Water Heater Unit
e1
Thermo Top V Additional Heater
00 0018
Installation Instructions
Citroen C5 / Peugeot 407
2.7 HDI from Model Year 2008
Left-hand drive vehicle
Automatic air-conditioning
Automatic transmission
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, 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.
Ident. No.:1314450A_EN Fee Euro 10.00
© Webasto AG
Table of Contents
Heater Unit/Installation Kit
General Instructions
Special Tools
Explanatory Notes on Document
Preliminary Work
Heater unit installation location
Preparing electrical system
Electrical system
Citroen C5 / Peugeot 407
3
5
6
7
3
3
4
5
Heater controls
Remote option (Telestart)
Preparing installation location
Installing heater unit
Final Work
Template for Fuel Standpipe
8
10
11
11
13
13
19
20
Validity
Manufacturer
Citroen
Manufacturer
Peugeot
Model
C5
Model
407
Type
R....
Type
6
EG-BE No./ABE
e2 * 2001/116 * 0360 *...
EG-BE No./ABE
e2 * 2001/116 * 0328 * ...
Engine type
UHZ
Engine model
Diesel
Output in kW
150
Displacement in cm³
2720
Vehicle and engine types, equipment variants and national specifications not listed in these installation instructions have not been tested. However, installation according to these installation instructions may be possible.
The installation location of the digital timer should be confirmed with the end customer before installation.
1314450A_EN
2
Citroen C5 / Peugeot 407
Heater Unit/Installation Kit
Quantity Description
1 Delivery Scope of Citroen C5 / Peugeot 407 Diesel
Automatic Transmission
Optional heater control either:
Quantity Description
1
1
1
1
Digital timer
Telestart T91
Telestart T100 HTM
Y-adapter (with combination of digital timer and Telestart)
Order No.:
1313878B
Order No.:
See price list
See price list
See price list
9001505A
Foreword
These installation instructions apply to Citroen C5 / Peugeot 407 2.7 HDI vehicles - for validity, see page 2 - from model year 2008 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, where this is the case the stipulations in the "installation instructions" and "operating and maintenance instructions" for the Thermo Top V should 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
1314450A_EN
3
Citroen C5 / Peugeot 407
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.
Mechanical system
Electrical system
Water
Fuel
Exhaust gas
Combustion air
Special features are highlighted using the following symbols:
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.
The arrow in the vehicle icon indicates the position on the vehicle and the viewing
angle.
All dimensions are in mm!
Tightening torque of hose clamps = 2.0 + 0.5 Nm!
Tightening torque of Ejot screws, Ejot studs = 10 Nm!
1314450A_EN
4
Citroen C5 / Peugeot 407
Preliminary Work
WARNING!
- Open fuel tank cap, ventilate tank.
- Close the tank cap again.
- 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.
- Remove the left-hand wheel well trim.
- Remove the left front wheel.
- Remove the front underride protection.
- Remove the right rear underride protection.
- Fold over the right-hand rear seat
- Open the right-hand fuel sender service lid.
- Remove the instrument panel trim on the driver's side (only with Telestart).
- Remove the footwell trim on the driver's side.
- Remove the driver's side storage compartment.
1314450A_EN
1
1
Heater unit installation location
1 Heater unit
Installation location
5
6
3
5
1
1
4
2
Citroen C5 / Peugeot 407
3
Preparing electrical system
Cut off black (sw) wire 5 (0.75 mm²) from wiring harness of heater unit. Cut off red/white
(rt/ws) wire 6 (4 mm²) of fuse F3. Remove insulation from ground wires to node point and cut off brown (br) wire 4 (0.75 mm²) from wiring harness of digital timer.
Remove red/white (rt/ws) wire 1 (4 mm²) from
K3/87, red (rt) wire 3 (4 mm²) from K3/87a and black (sw) wire 2 (4 mm²) from K3/30.
Preparing fuse F3 and K3 relay
2
2
Insulate and tie back ends of red/white (rt/ws) wire 3 and black (sw) wire 2. Insulate ground wires 1.
Insert brown (br) wire 2 (0.75 mm²) from wiring harness of heater controls in K3/30.
Also connect black (sw) wire 1 to K3/85 and to K3/87.
Preparing
K3 relay
1
3
1
2
2
1
3
Strip insulation from approx. 50 mm of wiring harness of digital timer 3. Crimp microtimer 1 onto brown (br) wire (0.75 mm²). Insert yellow
(ge) wire 2 in free socket of digital timer connector.
Preparing wiring harness of digital timer
1
4
Illustration shows Citroen C5!
Connect positive wire 1 to positive terminal and ground wire 2 to original vehicle ground support point.
