Webasto Thermo Top C User manual

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.
e1
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
1
5 6

Thermo Top C, E Peugeot 307
2
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
3
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
4
Heater unit / Installation kit
Quantity Name Order No.
1 Water heater unit Thermo Top E - gasoline with scope of delivery 668 90C
or
1 Water heater unit Thermo Top E - diesel with scope of delivery 668 89C
or
1 Water heater unit Thermo Top Z/C - gasoline with scope of delivery 906 04D
or
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
5
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.
2
1

Thermo Top C, E Peugeot 307
6
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).
3
1
6
42
9
8
7
5
3

Peugeot 307 Thermo Top C, E
7
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/
ws
rt
sw
30
15
31
Webasto Peugeot 307
br
br
sw
rt
rt/ws
F18
rt
ws
ws
rt
br
rt
br
F3
Pin 4
HG
X1
K3
87a
87
86
85 30
K3.1
87a
87
86
85 30
R1
sw
M
2
1
GM
IT
sw rt
sw
GR
341 2
ST 02
ST 01 43
ST 04
KB
9
ST 03
9
ZS
ws
ws
4
Blower control
For vehicles with automatic air conditioning

Thermo Top C, E Peugeot 307
8
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.
5
1
2
3
6
5
1 2
3
4
7
2
6
5
1
4
3

Peugeot 307 Thermo Top C, E
9
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
8
1
2

Thermo Top C, E Peugeot 307
10
10
1
2
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.
9
1
2
3

Peugeot 307 Thermo Top C, E
11
Blower control
Automatic air conditioning
NOTE:
The positive triggering of the blower engine is
between the six-pin plug connection (2) pin 3 and the
two pin connector (1) pin 2 on the blower motor.
- Separate the red wire (2.4) from the original vehicle
fuses to the blower motor approx. 500 mm before
the connector (3) pin 3.
- Connect according to illustration 4 in the circuit
diagram.
- Connect the red (rt) wire (1) from the blower relay
K3/87a with the red (rt) from the original vehicle
fuse.
- Connect the black wire (5) from K3/30 with the red
(4) wire to the blower motor.
NOTE:
The ground triggering of the blower motor is between
the two pin connector (3) on the blower motor pin 1
and the 6 pin connector on the blower controller pin 4.
- Separate the original vehicle black wire (2,4) from
the blower motor to the blower regulator pin 1 as
shown in the figure approx. 50 mm before the
connector (3).
- Connect according to illustration 4 in the circuit
diagram.
- Connect the brown wire (1) from the supplementary
relay K3.1/87 with the black wire (2) to the blower
controller.
- Connect the black wire (5) from the supplementary
relay K3.1/30 with the black wire (4) from the blower
motor.
NOTE:
On the vehicles checked with passenger
compartment monitoring, no alarms were triggered
during heating operation (test with maximum blower
speed).
Triggering the passenger compartment monitoring is
not provided for in the current vehicles.
11
1
2
12
1
2
4
3
5
13
1 2 3
4
5

Thermo Top C, E Peugeot 307
12
Manual air conditioning
Re-connect the connections with the enclosed round
connectors in accordance with circuit diagram Figure 15
The air conditioning control is triggered at pin 4 on the
5 pin connector in the air conditioning control.
- Run the blower control cable harness (1) as shown
in figure 22 to the air conditioning control.
- Separate the white wire (3.5) to the air conditioning
control approx. 50mm before pin 4 on the 5 pin
connector (4) in the air conditioning control.
- Connect the white wire (5) to the air conditioning
control as shown in the figure with the red wire (6)
K3/87a blower relay.
- Connect the white wire (3) to the resistor group as
shown in the figure with the black wire (2) K3/30
blower relay.
NOTE:
On the vehicles checked with passenger
compartment monitoring, no alarms were triggered
during heating operation (test with maximum blower
speed).
Triggering the passenger compartment monitoring is
not provided for in the current vehicles.
14
1
6
5
3
2
4
gn/
ws
sw
br
rt/ws
Webasto
31
30
15
Peugeot 307
rt
Pin 4
HG
X1 F3
10A
WG
ws
ws
K3
87a
87
86
85 30
Pin 4
KB
ST 01
KB Klimabedienteil
ST 01 Stecker 5- polig
WG Widerstandsgruppe 14

Peugeot 307 Thermo Top C, E
13
Time Switch and
Summer / winter switch option
CAUTION
When installing the time switch, do not press on the
LCD display.
NOTE
The installation location shown for the time switch (1)
and the summer / winter switch (2) is a
recommendation.
Before installing, please confirm the installation
location with your customer.
- Attach the drilling template for the time switch at the
desired position.
- Drill two holes as on the template.
- Remove the template.
- Pull the time switch cable harness through the hole
and connect the plug to the time switch.
- Fasten the time switch (1) with the self-tapping
screw.
- Attach cover to time switch.
- Transfer the hole image for the summer / winter
switch (2) to the desired position and drill Ø 12mm
hole.
- Pull the summer / winter switch cable through the
hole.
- Connect the brown and violetwires, as shown in the
figure, to the switch (lower contacts).
- Fasten the summer / winter switch with the tooth
lock washer and nut.
16
12
17

Thermo Top C, E Peugeot 307
14
Remote start option
NOTE:
Please observe the general installation instructions for
the Telestart remote start option.
- Fasten the bracket (2) with bolt M5x12, washer and
flanged nut in previously drilled hole.
- Slide the receiver (1) on the bracket (2)
NOTE:
Clean/degrease the mounting surface for the antenna
before fitting the antenna!
- Attach the antenna (1) as shown.
- Run antenna cable to the receiver.
- Make all connections according to the enclosed
installation instructions.
- Secure all wiring harnesses with cable ties
1
18
2
1
19

