32
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

Installation Instructions Citroen C4 Picassoавтоотопитель.рф/manual/Citroen/C4-DS4-Aircross/2006... · Citroen C4 Picasso 1311842C_EN 2 Table of Contents Validity Vehicle

Embed Size (px)

Citation preview

Page 1: Installation Instructions Citroen C4 Picassoавтоотопитель.рф/manual/Citroen/C4-DS4-Aircross/2006... · Citroen C4 Picasso 1311842C_EN 2 Table of Contents Validity Vehicle

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 PicassoGasoline and Dieselfrom Model Year 2006Left-hand drive vehicle

Feel the drive

Thermo Top E Additional Heatere1

00 0003

Thermo Top C Additional Heatere1

00 0002

Thermo Top P Additional Heatere1

00 0104

Page 2: Installation Instructions Citroen C4 Picassoавтоотопитель.рф/manual/Citroen/C4-DS4-Aircross/2006... · Citroen C4 Picasso 1311842C_EN 2 Table of Contents Validity Vehicle

Citroen C4 Picasso

Table of Contents

Validity

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 a digital timer and summer/winter switch should be confirmed with the end customer before installation.

Manufacturer Model Type EG-BE No./ABECitroen C4 Picasso U e2 * 2001 / 116 * 0345

Engine type Engine model Output in kW Displacement in cm³6FY Gasoline 92 17499 Hz Diesel 80 1560RHJ Diesel 100 1997

Validity 2Heater Unit/Installation Kit 3Foreword 3General Instructions 3Special Tools 3Explanatory Notes on Document 4Preliminary Work 5Heater unit installation location 5Preparing electrical system 6Electrical system 7Fan controller for manual air conditioning 8Automatic air-conditioning fan controller 9Digital timer, summer/winter switch option 12

Remote option (Telestart) 12Preparing heater unit 13Preparing installation location 14Installing heater unit 16Water 18Fuel 24Gasoline 24Diesel 26Combustion air 28Exhaust gas 29Final Work 30Operating Instructions for End Customer 31Template for Gasoline Fuel Standpipe 32

1311842C_EN 2

Page 3: Installation Instructions Citroen C4 Picassoавтоотопитель.рф/manual/Citroen/C4-DS4-Aircross/2006... · Citroen C4 Picasso 1311842C_EN 2 Table of Contents Validity Vehicle

Citroen C4 Picasso

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!

ForewordThese 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, the stipulations in the "installation instructions" and "operating and maintenance instructions" 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 InstructionsInstallation 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 list1 Installation kit for Citroen C4 Picasso Gasoline 1311819B

or1 Installation kit for Citroen C4 Picasso Diesel 1311846B

Vehicle Heater unitCompact car Thermo Top EMid-size car, station wagon Thermo Top CFull-size car, van, offroader Thermo Top P

1311842C_EN 3

Page 4: Installation Instructions Citroen C4 Picassoавтоотопитель.рф/manual/Citroen/C4-DS4-Aircross/2006... · Citroen C4 Picasso 1311842C_EN 2 Table of Contents Validity Vehicle

Citroen C4 Picasso

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.

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

Page 5: Installation Instructions Citroen C4 Picassoавтоотопитель.рф/manual/Citroen/C4-DS4-Aircross/2006... · Citroen C4 Picasso 1311842C_EN 2 Table of Contents Validity Vehicle

Citroen C4 Picasso

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.

Installation location

Heater unit installation location

1 Heater unit

11

1311842C_EN 5

Page 6: Installation Instructions Citroen C4 Picassoавтоотопитель.рф/manual/Citroen/C4-DS4-Aircross/2006... · Citroen C4 Picasso 1311842C_EN 2 Table of Contents Validity Vehicle

Citroen C4 Picasso

Cutting wires to length

Preparing K3 relay

Preassem-bling IPCU

Preparing additional relay K3.1

Preparing electrical system

Wires 6 to 9 only with automatic air-conditioning

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.

Connect wires to IPCU (IPCU view on contact side).Pull wire 5 into the protective sleeving provided and route to OBD socket outlet.Wire 8 only with automatic air-conditioning

Automatic air-conditioning

Produce connections as shown in wiring diagram.

