installa-tion instructions" for the Thermo Top Evo must always be observed.The corresponding rules of technology and any information from the vehicle manufacturer should be observed during the installation work.

General InstructionsInstallation 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 must be provided with rub protection (cut-open fuel hose)!Spray unfinished body areas, e.g. drilled holes, with anti-corrosion wax (Tectyl 100K, Order No. 111329).When installing an IPCU, the corresponding settings must be checked or adjusted before the installa-tion.

Special Tools- Torque wrench for 2.0 - 10 Nm- Hose clamping pliers

Quantity Description Order No.:1 Delivery scope Thermo Top EvoCitroen C5 / Peugeot 407

2008 2.7 and 3.0 HDI1316732A

1 Heater control See price list

1316733B_EN 3


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.

1316733B_EN 4

Special features are highlighted using the following symbols:

The arrow in the vehicle icon indicates the position on the vehicle and the viewing angle.

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

All dimensions are in mm!Tightening torque of 5x13 heater bolts = 8Nm!Tightening torque of 5x15 bolt of water connection piece retaining plate = 7Nm!


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.- Attach the duplicate label (type label) in the appropriate place.- Remove the left-hand wheel well trim.- Remove the left front wheel.- Remove the front underride protection.- Remove the right rear underride protection.- Remove right underbody trim- Fold over the right-hand rear seat- Open the right-hand fuel sender service lid.- Remove radio- Remove A/C control panel- Remove the instrument panel trim on the driver's side (only with Telestart).- Remove the footwell trim on the driver's side.- Remove the driver's side storage compartment.

Installa-tion loca-tion

Heater installation location

1 Heater

1

1

1316733B_EN 5


Preparing fuse holder of passen-ger com-partment

Cutting wire to length



Preparing electrical system

Remove brown (br) line 1 from socket K1/85 and detach tab receptacle. Remove red (rt) line 3 from K1/87 and socket F4 and discard.

2 Fuse holder of passenger compartment

Connect brown (br) wire to K1/87 and con-nect with brown (br) wire from K1/85. Con-nect brown (br) wire to K1/30.

Crimp micro-timer 2 to brown (br) wire .

1 Fuse holder of passenger compartment3 Brown (br) wire 4 Brown (br) wire

1

23

2

1

100

2br

0,75²

86

85 30

87a87

K1

gn/ws0,75²

br0,5²

rt4²

rt/sw0,5²

F3

1

br0,75²

2br

0,75²

4

2

1

33

3

1316733B_EN 6



1 M5x16 bolt, large diameter washer [2x], nut

2 Relay mounted3 Angle bracket

1

4

2

3

1316733B_EN 7


Wiring har-ness in-stallation diagram

Electrical system

Fuse holder of engine compartment

1 Detach original vehicle bolt, large diameter washer2 M5x16 bolt, large diameter washer [2x], re-

taining plate, fuse holder, nut3 F1-2 fuses mounted4 Angle bracket

Earth wire

Earth wire1 on original vehicle earth point!

Wiring harness routing

Fasten wiring harness of fuse holder in engine compartment 2 in wheel well with adhesive base 1 and cable tie [total of 4x each].

Wiring harness pass through of passenger compartment

1 Drill out existing protective rubber plug2 Wiring harness, fuse holder, engine compartment3 Adhesive base, cable tie

5

2

3

1

4 6

1

Do not install the metering pump cable harness until later together with fuel pipe in the corrugated tube along the original vehicle line on the underbody

