Webasto Thermo Top E Bedienerhandbuch

Water Heater

Installation documentation

Ident. No.: 1314460B_EN Fee Euro 10.00 © Webasto AG

Citroen Berlingo / Peugeot Partner

Petrol

from Model Year 2008

Left-hand drive vehicle

Manual 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 E Parking Heater

00 0003

Thermo Top C Parking Heater

00 0002

Thermo Top P Parking Heater

00 0104

Citroen Berlingo / Peugeot Partner

1314460B_EN 2

Table of Contents

Validity

Vehicle and engine types, equipment variants and national specifications not listed in this installation

documentationhavenot beentested. However,installationaccordingtothis installationdocumentation

may be possible.

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 Berlingo 7 e1 * 2001/116 * 0366 * ...

Peugeot Partner 7 e2 * 2001/116 * 0365 * ...

Engine type Engine model Output in kW Displacement in cm³

NFU Petrol 80 1587

5FS Petrol 88 1598

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

Preparing electrical system 6

Electrical system 7

Fan controller for manual air conditioning 8

Automatic air-conditioning fan controller 10

Digital timer, summer/winter switch option 12

Remote option (Telestart) 12

Preparing bracket 13

Installing bracket 14

Installing heater 14

Fuel 18

Exhaust gas 21

Combustion air 23

Final Work 24

Template for Fuel Standpipe 25

Operating Instructions for End Customer 26

Citroen Berlingo / Peugeot Partner

1314460B_EN 3

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 is applicable to Citroen Berlingo / Peugeot Partner Petrol

vehicles - For the validity, see Page 2 - from model year 2008 and later, assuming technical modifica-

tions 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 instal-

lation documentation.

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.

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).

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

- Metric thread-setter kit

Quantity Description Order No.:

1 Retail accessories with desired heater control See price list

1 Installation Kit for PSA Berlingo/Partner Petrol manual air con-

ditioning 1313670D

1 Installation Kit for PSA Berlingo/Partner Petrol Automatic Air-

Conditioning 1313671D

Vehicle Heater

Compact car Thermo Top E

Mid-size car, station wagon Thermo Top C

Full-size car, van, offroader Thermo Top P

Citroen Berlingo / Peugeot Partner

1314460B_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.

Referenceto generalinstallationinstructions ofWebas-

tocomponentsortothemanufacturer'svehicle-specific

documents.

Reference to a special technical feature.

All dimensions are in mm!

Tightening torque of hose clamps = 2.0 + 0.5 Nm!

Tightening torque of Ejot screws, Ejot studs = 10 Nm!

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 Berlingo / Peugeot Partner

1314460B_EN 5

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.

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

- Close the fuel tank cap again.

- Remove the engine cover (depending on the vehicle equipment, if installed)

- Remove the air filter box with the intake hose and the resonator.

- Remove the bracket for the resonator.

- Completely remove the battery and the battery carrier.

- Remove the exhaust system (only on gasoline vehicles).

- Lower the fuel tank (wait until working on: fuel).

- Remove the left front wheel.

- Remove the left-hand wheel well trim.

- Remove the lower instrument panel trim on the driver's and front passenger side

- Remove the glove compartment.

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

tions.

Heater installation location

1Heater

Installa-

tion loca-

tion

Citroen Berlingo / Peugeot Partner

1314460B_EN 6

Preparing electrical system

Manual air conditioning

Cut one end of 0.75² brown (br) wire, to ap-

prox. 80 mm.

Produce connections as shown in wiring dia-

gram.

1Red (rt) wire, 0.75² - 1000

2Black (sw) wire, 4² - 1000

3Blue (bl) wire, 1.5² - 300

4Brown (br) wire, 4² - 1000

5Brown (br) wire, 0.75² - 80

Preparing

additional

relay K3.1

Automatic air-conditioning

Cuttingred

(rt) wire,

0.75² to

length

Produce connections as shown in wiring dia-

gram. Uncrimp green/white (gn/ws) wire from

K3/87a and connect together with wire sec-

tion 1 to K3/86.

Preparing

K3 relay

ConnectwirestoIPCU (IPCUviewoncontact

side).

Pull wire 5 into the protective sleeving provid-

ed and route to OBD socket outlet.

2Brown (br) wire, 0.75² - 500

3Black (sw) wire, 0.75² - 500

4Red (rt) wire, 0.75² - 500

5Red (rt) wire, 0.75² - 2000

Premount-

ing IPCU

85 30

87a87

K3.1

500

2000 0,75²

85 30

87a87

gn/ws

0,75²

4²

86 85

E86 85

IPCU

Citroen Berlingo / Peugeot Partner

1314460B_EN 7

Electrical system

Connecting positive wire

Before installing, crimp 8 mm dia. cable lug onto

positive wire.

