Webasto Thermo Top E User manual

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.
Webasto does not accept any liability for defects and damage that are attributable to installa-
tion by untrained staff.
Water Heater
Installation instructions
Ident. No.: 1303571D_EN Fee Euro 10.00 © Webasto AG
Citroen C4
Gasoline and Diesel
from Model Year 2004
Left-hand drive vehicle
Feel the drive
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 C4
1303571D_EN 2
Table of Contents
Validity
Vehicle and engine types, equipment variants and national specifications not listed in these installation
instructionshavenotbeentested.However,installation according to these installationinstructions 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 C4 L e2 * 2001/116 * 0360 *...
Engine type Engine model Output in kW Displacement in cm³
KFU Gasoline 65 1360
NFU Gasoline 80 1587
5FW Gasoline 88 1598
RFN Gasoline 100 1997
9HX Diesel 66 1560
9HZDiesel 80 1560
9HY Diesel 80 1560
RHR Diesel 100 1997
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 9
Digital timer, summer/winter switch option 11
Remote option (Telestart) 11
Remote option Thermo Call 12
Preparing heater 13
Preparing installation location 14
Installing bracket 15
Installing heater 16
Coolant circuit 17
Fuel 24
Combustion air 29
Exhaust gas 30
Final Work 32
Gasoline fuel standpipe 33
Diesel fuel standpipe 34
Operating Instructions for End Customer 35
https://webasto-russia.ru

Citroen C4
1303571D_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
These installation instructions apply to the vehicles Citroen C4 Gasoline and Diesel - for validity, see
page 2 - from model year 2004 and later, assuming technical modifications to the vehicle do not affect
installation, any liability claims excluded. Depending on the vehicle version and equipment, modifica-
tions may be necessary during installation with respect to these installation instructions.
However, the stipulations in these "installation instructions" and "operating and maintenance instruc-
tions" for the Thermo Top C/P/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 must be provided with rub protection (cut-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 Description Order No.:
1 Retail accessories Thermo Top E / C / P See price list
1 Heater control See price list
1 Installation kit for Citroen C4 Gasoline and Diesel
Manual air conditioning 1303584B
or
1 Installation kit for Citroen C4 Gasoline and Diesel
Automatic air-conditioning 1303568C
Vehicle Heater
Compact car Thermo Top E
Mid-size car, station wagon Thermo Top C
Full-size car, van, offroader Thermo Top P

Citroen C4
1303571D_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.
ReferencetogeneralinstallationinstructionsofWebas-
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
Software
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 C4
1303571D_EN 5
Preliminary Work
WARNING!
- Open the fuel tank cap and vent the fuel tank.
- Close the tank cap again.
- Disconnect the battery "earth" or "ground" connection.
-Depressurizethe 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 and the battery carrier.
- Remove the engine cover (depending on the vehicle equipment, if installed)
- Remove the air cleaner box with the intake hose and resonator (depending on the vehicle equip-
ment, if installed)
- Detach the wheel well trim on the right and left.
- Remove the bumper.
- Remove the underride protection
- Open the right-hand fuel sender service lid.
- Remove the lower instrument panel trim on the driver's side.
- Remove radio
- Remove the A/C control panel (only with automatic air-conditioning).
Remove page 35 "Operating Instructions for End Customer" and add to the vehicle operating instruc-
tions.
Heater installation location
1Heater
Installa-
tion loca-
tion
11

Citroen C4
1303571D_EN 6
Preparing electrical system
Automatic air-conditioning
Pull 2000 mm long green/white (gn/ws)
wire into the attached insulation hose. Preparing
K3 relay
Connect wires to IPCU.
IPCU view on contact side!
Preassem-
bling IPCU
86
85 30
87a87
K3
1
gn/ws
86 85
E
A
15
IPCU
4
2
3
A
15
86 85
E
sw
rt
br

Citroen C4
1303571D_EN 7
Electrical system
Positive wire
1Red (rt) wire
2Original vehicle positive support point
Wiring harness pass through
Route wiring harnesses (digital timer, fan control
and red (rt) wire in the insulation hose of the au-
tomatic A/C) just behind the rubber plug 1in the
direction of the upper vehicle centre!
Wiring har-
ness in-
stallation
diagram
Fuse holder, K3 relay
1Retaining plate for fuse holder
3K3 relay
2 5.5x13 self-tapping screw; plastic nut [2x each]
4F1-3 fuses mounted
Ground wire
1Brown (br) wire
2Original vehicle ground support point
2
1
2
3
1
Do not installthe metering pump
cableharnessuntillatertogether
with fuel pipe along the original
vehicle fuel lines on the under-
body
4
4
21 2
3
5
2
2
1

