Webasto Thermo Top E User 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, 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.
Feel the drive
Peugeot 207
Gasoline and diesel
From model year 2006
For left-hand drive vehicles only
Ident. no. 1311168A €10 fee © Webasto AG
Water Heater Unit
Thermo Top E Auxiliary
Heating
Thermo Top C Auxiliary
Heating
Thermo Top P Auxiliary
Heating
e1
00 0003
e1
00 0002
e1
00 0104

22
Peugeot 207
Validity
Vehicle and engine types, equipment variants as well as national specifications, which are not listed in
these installation instructions, have not been tested. Installation according to these installation
instructions may, however, be possible.
The installation location of a time switch 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 Power in kW Engine capacity in cm³
KFU Gasoline 65 1360
NFU Gasoline 80 1587
9 Hz Diesel 80 1560
Validity 2
Heater Unit / Installation Kit 3
Foreword 3
General Instructions 3
Special Tools 3
Explanatory Notes on the Document 4
Preliminary Work 5
Heater Unit Installation Location 5
Preparing the Electronics 6
Electrical Connections 8
Manual air conditioning blower control 9
Automatic air conditioning blower control 10
Remote Start Option 13
Preparing the Heater Unit 14
Preparing the Installation Location 14
Installing the Heater Unit 15
Water Connection for Gasoline Engines 16
Water Connection for Diesel Engines 19
Combustion Air 22
Fuel Connection 23
Exhaust System 26
Final Work 28
Operating instructions for the end customer 29
Petrol vehicle tank extracting device template 30
Diesel vehicle tank extracting device template 31
Table of Contents

33
Peugeot 207
Heater Unit / Installation Kit
Also required for manual air conditioning:
Also required for automatic air conditioning:
Recommended heater unit for the relevant vehicle class:
Select the heater unit based on the size of the vehicle passenger compartment and the customer's
comfort requirements.
Foreword
These installation instructions apply to vehicles Peugeot 207 with Gasoline and diesel engines.
– Re. 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,thestipulations in the "installationinstructions"and"operatingand maintenanceinstructions"
for the Thermo Top C/P/E are to be observed in any event.
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 cable harnesses to original vehicle lines and cable
harnesses using cable clips.
Sharp edges should be fitted with edge protectors (split open plastic hose).
Spray unfinished body areas, such as bore holes, with anti-corrosion wax (Tectyl 100K, Order no.
111329).
Special Tools
- Torque spanner for 2.0 - 10 Nm
- Vise-grip wrench
- Riveting nut tool
Amount Description Order No.:
1 Commercial supply of required control See price list
Amount Description Order No.:
1 Installation kit Peugeot 207 Gasoline and diesel manual air
conditioning 1311147A
Amount Description Order No.:
1 Installation kit for Peugeot 207 Gasoline and diesel automatic air
conditioning 1311169A
Vehicle Heater unit
Compact car Thermo Top E
Mid class, station wagon Thermo Top C
Luxury, van, off-roader Thermo Top P

44
Special features are highlighted using the following symbols:
Mechanics
Electrics
Water connection
Fuel connection
Exhaust system
Combustion air
The arrow in the vehicle icon indicates the position on
the vehicle and the viewing angle.
Peugeot 207
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.
i
Explanatory Notes on the 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.

5
Peugeot 207
Heater Unit Installation Location
1Heater unit
Installation
location
1
1
Preliminary Work
WARNING!
- Disconnect the battery.
- Let off pressure in 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.
- Completely remove the battery.
- Completely remove the air filter with intake hose.
- Open the tank cap, ventilate the tank.
- Close the tank cap again.
- Remove the left underride protection
- Open the tank mounting service lid
- Remove tank mounting according to manufacturer's instructions.
- Remove the panel on the middle tunnel in the left footwell.
- Remove the lower left dashboard panel.
- Remove the air conditioning control (only for automatic air conditioning systems)
- Please remove page 29 “Operating instructions for the end customer” and add this to the vehicle
operating instructions.

6
Peugeot 207
Preparing the Electronics
Only for automatic air conditioning
Wire sections 3, 4, 5, 7 for K3.1 relay
connection
Wire sections 1, 2, 6, 8 for connecting the
IPCU. Cutting
wires into
sections
Cutting
wires into
sections
Connect according to the circuit diagram.
Pull the wire section 9into the enclosed
insulating hose.
Pre-
assem-
bling the
K3 relay
Connect according to the circuit diagram.
Pre-
assem-
bling the
K3.1 relay
300
2rt 0,5mm²
700
1
rt 0,5mm²
300
3 4
300
300
6sw 0,5mm²
700
5
br 0,5mm²
300
7 8
300
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

7
Peugeot 207
Connect according to the circuit diagram.
Pre-
assem-
bling the
IPCU
86 85
A
E
15
IPCU
1
rt
2
6
sw
rt
br
8
A
15
86 85
E

