Webasto Thermo Top C Manual de usuario

Water heater unit

Thermo Top C Additional heating

Thermo Top E Additional Heating

Legend for figure 1:

1 Thermo Top C, E – B/D Heater Unit

2 Blade-Type Fuse Holder and Blower Relay

3 Time switch

4 Exhaust silencer

5 Combustion air intake pipe

6 Metering pump

WARNING!

Hazard warning:

Incorrect installation or repair of Webasto heating and cooling 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 warning

instructions.

Webasto does not accept any liability for defects and damage that are attributable to an

installation by untrained staff.

00 0003

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Installation instructions

Peugeot 307

Peugeot 307 CC

Peugeot 307 SW / Break

Gasoline and diesel

For left-hand drive vehicles only

For validity, see page 2

Ident. no. 13 006 80EEN €10 fee © Webasto AG

4321

5 6

Thermo Top C, E Peugeot 307

Table of Contents

Validity

Manufacturer Model Type EG-BE no.

Peugeot 307 3*KFW e2*98/14*0242*..

Engine type Engine model Power in kW Engine capacity in cm3

KFW Otto (spark-ignition) 55 1360

Manufacturer Model Type EG-BE no.

Peugeot 307 3*NFU e2*98/14*0243*..

Engine type Engine model Power in kW Engine capacity in cm3

NFU Otto (spark-ignition) 80 1587

Manufacturer Model Type EG-BE no.

Peugeot 307 3*RFN e2*98/14*0244*..

Engine type Engine model Power in kW Engine capacity in cm3

RFN Otto (spark-ignition) 100 1997

Manufacturer Model Type EG-BE no.

Peugeot 307 3*RFK e2*2001/116*0290*..

Engine type Engine model Power in kW Engine capacity in cm3

RFK Otto (spark-ignition) 130 1997

Peugeot 307 1

Peugeot 307 SW / Break 1

Validity 2

Heater Unit / Installation Kit 4

Foreword 4

Special Tools 4

General Instructions 4

Heater Unit Installation Location 5

Cable harness assembly 6

Blower control 11

Time Switch and

Summer / winter switch option 13

Remote start option 14

Thermo Call TC1.1 option 15

Installing the Heater Unit 16

Connection to the water circuit 19

Preparing the water hoses 19

Water connection 26

Fuel connection 46

Exhaust System 49

Combustion air intake pipe 50

Final work 50

Operating instructions for the end customer 51

Peugeot 307 Thermo Top C, E

NOTE:

Vehicle types, engine types and equipmentvariants, which are not listed in these installation

instructions, have not been tested.

Installation according to these installation instructions may, however, be possible.

Manufacturer Model Type EG-BE no.

Peugeot 307 3*RHY e2*98/14*0245*..

Engine type Engine model Power in kW Engine capacity in cm3

RHY Diesel 66 1997

Manufacturer Model Type EG-BE no.

Peugeot 307 3*8HZ e2*98/14*0251*..

Engine type Engine model Power in kW Engine capacity in cm3

8HZ Diesel 50 1398

Manufacturer Model Type EG-BE no.

Peugeot 307 3*RHS e2*98/14*0252*..

Engine type Engine model Power in kW Engine capacity in cm3

RHS Diesel (FAP) 79 1997

Manufacturer Model Type EG-BE no.

Peugeot 307 3*RHR e2*2001/116*0290*..

Engine type Engine model Power in kW Engine capacity in cm3

RHR Diesel (FAP) 100 1997

Manufacturer Model Type EG-BE no.

Peugeot 307 3*9HZ e2*2001/116*0290*..

Engine type Engine model Power in kW Engine capacity in cm3

9 Hz Diesel (FAP) 80 1560

Thermo Top C, E Peugeot 307

Heater unit / Installation kit

Quantity Name Order No.

