Webasto Thermo Top E Operator's manual

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
e1
00 0003
Thermo Top C Parking Heater
e1
00 0002
Thermo Top P Parking Heater
e1
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
or
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
11

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
86
85 30
87a87
K3.1
1
2
3
4
5
4
500
5
2000 0,75²
rt
86
85 30
87a87
K3
1
gn/ws
0,75²
rt
4²
3
4
2
A
15
86 85
E86 85
A
E
15
IPCU
5

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
2
1
2
3
1
2
Donotinstallthe meteringpump
wiring harness until later togeth-
er with fuel pipe along the origi-
nal vehicle fuel lines on the
underbody
4
4
21 2
3
5
2
1

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
31
30
D+61
Citroen, Peugeot
F3
86
85 30
87a87
K3
HG
X1 4
5GS
1234
0
1 2 3 4
sw 4²
br 4²
WG
5
4321
bl
bl
bl 1,5²
+
-GM
M
ws
4²
ws
4²
rt 4²
sw 4²
Fx
GR
86
85 30
87a87
K3.1
rt 0,75²
12
3
4
5
gn/ge
4²
A
2
gn/ge
4²
br
0,75²
6
1
2

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
A
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
7
3
4
1
2
8
1
9
5
6
1 2 3
4
10
1
4
5
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 1
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
sw
Webasto
31
30
15
Citroen, Peugeot
or
or
rt
sw
rt
MF6
F3 rt
sw/ws
ge/gr
ge/gr
ws/
rt
1
2
4
86
85 30
87a87
K3
3
Y
4²
rt
4²
rt 6²
rt 6²
4²
4²
0,75²
0,75²
0,5²
0,5²
HG
X1 4
2 1
GM M
A
12
10 4
KB
86 85
E
A
15
IPCU
GR
5
0,75²
4²
11
4
3
1
2
5

Citroen Berlingo / Peugeot Partner
1314460B_EN 11
Before installing, connect red (rt) wire 2from
K3/86 to socket of IPCU terminal 86.
1IPCU covered (installed behind original ve-
hicle strut)
3M5x16 bolt, large diameter washer, flang-
ed nut Installing
IPCU
1Original vehicle bolt
2Brown (br) wire of IPCU/85, cable lug
Connect-
ing IPCU
1Red (rt) wire IPCU/15
2Brown (br) wire of terminal 15 of OBD
socket outlet, Pin1
3OBD socket outlet disconnected
Connect-
ing IPCU
Fan controller is controlled before 2-pin con-
nector 3of fan module.
Produce connections as shown in wiring dia-
gram.
1Yellow/gray (ge/gr) wire on connector of
A/C control panel
2Black (sw) wire of IPCU/A
4Yellow/gray (ge/gr) wire of connector 2V
NR, Pin 2
5Red (rt) wire of IPCU/E
Connect-
ing fan
controller
12
1
2
3
13
1
2
14
2
3
1
15
2
54
13

Citroen Berlingo / Peugeot Partner
1314460B_EN 12
Digital timer, summer/winter
switch option
Installation location shown is a recommenda-
tion. Agree upon with end customer before in-
stalling.
1Digital timer
212 mm dia. hole, summer/winter switch
Installing
digital tim-
er
Remote option (Telestart)
Fastenreceiver1with double-sidedadhesive
tape.
Installing
receiver
1Antenna
Installing
antenna
Temperature sensor only for T100 HTM
1Fasten temperature sensor with adhesive
tape
Installing
tempera-
ture sensor
1
216
117
1
18
1
19

1314460B_EN 13
Citroen Berlingo / Peugeot Partner
Preparing bracket
1M6x12 bolt, flanged nut [2x each]
2Bracket A
3Bracket B Preparing
bracket
Preparing installation location
Dismantle bracket resonator 1. Original vehi-
cle bolts at position 2will be reused.
Disman-
tling brack-
et
Install premounted brackets (A and B) 5to-
gether with resonator bracket 2loosely.
1M6x20 bolt, spring lockwasher, large diam-
eter washer
3Original vehicle bolt [2x]
4 Transfer hole pattern to frame side member
Installing
bracket
loosely
Dismantling bracket
1Drill 9.1 mm dia. hole; rivet nut
Installing
rivet nut
20
2
1
3
1
21
1
2
2
22
3
1 3
4
2
5
23
1