8
Peugeot 207
Electrical Connections
Cable harness feed-through
1Ø 18 mm bore hole, enclosed protective
rubber sleeve
Summer / winter switch option
1Summer / winter switch, bore hole Ø 12 mm.
Cable
harness
installation
diagram
Fuse holder, K3 relay
1K3 relay, 5.5x13 bolt, bore hole
Ø 4.5 mm
2Fuse holder retaining plate, 5.5x13 bolt, Ø 4.5
mm bore hole
3Fuse holder
Time switch
1Time switch
2
1
3
1
rt
sw
gr/ws
bl
br
Waittoinstallthemeteringpump
cable harness until later,
together with fuel pipe along the
original vehicle fuel lines on the
underbody.
i
4
2
3
1
5
1

9
Peugeot 207
Manual air conditioning blower
control
Connectiontothe6-pinplugconnectionIC26
3from the blower motor cable harness.
Connect with enclosed butt connectors
according to the circuit diagram.
1Black (sw) wire from K3/30
2White (ws) wire to connector IC 26
4White (ws) wire from main power supply
PSF 1
5Red (rt) wire to K3/87a
Connec-
ting the
blower
motor
Manual air
condition-
ing circuit
diagram
Webasto components Components Peugeot 207 Colors and symbols
Legend
HG Heater unit TT-C/E 8050 Blower motor rt red
X1 6-pin connector 8025 Air conditioning control ws white
F3 Fuse, 25A PSF1 Main power supply sw black
K3 Blower relay IC 26 6-pin connector br brown
gn green
XSplitting point
Cable colors may vary.
6
1
4
2
5
3
gn/
ws
ws
sw
rt/ws
rt
Webasto
31
30
15
Peugeot
ws
rt
HG
4X1
F3
86
85 30
87a87
K3
PSF 1
F11
R7 2
2V NR
8025
8V NR 1
8050
2V NR 2
M
1
3
IC26
6
i

10
Peugeot 207
Automatic air conditioning blower
control
Connectiontothe6-pinplugconnectionIC26
3from the blower motor cable harness..
Connect with enclosed yellow butt
connectors according to the circuit diagram.
1Black (sw) wire from K3/30
2White (ws) wire to connector IC 26
4White (ws) wire from main power supply
PSF 1
5Red (rt) wire to K3/87a
Connec-
ting the
blower
motor
1Connector 18V NR
2Connector 40V BE
Air
condition-
ing control
1Original vehicle bolt [2x]
2Relay K3.1
3IPCU socket
Assem-
bling the
K3.1 and
IPCU
Connect with enclosed cable sockets.
1Original vehicle bolt
2Brown (bn) wire to K3.1/85
3Brown (bn) wire to IPCU/85
Connect-
ing the
ground for
IPCU and
K3.1
7
1
4
2
5
3
8
1
2
9
1
32
1
10
1
3
2

11
Peugeot 207
Connection to 18-pin connector 18V NR 4
from the air conditioning control.
Connect with enclosed blue butt connector 2
according to the circuit diagram.
1Red (rt) wire to K3.1/86
3Red (rt) wire to IPCU terminal 15
5Grey (gr) wire to connector 18V NR
6Grey (gr) wire from terminal 15
Connect-
ing
terminal 15
for K3.1
and IPCU
Connection to 18-pin connector 18V NR 5
from the air conditioning control.
Connect with enclosed red butt connectors 2
[2x] according to the circuit diagram.
1Pink (ro) wire from BSI1/6
3Red (rt) wire from K3.1/87
4Black (sw) wire from K3.1/30
6Pink (ro) wire to connector 18V NR/18 Connect-
ing relay
K3.1
Connection to the green 6-pin connector 6V
VE 3from the blower controller.
Connect with enclosed red butt connectors 2
[2x] according to the circuit diagram.
1Red (rt) wire from IPCU/E
4Black (sw) wire from IPCU/A
5Red (rt) wire to connector 6V VE/6
6Red (rt) wire to connector 40V BE/39
Connect-
ing the
blower
controller
11
1
5
2
3
6
4
12
1
5
4
2
2
6
3
13
1
6
4
2
5
2 3

12
Peugeot 207
Automatic
air
condition-
ing circuit
diagram
Webasto components Components Peugeot 207 Colors and symbols
Legend
HG Heater unit TT-C/E 8050 Blower motor rt red
X1 6-pin connector PSF1 Main power supply ws white
F3 Fuse 8045 Blower controller sw black
K3 Blower relay 8080 Air conditioning control br brown
K3.1 Supplementary relay BSI1 Central electrics in the
passenger compartment gn green
IPCU Pulse width modulator IC 26 6-pin connector ro pink
gr grey
XSplitting point
Cable colors 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
2V NR
1 2
8050 M
PSF 1
F11
R7 MF5
2
2V NR 5 8V NR
6
8045
6V VE 5
3 4
2V VE
12
sw
18
40V 40
8080
18V NR
39
3
86
85 30
87a87
K3.1
sw
rt
rt ro
ro
gr
br
br
8685
A
E
15
IPCU
br
gn/
ws
rt
sw
rt
rt
rt
4
3
5
7
9
1
8
6
2
i

