Webasto Thermo Top E Operator's manual

Water Heater
Installation documentation
Ident. No.: 1313460C_EN Fee Euro 10.00 © Webasto AG
Citroen C4 Picasso
Gasoline
from Model Year 2006
Left-hand drive vehicle
Electr. 6-gear transmission (EGS6)
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.
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 C4 Picasso
1313460C_EN 2
Table of Contents
Validity
Vehicle and engine types, equipment variants and national specifications not listed in these installation
instructionshavenotbeentested.However, installationaccordingtotheseinstallationinstructions 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 Picasso U e2 * 2001 / 116 * 0345 * ...
Engine type Engine model Output in kW Displacement in cm³
6FY Gasoline 92 1749
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
A
utomatic air-conditioning fan controller 11
Digital timer, optional Summer/winter
switch option 15
Remote option (Telestart) 15
Preparing heater 16
Preparing installation location 17
Installing heater 19
Coolant circuit 20
Fuel 24
Combustion air 27
Exhaust gas 28
Final Work 29
Template for Fuel Standpipe 30
Operating Instructions for End Customer 31

Citroen C4 Picasso
1313460C_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
TheseinstallationinstructionsapplytothevehiclesCitroenC4PicassoGasoline-forvalidity,seepage
2 - from model year 2006 and later, assuming technical modifications to the vehicle do not affect instal-
lation, any liability claims excluded. Depending on the vehicle version and equipment, modifications
may be necessary during installation with respect to these installation instructions.
However, the stipulations in the"installationinstructions"and"operatingandmaintenanceinstructions"
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).
When using an IPCU, the settings specified in this document must be checked on the vehicle and ad-
justed if necessary, before installation.
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 Installation Kit for Citroen C4 Picasso 2006 Gasoline EGS6 1311819E
1 Heater control See price list
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 Picasso
1313460C_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
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 Picasso
1313460C_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 tank cap again.
- 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)
- Completely remove the battery and the battery carrier.
- Remove the exhaust system.
- Remove the fuel tank according to the manufacturer's specifications.
- Remove the bumper.
- Remove the underride protection
- Remove the lower instrument panel trim on the driver's and front passenger side
- Remove the glove compartment.
Remove page 31 "Operating Instructions for End Customer" and add to the vehicle operating instruc-
tions.
Heater installation location
1Heater
Installa-
tion loca-
tion
1
1

Citroen C4 Picasso
1313460C_EN 6
Preparing electrical system
Wires 6to 9only with automatic air-condition-
ing
Cutting
wires to
length
Produce connections as shown in wiring dia-
gram. Pull wire section 1 into protective
sleeving provided and route togetherwith wir-
ing harness of digital timer and fan controller
into passenger compartment. Preparing
K3 relay
Connectwires toIPCU(IPCUviewoncontact
side).
Pull wire 5 into the protective sleeving provid-
ed and route to OBD socket outlet.
Wire 8 only with automatic air-conditioning
The IPCU is pre-programmed with the follow-
ing settings:
The fan level corresponding to 2 - 3 on the ve-
hicleandthe current intakeofthe fan motor is
to be checked in the function control; correct
the settings if necessary
Preassem-
bling IPCU
Automatic air-conditioning
Produce connections as shown in wiring dia-
gram.
Preparing
additional
relay K3.1
1gn/ws 3000
0,5²
40,75²
rt 500
50,75²
rt 2000
30,75²
sw 500
20,75²
br 500
60,75²
sw 500
70,75²
rt 500 80,75²
rt 500
90,75²
br 500
86
85 30
87a87
K3
1
3
4
2
A
15
86 85
E86 85
A
E
15
IPCU
5
8
Duty cycle: 46% Frequency: 400 Hz
Voltage: 10 V Function: Low-side
7
9 6
86
85 30
87a87
K3.1

