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Webasto thermo top evo Installation Documentation

Other manuals for thermo top evo: Installation Documentation, Workshop Manual
Manual is about: petrol/diesel

Summary of thermo top evo

  • Page 1

    Water heater installation documentation citroen berlingo ident. No.: 1318865a_en status: 31.10.2012 © webasto thermo & comfort se validity manufacturer model type eg-be no./abe citroen berlingo 7 e2 * 2001 / 116 * 0366 * ... Motorisation fuel transmis- sion type output in kw displacement in cm³ engi...

  • Page 2

    Citroen berlingo the total installation time includes the time needed for mounting and demounting of the vehicle-specific components, the heater specific installation time and all other times required for the system integration and initial start-up of the heater. The total installation time may vary...

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    Citroen berlingo ident. No.: 1318865a_en status: 31.10.2012 © webasto thermo & comfort se 3 1 important information (not complete) 1.1 installation and repair the improper installation or repair of webasto heating and cooling sys- tems can cause fire or the leakage of deadly carbon monoxide, leading...

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    Special features are highlighted using the following symbols: you will find an identification mark on the outside top right corner of the page in question to provide you with a quick overview of the individual working steps. Citroen berlingo mechanical system electrical system coolant circuit combus...

  • Page 5

    Citroen berlingo ident. No.: 1318865a_en status: 31.10.2012 © webasto thermo & comfort se 5 preliminary work vehicle • open the fuel tank cap. • ventilate the fuel tank. • close the fuel tank cap again. • depressurise the cooling system. • disconnect and completely remove the battery with carrier. -...

  • Page 6

    Citroen berlingo ident. No.: 1318865a_en status: 31.10.2012 © webasto thermo & comfort se 6 preparing electrical system connect wires according to the following wir- ing diagram. Manual air-conditioning 1 fuse holder of passenger compartment red (rt) 4² wire of k1/87a black (sw) 4² wire of k1/30 pre...

  • Page 7

    Citroen berlingo ident. No.: 1318865a_en status: 31.10.2012 © webasto thermo & comfort se 7 connect wires to socket of k1 relay. Insert 25a fuse f4. K1 relay will only be inserted af- ter installation of fuse holder. Pull green/white (gn/ws) wire into protective sleeving. Preparing fuse holder of pa...

  • Page 8

    Citroen berlingo ident. No.: 1318865a_en status: 31.10.2012 © webasto thermo & comfort se 8 electrical system earth wire 1 earth wire on original vehicle earth support point positive wire 1 positive wire on positive distributor wiring har- ness rout- ing diagram fuse holder of engine compartment 1 5...

  • Page 9: Webasto

    Citroen berlingo ident. No.: 1318865a_en status: 31.10.2012 © webasto thermo & comfort se 9 fan controller for manual air-conditioning wiring dia- gram webasto components vehicle components colours and symbols legend hg tt-evo heater gm fan motor rt red x1 6-pin heater connector grs fan relay sw bla...

  • Page 10

    Citroen berlingo ident. No.: 1318865a_en status: 31.10.2012 © webasto thermo & comfort se 10 connect wiring harness of passenger com- partment fuse holder 2 to wiring harness of heater 1 according to wiring diagram, in such a way that the wires of the same colour are connected to each other. Connect...

  • Page 11

    Citroen berlingo ident. No.: 1318865a_en status: 31.10.2012 © webasto thermo & comfort se 11 connection on 6-pin connector a! Disconnect- ing connec- tor a connection on 6-pin connector a 2. Produce connections as shown in wiring diagram. 1 white (ws) wire of fan relay 3 white (ws) wire 6-pin connec...

  • Page 12: Webasto

    Citroen berlingo ident. No.: 1318865a_en status: 31.10.2012 © webasto thermo & comfort se 12 fan controller for automatic air-conditioning wiring dia- gram webasto components vehicle components colours and symbols legend hg tt-evo heater kb a/c control unit rt red x1 6-pin heater connector gr fan re...

  • Page 13

    Citroen berlingo ident. No.: 1318865a_en status: 31.10.2012 © webasto thermo & comfort se 13 connect wiring harness of passenger com- partment fuse holder 2 to wiring harness of heater 1 according to wiring diagram, in such a way that the wires of the same colour are connected to each other. Connect...

  • Page 14

    Citroen berlingo ident. No.: 1318865a_en status: 31.10.2012 © webasto thermo & comfort se 14 the fan controller is controlled on 2-pin connector a 2 of fan module. Produce connections as shown in wiring dia- gram. 1 yellow/grey (ge/gr) wire of a/c control panel 3 yellow/grey (ge/gr) wire of connecto...

  • Page 15

    Citroen berlingo ident. No.: 1318865a_en status: 31.10.2012 © webasto thermo & comfort se 15 digital timer 1 digital timer installing digital tim- er remote option (telestart) fasten receiver 1 with double-sided adhesive tape. Installing receiver 1 antenna installing antenna temperature sensor for h...

  • Page 16

    Citroen berlingo ident. No.: 1318865a_en status: 31.10.2012 © webasto thermo & comfort se 16 preparing installation location 1 perforated bracket twisting perforated bracket in longitudi- nal axis insert one 5mm shim 2 each between retain- ing plate 1 and bracket 3 at position 4 and 6. 4 m6x16 bolt,...

