Webasto Thermo Top E Operator's manual

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, specialised tools and equipment are
required to install and repair Webasto heating and cooling systems.
Only original Webasto parts must be used. For this, also see the catalog of air and water heat-
er accessories from Webasto.
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 tech-
nical 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.
The initial startup is to be executed with the Webasto Thermo Test Diagnosis.
Webasto does not accept any liability for defects and damage that are attributable to installa-
tion by untrained staff.
Ident. No.: 1311149E_EN Fee Euro 10.00 © Webasto AG
Feel the drive
Peugeot 207 / 207 SW / 207 CC
Petrol and Diesel
from Model Year 2006
Left-hand drive vehicle
Manual transmission
Water Heater
Thermo Top E Parking Heater
Thermo Top C Parking Heater
Installation documentation
e1
00 0003
e1
00 0002

22
Peugeot 207 / 207 SW / 207 CC
Validity
Vehicle and engine types, equipment variants and national specifications not listed in this installation
documentationhavenot beentested. However,installationaccordingtothis installationdocumentation
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. / ABE
Peugeot W 207 e2 * 2001 / 116 * 0340
Engine type Engine model Output in kW Displacement in cm³
KFU Petrol 65 1360
NFU Petrol 80 1587
5FW Petrol 88 1598
5FX Petrol 110 1598
5FY Petrol 128 1598
9HV Diesel 66 1560
9HX Diesel 66 1560
9HY Diesel 80 1560
9 Hz Diesel 80 1560
Validity 2
Heater/Installation Kit 3
Foreword 3
General Instructions 3
Special Tools 3
Explanatory Notes on Document 4
Preliminary Work 5
Heater installation location 5
Automatic air-conditioning 6
Electrical system 9
Fan control for manual air conditioning 10
Automatic air-conditioning fan control 12
Remote option (Telestart) 16
Preparing heater 17
Preparing installation location 18
Installing heater 19
Petrol coolant circuit 21
Diesel coolant circuit 26
Combustion air 29
Fuel 30
Exhaust gas 33
Final Work 35
Operating Instructions for End Customer 37
Table of Contents

33
Peugeot 207 / 207 SW / 207 CC
Heater/Installation Kit
Also required with manual air conditioning:
Also required with automatic air-conditioning:
Heater recommended for the respective vehicle class:
The selection of the heater is based on the passenger compartment size of the vehicle and the level of
comfort required by the customer.
Foreword
This installation documentation appliesto the vehicles Peugeot 207 / 207 SW / 207 CC with Petrol and
Diesel engine - for validity, see page 2 - from model year 2006 and later, assuming technical modifica-
tions 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 this instal-
lation documentation.
However, the stipulations in this "installation documentation", the "operating instructions" and the "in-
stallation instructions" for the Thermo Top C/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 Instructions
Installation should be carried out according to the general, standard rules of technology. Unless spec-
ified otherwise, fasten hoses, lines and wiring harnesses to original vehicle lines and wiring harnesses
using cable ties.
Sharp edges must be provided with rub protection (cut-open fuel hose).
Spray unfinished body areas, e.g. drilled holes, with anti-corrosion wax (Tectyl 100K, Order No. 111329).
While installing an IPCU, the corresponding settings must be checked or adjusted before the installa-
tion.
Special Tools
- Torque wrench for 2.0 - 10 Nm
- Hose clamping pliers
- Metric thread-setter kit
Quantity Designation Order No.:
1 Retail accessories of Thermo Top C / E See price list
1 Heater control See price list
Quantity Designation Order No.:
1
Installation kit for Peugeot 207 / 207 SW / 207 CC Petrol and Diesel
with manual air conditioning 1311147C
Quantity Designation Order No.:
1
Installation kit for Peugeot 207 / 207 SW / 207 CC Petrol and Diesel
Automatic air-conditioning 1311169D
Vehicle Heater
Compact car Thermo Top E
Mid-size car, estate car Thermo Top C

44
Special features are highlighted using the following symbols:
Mechanical system
Electrical system
Coolant circuit
Fuel
Exhaust gas
Combustion air
The arrow in the vehicle icon indicates the position on
the vehicle and the viewing angle.
Peugeot 207 / 207 SW / 207 CC
Specific risk of injury or fatal accidents.
Specific risk of damage to components.
Specific risk of fire or explosion.
Referenceto generalinstallationinstructions ofWebas-
tocomponentsortothemanufacturer'svehicle-specific
documents.
Reference to a special technical feature.
i
Explanatory Notes on Document
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.

