Webasto Thermo Top E Operator's manual

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

11
Citroen C1 / Peugeot 107 / 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:
Hose rout-
ing dia-
gram
All hose clamps = 20-27 mm dia. All connecting pipes = 20x20 dia.
1= Throttle valve pre-heating. 2= Black (sw) rubber isolator.
B
A
1
C
2
2

12
Citroen C1 / Peugeot 107 / Toyota Aygo
Discard section X.
Hose Bwith long 90° elbow.
Hose C=90° elbow
A= 460 mm
B= 550 mm
Cutting
hoses to
length
Coolant reservoir cap removed for demon-
stration purposes.
Connect-
ing heater
inlet
1Slide on black (sw) rubber isolator and
align
Connect-
ing heater
outlet
1M6 flanged nut, original vehicle stud bolt
238 mm dia. rubber-coated p-clamp
Installing
p-clamp
AB
X
CX
16
A
17
B1
18
A
B 1
2

13
Citroen C1 / Peugeot 107 / Toyota Aygo
Pull out hose of engine outlet 3from T-piece.
Spring clip 2will be reused. Remove hose of
heat exchanger inlet 1with supply line of
throttle valve.
Cutting
point
Dismantle supply line of throttle valve 4at po-
sition 1, shorten by 20 mm and reinstall.
2Hose on heat exchanger inlet
3Twist original vehicle spring clips
Preparing
hoses
TurnoriginalvehiclespringclipsonT-pieceto
Position 3downwards.
1Supply line of throttle valve
2Hose on heat exchanger inlet
Installing
hose of
heat ex-
changer in-
let
1Slide on black (sw) rubber isolator and
align
Connect-
ing heat
exchanger
inlet
19
1
3
2
20
C
2
3
4
1
3
21
2
C
1
3
22
C
1
B

14
Citroen C1 / Peugeot 107 / Toyota Aygo
Before connecting, fill the coolant hoses with
coolant.
Aligning hoses. Ensure sufficient distance
from neighbouring components.
1Install hose bracket (on 2and hose C)
2Hose of engine outlet Connect-
ing engine
outlet
23
1
2
A

15
Citroen C1 / Peugeot 107 / 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:
Hose rout-
ing dia-
gram
All hose clamps = 20-27 mm dia.
All connecting pipes = 18x20 dia.
1= Black (sw) rubber isolator.
B
A
1

16
Citroen C1 / Peugeot 107 / Toyota Aygo
Discard section X.
Hose Bwith long 90° elbow.
A= 460 mm
B= 550 mm
Cutting
hoses to
length
Coolant reservoir removed for better display.
Figure shows vehicle with throttle valve pre-
heating.
Connect-
ing heater
inlet
Figure shows vehicle with throttle valve pre-
heating.
1Slide on black (sw) rubber isolator and
align
Connect-
ing heater
outlet
Figure shows vehicle with throttle valve pre-
heating.
1M6 flanged nut, original vehicle stud bolt
238 mm dia. rubber-coated p-clamp
Installing
p-clamp
AB
X
XX
24
A
25
B1
26
A
B 1
2

17
Citroen C1 / Peugeot 107 / Toyota Aygo
1Hose of engine outlet
2Hose on heat exchanger inlet
Cutting
point
1Hose of heat exchanger inlet turned up-
ward by approx. 30°
Connect-
ing heat
exchanger
inlet
Before connecting, fill the coolant hoses with
coolant.
Aligning hoses. Ensure sufficient distance
from neighbouring components.
1Install hose bracket (on hose Aand B)
2Hose of engine outlet Connect-
ing engine
outlet
27
1
2
28
1
B
29
A 1
2
B

18
Citroen C1 / Peugeot 107 / Toyota Aygo
Combustion air
1Combustion air pipe
a = 310mm
Discard section XCutting
combus-
tion air
pipe to
length
1Combustion air pipe
227 mm dia. hose clamp
3Cable tie
Installing
combus-
tion air
pipe
1Retaining clip in hole
2Silencer
Mounting
silencer
a
1
X
30
1 3 2
3
i
31
1
2

19
Citroen C1 / Peugeot 107 / 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. 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.
Complete connector of metering pump after
routing. Pin assignment is not relevant.
1Connector housing
2Lock
3Blue/brown (bl/br) wires
4Coding
5Time lock Disman-
tling con-
nector
1Fuel line
2Hose section, 10 mm dia. hose clamp [2x]
Connect-
ing heater
Pull fuel line through attached corrugated
tube 1and route with heater wiring harness 2
to existing lines. Routewiring harness of me-
tering pump 3 together with fuel line to under-
body.
Installing
lines
32
1 42 3
5
5
33
1
2
34
1 2 3

20
Citroen C1 / Peugeot 107 / Toyota Aygo
RouteMecanylfuel lineandwiringharnessof
metering pump in corrugated tube 1to origi-
nal vehicle fuel lines at installation location of
metering pump.
Installing
lines
Ensure proper installation position of meter-
ing pump 4, see "Installation Instructions“.
Installation location at left on vehicle fuel tank.
1Angle bracket
2Original vehicle bolt
3Rubber-coated p-clamp, silent block, M6
flanged nut [2x] Installa-
tion loca-
tion of
metering
pump
Check the position of the components; adjust
ifnecessary.Check thattheyhavefreedomof
movement.
1Wiring harness of metering pump, connec-
tor mounted
2Fuel line of Heater
3Hose section, 10 mm dia. hose clamps [2x] Connect-
ing meter-
ing pump
Remove fuel-tank sending unit 1accordingto
manufacturer's instructions and remove plas-
tic bar 2 carefully.
2Template, copy hole pattern, 6 mm dia.
hole
Removing
fuel
35
1
1
36
1 2
3
4
i
37
2
3
1
38
1
3
2