1 gn/ws 30000,5²

40,75²

rt 500

5 0,75²rt 2000

3 0,75²sw 500

20,75²

br 500

6 0,75²sw 500

70,75²

rt 500 80,75²

rt 500

90,75²

br 500

86

85 30

87a87

K3

1

3

4

2

A1586 85

E86 85

A

E

15

IPCU

5

8

86

85 30

87a87

K3.1

7

9 6

1311842C_EN 6

Page 7: Installation Instructions Citroen C4 Picassoавтоотопитель.рф/manual/Citroen/C4-DS4-Aircross/2006... · Citroen C4 Picasso 1311842C_EN 2 Table of Contents Validity Vehicle

Citroen C4 Picasso

Wiring harness installation diagram

Electrical system

Connecting positive wire

Before installing, crimp 8 mm dia. cable lug onto positive wire.

1 Red (rt) wire2 Original 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 2 and route into passenger compartment.

Fuse holder, relay K3

1 Retaining plate for fuse holder2 4 mm dia. hole, 5.5x13 self-tapping screw;

plastic nut [2x each]3 K3 relay4 Fuse holder

Connecting ground wire

1 Brown (br) wire2 Original vehicle ground support point

2

1

2

3

1

2

Do not install the metering pump cable harness until later together with fuel pipe along the original vehicle fuel lines on the underbody

44

21 2

3

5

2

1

1311842C_EN 7

Page 8: Installation Instructions Citroen C4 Picassoавтоотопитель.рф/manual/Citroen/C4-DS4-Aircross/2006... · Citroen C4 Picasso 1311842C_EN 2 Table of Contents Validity Vehicle

Citroen C4 Picasso

Wiring diagram

Legend

Fan controller for manual air conditioning

Webasto components Vehicle components Colors and symbolsHG Heater unit TT-C/E 8021 Air-conditioning control unit rt redX1 6-pin heater unit connector 8071 Air distribution ws whiteF3 25 A fuse 8048 Fan relay sw blackK3 Fan relay 8045 Fan module br brownIPCU Pulse width modulator 2V NR 2-pin connector gn greenY Wiring adapter 4V NR 4-pin connector bl blue

26V JN 26-pin connector or orangeMF6 Fuse gr gray

IPCU adjustment values: Press out wire end, insulate and tie backDuty cycle: 42 %

Frequency: 1000 HzVoltage: 5 V X Cutting pointFunction: High-side Wiring colors may vary.

gn/ws

sw

rt/ws

Webasto

31

3015

Citroen

rtor

or

br

rt

sw

gn/ws

MF6F3

rt

sw/ws

gr/br ws/rt

1

2

4

86

85 30

87a87

K3

3

! Y

rt4²

rt 6²

rt 6²

0,75²

0,75²

0,5²

0,5²

HGX1 4

2V NR 2 1

8045 M

2V NR12

19 20

8021

26V JN

86 85

E

A

15

IPCU

8048

br

5

gr/br

0,75²

0,5²

1311842C_EN 8

Page 9: Installation Instructions Citroen C4 Picassoавтоотопитель.рф/manual/Citroen/C4-DS4-Aircross/2006... · Citroen C4 Picasso 1311842C_EN 2 Table of Contents Validity Vehicle

Citroen C4 Picasso

Wiring diagram

Legend

Automatic air-conditioning fan controller

Webasto components Vehicle components Colors and symbolsHG Heater unit TT-C/E 8080 Air-conditioning control unit rt redX1 6-pin heater unit connector 8071 Air distribution ws whiteF3 25 A fuse 8048 Fan relay sw blackK3 Fan relay 8045 Fan module br brownIPCU Pulse width modulator 2V NR 2-pin connector gn greenY Wiring adapter 4V NR 4-pin connector bl blueK3.1 Additional relay 26V JN 26-pin connector ge yellow

MF6 Fuse gr grayor orange

IPCU adjustment values: Press out wire end, insulate and tie backDuty cycle: 42 %

Frequency: 1000 HzVoltage: 5 V X Cutting pointFunction: High-side Wiring colors may vary.