1 Water heater unit Thermo Top E - gasoline with scope of delivery 668 90C

1 Water heater unit Thermo Top E - diesel with scope of delivery 668 89C

1 Water heater unit Thermo Top Z/C - gasoline with scope of delivery 906 04D

1 Water heater unit Thermo Top Z/C - diesel with scope of delivery 892 44D

Also required:

1 Peugeot 307 installation kit Thermo Top C, E 13 006 77C

Also required for automatic air conditioning:

1 Peugeot 307/406 installation kit Thermo Top C, E 662 99A

Foreword

These installation instructions apply to Peugeot 307 / SW / Break gasoline and diesel vehicles - for validity, see

title page - from model year 2001 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 C should be observed.

The corresponding rules of technology and any information from the vehicle manufacturer should be

observed during the installation work.

Special tools

Vice-grip wrench

Torque spanner for 2.0 - 10 Nm

General instructions

- Cover unfinished body areas, such as drill holes, with corrosion protection.

- Secure hoses, wires, and cable harnesses with cable clips and cover with protective hoses at friction

locations.

- Fit sharp edges with edge protection (split open plastic hose).

Peugeot 307 Thermo Top C, E

Preliminary work

- Remove years that do not apply from the duplicate

label.

- Attach the duplicate label (type label) in the

appropriate location.

Engine Compartment

WARNING:

Disconnect the battery.

- Remove the batters and the bracket.

- Open the cooler cap, let off pressure.

- Close the cooler cap again.

- Remove the air filter housing

- Remove the cable holder.

Only for vehicles with diesel engines.

- Remove the engine cover.

Only for vehicles with 8 Hz engines.

- Remove the battery holder.

Vehicle Exterior

- Open the filler cover, release the pressure in the fuel

system, close the filler cover.

- Remove the front left wheel-house panel

- Remove the front bumper.

- Remove the underbody panel on the right in front of

the original vehicle tank.

Interior

- Remove the lower dashboard panel on the driver’s

side.

- Remove the A pillar and rocker panel strip in the foot

area on the driver's side.

- Lift up the rear seat bench.

- Remove the service cap on the tank mounting.

Heater unit installation location

The heater unit (1) is installed on the front right behind

the bumper according the to the figure.

This is installed vertically, with the exhaust outlet to

the left.

Thermo Top C, E Peugeot 307

Cable harness assembly

Pre-assembly for automatic air

conditioning

- Cut two a 300 mm section and two 100 mm sections

each from the enclosed brown 2.5 mm wire 2.

- Uncrimp the brown wire (3) from the K3 blower relay

(4) terminal 85.

- Connect the cut brown 2.5 mm wire 2that is 100 mm

long (2) and the brown wire (3) to the K3 blower

relay (4) terminal 85.

- Connect the free end of the brown 2.5 mm wire 2

that is 100 mm long (2) to the supplementary relay

K3.1 (1) terminal 85.

- Connect the cut brown 2.5 mm wire 2that is 300mm

long (9) to the supplementary relay K3.1 (1) terminal

87a.

- Connect the enclosed red 0.75mm wire 2that is

500mm long (5) to the supplementary relay K3.1 (1)

terminal 86.

- Connect the enclosed black wire (6) to the

supplementary relay K3.1 (1) terminal 30.

- Connect the remaining brown wire (8) to the

supplementary relay K3.1 (1) terminal 87.

- Pull the brown wire (8) and black wire (6) together

into the enclosed insulating hose (7).

Peugeot 307 Thermo Top C, E

GM Gebläsemotor

GR Gebläseregler

ST 02 Steckverbindung 6-polig

KB Klimasteuergerät

ST 03 Steckverbindung 18-polig

IT Innenraumtemperaturfühler

F18 Fzg.eigene Sicherung

ST 01 Steckverbindung 6-polig

ST 04 Stecker 16VGR im

Sicherungs-/ Relaisträger

Motorraum

ZS Zündschloß

R1 Festwiderstand 0,9 Ohm

restliche Bezeichnung Standard

gn/

Webasto Peugeot 307

rt/ws

F18

Pin 4

87a

85 30

K3.1

87a

85 30

sw rt

341 2

ST 02

ST 01 43

ST 04

ST 03

Blower control

For vehicles with automatic air conditioning

Thermo Top C, E Peugeot 307

Installation with automatic air

conditioning

The installation location is the fuse and relay box to

the left of the air filter.