Citroen C4
1303571D_EN 8
Fan controller for manual air conditioning
Wiring dia-
gram
Webasto components Vehicle components Colours and symbols
Legends
HG TT-C/E/P heater GM Fan motor rt red
X1 6-pin heater connector GR Fan relay sw black
F3 Fuse GS Fan switch 8025
K3 Fan relay St 01 10-pin connector
IC 26 6-pin connector
F11 Fuse
XCutting point
Wiring colours may vary.
Connection to 6-pin connector 5from IC 26.
Produce connections as shown in wiring dia-
gram.
1Red (rt) wire from K3/87a
2Black (sw) wire from K3/30
3Red (rt) wire of fan switch
4Red(rt) wire for 6-pinconnectorIC 26 Pin 3
Connect-
ing fan-mo-
tor
Webasto
31
30
15
Citroen
F3
86
85 30
87a87
K3
HG
X1 4GR F11
3
IC26
GS
A1
St 01
2
1GM
M
rt
sw
rt
rt
6
1
34
2
5

Citroen C4
1303571D_EN 9
Automatic air-conditioning fan controller
Wiring dia-
gram
Webasto components Vehicle components Colours and symbols
Legends
HG TT-C/EP heater GM Fan motor 8050 rt red
X1 6-pin heater connector GR Fan controller 8045 ws white
F3 Fuse St 02 4-pin connector GR sw black
K3 Fan relay St 03 2-pin connector GM br brown
IPCU Pulse width modulator GRs Fan relay gn green
KB 8080 A/C control panel ge yellow
St 04 6-pin connector, green
St 05 6-pin connector brown
IC 26 6-pin connector
IPCU adjustment values: BSI Central switching unit
Duty cycle: 100% 10 V NR BSI connector *15 mm terminal from
BSI delayed power-off
Frequency: 14 kHz GM Fan motor 8050
Voltage: 1.7 V GR Fan controller 8045 XCutting point
Function: High-side St 02 4-pin connector GR Wiring colours may vary.
Webasto
31
30
15
Citroen
F3
86
85 30
87a87
K3
HG
X1 4
GRs
F11
3
IC26
F14
R7
2 6 10V NR
BSI
MF5
GM
M
St 03 2 1
GRr
St 02 2 3 4 1
KB
St 05
1 41
St 04
rt
sw
rt
rt
86 85
E
A
15
IPCU
sw
rt
ws
ws
br/ge
gn/ge
gn/
ge
br
br
1
gn/ws
3
4
2
*

Citroen C4
1303571D_EN 10
Connection to 6-pin connector 5from IC 26.
Produce connections as shown in wiring dia-
gram.
1Red (rt) wire from K3/87a
2Black (sw) wire from K3/30
3Red (rt) wire of fan switch
4Red(rt) wire for 6-pinconnectorIC 26 Pin 3
Connect-
ing fan-mo-
tor
Before installing, connect green/white
(gn/ws) wire from K3/86 to base of IPCU
terminal 86.
13.5x9.5 self-tapping screw; washer
2Base of IPCU Installing
base from
IPCU
Connection to green 6-pin connector 3and
brown 6-pin connector 6of A/C control panel.
Secure IPCU base with adhesive tape!
1IPCU mounted
2Black (sw) wire of IPCU/A to white (ws)
wire of motor controller Pin 2
4Red (rt) wire of IPCU/E to white (ws)
wire of 6-pin connector Pin 1
5Slide Brown (br) wire of IPCU/85 onto
green/yellow (gr/ge) wire of brown 6-pin
connector Pin 4
Connect-
ing A/C
control
panel
7
1
34
2
5
8
1
2
9
1
3
2
45
6

Citroen C4
1303571D_EN 11
Digital timer, summer/winter
switch option
The installation location according to this or
the following figure is only a recommenda-
tion. Agree upon with final customer before
installing.
Variant 1
1Digital timer
2Summer/winter switch, drilled hole 12 mm
dia.
Installing
digital tim-
er
Variant 2
1Summer/winter switch, drilled hole 12 mm
dia.
2Digital timer Installing
digital tim-
er
Remote option (Telestart)
In case of simultaneous installation with Ther-
mo-Call, the Telestart receiver is fastened un-
der the bracket 4.
1Receiver
2Receiver bracket
3M5x16 bolt, flanged nut, existing hole
Installing
receiver
1Antenna
Installing
antenna
1
210
1
211
1
212 3
4
1
13

Citroen C4
1303571D_EN 12
Remote option Thermo Call
Secure the receiver of Thermo Call 1on the
bracket 2with adhesive tape.
Installing
receiver
1Antenna
Installing
antenna
1Pushbutton
Installing
push but-
ton
1
214
1
15
1
16

1303571D_EN 13
Citroen C4
Preparing heater
Hose B= 90° elbow
Discard section X
A= 1240 mm Cutting
coolant
hoses to
length
Hose C= 90° elbow
Discard section X
D= 1240 mm
Cutting
coolant
hoses to
length
Push braided protection hoses onto hose A
and Dand cut to length.
Cut heat shrink plastic tubing to length and
shrink to size.
125 mm long heat shrink plastic tubing [4x] Preparing
coolant
hoses
127 mm dia. hose clamp [2x]
2Hose clamp
3Exhaust manifold
420x20 connecting pipe
Preassem-
bling heat-
er
B
A X
C
D X
A
D
1 1
1 1
17
4
C 1
1
3
2