Peugeot 307 Thermo Top C, E
15
Thermo Call TC1.1 option
NOTE:
Please observe the general installation instructions for
the TC1.1 option.
- Position the receiver (1) on the fuse holder.
- Position the receiver (1) with the cable clip (2) on the
fuse holder.
NOTE:
Clean/degrease the mounting surface for the antenna
before fitting the antenna!
- Attach the antenna (1) as shown in the figure.
- Run antenna cable to the receiver.
- Assemble the tip switch (1) as shown in the figure.
- Make all connections according to the enclosed
installation instructions.
- Secure all wiring harnesses with cable ties
1
20
2
1
21
1
22

Thermo Top C, E Peugeot 307
16
Installing the Heater Unit
Preparing the Installation Location
For vehicles with wind deflector
- Remove wind deflector (1) and dispose.
For all vehicles
- Transfer the hole image (1) to the cross strut as
shown in the figure.
- Drill a Ø 7.0mm bore hole according to the figure.
- Insert the M6x20 screw (2) from below in the hole
(24/1) and from above add two washers and a bolt
protector.
- Unscrew the original vehicle bolt in position (1).
- Unscrew the original vehicle nut in position (3).
25
2
3
1
23
1
24
37mm
91mm
1

Peugeot 307 Thermo Top C, E
17
Pre-assemble the Heater Unit
Cut the supplied water hose into a section, as shown
in the figure:
1 x 80 mm + 90° bend (1)
(from the heater unit water outlet to the 1,200mm long
water hose).
- Slide the 80mm long water hose (1) with the straight
end onto the heater unit water outlet, align as shown
in the figure and fasten with spring band clamp.
- Insert the 20x20 (1) connecting pipe in the 80 mm
long water hose (27/1) and secure with hose
clamps.
- Replace the circulation pump cover with the
enclosed cover (2) with axial water inlet.
WARNING:
Only use the special EJOT PT screws included in the
delivery to fasten the heater unit. (Tightening torque
10 Nm)
NOTE:
Insert two washers at position (4) between the heater
unit and the bracket.
- Fasten the pre-assembled heater unit on the
bracket (3) with Ejot screw bolts (2, 3, 4), also add
two washers between the heater unit and the
bracket at position (4) (tightening torque 10 Nm).
29
4
1 2
3
28
2
1
1
80
Section
26
Section
(Will be used again)
27
1

Thermo Top C, E Peugeot 307
18
Installing the heater unit
- Assemble the bracket with heater unit on the
preassembled M6x20 bolt and the original vehicle
bolt (31/2) as shown in figure 30 and figure 31.
NOTE:
Insert a 10mm spacer washer between the bracket
and the crossarm at position (31/2; 32/1).
- Fasten the heater unit bracket to position (1) with
the original vehicle nut.
- Fasten the heater unit bracket to position (30/1) with
the flanged nut as shown in figure 30.
- Fasten the heater unit bracket to position (1) with
the original vehicle bolt and 10 mm spacer washer.
30
1
31
1
2
32
1

Peugeot 307 Thermo Top C, E
19
Connection to the water circuit.
NOTE:
Tighten all hose clamps to 2.0 + 0.5 Nm. Any fuel
running off should be collected using an appropriate
container!
Install hoses so that they are kink-free!
The following sections describe the installation of the
heater unit “inline” in the cooling water circulation of
the vehicle.
Legend:
1 Expansion reservoir
2 Coolant thermostat
3 Vehicle engine
4 Circulation pump (heater unit)
5 Heater unit
6 Heat exchanger (vehicle)
7 Cooler
Preparing the water hoses
KFW 1.4 l gasoline and
NFU 1.6 l gasoline with shift gears
- Cut the supplied water hose into two sections, as
shown:
1 x 80 mm + 90° bend (31)
(preassembled on the heater unit)
1 x 1,200 mm + 90° bend (2)
(from the 80mm long water hose (34/1) to the
380mm long water hose (35/2)).
- Cut the water hose supplied in the kit into three
sections, as shown:
1 x 1,150 mm + 90° bend (1)
(from the heater unit water inlet to the 400mm long
water hose (3)).
1 x 380 mm straight (2)
(from the 1200 mm long water hose (34/2) to the
original vehicle water hose / heat exchanger water
inlet).
1 x 400 mm + 180° bend (3)
(from the 1,150mm long water hose (1) to the
original vehicle water hose / engine exhaust).
ϑ
33
80
34
Section 1200
Section
Section
21
400
31
1150
35
Section 380
2

Thermo Top C, E Peugeot 307
20
NFU 1.6 l gasolinewith automatic drive
- Cut the supplied water hose into three sections, as
shown:
1 x 80 mm + 90° bend (1)
(preassembled on the heater unit)
1 x 660 mm straight (2)
(from the 1200 mm long water hose (3) to the
original vehicle water hose / heat exchanger water
inlet).
- 1 x 1,200 mm + 90° bend (3)
(from the 80mm long water hose (1) to the 660 mm
long water hose (2)).
- Cut the water hose supplied in the kit into two
sections, as shown:
1 x 1,150 mm + 90° bend (1)
(from the heater unit water inlet to the 650mm long
water hose (2)).
1 x 650 mm + 180° bend (2)
(from the 1,150mm long water hose (1) to the
original vehicle water hose / engine water outlet).
1200
31
80
36
Section 660
2
Section
Section
1
1150
37
Section 650
2
Section