gn/ws

sw

rt/ws

Webasto

31

3015

Citroen

rtor

or

br

rt

sw

gn/ws

MF6F3

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

rt4²

rt 6²

rt 6²

0,75²

0,75²

0,5²

0,5²

HGX1 4

2V NR 2 1

8045 M

2V NR12

rt/gr

0,5²

10 4

8080

26V JN8

MMMM

4V NR4

86 85

E

A

15

IPCU

8048

8

br 8071

rt

5

0,75²

0,75²

0,75²

0,75²

0,5²

rt/gr

1311842C_EN 9

Page 10: Installation Instructions Citroen C4 Picassoавтоотопитель.рф/manual/Citroen/C4-DS4-Aircross/2006... · Citroen C4 Picasso 1311842C_EN 2 Table of Contents Validity Vehicle

Citroen C4 Picasso

Connec-tion to fan module

Installing socket from IPCU

Power supply of IPCU

Connect-ing fan controller

Fan controller on all vehicles

Fan motor is controlled on 2-pin connector 2 of fan module.Produce connections as shown in wiring diagram.

1 Orange (or) wire connector 2V NR, Pin 23 Orange (or) wire of fan relay 80484 Y-adapter5 Black (sw) wire from K3/30

Before installing, connect green/white (gn/ws) wire 4 from K3/86 to socket of IPCU terminal 86.

1 IPCU2 Double-sided adhesive tape

Control changeover of IPCU is carried out on 16-pin OBD socket outlet 3.Produce connections as shown in wiring diagram.

1 Red (rt) wire IPCU/152 Socket of OBD socket outlet3 Pink (pk) wire (terminal 15)5 Pink (pk) wire of 16-pin OBD socket outlet,

Pin 1

Fan controller is controlled before 2-pin connector from fan module.Brown (br) wire of IPCU/85 1 with 6 mm dia. cable lug on original vehicle bolt.Produce connections as shown in wiring diagram.

1 Black (sw) wire of IPCU/A3 Yellow/gray (ge/gr) (gray/brown (gr/br))

wire of connector 2V NR, Pin 24 Red (rt) wire of IPCU/E5 Yellow/gray (ge/gr) (gray/brown (gr/br))

wire of A/C control panel connector 26V JN

6

1

5

4

32

7

1

2

34

8

1

5

3

2

3

9

1

5

4

3

2

1311842C_EN 10

Page 11: Installation Instructions Citroen C4 Picassoавтоотопитель.рф/manual/Citroen/C4-DS4-Aircross/2006... · Citroen C4 Picasso 1311842C_EN 2 Table of Contents Validity Vehicle

Citroen C4 Picasso

Installing K3.1 relay

Connec-tion to air distribu-tion

Also with automatic air-conditioning

Brown (br) wire 2 with 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.

1 Self-tapping screw on existing hole3 K3.1 relay

Control changeover of air distribution is carried out on 4-pin connector 4V NR 2 from flap motor 6.Produce connections as shown in wiring diagram.

1 Red (rt) wire to K3.1/873 Red/gray (rt/gr) wire of connector 8071 4V

NR, Pin 44 Black (sw) wire K3.1/305 Red/gray (rt/gr) wire of A/C control unit

10

1

2

3

4

11

1

4

3

5

2

6

1311842C_EN 11

Page 12: Installation Instructions Citroen C4 Picassoавтоотопитель.рф/manual/Citroen/C4-DS4-Aircross/2006... · Citroen C4 Picasso 1311842C_EN 2 Table of Contents Validity Vehicle

Citroen C4 Picasso

Installing digital timer

Installing receiver

Installing antenna

Installing tempera-ture sensor

Digital timer, summer/winter switch option

Installation location shown is a recommendation. Agree upon with final customer before installing.

1 Digital timer2 12 mm dia. hole, summer/winter switch

Remote option (Telestart)

1 Double-sided adhesive tape2 Receiver

1 Antenna

Temperature sensor for HTM100 only

1 Fasten temperature sensor with adhesive tape

1

2 12

1

2 13

1

14

1

15

1311842C_EN 12

Page 13: Installation Instructions Citroen C4 Picassoавтоотопитель.рф/manual/Citroen/C4-DS4-Aircross/2006... · Citroen C4 Picasso 1311842C_EN 2 Table of Contents Validity Vehicle

Citroen C4 Picasso

Cutting coolant hoses to length

Cutting coolant hoses to length

Preparing coolant hoses

Preparing exhaust pipe

Preparing heater unit

1.8 liter gasoline enginea = 1240 mm

1.6 liter diesel enginea = 1100 mm

2.0 liter diesel enginea = 1200 mm

Discard section X

1.8 liter gasoline engined = 1240 mm

1.6 liter diesel engined = 1180 mm

2.0 liter diesel engined = 1200 mm

Discard section X

Push braided protection hoses onto hose A and D and cut to length.Cut heat shrink plastic tubing to length and shrink to size.