7

11

2 83 2

1

1316733B_EN 8


Wiring dia-gram

Legends

Fan controller

Webasto components Vehicle components Colours and symbolsHG TT-Evo heater BSI Central electrical

box for passenger compartment

gn greenX1 6-pin heater connector ws white

X2 2-pin heater connector St A 20-pin connector BSI

rt redX10 4-pin connector

Heater controlbr brownsw black

K1 Fan relay ge yellowF1 20A fuseF2 30A fuse Cable and connector colours may

vary.F3 1A fuse

Webasto

31

3015

Citroen / Peugeot

HG

X2 1 2 X152

F2 F1

br0,5²

gn/ws0,75²

ge0,5²

rt/sw0,5²

rt4²

br0,5²

X10

86

85 30

87a87

K1

gn/ws0,75²

rt4²

rt/sw0,5²

F3

br0,75²

BSI

6 St A

2br

0,75²

1

br0,5²

1316733B_EN 9


Positive wire

Positive wire

Installing fuse holder of passen-ger com-partment

Connect wiring har-nesses

The connection of the positive wire depends on the equipment.

3.0 l HDIPositive distributor, front right

1 Positive wire on positive distributor

2.7 l HDIBattery, front right

1 Positive wire on positive terminal of battery

1 Bracket, original vehicle stud bolt, flanged nut

Connect wiring harness of heater 1 with wir-ing harness of fuse holder of passenger com-partment 2 according to circuit diagram, such that the wires of the same colour are connect-ed.

91

101

11

1

12

2 1

1316733B_EN 10


Detaching BSI and routing downward

Pulling connector off BSI and removing

Connec-tion of BSI

Installing digital tim-er

View of BSI.

1 Socket for 2-piece connector, 40-pin

Illustration shows Citroen C5!Press in locking lug 1 and fold down bar 2.

3 2-piece connector

Illustration shows Citroen C5!Connection on 20-pin connector 1 from BSI (connector colour may vary)!Insert microtimer from brown (br) wire 3 in PIN 6. Remove any existing wires on pin 6 and insulate.Route wiring harness of digital timer 2 upward to installation location of digit-al timer.Produce connections as shown in wiring dia-gram.

Digital timer option

Citroen C5

1 Digital timer

13

1

1

14

1

3

2

15

1

2

3

1 16

1316733B_EN 11


Installing digital tim-er

Installing receiver

Installing receiver

Installing antenna

Peugeot 407

1 Digital timer

Remote option (Telestart)

Citroen C5

Mount connector (6-pin) from adapter wiring harness on receiver 2.

1 Double-sided adhesive tape

Peugeot 407

Mount connector (6-pin) from adapter wiring harness on receiver 2.

1 Double-sided adhesive tape

All vehicles

1 Antenna

1 17

1

2 18

1

2

19

1 20

1316733B_EN 12


Reposi-tioning connector

Installing edge pro-tection

Installing heater

Installing bracket

Preparing installation location

Move connector from position 2 (if present) to position 3.

1 Fastening point for heater (existing hole)2 Fastening point for heater (existing hole)

Figure shows 2.7 HDI.Loosen bolt at position 2 (fastening point for heater).

1 100 mm edge protection

Installing heater

Mount stud bolts from bracket in existing holes.

1 Large diameter washer, flanged nut [2x each], stud bolt

1 Mount wiring harness of heater2 Bracket of heater3 Original vehicle bolt or flanged nut on orig-

inal vehicle stud bolt

21

1 2

3

22

1 2

23

1 1

24

2 31

1316733B_EN 13


Hose rout-ing dia-gram

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" based on the following diagram:

All spring clips without a specific designation = 27 mm dia. 1 = Original vehicle spring clip .All connecting pipes without a specific designation = dia. 20x20.

A

C

Ø 25

1

B

Ø 2

0x1

8

1316733B_EN 14


Premount-ing hoses

Cutting point

Connect-ing heat exchanger inlet

Connect-ing engine outlet

Hose B = 20mm dia. 180° moulded hoseHose C = 20mm dia. 180° moulded hose

2.7 HDI

Remove hose section of heat exchanger inlet 1 and discard. Spring clip 2 will be reused.

3 Engine-outlet hose section

1 Original vehicle spring clip2 Pipe of heat exchanger inlet

Connect hose A on circulating pump inlet. Cut hose A accordingly to length and connect with hose of engine outlet 1. Check the posi-tion of the components; adjust if necessary. Check that they have free clearance.