  • Page 17

    Citroen berlingo ident. No.: 1318865a_en status: 31.10.2012 © webasto thermo & comfort se 17 remove retaining plate with bracket. 1 7 mm dia. Hole hole in frame side member 1 9.1 mm dia. Hole; rivet nut [2x each] installing rivet nut cut out tab at position 2. 1 bracket of air intake pipe 3 12 mm di...

  • Page 18

    Citroen berlingo ident. No.: 1318865a_en status: 31.10.2012 © webasto thermo & comfort se 18 1 bracket of air intake pipe 2 original vehicle bolt installing bracket of air intake pipe insert one 20 mm shim each between bracket 1 and frame side member at position 2. 2 m6x35 bolt, spring lockwasher, 2...

  • Page 19

    Citroen berlingo ident. No.: 1318865a_en status: 31.10.2012 © webasto thermo & comfort se 19 discard section x. Hose a = 180°, 18mm dia. Moulded hose b = 440 c = 60 d = 60 e = 60 f = 100 g = 550 cutting hoses to length push braided protection hoses onto hose b and g and cut to length. Cut heat shrin...

  • Page 20

    Citroen berlingo ident. No.: 1318865a_en status: 31.10.2012 © webasto thermo & comfort se 20 1 combustion air pipe 2 90° moulded hose, 10 mm dia. Clamp [2x] 3 fuel line premount- ing heater images show vehicle with egs 6. 1 tighten 5x13 self-tapping bolt [2x] installing heater 1 tighten 5x13 self-ta...

  • Page 21

    Citroen berlingo ident. No.: 1318865a_en status: 31.10.2012 © webasto thermo & comfort se 21 combustion air 1 combustion air pipe 2 cable tie [2x each] 3 silencer 4 abs bracket installing silencer 41 3 4 2 2 1.

  • Page 22

    Citroen berlingo ident. No.: 1318865a_en status: 31.10.2012 © webasto thermo & comfort se 22 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 ...

  • Page 23

    Citroen berlingo ident. No.: 1318865a_en status: 31.10.2012 © webasto thermo & comfort se 23 1 perforated bracket 2 drill 9 mm dia. Hole preparing perforated bracket 1 original vehicle bolt 2 perforated bracket 3 insert m6x25 bolt installing perforated bracket 1 flanged nut 2 metering pump 3 mountin...

  • Page 24

    Citroen berlingo ident. No.: 1318865a_en status: 31.10.2012 © webasto thermo & comfort se 24 cut off fuel supply line 4 at position 3. 1 fuel line 2 90° moulded hose, 10 mm dia. Clamp [2x] 3 8x5x8 fuel standpipe, 10mm dia. Clamp [2x] fuel ex- traction check the position of the components; adjust if ...

  • Page 25

    Citroen berlingo ident. No.: 1318865a_en status: 31.10.2012 © webasto thermo & comfort se 25 coolant circuit warning! Any coolant running off should be collected in an appropriate container. Route hoses so that they are kink-free. Unless specified otherwise, always fasten using cable ties. Position ...

  • Page 26

    Citroen berlingo ident. No.: 1318865a_en status: 31.10.2012 © webasto thermo & comfort se 26 1 circulating pump mounting 2 circulating pump 3 wiring harness of circulating pump premount- ing circu- lating pump 1 m6x25 bolt, flanged nut 2 perforated bracket 3 circulating pump mounting mounting circul...

  • Page 27

    Citroen berlingo ident. No.: 1318865a_en status: 31.10.2012 © webasto thermo & comfort se 27 routing in engine compart- ment cut off hose on engine outlet/heat exchanger inlet at marking. 1 engine outlet hose section 2 hose section of heat exchanger inlet cutting point 1 slide on black (sw) rubber i...

  • Page 28

    Citroen berlingo ident. No.: 1318865a_en status: 31.10.2012 © webasto thermo & comfort se 28 1 hose of engine outlet connect- ing engine outlet 1 slide on black (sw) rubber isolator and align connect- ing circu- lating pump align hoses. Ensure sufficient distance from neighbouring components. 1 hose...

  • Page 29

    Citroen berlingo ident. No.: 1318865a_en status: 31.10.2012 © webasto thermo & comfort se 29 exhaust gas discard section x. 1 exhaust pipe a = 160 2 exhaust end section b =100 preparing exhaust pipe twist perforated bracket 1 by 90° in the longi- tudinal axis and angle down. Preparing perforated bra...

  • Page 30

    Citroen berlingo ident. No.: 1318865a_en status: 31.10.2012 © webasto thermo & comfort se 30 1 silencer 2 perforated bracket 3 m6x16 bolt, spring lockwasher premount- ing silencer 1 perforated bracket 2 m6x20 bolt, flanged nut installing silencer 1 exhaust pipe 2 hose clamp [2x] installing exhaust p...

  • Page 31

    Citroen berlingo webasto thermo & comfort se postfach 1410 82199 gilching germany internet: www.Webasto.Com technical extranet: http://dealers.Webasto.Com ident. No.: 1318865a_en status: 31.10.2012 © webasto thermo & comfort se 31 final work warning! Mount removed parts in reverse order. Check all h...

  • Page 32

    Citroen berlingo operating instructions for manual air-conditioning please remove this page in case of manual air-conditioning and add it to the vehicle operating instructions. Note: we recommend matching the heating time to the driving time. Heating time = driving time example: for a driving time o...

  • Page 33

    Citroen berlingo operating instructions automatic air-conditioning please remove this page in case of automatic air-conditioning and add it to the vehicle operating instructions. Note: we recommend matching the heating time to the driving time. Heating time = driving time example: for a driving time...