1 25 mm long heat shrink plastic tubing [4x]

1 Exhaust pipea = 120

2 Exhaust end sectionb = 110

Discard section X

B

A X

C

D X

A

D

1 1

1 1

a b

1 2

X

1311842C_EN 13

Page 14: Installation Instructions Citroen C4 Picassoавтоотопитель.рф/manual/Citroen/C4-DS4-Aircross/2006... · Citroen C4 Picasso 1311842C_EN 2 Table of Contents Validity Vehicle

Citroen C4 Picasso

Preassem-bling bracket

Premount-ing coolant hoses

Premount-ing ex-haust system

Mounting rivet nut

Insert two washers at position 3 between bracket 2 and heater unit 1.

1 Ejot screw [2x]3 Ejot screw, washer [2x]

1 Hose clamp [4x]2 20x20 connecting pipe [2x]

1 Exhaust pipe2 Hose clamp [2x]3 Exhaust manifold

Preparing installation location

Copy hole pattern as shown.

1 Drill 9.1 mm dia. hole; install rivet nut

16

3

1

2

17

C

1

1

B

2

1

1

18

1

32 2

19

1

610 mm

1311842C_EN 14

Page 15: Installation Instructions Citroen C4 Picassoавтоотопитель.рф/manual/Citroen/C4-DS4-Aircross/2006... · Citroen C4 Picasso 1311842C_EN 2 Table of Contents Validity Vehicle

Citroen C4 Picasso

Mounting rivet nut

Holes for bracket in radiator cross member

Hole for exhaust muffler in radiator cross member

Cutting out partition wall

Copy hole pattern as shown.

1 Drill 9.1 mm dia. hole; install rivet nut

Square cut-out at position 2.

1 7 mm dia. hole [2x] (centered from bar)

Cut-out of oblong hole at position 2.

1 7 mm dia. hole (centered from bar)

Cut away partition wall 1 at markings.

2 Discard remaining piece

20

1610 mm

211

12

67 mm318 mm

221

30 mm

2

23

1

2

1311842C_EN 15

Page 16: Installation Instructions Citroen C4 Picassoавтоотопитель.рф/manual/Citroen/C4-DS4-Aircross/2006... · Citroen C4 Picasso 1311842C_EN 2 Table of Contents Validity Vehicle

Citroen C4 Picasso

Cutting away edge on radiator cross member

Installing edge protection

Installing edge protection

Installing heater unit

2.0 liter gasoline engine only

Cut away edge 1 at marking and discard.

Cut 5 consecutive 500 mm ends from edge protection provided and install.

1 Edge protection 502 Edge protection 703 Edge protection 1304 Edge protection 605 Edge protection 60

All vehicles except 2.0 liter gasoline engine

Cut 4 consecutive 500 mm ends from edge protection provided and install.

1 Edge protection 602 Edge protection 403 Edge protection 404 Edge protection 40

Installing heater unit

Install one shim 10 each at position 2 between bracket and radiator cross member.

1 Preassembled heater unit2 M6x25 bolt, flanged nut [2x each]

24

1

25

24

1

5

3

263

4

2

1

272

2

1

1311842C_EN 16

Page 17: Installation Instructions Citroen C4 Picassoавтоотопитель.рф/manual/Citroen/C4-DS4-Aircross/2006... · Citroen C4 Picasso 1311842C_EN 2 Table of Contents Validity Vehicle

Citroen C4 Picasso

Installing strut

Installing strut

Before installing wind deflector plate 3, mount wiring harness for heater unit 4.

1 Loosely mount M6x20 bolt, spring lockwasher and large diameter washer

2 Strut5 Loosely mount Ejot screw [2x]

Tighten all connections following installation.