5
Peugeot 207 / 207 SW / 207 CC
Heater installation location
1Heater
Installa-
tion loca-
tion
1
1
Preliminary Work
WARNING!
- Disconnect the battery.
-Depressurisethe 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 battery completely.
- Remove the air filter together with the intake hose.
- Open the fuel tank cap, ventilate the tank.
- Close the fuel tank cap again.
- Remove the underride protection on the left.
- Remove the rear bench seat and backrest.
- Open the tank-fitting service lid
- Remove the fuel-tank sending unit in accordance with manufacturer's instructions.
- Remove the trim of the centre tunnel in the left-hand footwell
- Remove the lower instrument panel trim on the left.
- Remove the A/C control panel.
Please remove page 35 “Operating instructions for the end customer” and add this to the vehicle op-
erating instructions.

6
Peugeot 207 / 207 SW / 207 CC
Preparing electrical system
Manual air conditioning
Wire sections 1 - 5 for connection K3.1 relay.
Cutting
wires to
length
Produce connections as shown in wiring dia-
gram.
Premount-
ing K3 re-
lay
Pull wire section 4 into protective sleeving C,
wire section 1 into protective sleeving A and
wire section 2, 3, 5 into protective sleeving B.
Cutting
protective
sleeving to
length
Automatic air-conditioning
Wire sections 1, 3, and 4 for connection K3.1
relay.
Wire section 2for connecting K3.2 relay.
Cutting
wires to
length
3
600
sw
4²
5
600
br
4²
4
200
rt
1²
1
600
2br
1,5²
86
85 30
87a87
K3.1
5br
3swbr 1
4
rt
2br
550mm550mm 150mm
BA C
300
rt 0,5mm²
rt 0,5mm²
300
12
3 4

7
Peugeot 207 / 207 SW / 207 CC
Wire sections 5, 7, and 10 for connection
K3.1 relay.
Wire sections 6 and 8 for connection IPCU.
Wire section 9for connection K3.
Cutting
wires to
length
Produce connections as shown in wiring dia-
gram.
Install wire section 9in protective sleeving
provided.
Premount-
ing K3 re-
lay
Produce connections as shown in wiring dia-
gram.
Premount-
ing K3.1 re-
lay
Produce connections as shown in wiring dia-
gram.
Premount-
ing K3.2 re-
lay
300
sw 0,5mm²
br 0,5mm²
3000
gn/ws 0,75mm²
5 6
7 8
9
200 200
10
86
85 30
87a87
K3
br sw
rt/ws
9
gn/ws
gn/ws
86
85 30
87a87
K3.1
3rt
5swbr 7
4
rt
10
br
1
rt
86
85 30
87a87
K3.2
2rt

8
Peugeot 207 / 207 SW / 207 CC
Produce connections as shown in wiring dia-
gram.
The IPCU included in the kit is pre-pro-
grammed with the following settings:
Duty cycle: 75%
Frequency: 2000Hz
Voltage: 10V
Function: Low-side
The settings are to be checked during start-
up of heater, and adjusted if necessary.
Premount-
ing IPCU
86 85
A
E
IPCU
6
sw
br
8
A
15
86 85
E

9
Peugeot 207 / 207 SW / 207 CC
Electrical system
Wiring harness pass through
1
18 mm dia. hole, included protective rubber plug
Summer/winter switch option
1Summer/winter switch, drilled hole 12 mm dia.
Wiring har-
ness rout-
ing
diagram
Fuse holder, K3 relay
1K3 relay, 5.5x13 bolt, hole 4.5 mm dia.
2Retaining plate of fuse holder, 5.5x13 bolt,
4.5 mm dia. hole
3Fuse holder
Digital timer
1Digital timer
2
1
3
1
rt
sw
gr/ws
bl
br
Wait until later to route wiring
harness of metering pump to-
gether with fuel line in corrugat-
ed tube along original vehicle
brake lines on underbody
i
4
2
3
1
5
1

