Water Heater - xn--80aejlqpaaj0acd6k.xn--p1aiавтоотопитель.рф/manual/Citroen/C5/1316436B_EN_Citroen_C5_Peugeot_407...Citroen C5 / Peugeot 407 1316436B_EN 3 Heater/Installation

Water Heater

Installation documentation

Ident. No.: 1316436B_EN Fee Euro 10.00 © Webasto AG

Citroen C5 / Peugeot 407

Petrol and Diesel

from model year 2008

Left-hand drive vehicle

Automatic air-conditioning

Manual transmission / 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.

Manufacturer Model Type EG-BE No./ABECitroen C5 R.... e1 * 2001/116 * 0347 *...Citroen C5 R.... e1 * 2001/116 * 0360 *...

Manufacturer Model Type EG-BE No./ABEPeugeot 407 6 e2 * 2001/116 * 0292 *...Peugeot 407 6 e2 * 2001/116 * 0296 *...Peugeot 407 Coupe 6 e2 * 2001/116 * 0328 * ...Peugeot 407 6 e2 * 2001/116 * 0346 *...Peugeot 407 6 e2 * 2001/116 * 0369 *...

Engine type Engine model Output in kW Displacement in cm³5FV Petrol 115 15986FY Petrol 92 1749RFJ Petrol 103 19979 HZ Diesel 80 1560RHR Diesel 100 1997RHF Diesel 103 1997RHH Diesel 120 19974HT Diesel 125 2179

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

Preparing installation location 13Installing heater 13Coolant circuit 1.8 / 2.0 B and 1.6 D 14Coolant circuit 2.0 D RHR / RHF 19Coolant circuit 2.0 D RHH 22Coolant circuit 1.6 B and 2.2 D 25Fuel 30Final Work 35Template for petrol fuel standpipe 36Template for diesel fuel standpipe 37Operating Instructions for End Customer 38

1316436B_EN 2


Heater/Installation Kit

ForewordThis installation documentation applies to the Citroen C5 / Peugeot 407 Petrol and Diesel vehicles - 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 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 Designation Order No.:1 Delivery scope Thermo Top Evo Citroen C5 / Peugeot 407petrol 1316396Bor1 Delivery scope Thermo Top Evo Citroen C5 / Peugeot 407diesel 1316397Band1 Heater control See price list

1316436B_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.

1316436B_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 fuel tank cap again.- Disconnect the battery "earth" or "ground" connection.- 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.- Completely remove the battery together with the carrier.- Remove the air filter together with the intake hose- Remove the left-hand wheel well trim.- Remove the left front wheel.- Remove the front underride protection.- Remove right underbody trim- Remove the right rear underride protection.- Fold over the right-hand rear seat- Open the right-hand fuel-tank sending unit lid.- 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

1316436B_EN 5


Preparing fuse carrier of passen-ger com-partment

Cutting wire to length



Preparing electrical system

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

2 Fuse carrier 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 microtimer 2 to brown (br) wire .

1 Fuse carrier 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

1316436B_EN 6



1 M5x16 bolt, large diameter washer [2x], nut2 Relay mounted3 Angle bracket

1

3

2

3

1316436B_EN 7


Wiring har-ness rout-ing 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

Positive and earth wire

1 Positive wire2 Earth wire on original vehicle earth support

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

4

1

3

2

4 5

1 2

Do not install the metering pump wiring harness until later togeth-er with fuel pipe in the corrugat-ed tube along the original vehicle line on the underbody

6

11

2 73 2

1

1316436B_EN 8


Wiring dia-gram

Legend

Fan control

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

1316436B_EN 9


Installing fuse holder of passen-ger com-partment

Connect-ing wiring harnesses

Detaching BSI and routing downward

Pulling connector off BSI and removing

1 Angle 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 wiring diagram, so that the wires of the same colour are connect-ed.

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

8

1

9

2 1

10

1

1

11

1

3

2

1316436B_EN 10


Connec-tion of BSI

Installing digital tim-er

Installing digital tim-er

Installing receiver

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

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

12

1

2

3

1 13

1 14

1

15

1316436B_EN 11


Installing receiver

Installing antenna

Peugeot 407

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

1 Double-sided adhesive tape

All vehicles

1 Antenna

1

16

1 17

1316436B_EN 12


Copying hole pat-tern

Installing heater

Installing bracket

Preparing installation location

Move connector from position 2 (if present) to position 5.

