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.
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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
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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.
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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
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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
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2

Thermo Top C, E Peugeot 307
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10
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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
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2
3