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, specialized tools and equipment are
required to install and repair Webasto heating and cooling systems.
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.
Webasto does not accept any liability for defects and damage that are attributable to
installation by untrained staff.
Water Heater Unit
Installation Instructions
Ident. No.:1311842C_EN Fee Euro 10.00 © Webasto AG
Citroen C4 Picasso
Gasoline and Diesel
from Model Year 2006
Left-hand drive vehicle
Feel the drive
Thermo Top E Additional Heater e1
00 0003
Thermo Top C Additional Heater
e1
00 0002
Thermo Top P Additional Heater e1
00 0104

Citroen C4 Picasso
1311842C_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 Picasso U e2 * 2001 / 116 * 0345
Engine type Engine model Output in kW Displacement in cm³
6FY Gasoline 92 1749
9 Hz Diesel 80 1560
RHJ Diesel 100 1997
Validity 2
Heater Unit/Installation Kit 3
Foreword 3
General Instructions 3
Special Tools 3
Explanatory Notes on Document 4
Preliminary Work 5
Heater unit installation location 5
Preparing electrical system 6
Electrical system 7
Fan controller for manual air conditioning 8
A
utomatic air-conditioning fan controller 9
Digital timer, summer/winter switch option 12
Remote option (Telestart) 12
Preparing heater unit 13
Preparing installation location 14
Installing heater unit 16
Water 18
Fuel 24
Gasoline 24
Diesel 26
Combustion air 28
Exhaust gas 29
Final Work 30
Operating Instructions for End Customer 31
Template for Gasoline Fuel Standpipe 32

Citroen C4 Picasso
1311842C_EN 3
Heater Unit/Installation Kit
Heater unit recommended for the respective vehicle class:
The selection of the heater unit 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 Citroen C4 Picasso Gasoline and Diesel vehicles - for validity,
see page 2 - from model year 2006 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 these installation instructions.
However,thestipulations in the "installationinstructions"and"operating and maintenanceinstructions"
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
specified otherwise, fasten hoses, lines and wiring harnesses to original vehicle lines and wiring
harnesses using cable ties.
Sharp edges should be fitted with edge protectors (split-open plastic 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
Quantity Description Order No.:
1 Retail accessories with desired heater control See price list
1 Installation kit for Citroen C4 Picasso Gasoline 1311819B
or
1 Installation kit for Citroen C4 Picasso Diesel 1311846B
Vehicle Heater unit
Compact car Thermo Top E
Mid-size car, station wagon Thermo Top C
Full-size car, van, offroader Thermo Top P

Citroen C4 Picasso
1311842C_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.
Reference to general installation instructions of
Webasto components or to the manufacturer's vehicle-
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
Water
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
1311842C_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, ventilate the 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
equipment, if installed)
- Completely remove the battery and the battery carrier.
- Remove the exhaust system (only on gasoline vehicles)
- Remove the tank according to the manufacturer's specifications (only on gasoline vehicles)
- Detach the wheel well trim on the right and left.
- 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
instructions.
Heater unit installation location
1Heater unit
Installation
location
1
1

Citroen C4 Picasso
1311842C_EN 6
Preparing electrical system
Wires 6to 9only with automatic air-
conditioning
Cutting
wires to
length
Produce connections as shown in wiring
diagram. Pull wire section 1 into protective
sleeving provided and route together with
wiring harness of digital timer and fan
controller into passenger compartment. Preparing
K3 relay
ConnectwirestoIPCU(IPCUviewoncontact
side).
Pull wire 5 into the protective sleeving
provided and route to OBD socket outlet.
Wire 8 only with automatic air-conditioning Preassem-
bling IPCU
Automatic air-conditioning
Produce connections as shown in wiring
diagram.
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
86
85 30
87a87
K3.1
7
9 6

Citroen C4 Picasso
1311842C_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
Wiring harness pass through
Route wiring harnesses (digital timer, fan
controller and green/white (gn/ws wire in
protective sleeving) on original vehicle wiring
harness 1 to protective rubber plug 2and route
into passenger compartment.
Wiring
harness
installation
diagram
Fuse holder, relay K3
1Retaining plate for fuse holder
24 mm dia. hole, 5.5x13 self-tapping screw;
plastic nut [2x each]
3K3 relay
4Fuse holder
Connecting ground wire
1Brown (br) wire
2Original vehicle ground support point
2
1
2
3
1
2
Donot installthe meteringpump
cableharnessuntillatertogether
with fuel pipe along the original
vehicle fuel lines on the
underbody
4
4
21 2
3
5
2
1