Citroen C4 Picasso
1313460C_EN 7
Electrical system
Positive wire
Before installing, crimp 8 mm dia. cable lug onto
positive wire.
1Red (rt) wire
2Original vehicle positive support point
Wiring harness pass through
Route wiring harnesses (digital timer, fan control-
ler and green/white (gn/ws wire in protective
sleeving) on original vehicle wiring harness 1 to
protective rubber plug 2and route into passen-
ger compartment.
Wiring har-
ness in-
stallation
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
Ground wire
1Brown (br) wire
2Original vehicle ground support point
2
1
2
3
1
2
Donot installthemeteringpump
cableharnessuntillatertogether
with fuel pipe along the original
vehicle fuel lines on the under-
body
4
4
21 2
3
5
2
1

Citroen C4 Picasso
1313460C_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 8021 Air-conditioning con-
trol unit rt red
X1 6-pin heater connector 8045 Fan module ws white
F3 25 A fuse 8048 Fan relay sw black
K3 Fan relay MF6 Fuse br brown
IPCU Pulse width modulator gn green
Y Wiring adapter bl blue
or orange
gr gray
Press out wire end, insu-
late and tie back
*Thevaluesspecifiedin
bracketsarevalidfrom
Model Year 2010! XCutting point
Wiring colours may vary.
gn/
ws
sw
rt/ws
Webasto
31
30
15
Citroen
rt or
or
br
rt
sw
gn/ws
MF6
F3
rt
sw/ws
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
HG
X1 4
8045 M
8021
86 85
E
A
15
IPCU
8048
br
5
0,75²
0,5²
gr/br
0,5²
(ws/rt)
gr/br
0,5²
(ws/rt)
(gr/br)
*
*
*

Citroen C4 Picasso
1313460C_EN 9
Produce connections as shown in wiring dia-
gram.
The control takes place on connector 2from
fan module - connector, depending on the ve-
hicle
1wire or connector of fan controller
3Wire or fan relay
4Y-adapter
5Black (sw) wire from K3/30
Connec-
tion to fan
module
Before installing, connect green/white
(gn/ws) wire 4from K3/86 to base of IPCU 3
terminal 86.
1IPCU
2Double-sided adhesive tape Installing
base from
IPCU
Control changeover of IPCU is carried out on
16-pin OBD socket outlet 4.
Produce connections as shown in wiring dia-
gram.
1Red (rt) wire IPCU/15
2Socket of OBD socket outlet
3Pink (pk) wire (terminal 15)
5Pink (pk) wire of OBD socket outlet, Pin 1
Power sup-
ply of IPCU
Model year up to 2009
Produce connections as shown in wiring dia-
gram.
The control takes place before the fan con-
troller connector.
1Black (sw) wire of IPCU/A
2Green/brown (gr/br)wire or connector of
fan controller
3Red (rt) wire of IPCU/E
4Green/brown (gr/br)wire of connector of
A/C control panel
Connect-
ing fan
controller
6
1
5
4
2
3
7
1
2
34
8
1
5
4
2
3
9
4
3
2
1

Citroen C4 Picasso
1313460C_EN 10
Model year from 2010
Produce connections as shown in wiring dia-
gram.
The control takes place at connector 1from
fan controller.
2White-red (ws/rt) wire of fan motor connec-
tor
3Black (sw) wire of IPCU/A
4Red (rt) wire of IPCU/E
5White-red (ws/rt) wire of A/C control panel
Connect-
ing fan
controller
10
5
4
2
1
3