1 M6x20 bolt, spring lockwasher, large diameter washer

2855

2

1

3

4

1

29

1311842C_EN 17

Page 18: Installation Instructions Citroen C4 Picassoавтоотопитель.рф/manual/Citroen/C4-DS4-Aircross/2006... · Citroen C4 Picasso 1311842C_EN 2 Table of Contents Validity Vehicle

Citroen C4 Picasso

Coolant routing diagram

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:

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. 20x201 = 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

1311842C_EN 18

Page 19: Installation Instructions Citroen C4 Picassoавтоотопитель.рф/manual/Citroen/C4-DS4-Aircross/2006... · Citroen C4 Picasso 1311842C_EN 2 Table of Contents Validity Vehicle

Citroen C4 Picasso

Preparing perforated bracket

Installing coolant hoses

Coolant connection on heater unit

Preparing perforated bracket

Turn perforated bracket 2 by approx. 75° in longitudinal axis.

1 M6x20 bolt, flanged nut2 Perforated bracket3 Rubber-coated pipe clamp

Slide on heat protection hoses. Route coolant hoses A and D through original vehicle pass through on radiator at left to heater unit. When doing so, guide hose A through rubber-coated p-clamp.

1 Prepared perforated bracket2 Original vehicle bolt

Only loosely preassemble connecting point from hose A and B (hose clamps will be tightened later).

Cut perforated bracket to approx. 58 mm.

1 Perforated bracket2 M6x20 bolt, flanged nut3 Rubber-coated p-clamp [2x]

30

21

3

C

31

D

A

1

2

C

32B

D

A

33

1

3

2

3

1311842C_EN 19

Page 20: Installation Instructions Citroen C4 Picassoавтоотопитель.рф/manual/Citroen/C4-DS4-Aircross/2006... · Citroen C4 Picasso 1311842C_EN 2 Table of Contents Validity Vehicle

Citroen C4 Picasso

Installing perforated bracket

Routing to cutting point

Cutting point

Connect-ing heat exchanger inlet and engine out-let

Fasten perforated bracket on transmission block.

1 Prepared perforated bracket2 Original vehicle bolt

1.8 liter gasoline

Route hose A and D through rubber-coated p-clamps.

1 Rubber-coated p-clamp [2x]

Disconnect hose from engine outlet to heat exchanger inlet with hose clamping pliers.

1 Engine-outlet hose section2 Hose section of heat exchanger inlet

Before installation, push black (sw) rubber isolator 1 onto hose D.

2 Engine outlet hose section3 Hose section of heat exchanger inlet

34

21

35

1 A

D 1

36

1

2

37

1

D

3

2A

1311842C_EN 20

Page 21: Installation Instructions Citroen C4 Picassoавтоотопитель.рф/manual/Citroen/C4-DS4-Aircross/2006... · Citroen C4 Picasso 1311842C_EN 2 Table of Contents Validity Vehicle

Citroen C4 Picasso

Routing in engine compart-ment

Position-ing hose A and D

Routing to cutting point

Cutting point

Fasten rubber isolator on hose A with cable tie.

1 Black (sw) rubber isolator

Align hoses and tighten hose clamps at connecting point of hose A and B on heater unit.Check the position of the components; adjust if necessary. Check that they have free clearance.

1.6 liter diesel

Route hose A and D through rubber-coated p-clamps.

1 Rubber-coated p-clamp [2x]

Disconnect hose from engine outlet to heat exchanger inlet with hose clamping pliers.

1 Engine-outlet hose section2 Hose section of heat exchanger inlet

381

A

D

39

D

A

40

1D

A 1

41

1

2

1311842C_EN 21

Page 22: Installation Instructions Citroen C4 Picassoавтоотопитель.рф/manual/Citroen/C4-DS4-Aircross/2006... · Citroen C4 Picasso 1311842C_EN 2 Table of Contents Validity Vehicle

Citroen C4 Picasso

Connect-ing heat exchanger inlet and engine out-let

Routing in engine compart-ment

Position-ing hose A and D

Cutting point

Before installation, push black (sw) rubber isolator 1 onto hose A.

2 Engine outlet hose section3 Hose section of heat exchanger inlet

Fasten black (sw) rubber isolator 1 on hole of transmission block with cable tie.

Align hoses and tighten hose clamps at connecting point of hose A and B on heater unit.Check the position of the components; adjust if necessary. Check that they have free clearance.

1 Edge protection 50

2.0 liter diesel

Remove braided protection hose in area of cutting point.