Citroen C4 Picasso
1311842C_EN 8
Fan controller for manual air conditioning
Wiring
diagram
Webasto components Vehicle components Colors and symbols
Legend
HG Heater unit TT-C/E 8021 Air-conditioning control unit rt red
X1
6-pin heater unit 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 2V NR 2-pin connector gn green
Y Wiring adapter 4V NR 4-pin connector bl blue
26V JN 26-pin connector or orange
MF6 Fuse gr gray
IPCU adjustment values: Press out wire end,
insulate and tie back
Duty cycle: 42 %
Frequency: 1000 Hz
Voltage: 5 V XCutting point
Function: High-side Wiring colors 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
gr/br 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
2V NR 2 1
8045 M
2V NR
12
19 20
8021
26V JN
86 85
E
A
15
IPCU
8048
br
5
gr/br
0,75²
0,5²

Citroen C4 Picasso
1311842C_EN 9
Automatic air-conditioning fan controller
Wiring
diagram
Webasto components Vehicle components Colors and symbols
Legend
HG Heater unit TT-C/E 8080 Air-conditioning control unit rt red
X1
6-pin heater unit 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 2V NR 2-pin connector gn green
Y Wiring adapter 4V NR 4-pin connector bl blue
K3.1 Additional relay 26V JN 26-pin connector ge yellow
MF6 Fuse gr gray
or orange
IPCU adjustment values: Press out wire end,
insulate and tie back
Duty cycle: 42 %
Frequency: 1000 Hz
Voltage: 5 V XCutting point
Function: High-side Wiring colors 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
ge/gr
ge/gr
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
0,5²
0,5²
HG
X1 4
2V NR 2 1
8045 M
2V NR
12
rt/gr
0,5²
10 4
8080
26V JN
8
MMM
M
4V NR
4
86 85
E
A
15
IPCU
8048
8
br 8071
rt
5
0,75²
0,75²
0,75²
0,75²
0,5²
rt/gr

Citroen C4 Picasso
1311842C_EN 10
Fan controller on all vehicles
Fan motor is controlled on 2-pin connector 2
of fan module.
Produce connections as shown in wiring
diagram.
1Orange (or) wire connector 2V NR, Pin 2
3Orange (or) wire of fan relay 8048
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 socket of IPCU
terminal 86.
1IPCU
2Double-sided adhesive tape Installing
socket
from IPCU
Control changeover of IPCU is carried out on
16-pin OBD socket outlet 3.
Produce connections as shown in wiring
diagram.
1Red (rt) wire IPCU/15
2Socket of OBD socket outlet
3Pink (pk) wire (terminal 15)
5Pink (pk) wire of 16-pin OBD socket outlet,
Pin 1
Power
supply of
IPCU
Fan controller is controlled before 2-pin
connector from fan module.
Brown (br) wire of IPCU/85 1with 6 mm dia.
cable lug on original vehicle bolt.
Produce connections as shown in wiring
diagram.
1Black (sw) wire of IPCU/A
3Yellow/gray (ge/gr) (gray/brown (gr/br))
wire of connector 2V NR, Pin 2
4Red (rt) wire of IPCU/E
5Yellow/gray (ge/gr) (gray/brown (gr/br))
wire of A/C control panel connector 26V JN
Connect-
ing fan
controller
6
1
5
4
32
7
1
2
34
8
1
5
3
2
3
9
1
5
4
3
2

Citroen C4 Picasso
1311842C_EN 11
Also with automatic air-conditioning
Brown (br) wire 2with 6 mm dia. cable lug on
original vehicle bolt. Connect red (rt) wire 4
from IPCU/15 to K3.1/86 according to wiring
diagram.
1Self-tapping screw on existing hole
3K3.1 relay
Installing
K3.1 relay
Control changeover of air distribution is
carried out on 4-pin connector 4V NR 2from
flap motor 6.
Produce connections as shown in wiring
diagram.
1Red (rt) wire to K3.1/87
3Red/gray (rt/gr) wire of connector 8071 4V
NR, Pin 4
4Black (sw) wire K3.1/30
5Red/gray (rt/gr) wire of A/C control unit
Connec-
tion to air
distribu-
tion
10
1
2
3
4
11
1
4
3
5
2
6

Citroen C4 Picasso
1311842C_EN 12
Digital timer, summer/winter
switch option
Installation location shown is a
recommendation. Agree upon with final
customer before installing.
1Digital timer
212 mm dia. hole, summer/winter switch
Installing
digital
timer
Remote option (Telestart)
1Double-sided adhesive tape
2Receiver
Installing
receiver
1Antenna
Installing
antenna
Temperature sensor for HTM100 only
1Fasten temperature sensor with adhesive
tape
Installing
tempera-
ture sensor
1
212
1
213
1
14
1
15

1311842C_EN 13
Citroen C4 Picasso
Preparing heater unit
1.8 liter gasoline engine
a = 1240 mm
1.6 liter diesel engine
a = 1100 mm
2.0 liter diesel engine
a = 1200 mm
Discard section X
Cutting
coolant
hoses to
length
1.8 liter gasoline engine
d = 1240 mm
1.6 liter diesel engine
d = 1180 mm
2.0 liter diesel engine
d = 1200 mm
Discard section X
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
1Exhaust pipe
a = 120
2Exhaust end section
b = 110
Discard section XPreparing
exhaust
pipe
B
AX
C
DX
A
D
1 1
1 1
a b
1 2
X

