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

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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

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Table of Contents

Validity 2Heater/Installation Kit 3Foreword 3General Instructions 3Special Tools 3Explanatory notes on document 4Preliminary Work 5Heater installation location 5Electrical system 6Fan control 7Remote option (Telestart) 8

Preparing installation location 9Installing heater 10Coolant circuit 11Combustion air 18Fuel 19Exhaust gas 22Final Work 24Template for fuel standpipe 25Template for fuel-tank sending unit 25Operating Instructions for End Customer 26

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 * 0238Peugeot 107 P e11 * 2001 / 116 * 0237Toyota Aygo AB1 e11 * 2001 / 116 * 0236

Engine type Engine model Output in kW Displacement in cm³

1KR-FE Petrol 50 9981KR-(CFA) Petrol 50 998

22


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.

ForewordThis 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 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 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 list1 Installation kit for Citroen C1 / Peugeot 107 / Toyota Aygo

Petrol1310257B

1 Heater control See price list

Vehicle Heater

Compact car Thermo Top EMid-size car, estate car Thermo Top C

33


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.

44

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.

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Mechanical system

Electrical system

Coolant circuit

Fuel

Exhaust gas

Combustion air


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.

Heater installation location

1 Heater

Installa-tion loca-tion

1

1

5


Electrical system

Wiring harness pass through

1 Protective rubber plug

Digital timer, summer/winter switch option

1 Digital timer2 Summer/winter switch, 12 mm dia. drilled hole

Wiring har-ness rout-ing diagram

Fuse holder, K3 relay

1 Original vehicle bolt2 M5x16 bolt, washers, retaining plate of fuse

holder, perforated bracket (turned by 90°), K3 relay, M5 flanged nut

Earth support point

If bracket at Position 3 is not available, route wiring harnesses into the corrugated tube to the firewall.

1 Original vehicle M6 bolt2 Earth wire of heater

2

1

3

1 2

br

bl

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

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4

1

2

5

1

2

3

6


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.

1 4-pin connector 3K2 Instrument 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 redF3 25 A fuse KI Instrument cluster ws whiteK3 Fan relay 3K Connector 3K on KI sw black

GM Fan motor br brownbl blueX Cutting point

6

1

2

Webasto

31

30

15

C1 / 107 / Aygo

4

HGX1

F3

K3

87a8786

85 30

GM

GRs

F

gr/ws

rt/ws

sw 3

KI

4

3K

blrt

bl

rt

sw

sw

M

+-

br

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7


Remote option (Telestart)

Fasten receiver 2 with adhesive tape.

1 Upper centre console

Installing receiver

1 Antenna

Installing antenna

Only with Telestart T100 HTM

Fasten temperature sensor 2 with adhesive tape.

1 Upper centre console

Installing tempera-ture sensor

1

2 7

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1

8

1

92

8


Preparing installation location

1 Detach retaining clip [3x]2 Original 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

1 Position heater loosely

Position-ing heater

1 Bracket2 M6x12 bolt, large diameter washer, M6

flanged nut, existing hole [2x each]3 M8x20 bolt, large diameter washer, M8

flanged nut, existing hole

Installing bracket

10

1 2

1

1

2

11

1

3

2

12

1

13

1 2 3

2

9


Installing heater

Mount wiring harness on heater before in-stalling.Tighten Ejot screws to 10 Nm.

1 Bracket2 Ejot screw [2x] Installing

heater

Tighten Ejot screws to 10 Nm.

1 Ejot screw [2x]2 Bracket

Installing heater

14

2

1

2

15

1

2 1

10


Coolant circuitWith 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.

B

A

1

C

2

2

11


Discard section X.Hose B with long 90° elbow.Hose C =90° elbow

A = 460 mmB = 550 mm

Cutting hoses to length

Coolant reservoir cap removed for demon-stration purposes.

Connect-ing heater inlet

1 Slide on black (sw) rubber isolator and align

Connect-ing heater outlet

1 M6 flanged nut, original vehicle stud bolt2 38 mm dia. rubber-coated p-clamp

Installing p-clamp

A BX

C X

16

A

17

B1

18A

B 1

2
12


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.

2 Hose on heat exchanger inlet3 Twist original vehicle spring clips

Preparing hoses

Turn original vehicle spring clips on T-piece to Position 3 downwards.

1 Supply line of throttle valve2 Hose on heat exchanger inlet

Installing hose of heat ex-changer in-let


Connect-ing heat exchanger inlet

19

1

3

2

20C

2

3

4

1

3

21

2

C

1

3

22C

1

B

13


Before connecting, fill the coolant hoses with coolant.Aligning hoses. Ensure sufficient distance from neighbouring components.