1 Engine-outlet hose section2 Hose section of heat exchanger inlet3 Edge protection 50

42

D

3

21

A

431

D

A

44

AD

1

45

1

23

1311842C_EN 22

Page 23: Installation Instructions Citroen C4 Picassoавтоотопитель.рф/manual/Citroen/C4-DS4-Aircross/2006... · Citroen C4 Picasso 1311842C_EN 2 Table of Contents Validity Vehicle

Citroen C4 Picasso

Connect-ing heat exchanger inlet and engine out-let

Position-ing hose A and D

Position-ing hose A and D

Before installing, push black (sw) rubber isolator 1 onto hose A and onto hose section of heat exchanger inlet 3.

2 Engine outlet hose section

Fasten black (sw) rubber isolator 1 on original vehicle wiring harness bracket with cable tie.

Align hoses and tighten hose clamps at connecting point of hose A and B.Check the position of the components; adjust if necessary. Check that they have free clearance.

1 Edge protection 50

46

D 3

1

1

A

2

471

D

A

48

A

1

D

1311842C_EN 23

Page 24: Installation Instructions Citroen C4 Picassoавтоотопитель.рф/manual/Citroen/C4-DS4-Aircross/2006... · Citroen C4 Picasso 1311842C_EN 2 Table of Contents Validity Vehicle

Citroen C4 Picasso

Connec-tion on heater unit

Installing lines

Installing lines

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.

Gasoline

1 Fuel line2 Hose section, 10 mm dia. clamp [2x]

1 Fuel line2 Edge protection 70

1 Metering pump wiring harness2 Fuel line from heater unit

49

1

2

501

2

1

51

1

2

1311842C_EN 24

Page 25: Installation Instructions Citroen C4 Picassoавтоотопитель.рф/manual/Citroen/C4-DS4-Aircross/2006... · Citroen C4 Picasso 1311842C_EN 2 Table of Contents Validity Vehicle

Citroen C4 Picasso

Removing fuel

Installing fuel standpipe

Connect-ing fuel line

Installing metering pump

Remove fuel tank and fuel-tank sending unit 1 according to manufacturer's information.

2 Large diameter washer3 Copy hole pattern, 6 mm dia. hole

Shape fuel standpipe 1 according to template, cut to length and install.

Install fuel-tank sending unit according to manufacturer's specifications.Install fuel tank in accordance with manufacturer's specifications.

1 Hose section, 10 mm dia. Caillau clamp [2x]

2 Fuel line

Ensure proper installation position of metering pump, see "Installation Instructions“.Installation location behind vehicle fuel tank!

1 Rubber-coated pipe clamp2 Silent block, flanged nut [2x]3 Angle bracket4 Original vehicle nut, washer

52

1

3

2

53

1

1

542

1

55

1 2

4

3

1311842C_EN 25

Page 26: Installation Instructions Citroen C4 Picassoавтоотопитель.рф/manual/Citroen/C4-DS4-Aircross/2006... · Citroen C4 Picasso 1311842C_EN 2 Table of Contents Validity Vehicle

Citroen C4 Picasso

Connect-ing meter-ing pump

Connec-tion on heater unit

Installing lines

Installing metering pump

Connect fuel line from heater unit 1 to pressure side and fuel line from fuel standpipe 3 to intake side of metering pump.

2 Wiring harness of metering pump, connector mounted

4 Hose section, 10 mm dia. clamps [2x]5 Hose section, 10 mm dia. clamps [2x]

Diesel

1 Fuel line2 Hose section, 10 mm dia. clamp [2x]

Route wiring harness of metering pump 1 together with fuel line 2 along original vehicle fuel lines to installation location of metering pump.

Ensure proper installation position of metering pump, see "Installation Instructions“.Installation location on vehicle fuel tank at side.

1 Original vehicle stud bolt; M8 flanged nut2 Angle bracket3 Rubber-coated p-clamp, silent block,

flanged nut [2x]

56

1 2

4

3

5

57

1

2

58

1

2

59

1 2

3

1311842C_EN 26

Page 27: Installation Instructions Citroen C4 Picassoавтоотопитель.рф/manual/Citroen/C4-DS4-Aircross/2006... · Citroen C4 Picasso 1311842C_EN 2 Table of Contents Validity Vehicle

Citroen C4 Picasso

Connect-ing meter-ing pump

Removing fuel

Connect fuel line from heater unit 1 on pressure side and fuel line to fuel standpipe 3 on intake side of metering pump.