1303571D_EN 14
Citroen C4
Preparing installation location
Hole at the centre of the bumper.
1Drill 9.1 mm dia. hole; rivet nut Mounting
rivet nut
Hole at the centre of the bumper.
1Drill 9.1 mm dia. hole; rivet nut
Mounting
rivet nut
Rectangular recess at Position 4, recess for
oblong hole at Position 3!
17 mm dia. hole [2x] (centered from bar)
27 mm dia. hole Holes in
the radia-
tor cross
member
If left partition wall 1exists, cut it off at the
markings.
2Discard section
Cuttingout
partition
wall
18
1
19
1
20
1
1
4
320
65
30
2
3
21
1
2

1303571D_EN 15
Citroen C4
2.0l gasoline
Cut away edge 1at marking and discard.
Cutting
away edge
on radiator
cross
member
Cut consecutive 500 mm ends from edge pro-
tection provided and install.
150 mm edge protection
270 mm edge protection
3130 mm edge protection
460 mm edge protection
560 mm edge protection
Installing
edge pro-
tection
All vehicles except 2.0l Gasoline
Cut 4 consecutive 500 mm ends from edge
protection provided and install.
160 mm edge protection
240 mm edge protection
340 mm edge protection
440 mm edge protection
Installing
edge pro-
tection
Installing bracket
Insert one 10 mm shim 1between bracket 3
and cross member!
2M6x20 bolt, 10 mm shim, flanged nut
[2x each] Installing
bracket
22
1
23
2
4
1
5
3
24
3
4
2
1
25
1
3
2
1
2

1303571D_EN 16
Citroen C4
1M6x20 bolt, spring lockwasher
2Strut
3Ejot screw, washer [2x], pin lock
Installing
strut
1M6x20 bolt, spring lockwasher
2Strut
Fastening
strut
Installing heater
Mount wiring harness of heater before instal-
lation.
1Ejot screw [3x] Installing
heater
1Strut
250 mm edge protection
3Wind deflector plate
4Ejot screw [2x]
Installing
heater
26
1
3
2
2
1
27
28
1 1
1
29
1
4
2
3
4

Citroen C4
1303571D_EN 17
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 no other hose
can 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 not designated connecting pipes as follows:
1.4 and 1.6l Gasoline = 15x20 dia or 18x20 dia! 2.0l Gasoline and 1.6l Diesel = 18x20 dia
2.0 liter diesel = 20x20 dia. 1= Black (sw) rubber isolator (Gasoline). 2= Black (sw) rubber iso-
lator (Diesel).
C
B
D A
Ø 20x20
Ø 20x20
1
2

Citroen C4
1303571D_EN 18
Turn perforated bracket 2by approx. 75° on
longitudinal axis.
1M6x20 bolt, flanged nut
2Perforated bracket
3Rubber-coated pipe clamp Preparing
perforated
bracket
Sliding on heat protection hoses. Route hos-
es Aand Dthrough pass-through in the cool-
er at the left of the heater. When doing so,
guide hose Athroughrubber-coatedp-clamp.
1Prepared perforated bracket
2Original vehicle bolt Installing
coolant
hoses
Connec-
tion to
heater
Cut perforated bracket to approx. 58 mm.
1Perforated bracket
2M6x20 bolt, flanged nut
3Rubber-coated p-clamp [2x] Preparing
perforated
bracket
30
21
3
C
31
D
a
1
2
C
32
b
D
a
33
1
3
2
3

Citroen C4
1303571D_EN 19
Fasten perforated bracket on transmission
block.
1Prepared perforated bracket
2Original vehicle bolt Installing
perforated
bracket
Gasoline
Route hose Aand Dthrough rubber-coated
p-clamps.
1Rubber-coated p-clamp [2x] Routing to
cutting
point
1.4 and 1.6l Gasoline
Remove braided protection hose in area of
cutting point. Disconnect hose from engine
outlet to heat exchanger inlet with hose
clamping pliers.
1Engine-outlet hose section
2Hose section of heat exchanger inlet
Cutting
point
Before installation, push black (sw) rubber
isolator 3onto hose D.
1Engine-outlet hose section
2Hose section of heat exchanger inlet Connect-
ing heat
exchanger
inlet and
engine out-
let
34
2
1
35
1 a
D 1
36
1
2
37
1 2
D
a
3

Citroen C4
1303571D_EN 20
2.0l gasoline
Disconnect hose from engine outlet to heat
exchanger inlet with hose clamping pliers.
1Engine-outlet hose section
2Hose section of heat exchanger inlet Cutting
point
Before installation, push black (sw) rubber
isolator 1onto hose D.
2Engine-outlet hose section
3Hose section of heat exchanger inlet Connect-
ing heat
exchanger
inlet and
engine out-
let
Gasoline
Figure shows 2.0 l gasoline. Fasten rubber
isolator on hose Awith cable tie.
1Black (sw) rubber isolator Routing in
engine
compart-
ment
Figure shows 2.0 l gasoline.
Check the position of the components; adjust
if necessary. Check that they have free clear-
ance.
Position-
ing hose A
and D
38
1
2
39
1
D
3
2a
40
1
a
D
41
D
a