NOTE:

Pay attention to the free movement of the housing

cover.

Remove any reinforcements in the relay box near the

fastening points for the blower relay and the fuse

holder.

WARNING:

When drilling, watch out for underlying components

and wires.

- Bore 3 holes of Ø 5.5 mm in the fuse and relay box.

- Fasten the fuses (1), K3 blower relay (2) and K3.1

supplementary relay (3) with 3 M5x12 bolts, 6

washers, and 3 M5 flanged nuts as shown.

- Connect according to illustration 4 in the circuit

diagram.

- Connect the positive wires (5) to the positive

terminal in the fuse and relay box.

- Separate the white wire (1,3) from the ignition as

shown in figure 9 about 50 mm before the connector

16VGR (4) pin 9.

- Crimp in the red wire (2) from the supplementary

relay K3.1 terminal 86, together with the white wire

(1) into the blade receptacles.

- Crimp the white wire (3) in the flat connector.

- Slide on the housing and connect the flat connector

and the blade receptacles.

WARNING:

This resistor will be hot!

Ensure sufficient distance from adjacent components.

- Run the grounding line from the heater unit (2) and

the brown wire 2.5 mm 2(4) from the relay K3.1/87a

to the original vehicle grounding point (1).

- Fasten the grounding line from the heater unit (2)

and the cut 100mm brown wire (6) with 6 mm cable

socket together with the bracket (3) to the original

vehicle grounding point (1).

- Secure the resistor (5) with the bolt M5x20, washer

and nut to the bracket (3).

- Connect the brown 2.5 mm2wire (4) from the relay

K3.1/87a and the brown 100 mm long wire (6) from

the grounding point to the resistor.

1 2

Peugeot 307 Thermo Top C, E

Preassembly and installation with

manual air conditioning

NOTE:

Pay attention to the free movement of the housing

cover.

Remove any reinforcements in the relay box near the

fastening points for the blower relay and the fuse

holder.

WARNING:

When drilling, watch out for underlying components

and wires.

- Bore 2 holes of Ø 5.5 mm in the fuse and relay box.

- Fasten the fuses (1) and K3 blower relay (2) with 2

M5x12 bolts, 4 washers, and 2 M5 flanged nuts as

shown.

- Replace the F3 fuse with the enclosed 10 amp fuse.

- Connect the positive wire to the positive terminal in

the fuse and relay box.

- Connect the ground wire to the battery negative

terminal

Thermo Top C, E Peugeot 307

Installing the Cable Harnesses

For all vehicles

- Run the heater unit cable harness along the original

vehicle cable harness / battery positive terminal

from the fuse and relay box to the right and then

behind the original vehicle cooler to the heater unit

installation location.

- Run the metering pump cable harness on the wheel

house back to the cooling water reservoir.

- Run the metering pump cable harness behind the

cooling water reservoir cover to the right side of the

vehicle.

- Secure cable harnesses with cable ties.

- Run the time switch cable harness, blower controller

cable harness (from blower relay K3), and the cable

harness from the supplementary relay K3.1 (only

with automatic air conditioning) from the fuse and

relay box down and through the engine

compartment along the frame side rail to the brake

amplifier.

- Run the cable harnesses (3) from the brake

amplifier through the existing feed-through (1) into

the wheel house.

WARNING:

When drilling, watch out for underlying components

and wires.

- Drill Ø 18mm bore hole (2) in passenger

compartment as shown in the figure.

- Insert enclosed cable sleeves (10/1; 9/2) in the bore

hole.

- Run the cable harnesses (9/3; 10/2) from the wheel

house into the passenger compartment as shown in

figure 9 and 10.

- Secure cable harnesses with cable ties.

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