1 Fastening point for heater (existing holes)2 Fastening point for heater (existing holes)3 Fastening point for heater (existing thread-

ed hole or stud bolt)4 100 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 M6x20 bolt, spring lockwasher, large diam-

eter washer, threaded hole, or flanged nut on original vehicle stud bolt

18

1 2 3

4

5

19

1 1

20

2 31

1316436B_EN 13


Hose rout-ing dia-gram

Coolant circuit 1.8 / 2.0 B and 1.6 D

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 should be "inline" based on the following diagram:

1 = Original vehicle spring clip . Non-designated spring clips = 27 mm dia.All connecting pipes = 18x18 mm dia.

A

C

B

1

Ø 25Ø 25

Ø 25

Ø 25

1316436B_EN 14


Cutting hoses to length

Preparing hoses

Premount-ing hoses

Installing perforated bracket

Discard section XHose A = 180° elbow 18x18

1.8l / 2.0l petrol

B = 780C = 630

1.6l diesel

B = 650C = 470

Push braided protection hoses onto hose B and C and cut to length.Cut heat shrink plastic tubing to length.

1 50 mm long heat shrink plastic tubing [4x]

1.8l / 2.0l petrol

1 M6x20 bolt, engine mount, flanged nut2 Perforated bracket

A

B C

X

X

C

B

1 1

1 1

C

A B 21

22

1

2

1316436B_EN 15


Cutting point

Connect-ing engine outlet

Connect-ing heat exchanger inlet

Routing in engine compart-ment

Disconnect hose 1 from engine outlet. Spring clip 2 will be reused.

1 Hose on heat exchanger inlet

1 M6x20 bolt, flanged nut2 48 mm dia. rubber-coated p-clamp

23

1

2

24

B

A

25B

C

1

26

C

B

2

1

1316436B_EN 16



Connect-ing heater

Cutting point


Ensure sufficient distance from neighbouring components.

1.6l diesel

Disconnect hose 1 from engine outlet. Spring clip 2 will be reused.

27B

C

28B

C

29

1

2

30

B

A

1316436B_EN 17





Connect-ing heater


1 Hose section of heat exchanger inlet2 Cable tie [2x]


31B

C

1

32

C

1

B

2

2

33B

C

34B

C

1316436B_EN 18



Coolant circuit 2.0 D RHR / RHF


All spring clips without a specific designation = 27 mm dia. 1 = Original vehicle coupling.Connecting pipe = 18x18 dia. 2 = Black (sw) rubber isolator .

1

B

A

Ø 25

2

Ø 25

1316436B_EN 19



Preparing hoses

Removing hose

Process-ing hose

Discard section X

A = 740B = 640

Push braided protection hoses onto hose A and B and cut to length.Cut heat shrink plastic tubing to length.


Remove original vehicle hose 1. Remove braided protective hose and discard.

Cut open plastic clamp 5 and remove cou-pling of engine outlet 1. Discard plastic clamp and hose section 4. Twist coupling by 180° and mount on engine outlet.

2 Hose on heat exchanger inlet3 Cutting point

A B

X

X

B

A

1 1

1 1

35

1

365

1

4 3 2

1316436B_EN 20


Connect-ing engine outlet and heat ex-changer in-let



Connect-ing heater

1 Hose section of heat exchanger inlet2 Coupling on engine outlet twisted by 180°

Fasten black (sw) rubber isolator 2 on strut 1 with cable tie.


37A

1

2 B

38

B

A

21

39A

B

40A

B

1316436B_EN 21



Coolant circuit 2.0 D RHH


All spring clips without a specific designation = 27 mm dia.All connecting pipes = 18x18 mm dia. 1 = Black (sw) rubber isolator .

B

A

1

Ø 25

Ø 25

Ø 25

Ø 25

1316436B_EN 22



Preparing hoses

Cutting point

Connect-ing engine outlet and heat ex-changer in-let

Discard section X

A = 610B = 610

Push braided protection hoses onto hose A and B and cut to length.Cut heat shrink plastic tubing to length.


1 Engine outlet hose section2 Hose section of heat exchanger inlet

Figure shows an automatic transmission.Coupling of engine outlet 1 twisted forward by 180° on the connection piece.

2 Hose on heat exchanger inlet3 Original vehicle wiring harness4 Cable tie

A B

X

X

B

A

1 1

1 1

41

1

2

423

4

2A

B

1

1316436B_EN 23





Connect-ing heater

Figure shows an automatic transmission.Fasten black (sw) rubber isolator 2 on strut 1 with cable tie.

