Webasto Thermo Top E Manual del operador
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
e1
00 0003
e1
00 0002
22
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
33
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 bodyareas, e.g. drilled holes, with anti-corrosion wax(Tectyl 100K, OrderNo. 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
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.
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.
Referenceto generalinstallationinstructionsof Webas-
tocomponentsortothemanufacturer'svehicle-specific
documents.
Reference to a special technical feature.
i
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.
5
Citroen C1 / Peugeot 107 / Toyota Aygo
Heater installation location
1Heater
Installa-
tion loca-
tion
1
1
Preliminary Work
WARNING!
- Disconnect the battery
-Depressurisethe 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.
6
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
IfbracketatPosition
3
isnotavailable,routewiring
harnesses into the corrugated tube to the firewall.
1Original vehicle M6 bolt
2Earth wire of heater
2
1
3
12
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
i
4
1
2
5
1
2
3
7
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
6
1
2
Webasto
31
30
15
C1 / 107 / Aygo
4
HG
X1
F3
K3
87a8786
85 30
GM
GRs
F
gr/ws
rt/ws sw 3
KI
4
3K
bl
rt
bl
rt
sw
sw
M
+
-
br
i
8
Citroen C1 / Peugeot 107 / Toyota Aygo
Remote option (Telestart)
Fasten receiver 2with adhesive tape.
1Upper centre console
Installing
receiver
1Antenna
Installing
antenna
Only with Telestart T100 HTM
Fasten temperature sensor 2with adhesive
tape.
1Upper centre console
Installing
tempera-
ture sensor
1
27
i
1
8
1
9
2
9
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
10
1 2
1
1
2
11
1
3
2
12
1
13
1 2 3
2
10
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
14
2
1
2
15
1
2 1
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