Positive and ground connection
5
1314450A_EN
6
Citroen C5 / Peugeot 407
Electrical system
Fuse holder, K3 relay on Citroen C5
1 Original vehicle bolt
2 Angle bracket
3 M5x16 bolt, retaining plate for fuse holder, large diameter washer, flanged nut
4 K3 relay
1 2
Fuse holder, K3 relay on Peugeot 407
1 K3 relay
2 Angle bracket
3 Original vehicle bolt
4 M5x16 bolt, retaining plate for fuse holder, large diameter washer, flanged nut
1 2
3
4
3
6
4
7
Do not install the metering pump cable harness until later together with fuel pipe in the corrugated tube along the original vehicle line on the underbody
Wiring harness installation diagram
1 1
1
2
Wiring harness routing
8
Fasten wiring harness of digital timer 2 in wheel well with adhesive base 3 and cable tie [total of
4x each].
1314450A_EN
3 2
9
Wiring harness pass through of passenger compartment
1 Drill out existing protective rubber plug
2 Wiring harness of digital timer
3 Adhesive base, cable tie
7
Citroen C5 / Peugeot 407
Fan controller
Webasto
HG
F3 rt/ ws
!
1 gn/ws
0,5²
86 87 87a
85 30
K3 sw br
0,75²
2
Citroen / Peugeot
30
15
Wiring diagram
BSI
6
St A br
0,75² br
31
Webasto components Vehicle components
Colors and symbols
HG
VWU
Tele
F3
1
2
Heater unit TT-C/E
Digital timer
Telestart
Fuse removed
Wiring harness of heater unit
Wiring harness of digital timer
BSI Central electrical box for passenger compartment gn ws
St A 20-pin connector BSI rt br sw green white red brown black
Mount yellow (ge) wire in free socket of 4-pin connector of heater-unit wiring harness.
Insulate wire ends and tie back
Legend
Cable and connector colors may vary!
1314450A_EN
8
3
1
1 2
3
1
Citroen C5 / Peugeot 407
1
View of BSI.
1
Socket for 2-piece connector. 40-pin
Detaching
BSI and routing downward
10
Press in locking lug
1
and fold down bar
2
.
3
2-piece connector
Pulling connector off BSI and removing
11
Connection on 20-pin connector
1
from BSI
(connector color may vary)!
Insert microtimer from brown (br) wire
3
in
PIN 6. Route wiring harness of digital timer
2
upward to installation location of digital timer.
Produce connections as shown in wiring diagram.
Connection of BSI
2
12
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9
Citroen C5 / Peugeot 407
Heater controls
Digital timer only
9001810F
Heater unit
Diagram for digital timer
digital timer
2
2 5
1
Telestart T91
Modify wiring harness from remote control set
T91 as follows:
Remove violet (vi) wire
2
from socket
5
and insert in socket
2
.
1
6-pin connector
Preparing connector of Telestart receiver for
T91
2 5
13
1
Telestart T100 HTM
Modify wiring harness from remote control set
T100 as follows:
Disconnect yellow (ge) wire
2
from socket
2
.
Remove violet (vi) wire
3
from socket
5
and connect to yellow (ge) wire
2
. Discard microtimer of violet (vi) wire
3
.
1
6-pin connector
Preparing connector of Telestart receiver for
T100 HTM
9001505A
3 2 digital timer
14
9001810F
Heater unit
Switch-on display for Telestart in digital timer:
"Tele On"!
Y-adapter with T91 = 67089A
Y-adapter with HTM 100 = 9010951A
Diagram for digital timer with
Telestart
Temperature sensor only with HTM 100
Telestart
1314450A_EN
10
1314450A_EN
1
1
1
2
1
Citroen C5 / Peugeot 407
Digital timer option
Citroen C5
1
Digital timer
Installing digital timer
15
Peugeot 407
1
Digital timer
Installing digital timer
16
Remote option (Telestart)
Citroen C5
Mount connector (6-pin) from adapter wiring harness on receiver
2
.
1
Double-sided adhesive tape
Installing receiver
17
2
Peugeot 407
Mount connector (6-pin) from adapter wiring harness on receiver
2
.
1
Double-sided adhesive tape
Installing receiver
18
11
1
19
Citroen C5 / Peugeot 407
All vehicles
1
Antenna
Installing antenna
1314450A_EN
12
1
1
5
2
1
1
Citroen C5 / Peugeot 407
Preparing installation location
Move connector from position
2
(if present) to position
3
.
1
2
Fastening point for heater unit (existing hole)
Fastening point for heater unit (existing hole)
Repositioning connector
2
20
3
Loosen bolt at position
2
(fastening point for heater unit).
1
100 mm edge protection
Installing edge protection
21
4
Installing heater unit
Mount stud bolts from bracket in existing holes.