2 Wiring harness of metering pump, connector mounted

4 Hose section, 10 mm dia. clamps [2x]5 Hose section, 10 mm dia. clamps [2x]

Fuel is removed from original vehicle fuel supply line 3.

1 Fuel line from metering pump2 Hose section, 10 mm dia. clamps [2x]4 8x5x8 fuel standpipe

60

1 2

5 4 3

61

1

4

2

3

1311842C_EN 27

Page 28: Installation Instructions Citroen C4 Picassoавтоотопитель.рф/manual/Citroen/C4-DS4-Aircross/2006... · Citroen C4 Picasso 1311842C_EN 2 Table of Contents Validity Vehicle

Citroen C4 Picasso

Cutting combus-tion air pipe to length

Hole for muffler

Installing combus-tion air pipe

Combustion air

1 Combustion air pipea = 250

Discard section X

Drill 6.2 mm dia. hole 1 in center of grid as shown.

Ensure proper installation position of air intake muffler, see "Installation Instructions“.Check the position of the components; adjust if necessary. Check that they have free clearance.

1 27 mm dia. hose clamp2 Retaining clip in hole3 Combustion-air intake muffler4 Combustion-air intake pipe

a

1

X

62

1

300 mm

63

1 2

4

3

1311842C_EN 28

Page 29: Installation Instructions Citroen C4 Picassoавтоотопитель.рф/manual/Citroen/C4-DS4-Aircross/2006... · Citroen C4 Picasso 1311842C_EN 2 Table of Contents Validity Vehicle

Citroen C4 Picasso

Installing exhaust system

Cutting out underride protection

Mounting underride protection

Exhaust gas

Following installation, bend muffler upward approx. 30°.

1 Muffler2 Hose clamp3 Exhaust pipe4 M6x20 bolt, spring lockwasher5 Perforated bracket6 M6x20 bolt, flanged nut

Lay on red (rt) rubber isolator at position 1, copy hole pattern and drill 42 mm dia. hole in underride protection.

Insert rubber isolator 3 in 42 mm dia. hole.Check the position of the components; adjust if necessary. Check that they have free clearance.

1 Exhaust end section2 Hose clamp

64

1

5 4

6

2 3

65

1

1

66

2

3

1311842C_EN 29

Page 30: Installation Instructions Citroen C4 Picassoавтоотопитель.рф/manual/Citroen/C4-DS4-Aircross/2006... · Citroen C4 Picasso 1311842C_EN 2 Table of Contents Validity Vehicle

Citroen C4 Picasso

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 the 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.- Make settings on A/C control panel according to the "Operating Instructions for End Customer".- 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.

Feel the driveWebasto AGPostfach 80 - 82132 StockdorfHotline 01805 / 932278 - Hotfax 0395 / 5592-353http://www.webasto.de

Printed in Germany 10/2007 Printing: Steffen

1311842C_EN

Page 31: Installation Instructions Citroen C4 Picassoавтоотопитель.рф/manual/Citroen/C4-DS4-Aircross/2006... · Citroen C4 Picasso 1311842C_EN 2 Table of Contents Validity Vehicle

Citroen C4 Picasso

Manual air condition-ing

Automatic air-condi-tioning

Operating Instructions for End Customer

Please remove page and add to the vehicle operating instructions.

Note:We recommend matching the heating time to the driving time.Heating time = driving timeExample:For a driving time of approx. 20 min. (in one direction), we recommend not exceeding a switch-on time of 20 min.

If the summer/winter switch option has been installed, this must be switched in accordance with the time of year. The heater unit will then only switch on the vehicle fan to ventilate the vehicle interior in the position Winter heat and in the position Summer .

Before shutting off the engine, make the following settings:

1 Air outlet to windshield

1 Air outlet to windshield

671

68

1

1311842C_EN 31

Page 32: Installation Instructions Citroen C4 Picassoавтоотопитель.рф/manual/Citroen/C4-DS4-Aircross/2006... · Citroen C4 Picasso 1311842C_EN 2 Table of Contents Validity Vehicle

Citroen C4 Picasso

Template for Gasoline Fuel Standpipe

1311842C_EN 320

100 mm

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.