1314460B_EN 14
Citroen Berlingo / Peugeot Partner
Cut off tab 1 from resonator at the marking.
Preparing
resonator
Installing bracket
Install premounted brackets (A and B) 5to-
gether with resonator bracket 2.
1M6x20 bolt, spring lockwasher, large diam-
eter washer
3Original vehicle bolt [2x]
4M6x40 bolt, spring lockwasher, large diam-
eter washer, 20mm shim
Installing
bracket
Installing heater
Insert two washers between heater and
bracket at Position 1.
1Ejot screw, washer [2x]
2Ejot screw [2x] Installing
heater
1Ejot screw
Installing
heater
24
1
25
3
1 3
4
2
5
26
1
2
2
27
1

Citroen Berlingo / Peugeot Partner
1314460B_EN 15
Coolant circuit
WARNING!
Any coolant running off should be collected using 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:
Hose rout-
ing dia-
gram
All hose clamps = 20-27 mm dia. All connecting pipes without a specific designation = dia. 18x20.
1 = Black (sw) rubber isolator .
A
B
C
1
1
Ø 18x18

Citroen Berlingo / Peugeot Partner
1314460B_EN 16
Hose A= 180° moulded hose
Discard section X.
B= 770
C= 620 Cutting
hoses to
length
Cut off original vehicle hose on engine out-
let/heat exchanger inlet at marking. Remove
original vehicle braided protection hose, if
available.
1Engine outlet hose section
2Hose section of heat exchanger inlet Cutting
point
1Engine outlet hose section
2Hose section of heat exchanger inlet
Installing
hose A
Connect-
ing heater
C
BX
XX
A
28
1
2
29
2
a
1
30
B
C

Citroen Berlingo / Peugeot Partner
1314460B_EN 17
1 Push black (sw) rubber isolator onto hose C .
2Hose on heat exchanger inlet
Connect-
ing heat
exchanger
inlet
1Slide on black (sw) rubber isolator
Connect-
ing engine
outlet
Align and position black (sw) rubber isolator 1
[2x]. Ensure sufficient distance to neighbour-
ing components.
Aligning
hoses
31
C
1 2
32
B1
a
33
C
a a1
1

Citroen Berlingo / Peugeot Partner
1314460B_EN 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.
1Hose section, 10 mm dia. clamp [2x]
2Fuel line in corrugated tube
Connec-
tion to
heater
Route fuel line, wiring harness of metering
pump in corrugated tube 1to firewall at right
side of vehicle and further to the installation
location of the metering pump in the line duct
in the underbody. Installing
lines
1Fuel line of Heater
2Line duct
3Metering pump wiring harness
Installing
lines
34
2 1
35
1
36
1
2
3

Citroen Berlingo / Peugeot Partner
1314460B_EN 19
Lower fuel tank and fuel-tank sending unit 1
according to manufacturer's instructions.
2Large diameter washer
3Copy hole pattern, 6 mm dia. hole Removing
fuel
Shape fuel standpipe 1according to tem-
plate, cut to length and install.
Installing
fuel stand-
pipe
Fuel tank removed for improved depiction. In-
stall fuel-tank sending unit according to man-
ufacturer's instructions. Install fuel tank in
accordance with manufacturer's instructions.
1 Hose section, 10 mm dia. Caillau clamp [2x]
2Fuel line Connect-
ing fuel
line
1Angle bracket
2Original vehicle stud bolt of fuel tank
mount, large diameter washer, original ve-
hicle nut
Installing
metering
pump
37
1
3
2
38
1
1
39
2
1
40
1
2

Citroen Berlingo / Peugeot Partner
1314460B_EN 20
1Metering pump
2Rubber-coated pipe clamp
3Silent block, flanged nut [2x]
Installing
metering
pump
1Hose section [2x], 10mm dia. clamp [4x]
2Fuel line of Heater
3Wiring harness of metering pump, connec-
tor mounted
4Fuel line of fuel standpipe Installing
metering
pump
41
3
2 1
42
1
3
1
4
2