Webasto Thermo Top E User manual

Brand: Webasto

Model: Thermo Top E

Type: User manual

Webasto Thermo Top E: Experience cozy warmth even on the coldest days. Say goodbye to icy windscreens and shivering commutes. With its cutting-edge technology, this auxiliary heater ensures a comfortable cabin temperature before you start your journey. Program your desired heating time via the timer function and relish the convenience of pre-heating your vehicle.

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

00 0003

00 0002

00 0104

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

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, the stipulations in the "installation instructions" and "operating and maintenance instructions"

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

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.

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.

Peugeot 207

Heater Unit Installation Location

1Heater unit

Installation

location

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.

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 9 into 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

rt 0,5mm²

300

3 4

300

6sw 0,5mm²

700

br 0,5mm²

300

7 8

300

85 30

87a87

br sw

rt/ws

gn/ws

85 30

87a87

K3.1

3rt

5swbr 7

Peugeot 207

Connect according to the circuit diagram.

Pre-

assem-

bling the

IPCU

86 85

IPCU

86 85

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

gr/ws

Wait to install the metering pump

cable harness until later,

together with fuel pipe along the

original vehicle fuel lines on the

underbody.

Peugeot 207

Manual air conditioning blower

control

Connection to the 6-pin plug connection IC 26

3 from 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.

gn/

rt/ws

Webasto

Peugeot

4X1

85 30

87a87

PSF 1

F11

R7 2

2V NR

8025

8V NR 1

8050

2V NR 2

IC26

Peugeot 207

Automatic air conditioning blower

control

Connection to the 6-pin plug connection IC 26

3 from 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

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

2 3

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

rt/ws

Webasto

Peugeot

4X1

85 30

87a87

K3 IC26 4 3

BSI 1

F14

2V GR 610V NR

2V NR

1 2

8050 M

PSF 1

F11

R7 MF5

2V NR 5

8V NR

8045

6V VE 5

3 4

2V VE

40V 40

8080

18V NR

85 30

87a87

K3.1

rt ro

8685

IPCU

gn/

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

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

235 mm

90 mm

25 mm

1 1

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

2 2

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

Heat

exchanger

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 A with the straight

end on the heater unit inlet.

Connect-

ing to the

heater unit

Assemble the water hose B with 90° bend on

the heater unit outlet.

Connect-

ing to the

heater unit

A B

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

1 2

B 1

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. 1 is an original vehicle clamp.

Wärme-

tauscher

Motor

Heat

exchanger

Peugeot 207

b = 480 mm

c = 390 mm

Dispose of section X

Cutting

water hose

into

sections

Pull the water hose 1 off the engine outlet.

The clamp will be used again.

Splitting

point

Assemble the water hose B with the straight

end on the heater unit inlet.

Connect-

ing to the

heater unit

Assemble the water hose C with 90° bend on

the heater unit outlet.

1Black rubber profile

Connect-

ing to the

heater unit

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Webasto Thermo Top E User manual

Webasto Thermo Top E User manual

Webasto Thermo Top E User manual

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