13
Peugeot 207
Remote Start Option
1Bracket, drill 7 mm bore hole
2Original vehicle bolt
3Receiver
Assem-
bling the
receiver
1Antenna
Assem-
bling the
antenna
Temperature sensor for HTM100 only
1Temperature sensor
2Assembly tape
Assem-
bling the
tempera-
ture sensor
1
3
2
14
i
1
15
1
16
2

14
Peugeot 207
Preparing the Heater Unit
1Heater unit
2Hose section, Ø 10 mm hose clamps [2x]
3Mecanyl fuel line
Assem-
bling the
fuel line
Preparing the Installation Location
1Disassemble the original vehicle strut
Disassem-
bling the
strut
Transfer the hole image according to the
illustration and drill Ø 9.1 mm bore holes [2x]
through the strut at position 1.
Copying
the hole
image
1M6 rivet nuts [2x]
Inserting
rivet nuts
1
2
3
17
18
1
19
1
1
235 mm
90 mm
25 mm
20
1 1

15
Peugeot 207
1Loosely fit the bracket
2M6x16 bolt [2x], spring washer [2x]
Assem-
bling the
bracket
1Original vehicle bolt [2x]
Tighten the loosely pre-assembled M6x16
bolt with the spring washers [2x].
Assem-
bling the
strut
Installing the Heater Unit
For gasoline vehicles only
Ejot screw bolts tightening torque 10 Nm!
Insert two washers between the heater unit
and the bracket in position 2.
1Ejot screw bolt [2x]
2Ejot screw bolt
Assem-
bling the
heater unit
For diesel vehicles only
Ejot screw bolts tightening torque 10 Nm!
Insert two washers between the heater unit
and the bracket in position 2.
1Ejot screw bolt [2x]
2Ejot screw bolt Assem-
bling the
heater unit
21
1
2 2
22
1
1
23
1
1
2
24
1
1
2

16
Peugeot 207
Water Connection for Gasoline Engines
WARNING!
Tighten all hose clamps with 2.0 + 0.5 Nm.
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 clips.
Position hose clamps and spring band clamps so that no other hose can be damaged.
The connection should be "inline" based on the following diagram:
Water
installation
diagram
All undesignated clamps are Ø 20-27 mm hose clamps.
All connecting pipes = Ø 15x20.
Wärme-
tauscher
Motor
A
B
Heat
exchanger

17
Peugeot 207
a = 640 mm
b = 530 mm
Dispose of section X
Cutting the
water hose
into
sections
1Splitting point
Splitting
point
Assemble the water hose Awith the straight
end on the heater unit inlet.
Connect-
ing to the
heater unit
Assemble the water hose Bwith 90° bend on
the heater unit outlet.
Connect-
ing to the
heater unit
ab
A B
X
X
1
25
26
A
27
B

18
Peugeot 207
Before connecting, fill the water hoses with
coolant.
1Fasten black rubber profile with cable clips
to the gear bracket.
2Engine outlet hose Connect-
ing to the
engine
outlet
1Heat exchanger inlet hose
2Cable clip
Connect-
ing to the
heat
exchanger
inlet
1Black rubber profile
Placement
in the
engine
compart-
ment
28
1 2
A
29
A
B 1
2
30
B
A
1

19
Peugeot 207
Water Connection for Diesel Engines
WARNING!
Tighten all hose clamps with 2.0 + 0.5 Nm.
Any coolant running off should be collected using an appropriatecontainer.
Install hoses so that they are kink-free. Unless specified otherwise, always fasten using cable clips.
Position hose clamps and spring band clamps so that no other hose can be damaged.
The connection should be "inline" based on the following diagram:
Water
installation
diagram
All undesignated clamps are Ø 20-27 mm hose clamps.
All connecting pipes = Ø 18x20. 1is an original vehicle clamp.
Wärme-
tauscher
Motor
A
BC
1
Heat
exchanger

20
Peugeot 207
b = 480 mm
c = 390 mm
Dispose of section X
Cutting
water hose
into
sections
Pull the water hose 1off the engine outlet.
The clamp will be used again.
Splitting
point
Assemble the water hose Bwith the straight
end on the heater unit inlet.
Connect-
ing to the
heater unit
Assemble the water hose Cwith 90° bend on
the heater unit outlet.
1Black rubber profile
Connect-
ing to the
heater unit
cb
C
X
XB
1
31
32
B
33
C
B
1