B C

25

26

1

3

2

27

B

C

2

1

28a 1

1316733B_EN 15


Cutting point

Connect-ing heat exchanger inlet

Connect-ing engine outlet

3.0 HDI

Remove hose section of heat exchanger inlet 1 and discard. Spring clip 2 will be reused.

3 Hose of engine outlet

1 Original vehicle spring clip2 Pipe of heat exchanger inlet

Connect hose A on circulating pump inlet. Cut hose A accordingly to length and connect with hose of engine outlet 1. Check the posi-tion of the components; adjust if necessary. Check that they have free clearance.

29

1

3

2

30

B

C

1

2

31a 1

1316733B_EN 16


Remove lines

Connect-ing heater

Routing line

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.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 in as shown in the wiring harness routing diagram.

Remove outer connector housing 1 by releas-ing the lock 2 from the connector of metering pump 6. Pull off coding 4. Pull out blue (bl) wire 3 and brown (br) wire 7 from the connec-tor of metering pump 6 by releasing lock 5 [2x]. Will be re-installed later. Pin allocation is not relevant.

1 Fuel line, wiring harness of metering pump in corrugated tube

2 10 mm dia. Caillau clamp, 90° moulded hose


327

1 42 3

5

5

6

33

1

2

34

1

1316733B_EN 17


Installing lines

Installing metering pump

Installing metering pump

Connect-ing meter-ing pump


Remove original vehicle nut at position 1 and discard.

2 Large diameter washer, 30 mm spacer nut

1 Metering pump2 Bracket of metering pump3 M6x25 bolt, large diameter washer

1 Fuel line in corrugated tube 2 Hose section [2x], 10 mm dia. Caillau

clamp [4x]3 Fuel line, wiring harness of metering pump

in corrugated tube 4 Wiring harness of metering pump, connec-

tor mounted

35

1

36

1

2

37

1 2

3

38

21

4

2 3

1316733B_EN 18


Removing fuel

Installing fuel stand-pipe

Connect-ing fuel line

Remove fuel-tank sending unit 1 in accord-ance with manufacturer's specifications.

2 Copy hole pattern, 6 mm dia. hole3 5 mm dia. large diameter washer

Shape fuel standpipe 1 according to tem-plate, cut to length and install.

Check the position of the components; adjust if necessary. Check that they have free clear-ance.Install fuel-tank sending unit according to manufacturer's specifications.

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

2 Fuel line

39

1

2

3

40

1

41

21

1316733B_EN 19


Cutting out underride protection

Mounting underride protection

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. 111329).

- Connect the battery.- Fill and bleed the coolant circuit according to the vehicle manufacturer’s specifications.- Adjust digital timer, teach telestart transmitter- Code BSI to "external heater (parking heater)" according to manufacturer's specifications- Attach instruction label "Switch off parking heater before refueling" in the area of the filling

neck- See installation instructions for initial start-up and function test

1 Underride protection2 Cut out exhaust outlet along perforation

Align underride protection 1 (exhaust end section centered in cut-out).

2 Exhaust end section

422

1

432

1

1316733B_EN Printed in Germany 03/2011 Printing: Steffen 20

Feel the driveWebasto AGPostfach 80D-82132 Stockdorf / GermanyNational Hotline: 01805 93 22 78(14 Cent aus dem deutschen Festnetz)Hotfax: 0395 5592 353Hotmail: [email protected]://www.webasto.com


Template for Fuel Standpipe

1316733B_EN 21

0

100 mm

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.


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 timeExample:For a driving time of approx. 20 min. (in one direction), we recommend not exceeding a switch-on time of 20 min.

In vehicles with passenger compartment monitoring this must be deactivated in addition to the vehicle settings for the heating operation .Deactivation instructions can be taken from the operating instructions of the vehicle!

No further settings are required.

1316733B_EN 22

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