1Red (rt) wire

2Original vehicle positive support point (10 Nm)

Wiring harness pass through

Route wiring harnesses (digital timer, fan control-

ler and red (rt) wire in protective sleeving) on

original vehicle wiring harness 1 to protective

rubber plug 2and route into passenger compart-

ment.

Wiring har-

ness rout-

ing

diagram

Fuse holder, K3 relay

1Retaining plate for fuse holder

24 mm dia. hole, 5.5x13 self-tapping screw;

plastic nut [2x each]

3K3 relay

4Fuse holder

Connecting earth wire

1Brown (br) wire

2Original vehicle earth support point

Donotinstallthe meteringpump

wiring harness until later togeth-

er with fuel pipe along the origi-

nal vehicle fuel lines on the

underbody

21 2

Citroen Berlingo / Peugeot Partner

1314460B_EN 8

Fan controller for manual air conditioning

Wiring dia-

gram

Webasto components Vehicle components Colours and symbols

Legend

HG Heater TT-C/E GM Fan motor rt red

X1 6-pin heater connector GRs Fan relay ws white

F3 25 A fuse GS Fan switch sw black

K3 Fan relay WG Resistor group br brown

K3.1 Additional relay a 6-pin connector bl blue

Fx Fuse bl blue

XCutting point

Wiring colours may vary.

1K3.1 relay covered (installed behind origi-

nal vehicle strut)

2M5x16 bolt, large diameter washer, flang-

ed nut

Installing

K3.1 relay

Webasto

D+61

Citroen, Peugeot

85 30

87a87

X1 4

5GS

1234

1 2 3 4

sw 4²

br 4²

4321

bl 1,5²

-GM

4²

rt 4²

sw 4²

85 30

87a87

K3.1

rt 0,75²

gn/ge

4²

gn/ge

4²

0,75²

Citroen Berlingo / Peugeot Partner

1314460B_EN 9

Connection to 5-pin connector 2from resistor

group.

Produce connections as shown in wiring dia-

gram.

1Blue (bl) wire of fan switch

3Blue (bl) wire of connector, Pin 1, discon-

nected

4Blue (bl) wire to K3.1/87a

Connect-

ingresistor

group

Connection on 6-pin connector A!

Discon-

necting

connector

Connection on 6-pin connector A 5.

Produce connections as shown in wiring dia-

gram.

1Red (rt) wire from K3/87a

2Black (sw) wire from K3/30

3White (ws) wire of fan relay

4Red (rt) wire to K3.1/86

6White (ws) wire 6-pin connector A

Connect-

ing fan-mo-

tor

Connection on 6-pin connector A 4.

Produce connections as shown in wiring dia-

gram.

1Green/yellow (gn/ge) wire of earth wire

2Black (sw) wire K3.1/87

3Green/yellow (gn/ge) wire of 6-pin connec-

tor A

5Brown (br) wire K3.1/30

Connect-

ing fan

switch

1 2 3

Citroen Berlingo / Peugeot Partner

1314460B_EN 10

Automatic air-conditioning fan controller

Wiring dia-

gram

Webasto components Vehicle components Colours and symbols

Legend

HG Heater TT-C/E KB A/C control unit rt red

X1 6-pin heater connector GR Fan relay ws white

F3 25 A fuse GM Fan module sw black

K3 Fan relay a 2-pin connector GM ge yellow

IPCU Pulse width modulator MF6 Fuse gr gray

Y Wiring adapter Ter. 15 Measure

(e.g., 16-pin OBD socket

outlet, Pin 1)

or orange

IPCU adjustment values:

Duty cycle: 42%

Frequency: 1000Hz

Voltage: 5V XCutting point

Function: High-side Wiring colours may vary.

Fan motor is controlled on 2-pin connector A

of fan module.

Produce connections as shown in wiring dia-

gram.

2Orange (or) wire of connector A, Pin 2

3Y-adapter

4Black (sw) wire from K3/30

5Orange (or) wire of GR

Connec-

tion to fan

module

Webasto

Citroen, Peugeot

MF6

F3 rt

sw/ws

ge/gr

ws/

85 30

87a87

4²

rt 6²

4²

0,75²

0,5²

X1 4

2 1

GM M

10 4

86 85

IPCU

0,75²

4²

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