Citroen C1 / Peugeot 107 / Toyota Aygo

Transcription

1 Water Heater Feel the drive Thermo Top E Parking Heater Thermo Top C Parking Heater e e Installation documentation Citroen C / Peugeot 07 / Toyota Aygo Petrol from Model Year 005 For left-hand drive vehicles only Manual air conditioning 5-gear manual transmission 5-gear MultiMode transmission 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 heater 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 technical 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 installation by untrained staff. Ident. No.: 06B_EN Fee Euro 0.00 Webasto AG

2 Citroen C / Peugeot 07 / Toyota Aygo Table of Contents Validity Heater/Installation Kit Foreword General Instructions Special Tools 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 heater 0 Coolant circuit Combustion air 8 Fuel 9 Exhaust gas Final Work 4 Template for fuel standpipe 5 Template for fuel-tank sending unit 5 Operating Instructions for End Customer 6 Validity Manufacturer Model Type EG-BE No./ABE Citroen C P e * 00 / 6 * 08 Peugeot 07 P e * 00 / 6 * 07 Toyota Aygo AB e * 00 / 6 * 06 Engine type Engine model Output in kw Displacement in cm³ KR-FE Petrol KR-(CFA) Petrol 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 possible. The installation location of a digital timer and summer/winter switch should be confirmed with the end customer before installation.

3 Citroen C / Peugeot 07 / Toyota Aygo Heater/Installation Kit Quantity Designation Order No.: Thermo Top E / C retail accessories See price list Installation kit for Citroen C / Peugeot 07 / Toyota Aygo 057B Petrol Heater control See price list Heater recommended for the respective vehicle class: Vehicle Compact car Mid-size car, estate car Heater Thermo Top E Thermo Top C 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 C / Peugeot 07 / Toyota Aygo vehicles with Petrol engine - for validity, see page - from model year 005 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 documentation. However, the stipulations in this "installation documentation", the "operating instructions" and "installation 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 specified 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 00K, Order No. 9). Special Tools - Torque wrench for.0-0 Nm - Hose clamping pliers - Metric thread-setter kit

4 Explanatory notes on document Citroen C / Peugeot 07 / Toyota Aygo 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. Mechanical system Electrical system Coolant circuit Fuel Exhaust gas Combustion air Special features are highlighted using the following symbols: Specific risk of injury or fatal accidents. Specific risk of damage to components. Specific risk of fire or explosion. i Reference to general installation instructions of Webasto components or to the manufacturer's vehicle-specific documents. Reference to a special technical feature. The arrow in the vehicle icon indicates the position on the vehicle and the viewing angle. 4

5 Citroen C / Peugeot 07 / Toyota Aygo 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 6 "Operating Instructions for End Customer" and add to the vehicle operating instructions. Heater installation location Heater Installation location 5

6 Citroen C / Peugeot 07 / Toyota Aygo Electrical system Wiring harness pass through Protective rubber plug Digital timer, summer/winter switch option Digital timer Summer/winter switch, mm dia. drilled hole i rt/sw Do not install the metering pump wiring harness until later together with fuel pipe along the original vehicle fuel lines on the underbody br bl Wiring harness routing diagram 4 5 Fuse holder, K relay Original vehicle bolt M5x6 bolt, washers, retaining plate of fuse holder, perforated bracket (turned by 90 ), K relay, M5 flanged nut Earth support point If bracket at Position is not available, route wiring harnesses into the corrugated tube to the firewall. Original vehicle M6 bolt Earth wire of heater 6

7 Citroen C / Peugeot 07 / Toyota Aygo Fan control Connection to 4-pin connector K from instrument cluster. Make connections as shown in the wiring diagram with the provided connectors. 4-pin connector K Instrument cluster (view from rear.) Connecting fan-motor 6 Webasto C / 07 / Aygo 0 5 i X HG 4 rt/ws F sw F K 4 KI gr/ws a rt GRs rt bl Wiring diagram for manual air conditioning 85 0 br K sw sw - M GM + bl Webasto components C / 07 / Aygo components Colours and symbols HG Heater TT-C/E GRs Fan relay rt red F 5 A fuse KI Instrument cluster ws white K Fan relay K Connector K on KI sw black GM Fan motor br brown bl blue X Cutting point Legend 7