Citroen C4 Picasso
1313460C_EN 11
Automatic air-conditioning fan controller
Wiring dia-
gram
Webasto components Vehicle components Colours and symbols
Legends
HG TT-C/E/P heater 8080 Air-conditioning control unit rt red
X1 6-pin heater connector 8071 Air distribution ws white
F3 25 A fuse 8048 Fan relay sw black
K3 Fan relay 8045 Fan module br brown
IPCU Pulse width modulator MF6 Fuse gn green
Y Wiring adapter bl blue
K3.1 Additional relay ge yellow
gr gray
or orange
Press out wire end, in-
sulate and tie back
*The values specified in
brackets are valid from
Model Year 2010! XCutting point
Wiring colours may vary.
gn/
ws
sw
rt/ws
Webasto
31
30
15
Citroen
rt or
or
br
rt
sw
gn/ws
MF6
F3
86
85 30
87a87
K3.1
rt
9
br
sw/ws
ws/rt
7
6
1
2
4
86
85 30
87a87
K3
3
sw
rt
!Y
0,5²
4²
rt
4²
rt
6²
rt
6²
4²
4²
0,75²
0,75²
HG
X1 4
8045 M
ws/rt (br/sw)
8080
86 85
E
A
15
IPCU
8048
8
br
rt
5
0,75²
0,75²
0,75²
0,75²
0,5²
M
8071
0,5²
(ge/gr)
ge/gr
0,5²
(ws/rt)*
ge/gr
0,5²
(ws/rt)*
*
0,5²
ws/rt
(br/sw)*
*

Citroen C4 Picasso
1313460C_EN 12
Model year up to 2009
Produce connections as shown in wiring dia-
gram.
The control takes place at connector 2from
fan controller.
1wire or connector of fan controller
3Wire or fan relay
4Y-adapter
5Black (sw) wire from K3/30
Connec-
tion to fan
module
Model year from 2010
The fan motor is controlled on connector 1
from fan controller.
Produce connections as shown in wiring dia-
gram.
2Black (sw) wire from K3/30
3Y-adapter
4Wire or fan relay
5wire or connector of fan controller
Connec-
tion to fan
controller
All vehicles
Before installing, connect green/white
(gn/ws) wire 4from K3/86 to base of IPCU 3
terminal 86.
1IPCU
2Double-sided adhesive tape
Installing
base from
IPCU
Control changeover of IPCU is carried out on
16-pin OBD socket outlet 4.
Produce connections as shown in wiring dia-
gram.
1Red (rt) wire IPCU/15
2Socket of OBD socket outlet
3Pink (pk) wire (terminal 15)
5Pink (pk) wire of OBD socket outlet, Pin 1
Power sup-
ply of IPCU
11
1
5
4
2
3
12
3
1
2
4
5
13
1
2
34
14
1
5
4
2
3

Citroen C4 Picasso
1313460C_EN 13
Model year up to 2009
Produce connections as shown in wiring dia-
gram.
The control takes place before the fan con-
troller connector.
1Black (sw) wire of IPCU/A
2Yellow/gray (ge/gr) wire on connector of
fan controller
3Red (rt) wire of IPCU/E
4Yellow/gray (ge/gr) wire on connector of
A/C control panel
Connect-
ing fan
controller
Model year from 2010
The control takes place at connector 1from
fan controller.
Produce connections as shown in wiring dia-
gram.
2White-red (ws/rt) wire of fan motor connec-
tor
3Black (sw) wire of IPCU/A
4Red (rt) wire of IPCU/E
5White-red (ws/rt) wire of A/C control panel
Connect-
ing fan
controller
Model year up to 2009
Connect red (rt) wire 5of IPCU/15 to K3.1/86
according to wiring diagram.
Control changeover of air distribution is car-
ried out at connector 6 from flap motor.
Produce connections as shown in wiring dia-
gram.
1Black (sw) wire K3.1/30
2Red (rt) wire to K3.1/87
3Self-tapping screw on existing hole
4K3.1 relay
7White-red (ws/rt) wire of flap motor con-
nector
8White-red (ws/rt) wire of A/C control panel
Installing
K3.1 relay,
connect-
ing air dis-
tribution
15
4
3
2
1
16
5
4
2
1
3
17
3
8
2
4
7
1
5
6