Figure shows a manual transmission.Fasten black (sw) rubber isolator 2 on strut 1 with cable tie.

3 Cable tie


43

B

A

21

44

B

A

21

3

45A

B

46A

B

1316436B_EN 24



Coolant circuit 1.6 B and 2.2 D


All spring clips without a specific designation = 27 mm dia.All connecting pipes = 18x18 mm dia. 1 = Black (sw) rubber isolator (2.2 liter diesel only).

A

B

Ø 25Ø 25

Ø 25

1

C

Ø 25

Ø 25

Ø 25

1316436B_EN 25



Preparing hoses

Premount-ing hoses

Cutting point

Discard section XHose A = 180° elbow

1.6l petrol

B = 890C = 800

2.2l diesel

B = 750C = 630

Push braided protection hoses onto hose B and C and cut to length.Cut heat shrink plastic tubing to length.


1.6l petrol

Cut off original vehicle hose on engine out-let/heat exchanger inlet at marking.

1 Engine outlet hose section2 Hose section of heat exchanger inlet

A

B C

X

X

C

B

1 1

1 1

C

A B 47

48

1 2

1316436B_EN 26







1 Hose of engine outlet

Attach cable tie on position 3 on actuating ca-ble bracket and hose B and C.

1 Cable tie [2x]2 Bracket of actuating cable

49

C

1

50B

A

1

C

51

C

B

1

3

2

1

52B

C

1316436B_EN 27


Connect-ing heater

Cutting point




2.2l diesel

Cut off original vehicle hose on engine out-let/heat exchanger inlet at marking.

1 Hose section of heat exchanger inlet2 Engine outlet hose section

1 Hose of engine outlet


53B

C

54

1

2

55

B

A

1

56C

B

1

1316436B_EN 28




Connect-ing heater

Fasten black (sw) rubber isolator 2 on strut 1 with cable tie.


57

B

2

C

1

58B

C

59B

C

1316436B_EN 29


Removing lines

Connect-ing heater

Routing wire

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.

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 assignment is not relevant.

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

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


607

1 42 3

5

5

6

61

1

2

62

1

1316436B_EN 30


Routing wire

Mounting metering pump

Connect-ing meter-ing pump

Removing fuel

Petrol


1 Flanged nut on original vehicle stud bolt2 Metering pump3 Hose section, 10 mm dia. Caillau clamp [2x]4 Fuel line, wiring harness of metering pump

in corrugated tube5 Wiring harness of metering pump, connec-

tor mounted6 Bracket of metering pump

1 Fuel line in corrugated tube2 Hose section, 10 mm dia. Caillau clamp [2x]

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

2 Flanged nut3 Copy hole pattern, 6 mm dia. hole

63

1

1

64

2

6

431

5

65

21

66

1

3

2

1316436B_EN 31


Installing fuel stand-pipe

Connect-ing fuel line

Installing lines


Cut fuel standpipe 1 to length according to template and install.

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

1 Fuel line2 Hose section, 10 mm dia. Caillau clamp [2x]3 Fuel standpipe

Diesel


Remove original vehicle nut at position 1 and discard.

2 Large diameter washer, 30 mm spacer nut

67

1

682 13

69

1

70

1

2

1316436B_EN 32



Connect-ing meter-ing pump

Removing fuel

Installing fuel stand-pipe

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

1 Fuel line in corrugated tube2 Hose section [2x], 10 mm dia. Caillau

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

in corrugated tube4 Wiring harness of metering pump, connec-

tor mounted

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.

71

1 2

3

72

21

4

2 3

73

1

2

3

74

1

1316436B_EN 33


Connect-ing fuel line

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

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

75

21

1316436B_EN 34


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- 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

1 Underride protection2 Cut out exhaust outlet along perforation

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

2 Exhaust end section

762

1

772

1

1316436B_EN Printed in Germany 11/2011 Printing: Steffen 35

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.de


Template for petrol fuel standpipe

1316436B_EN 36

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.


Template for diesel fuel standpipe

1316436B_EN 37

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

No further settings are required.

1316436B_EN 38

Documents

Water Heater - xn--80aejlqpaaj0acd6k.xn--p1aiавтоотопитель.рф/manual/Citroen/C5/1316436B_EN_Citroen_C5_Peugeot_407...Citroen C5 / Peugeot 407 1316436B_EN 3 Heater/Installation