8 Citroen C / Peugeot 07 / Toyota Aygo Remote option (Telestart) Fasten receiver with adhesive tape. Upper centre console i receiver 7 Antenna antenna 8 Only with Telestart T00 HTM Fasten temperature sensor with adhesive tape. Upper centre console temperature sensor 9 8

9 Citroen C / Peugeot 07 / Toyota Aygo Preparing installation location Detach retaining clip [x] Original vehicle wiring harness [x] Detaching wiring harness 0 Detach original vehicle bolt at Position. Remove earth cable at Position, discard bolt and fasten at Position. Moving earth support point Position heater loosely Positioning heater Bracket M6x bolt, large diameter washer, M6 flanged nut, existing hole [x each] M8x0 bolt, large diameter washer, M8 flanged nut, existing hole bracket 9

10 Citroen C / Peugeot 07 / Toyota Aygo heater Mount wiring harness on heater before installing. Tighten Ejot screws to 0 Nm. Bracket Ejot screw [x] heater 4 Tighten Ejot screws to 0 Nm. Ejot screw [x] Bracket heater 5 0

11 Citroen C / Peugeot 07 / Toyota Aygo Coolant circuit With 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: B C Hose routing diagram A All hose clamps = 0-7 mm dia. All connecting pipes = 0x0 dia. = Throttle valve pre-heating. = Black (sw) rubber isolator.

12 Citroen C / Peugeot 07 / Toyota Aygo Discard section X. Hose B with long 90 elbow. Hose C =90 elbow A X B A = 460 mm B = 550 mm Cutting hoses to length C X A Coolant reservoir cap removed for demonstration purposes. Connecting heater inlet 6 B Slide on black (sw) rubber isolator and align Connecting heater outlet 7 B M6 flanged nut, original vehicle stud bolt 8 mm dia. rubber-coated p-clamp p-clamp A 8

13 Citroen C / Peugeot 07 / Toyota Aygo Pull out hose of engine outlet from T-piece. Spring clip will be reused. Remove hose of heat exchanger inlet with supply line of throttle valve. Cutting point 9 Dismantle supply line of throttle valve 4 at position, shorten by 0 mm and reinstall. Hose on heat exchanger inlet Twist original vehicle spring clips Preparing hoses 4 C 0 Turn original vehicle spring clips on T-piece to Position downwards. Supply line of throttle valve Hose on heat exchanger inlet C Slide on black (sw) rubber isolator and align B hose of heat exchanger inlet Connecting heat exchanger inlet C

14 Citroen C / Peugeot 07 / Toyota Aygo A Before connecting, fill the coolant hoses with coolant. Aligning hoses. Ensure sufficient distance from neighbouring components. Install hose bracket (on and hose C) Hose of engine outlet Connecting engine outlet 4

15 Citroen C / Peugeot 07 / Toyota Aygo Coolant circuit Without 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: B A Hose routing diagram All hose clamps = 0-7 mm dia. All connecting pipes = 8x0 dia. = Black (sw) rubber isolator. 5

16 Citroen C / Peugeot 07 / Toyota Aygo Discard section X. Hose B with long 90 elbow. A X B A = 460 mm B = 550 mm Cutting hoses to length X X A Coolant reservoir removed for better display. Figure shows vehicle with throttle valve preheating. Connecting heater inlet 4 B Slide on black (sw) rubber isolator and align Figure shows vehicle with throttle valve preheating. Connecting heater outlet 5 B Figure shows vehicle with throttle valve preheating. M6 flanged nut, original vehicle stud bolt 8 mm dia. rubber-coated p-clamp p-clamp A 6 6

17 Citroen C / Peugeot 07 / Toyota Aygo Hose of engine outlet Hose on heat exchanger inlet Cutting point 7 B Hose of heat exchanger inlet turned upward by approx. 0 Connecting heat exchanger inlet 8 A B Before connecting, fill the coolant hoses with coolant. Aligning hoses. Ensure sufficient distance from neighbouring components. Install hose bracket (on hose A and B) Hose of engine outlet Connecting engine outlet 9 7