Citroen C4 Picasso
1313460C_EN 14
Model year from 2010
Connect red (rt) wire 5of IPCU/15 to K3.1/86
according to wiring diagram.
Control changeover of air distribution is car-
ried out at connector 8 from flap motor.
Produce connections as shown in wiring dia-
gram.
1Brown/black (br/sw) wire of A/C control
panel connector
2Red (rt) wire to K3.1/87
3Self-tapping screw on existing hole
4K3.1 relay
6Black (sw) wire K3.1/30
7Brown/black (br/sw) wire of A/C flap motor
connector
Installing
K3.1 relay,
connect-
ing air dis-
tribution
All vehicles
1Original vehicle bolt
2Brown (br) wire of IPCU/85, 6 mm dia ca-
ble lug
3Brown (br) wire of K3.1/85, 6 mm dia cable
lug Ground
connec-
tion K3.1
and IPCU
18
4
3
6
1
7
8
2
5
19
3
1
2

Citroen C4 Picasso
1313460C_EN 15
Digital timer, optional Sum-
mer/winter switch option
1Digital timer
212 mm dia. hole, summer/winter switch Installing
digital tim-
er
Remote option (Telestart)
1Double-sided adhesive tape
2Receiver
Installing
receiver
1Antenna
Installing
antenna
Temperature sensor only for T100 HTM
Fasten temperature sensor 1with adhesive
tape.
Installing
tempera-
ture sensor
1
220
1
221
1
22
1
23

1313460C_EN 16
Citroen C4 Picasso
Preparing heater
Discard section X
A=330
B=630
D=350 Cutting
hose 1 to
length
Discard section X
C=240
E=930
Cutting
hose 2 to
length
Push braided protection hoses onto hose A,
B and Eand cut to length.
Cut heat shrink plastic tubing to length and
shrink on.
125 mm long heat shrink plastic tubing [6x] Preparing
hoses
1Exhaust pipe
a = 120
2Exhaust end section
b = 110
Discard section XPreparing
exhaust
pipe
AXB D
E
CX
X
A
B E
1 1
1
1
a b
1 2
X

1313460C_EN 17
Citroen C4 Picasso
Insert two washers between bracket 2and
heater at position 3.
1Ejot screw [2x]
3Ejot screw, washer [2x] Installing
bracket
Slide heat protection hose 1[2x] onto hose C
and Dand cut to length.
2Hose clamp [2x]
Premount-
ing hoses
1Exhaust pipe
2Hose clamp [2x]
3Exhaust manifold
Preassem-
bling ex-
haust pipe
Preparing installation location
Hole at the centre of the bumper.
1Drill 9.1 mm dia. hole; rivet nut Mounting
rivet nut
24
3
1
2
25
D 1 2
C 21
26
1
232
27
1

1313460C_EN 18
Citroen C4 Picasso
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
Cut away left partition wall 1at markings.
2Discard section
Cuttingout
partition
wall
Cut away side section of radiator carrier 1at
markings.
2Discard section
Cuttingout
radiator
carrier
28
1
29
1
1
4
320
65
30
2
3
30
1
2
2
1
31

1313460C_EN 19
Citroen C4 Picasso
Installing heater
Install one shim 10 each at position 2be-
tween bracket and radiator cross member.
1Preassembled heater
2M6x25 bolt, 10mm shim, flanged nut
[2x each]
Installing
heater
Beforeinstallingwinddeflectorplate3, mount
wiring harness of heater 4.
1Loosely mount M6x20 bolt, spring lock-
washer and large diameter washer
2Strut
5Loosely mount Ejot screw [2x] Installing
strut
Tighten all connections following installation.
1M6x20 bolt, spring lockwasher, large diam-
eter washer
Installing
strut
32
2
1
2
33
55
2
1
3
4
1
34

Citroen C4 Picasso
1313460C_EN 20
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 connecting pipes without a specific designation = dia. 20x20.
1= Black (sw) rubber isolator .
A
B
D
C
E
Ø 18x20 Ø 18x20
1
1
1