10
Peugeot 207 / 207 SW / 207 CC
Fan control for manual air condi-
tioning
Fasten additional relay K3.1 1with installa-
tion strap.
Mounting
K3.1
Connection to 6-pin connector IC 26 2 from
wiring harness of fan motor. Produce connec-
tions as shown in wiring diagram.
1White (ws) wire of connector IC 26
3White (ws) wire of PSF 1 connector 2V NR
Pin 2
4Red (rt) wire to K3.1/86
5Red (rt) wire from K3/87a
6Black (sw) wire from K3/30
Connect-
ing fan mo-
tor
Make connection with the help of attached 6
mm dia. cable lug.
1Original vehicle earth point
2Brown (br) wire K3.1/85
Earth con-
nection of
K3.1
Connection on connector 8V NR 3from fan
switch/A/C control panel. Produce connec-
tions as shown in wiring diagram.
1Violet (vi) wire of connector 4V NR, Pin 3
2Violet (vi) wire of connector 8V NR, Pin 3
4Black (sw) wire of connector 8V NR, Pin 1
5Brown (br) wire of K3.1/87a
6Brown (br) wire K3.1/87
7Black (sw) wire K3.1/30
8Black (sw) wire of earth point
Connect-
ing A/C
control
panel
6
1
7
6
4
1
5
2 3
8
1
2
9
5
74
1 2
8
6
3

11
Peugeot 207 / 207 SW / 207 CC
Wiring dia-
gram for
manual air
condition-
ing
Webasto components Vehicle components Colours and symbols
Legend
HG TT-C/E Heater 8050 Fan motor rt red
X1 6-pin connector 8025 Fan switch/A/C control
panel ws white
F3 25 A fuse sw black
K3 Fan relay 8046 Resistor group br brown
K3.1 Additional relay PSF1 Main power supply gn green
IC26 6-pin connector vi violet
2V NR 2-pin connector
4V NR 4-pin connector
8V NR 8-pin connector XCutting point
Wiring colours may vary.
gn/
ws ws
sw
rt/ws
rt
Webasto
31
30
15
Peugeot
ws
rt
F3 PSF 1
F11
R7 2
2V NR
3
IC26
2V NR 1 2
8050
M
86
85 30
87a87
K3
HG
X1 4
86
85 30
87a87
K3.1
rt
1,5²
br
1,5²
br
4²
sw
4²
sw
4²
sw
4²
vi
1²
vi
1²
br
1,5²
5
3
1
4
2
8046
3241 4V NR
8025
8V NR 6 7 5 4 3 1
i

12
Peugeot 207 / 207 SW / 207 CC
Automatic air-conditioning fan
control
Connection to 6-pin connector IC 26 3 from
wiring harness of fan motor.
Produce connections as shown in wiring dia-
gram.
1Black (sw) wire from K3/30
2White (ws) wire of connector IC 26, Pin 3
4White (ws) wire of PSF 1 connector 2V NR
Pin 2
5Red (rt) wire from K3/87a
Connect-
ing fan mo-
tor
1Connector 18V NR
2Connector 40V BE
A/Ccontrol
panel
Connect green/white (gn/ws) wire from K3/86
toIPCU/86.Connect red(rt)wire from K3.1/86
to K3.2/86. Connect brown (br) wire from
K3.1/85to K3.2/85.Bond K3.2
3 to K3.1 2 with
adhesive tape.
1Original vehicle bolt [2x]
4IPCU socket Mounting
K3.1 and
IPCU
Produce connection with included cable lugs.
1Original vehicle bolt
2Brown (br) wire K3.1/85
3Brown (br) wire of IPCU/85
Connect-
ing earth
for IPCU,
K3.1 and
K3.2
10
1
4
2
5
3
11
1
2
12
4
2
11
3
13
1
3
2