18 Citroen C / Peugeot 07 / Toyota Aygo Combustion air a Combustion air pipe a = 0mm Discard section X Cutting combustion air pipe to length X Combustion air pipe 7 mm dia. hose clamp Cable tie i combustion air pipe 0 Retaining clip in hole Silencer Mounting silencer 8

19 Citroen C / Peugeot 07 / Toyota Aygo 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. Unless 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 routing diagram. 4 Complete connector of metering pump after routing. Pin assignment is not relevant. 5 5 Fuel line Hose section, 0 mm dia. hose clamp [x] Connector housing Lock Blue/brown (bl/br) wires 4 Coding 5 Time lock Dismantling connector Connecting heater Pull fuel line through attached corrugated tube and route with heater wiring harness to existing lines. Routewiring harness of metering pump together with fuel line to underbody. lines 4 9

20 Citroen C / Peugeot 07 / Toyota Aygo Route Mecanyl fuel line and wiring harness of metering pump in corrugated tube to original vehicle fuel lines at installation location of metering pump. lines 5 Ensure proper installation position of metering pump 4, see "Installation Instructions. Installation location at left on vehicle fuel tank. i 4 Angle bracket Original vehicle bolt Rubber-coated p-clamp, silent block, M6 flanged nut [x] Installation location of metering pump 6 Check the position of the components; adjust if necessary. Check that they have freedom of movement. Wiring harness of metering pump, connector mounted Fuel line of Heater Hose section, 0 mm dia. hose clamps [x] Connecting metering pump 7 Remove fuel-tank sending unit according to manufacturer's instructions and remove plastic bar carefully. Template, copy hole pattern, 6 mm dia. hole Removing fuel 8 0

21 Citroen C / Peugeot 07 / Toyota Aygo Shape fuel standpipe according to template, cut to length and install, see "installation instructions". Fuel-tank sending unit 9 Install fuel-tank sending unit according to manufacturer's specifications. Shorten.5mm dia. moulded hose by 5mm. Fuel-tank sending unit Fuel line.5mm dia. x 4.5mm moulded hose, 9mm dia. hose clamp, 0mm dia. caillau clamp fuel standpipe Connecting fuel line 40 Check the position of the components; adjust if necessary. Check that they have freedom of movement. Hose section, 0 mm dia. hose clamp [x] Fuel line of fuel standpipe Connecting metering pump 4

22 Citroen C / Peugeot 07 / Toyota Aygo Exhaust gas Exhaust pipe a = 40mm Exhaust end section b = 40mm Discard section X Preparing exhaust pipe a b X M6 rivet nut, existing hole rivet nut 4 M6x50 bolt, spring lockwasher, 0 mm shim Exhaust silencer Mounting silencer 4 Ensure sufficient distance from neighbouring components. Exhaust pipe Hose clamp exhaust pipe 44

23 Citroen C / Peugeot 07 / Toyota Aygo Exhaust pipe Hose clamp exhaust pipe 45 Ensure sufficient distance from neighbouring components. Exhaust end section Hose clamp exhaust end section 46 Red (rt) rubber isolator [x] P-clamp Exhaust end section 4 M6x0 bolt, large diameter washer, flanged nut on existing hole Positioning rubber isolator 4 47

24 Citroen C / Peugeot 07 / Toyota Aygo 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 00K, Order No. 9). - 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 Customer". - 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 i Feel the drive Webasto AG Postfach 80 D-8 Stockdorf / Germany National Hotline: (4 Cent aus dem deutschen Festnetz) Hotfax: Hotmail: technikcenter@webasto.com 06B_EN Printed in Germany /0 Printing: Steffen 4

25 Citroen C / Peugeot 07 / Toyota Aygo Template for fuel-tank sending unit Template for fuel standpipe 00 mm Scale : Compare the size of the printed version with dimension lines. Permitted tolerance a maximum of %. Correct major differences in the printer settings or request an original printout mm 5

26 Citroen C / Peugeot 07 / Toyota Aygo 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 time Example: For a driving time of approx. 0 min. (in one direction), we recommend not exceeding a switch-on time of 0 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: Air outlet to windscreen Set temperature to "max." Set fan to level "", or possibly "" Manual air conditioning 48 6