1
Large diameter washer, flanged nut
[2x each], stud bolt
Installing heater unit
1 2 3
22
1
2
3
Mount wiring harness of heater unit
Bracket of heater unit
Original vehicle bolt
Installing bracket
23
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Citroen C5 / Peugeot 407
Coolant
WARNING!
Any coolant running off should be collected using an appropriate container. Install coolant hoses kinkfree. 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 spring clips without a specific designation
All connecting pipes = 18x20 mm dia.
= 27 mm dia.
1314450A_EN
Ø 25
A
B
Ø 25
14
B
45
X
1
A
135
X
Citroen C5 / Peugeot 407
Shorten hose
A
= straight end
Shorten hose
B
=180° elbow
Discard section
X
Cutting coolant hoses to length
1
2
Hose section of heat exchanger inlet
Engine outlet hose section
Cutting point
1
1
2 b
24
Connect hose
B
with long leg to heater unit outlet.
1
Hose on heat exchanger inlet
Connecting heat exchanger inlet
25
Connect hose
A
on circulating pump inlet.
1
Hose of engine outlet
Connecting engine outlet
1314450A_EN a 1
26
15
Citroen C5 / Peugeot 407
Fuel
CAUTION!
Open the vehicle's fuel tank cap, ventilate the tank and then re-close the tank lock.
Catch any fuel running off with an appropriate container.
Install fuel line and metering-pump wiring harness so that they are protected against stone impact. Unless 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 in as shown in the wiring harness routing diagram.
1
400
2
3
Preparing corrugated tube
4
1
27
Cut approx. 400 mm off first corrugated tube.
1
2
Fuel line in corrugated tube
1
10 mm dia. Caillau clamp, 90° molded hose
Connecting heater unit
2
1
28
1
2
3
Metering pump wiring harness
Fuel line in corrugated tube
1
Fuel line, wiring harness of metering pump in corrugated tube
2
Routing line
3
2
29
1314450A_EN
16
1
Citroen C5 / Peugeot 407
1
Fuel line, wiring harness of metering pump in corrugated tube
3
Installing lines
1
1 2
2
30
Remove original vehicle nut at position
1
and discard.
2
Large diameter washer, 30 mm spacer nut
Installing metering pump
31
1
2
3
Metering pump
Bracket of metering pump
M6x20 bolt, spring lockwasher, large diameter washer
Installing metering pump
1314450A_EN
1 2 2
3
3
32
1
2
3
4
Fuel line in corrugated tube
4
Hose section [2x], 10 mm dia. Caillau clamp [4x]
Fuel line, wiring harness of metering pump in corrugated tube
3
Wiring harness of metering pump, connector mounted
Connecting metering pump
4
33
17
1
1
3
2
Citroen C5 / Peugeot 407
Remove fuel-tank sending unit
1
in accordance with manufacturer's specifications.
2
3
Copy hole pattern, 6 mm dia. hole
5 mm dia. large diameter washer
Removing fuel
34
Shape fuel standpipe
1
according to template, cut to length and install.
Installing fuel standpipe
1 2
35
Check the position of the components; adjust if necessary. Check that they have free clearance.
Install fuel-tank sending unit according to manufacturer's specifications.
1
2
Hose section, 10 mm dia. Caillau clamp
[2x]
Fuel line
Connecting fuel line
36
1314450A_EN
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Citroen C5 / Peugeot 407
Final Work
WARNING!
Reassemble the disassembled components in reverse order.
Check all hoses, clamps and all electrical connections for firm seating.
Secure all loose cables using cable ties.
Only use manufacturer-approved coolant.
Spray heater unit components with anti-corrosion wax (Tectyl 100K, Order No. 111329).
- Connect the battery.
- Fill and bleed the coolant circuit according to the vehicle manufacturer’s specifications.
- Set the digital timer.
- Code the BSI for the additional heater in accordance with the manufacturer's instructions.
- Check the proper operation of the additional heater, see the operating instructions/installation instructions.
- Attach the "Switch off additional heater before refueling" sticker to the left-hand B-pillar.
1
1
2
Underride protection
Cut out exhaust outlet along perforation
Cutting out underride protection
2
2
37
Align underride protection
1
(exhaust end section centered in cut-out).
2
Exhaust end section
Mounting underride protection
1
38
1314450A_EN
Feel the drive
Webasto AG
Postfach 80 - 82132 Stockdorf
Hotline 01805 / 932278 - Hotfax 0395 / 5592-353 http://www.webasto.de
Printed in Germany 02/2009 Printing: Steffen
Template for Fuel Standpipe
Citroen C5 / Peugeot 407
100 mm
Scale 1:1
Compare the size of the printed version with dimension lines.
Permitted tolerance a maximum of 2%.
Set the printer settings to “no margin” or “minimize margins” and 100% of the normal size.
100 mm
0
1314450A_EN
20