13
Peugeot 207 / 207 SW / 207 CC
Connection on 18-pin connector 18V NR 4
from A/C control panel. Produce connection
as shown in wiring diagram.
1Gray (gr) wire of terminal 15
2Red (rt) wire to K3.1/86
3Gray (gr) wire to connector 18V NR Connect-
ing termi-
nal 15 for
K3.1 and
IPCU
Connection on 18-pin connector 18V NR 5
from A/C control panel. Produce connections
as shown in wiring diagram.
1Pink (ro) wire of BSI1 connector 10V NR,
Pin 6
2Red (rt) wire to K3.1/87
3Black (sw) wire K3.1/30
4Pink (ro) wire of connector 18V NR, Pin 18 Connect-
ing relay
K3.1
Variant 1
Connection on green (gn) 6-pin connector 6V
VE 2from fan controller.
Produce connections as shown in wiring dia-
gram.
18080 mm long red (rt) wire of connector
40V BE, Pin 39
3Red (rt) wire of connector 6V VE, Pin 6
4Red (rt) wire of K3.2/87a
Connect-
ing fan
controller
Variant 2
Connection on black (sw) 6-pin connector 6V
NR 4from fan controller. Produce connec-
tions as shown in wiring diagram.
18080 mm long red (rt) wire of connector
40V BE, Pin 39
2Red (rt) wire of K3.2/87a
3Red (rt) wire of connector 6V NR, Pin 5
Connect-
ing fan
controller
14
1
3
2
4
15
1
5
3
4
2
16
1
2
3
4
17
1
2
4
3

14
Peugeot 207 / 207 SW / 207 CC
Wiring diagram of automatic air-conditioning Variant 1
Wiring dia-
gram
Webasto components Vehicle components Colours and symbols
Legend
HG TT-C/E Heater 8050 Fan motor rt red
X1 6-pin connector PSF1 Main power supply ws white
F3 Fuse 8045 Fan controller sw black
K3 Fan relay 8080 A/C control panel br brown
K3.1 Additional relay BSI1 Central electrical box for
passenger compartment gn green
K3.2 Additional relay IC 26 6-pin connector ro pink
IPCU Pulse width modula-
tor gr gray
XCutting point
Wiring colours may vary.
gn/
ws ws
sw
rt/ws
rt
Webasto
31
30
15
Peugeot
ws
rt
HG
4X1 F3
86
85 30
87a87
K3 IC26 4 3
BSI 1
F14
R7
2
2V GR 610V NR
PSF 1
F11
R7 MF5
2
2V NR 5 8V NR
2V VE
12
sw
86
85 30
87a87
K3.1
sw
rt
rt ro
ro
gr
br
br
8685
A
E
IPCU
br gn/
ws
rt
sw
rt
rt
rt
4
3
5
7
9
1
8
6
6V VE
3456
86
8530
87a 87
K3.2
2
10
br
8050
2V NR 21
M
18V NR 18 3
40V BE 40 39
8080
8045
i

15
Peugeot 207 / 207 SW / 207 CC
Wiring diagram of automatic air-conditioning Variant 2
Wiring dia-
gram
Webasto components Vehicle components Colours and symbols
Legend
HG TT-C/E Heater 8050 Fan motor rt red
X1 6-pin connector PSF1 Main power supply ws white
F3 Fuse 8045 Fan controller sw black
K3 Fan relay 8080 A/C control panel br brown
K3.1 Additional relay BSI1 Central electrical box for
passenger compartment gn green
K3.2 Additional relay IC 26 6-pin connector ro pink
IPCU Pulse width modula-
tor gr gray
XCutting point
Wiring colours may vary.
gn/
ws ws
sw
rt/ws
rt
Webasto
31
30
15
Peugeot
ws
rt
HG
4X1 F3
86
85 30
87a87
K3 IC26 4 3
BSI 1
F14
R7
2
2V GR 610V NR
PSF 1
F11
R7 MF5
2
2V NR 5 8V NR
sw
86
85 30
87a87
K3.1
sw
rt
rt ro
ro
gr
br
br
8685
A
E
IPCU
br gn/
ws
rt
sw
rt
rt
rt
4
3
5
7
9
1
8
6
86
8530
87a 87
K3.2
2
10
br
8045 6V NR
214536 18V NR 18 3
40V BE 40 39
8080
8050
2V NR 21
M
i