1 Install hose bracket (on 2 and hose C)2 Hose of engine outlet

Connect-ing engine outlet

23

1

2

A

14


Coolant circuitWithout 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.

B

A

1

15


Discard section X.Hose B with long 90° elbow.

A = 460 mmB = 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.


Connect-ing heater outlet

Figure shows vehicle with throttle valve pre-heating.

1 M6 flanged nut, original vehicle stud bolt2 38 mm dia. rubber-coated p-clamp

Installing p-clamp

A BX

X X

24

A

25

B1

26A

B 1

2
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1 Hose of engine outlet2 Hose on heat exchanger inlet

Cutting point

1 Hose 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.

1 Install hose bracket (on hose A and B)2 Hose of engine outlet

Connect-ing engine outlet

27

1

2

281

B

29

A 1

2

B

17


Combustion air

1 Combustion air pipe a = 310mm

Discard section X Cutting combus-tion air pipe to length

1 Combustion air pipe2 27 mm dia. hose clamp3 Cable tie

Installing combus-tion air pipe

1 Retaining clip in hole2 Silencer

Mounting silencer

a

1

X

30

1 3 2

3

i

31

1

2

18


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.

1 Connector housing2 Lock3 Blue/brown (bl/br) wires4 Coding5 Time lock Disman-

tling con-nector

1 Fuel line2 Hose 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

32

1 42 3

5

5

33

1

2

34

1 2 3

19


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.

1 Angle bracket2 Original vehicle bolt3 Rubber-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.

1 Wiring harness of metering pump, connec-tor mounted

2 Fuel line of Heater3 Hose 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.

2 Template, copy hole pattern, 6 mm dia. hole

Removing fuel

35

1

1

36

1 2

3

4

i

37

2

3

1

38

1

3

2

20


Shape fuel standpipe 2 according to tem-plate, cut to length and install, see "installa-tion instructions".

1 Fuel-tank sending unit

Installing fuel stand-pipe

Install fuel-tank sending unit according to manufacturer's specifications. Shorten 3.5mm dia. moulded hose by 15mm.

1 Fuel-tank sending unit2 Fuel line3 3.5mm dia. x 4.5mm moulded hose, 9mm

dia. hose clamp, 10mm dia. caillau clamp Connect-ing fuel line

Check the position of the components; adjust if necessary. Check that they have freedom of movement.

1 Hose section, 10 mm dia. hose clamp [2x]2 Fuel line of fuel standpipe

Connect-ing meter-ing pump

39

1

2

40

1

2

3

41

1 2

21


Exhaust gas

1 Exhaust pipe a = 430mm2 Exhaust end section b = 430mm

Discard section XPreparing exhaust pipe

1 M6 rivet nut, existing hole

Installing rivet nut

1 M6x50 bolt, spring lockwasher, 30 mm shim2 Exhaust silencer

Mounting silencer

Ensure sufficient distance from neighbouringcomponents.

1 Exhaust pipe2 Hose clamp

Installing exhaust pipe

a b

1 2

X

42

1

1

2 43

2

1 44

22


1 Exhaust pipe2 Hose clamp

Installing exhaust pipe

Ensure sufficient distance from neighbouring components.

1 Exhaust end section2 Hose clamp

Installing exhaust end sec-tion

1 Red (rt) rubber isolator [2x]2 P-clamp3 Exhaust end section4 M6x20 bolt, large diameter washer, flang-

ed nut on existing hole

Position-ing rubber isolator

1

2 45

1

2 46

47

2

1 1

4

3

23


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- Make settings on A/C control panel according to the "Operating Instructions for End Cus-

tomer".- Place signboard "Switch off parking heater before refuelling" in the area of the filler neck- See installation instructions for initial start-up and function test

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Printed in Germany 11/2011 Printing: Steffen 241310261B_EN

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

0

100 mm

Scale 1:1

Compare the size of the printed version with dimension liPermitted tolerance a maximum of 2%.

Correct major differences in the printer settings or requesoriginal printout.


Template for fuel-tank sending unit

Template for fuel standpipe

25

100 mm

nes.

t an


2626

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 .Deactivating instructions can be taken from the operating instructions of the vehicle.

Before parking the vehicle, make the following settings:

1 Air outlet to windscreen2 Set temperature to "max."3 Set fan to level "1", or possibly "2"

Manual air condition-ing

48

1 2

3

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