1311842C_EN 14
Citroen C4 Picasso
Insert two washers at position 3between
bracket 2and heater unit 1.
1Ejot screw [2x]
3Ejot screw, washer [2x] Preassem-
bling
bracket
1Hose clamp [4x]
220x20 connecting pipe [2x]
Premount-
ingcoolant
hoses
1Exhaust pipe
2Hose clamp [2x]
3Exhaust manifold
Premount-
ing ex-
haust
system
Preparing installation location
Copy hole pattern as shown.
1Drill 9.1 mm dia. hole; install rivet nut Mounting
rivet nut
16
3
1
2
17
C
1
1
B
2
1
1
18
1
32 2
19
1
610 mm

1311842C_EN 15
Citroen C4 Picasso
Copy hole pattern as shown.
1Drill 9.1 mm dia. hole; install rivet nut
Mounting
rivet nut
Square cut-out at position 2.
17 mm dia. hole [2x] (centered from bar)
Holes for
bracket in
radiator
cross
member
Cut-out of oblong hole at position 2.
17 mm dia. hole (centered from bar)
Hole for
exhaust
muffler in
radiator
cross
member
Cut away partition wall 1at markings.
2Discard remaining piece
Cuttingout
partition
wall
20
1610 mm
21
1
1
2
67 mm
318 mm
22
1
30 mm
2
23
1
2

1311842C_EN 16
Citroen C4 Picasso
2.0 liter gasoline engine only
Cut away edge 1at marking and discard.
Cutting
away edge
on radiator
cross
member
Cut 5 consecutive 500 mm ends from edge
protection provided and install.
1Edge protection 50
2Edge protection 70
3Edge protection 130
4Edge protection 60
5Edge protection 60
Installing
edge
protection
All vehicles except 2.0 liter gasoline
engine
Cut 4 consecutive 500 mm ends from edge
protection provided and install.
1Edge protection 60
2Edge protection 40
3Edge protection 40
4Edge protection 40
Installing
edge
protection
Installing heater unit
Install one shim 10 each at position 2
between bracket and radiator cross member.
1Preassembled heater unit
2M6x25 bolt, flanged nut [2x each] Installing
heater unit
24
1
25
2
4
1
5
3
26
3
4
2
1
27
2
2
1

1311842C_EN 17
Citroen C4 Picasso
Beforeinstalling winddeflectorplate3,mount
wiring harness for heater unit 4.
1Loosely mount M6x20 bolt, spring
lockwasher and large diameter washer
2Strut
5Loosely mount Ejot screw [2x] Installing
strut
Tighten all connections following installation.
1M6x20 bolt, spring lockwasher, large
diameter washer
Installing
strut
28
55
2
1
3
4
1
29

Citroen C4 Picasso
1311842C_EN 18
Water
WARNING!
Any coolant running off should be collected using an appropriate container. Install hoses so that they
are kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that no
other hose can be damaged! When installing the coolant hose, the heater unit must be filled with
coolant.
The connection should be "inline" based on the following diagram:
Coolant
routing
diagram
All hose clamps = 20-27 mm dia.! All connecting pipes as follows:
1.8 liter gasoline = dia. 18x20! 1.6 liter diesel = dia. 18x20! 2.0 liter diesel = dia. 20x20
1= Black (sw) rubber isolator (1.8 liter gasoline only)! 2= Black (sw) rubber isolator (1.6 and
2.0 liter diesel)! 3 = Black (sw) rubber isolator (2.0 liter diesel only)!
C
BA
D
1
2
3

Citroen C4 Picasso
1311842C_EN 19
Turn perforated bracket 2by approx. 75° in
longitudinal axis.
1M6x20 bolt, flanged nut
2Perforated bracket
3Rubber-coated pipe clamp Preparing
perforated
bracket
Slideonheatprotection hoses. Routecoolant
hoses Aand Dthrough original vehicle pass
through on radiator at left to heater unit.
When doing so, guide hose Athroughrubber-
coated p-clamp.
1Prepared perforated bracket
2Original vehicle bolt
Installing
coolant
hoses
Only loosely preassemble connecting point
from hose Aand B(hose clamps will be
tightened later).
Coolant
connection
on heater
unit
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 Picasso
1311842C_EN 20
Fasten perforated bracket on transmission
block.
1Prepared perforated bracket
2Original vehicle bolt Installing
perforated
bracket
1.8 liter gasoline
Route hose Aand Dthrough rubber-coated
p-clamps.
1Rubber-coated p-clamp [2x] Routing to
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 1onto hose D.
2Engine outlet hose section
3Hose 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
D
3
2A