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- Installation Documentation
Webasto thermo top evo Installation Documentation - 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 of approx. 20 min. (in one direction), we recommend not exceeding a switch-on time
of 20 min.
Passenger compartment monitoring, if installed, must be deactivated in addition to the vehicle settings
for the heating operation.
For instructions on deactivation, please refer to the operating instructions of the vehicle.
Before parking the vehicle, make the following settings:
1
Air outlet to windscreen
2
Set temperature to "max"
A/C control
panel
1
30A heater fuse F2
2
20A main fuse F1 of passenger compart-
ment
Fuses of
engine
compart-
ment
1
25A fuse F4 of heater control
2
1A fan fuse F3
Fuses of
passenger
compart-
ment
68
1
2
69
2
1
70
2
1
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...
Page 3
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...
Page 4
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...