16
Peugeot 207 / 207 SW / 207 CC
Remote option (Telestart)
1Bracket, drill out hole to 7 mm dia.
2Original vehicle bolt
3Receiver
Mounting
receiver
1Antenna
Mounting
antenna
Temperature sensor for HTM100 only
1Temperature sensor
2Installation strap
Mounting
tempera-
ture sensor
1
3
2
18
i
1
19
1
20
2

17
Peugeot 207 / 207 SW / 207 CC
Preparing heater
KFU/NFU
1Fuel line
2Hose section, 10 mm dia. hose clamp [2x] Mounting
fuel line
5FW/X/Y
Thepremountingofthestrutdiffersaccording
to the vehicle-specific routing of the coolant
hose. One differentiates between variants A
and B, depending on the equipment.
1Coolant hose variant B
2Coolant hose variant APreparing
heater
Variant A
Ejot screw bolt, tightening torque 10 Nm.
1Fuel line
2Ejot screw
3Strut
420 mm spacer sleeve
5M6x40 bolt, pin lock
690° moulded hose, hose clamp
10 mm dia. [2x]
Preparing
heater
Variant B
7 mm dia. hole at position 2in strut 3.
Ejot screw bolt, tightening torque 10 Nm.
1Fuel line
2Ejot screw
490° moulded hose, hose clamp
10 mm dia. [2x] Preparing
heater
1
221
2
22a 122b
2
623
1 3 4
5
2
424
1 3
36

18
Peugeot 207 / 207 SW / 207 CC
Preparing installation location
1Remove original vehicle strut
Removing
strut
Copy hole pattern as shown and drill 9.1 mm
dia. holes [2x] in strut at pos. 1.
Copying
hole pat-
tern
1M6 rivet nut [2x]
Installing
rivet nuts
Expand hole at position 1to oblong hole.
2Bracket
Preparing
bracket
25
1
26
1
1
25mm
90mm
235mm
27
1 1
28
1 2
5
1

19
Peugeot 207 / 207 SW / 207 CC
1Loosely mount bracket
2M6x16 bolt [2x], spring lockwasher [2x]
Premount-
ing bracket
1Tighten M6x16 bolt with spring lockwasher
[2x]
2Original vehicle bolt [2x]
Mounting
bracket
Installing heater
Petrol
Tighten EJOT screws to 10 Nm.
Insert two washers between heater and brack-
et at position
2 . Align heater. Ensure sufficiant
distance from neighbouring components, es-
pecially between heat exchanger and trans-
mission at position
4 as well as between
circulating pump and carrier in position
3 . Cor-
rect if necessary.
1Ejot screw [2x]
2Ejot screw, washer [2x]
Mounting
heater
5FW/X/Y - Variant A
Align heater. Ensure sufficient distance from
neighbouring components, especially from
cooler hose. Correct if necessary. Tighten
Ejot screws.
152 mm dia. rubber-coated p-clamp
2Flanged nut on prepared bolt Mounting
heater
29
1
2 2
30
2
2
1
1
31
2
4
1 2
3
32
2
1

20
Peugeot 207 / 207 SW / 207 CC
5FW/X/Y - Variant B
Align heater. Ensure sufficient distance from
neighbouring components, especially from
cooler hose. Correct if necessary. Tighten
Ejot screws.
1M6x20 bolt, flanged nut on prepared strut
252 mm dia. rubber-coated p-clamp Mounting
heater
Diesel
Tighten EJOT screws to 10 Nm.
Insert two washers between heater and
bracket at position 2.
1Ejot screw [2x]
2Ejot screw Mounting
heater
33
21
34
1
1
2