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Webasto Thermo Top E Installation Documentation

Peugeot 207 / 207 sw / 207 cc parking water heater
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See also: Instructions for Using , Operating Instructions
Water Heater
Thermo Top E Parking Heater
Thermo Top C Parking Heater
Installation documentation
Peugeot 207 / 207 SW / 207 CC
Petrol and Diesel
from Model Year 2006
Left-hand drive vehicle
Manual transmission
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
e1
00 0003
e1
00 0002
Fee Euro 10.00
Feel the drive
© Webasto AG

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Summary of Contents for Webasto Thermo Top E

  • Page 1 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.

  • Page 2: Table Of Contents

    Peugeot 207 / 207 SW / 207 CC Table of Contents Validity Preparing heater Heater/Installation Kit Preparing installation location Foreword Installing heater General Instructions Petrol coolant circuit Special Tools Diesel coolant circuit Explanatory Notes on Document Combustion air Preliminary Work Fuel Heater installation location Exhaust gas...

  • Page 3: Heater/Installation Kit

    Heater recommended for the respective vehicle class: Vehicle Heater Compact car Thermo Top E Mid-size car, estate car Thermo Top C The selection of the heater is based on the passenger compartment size of the vehicle and the level of comfort required by the customer.

  • Page 4: Explanatory Notes On Document

    Peugeot 207 / 207 SW / 207 CC 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. Mechanical system Electrical system Coolant circuit...

  • Page 5: Preliminary Work

    Peugeot 207 / 207 SW / 207 CC Preliminary Work WARNING! - Disconnect the battery. - Depressurise 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.

  • Page 6: Automatic Air-Conditioning

    Peugeot 207 / 207 SW / 207 CC Preparing electrical system Manual air conditioning 4² 1² Wire sections 1 - 5 for connection K3.1 relay. Cutting 4² wires to length 1,5² Produce connections as shown in wiring dia- gram. Premount- ing K3 re- K3.1 Pull wire section 4 into protective sleeving C,...
  • Page 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. sw 0,5mm² Wire section 9 for connection K3. Cutting br 0,5mm² wires to length gn/ws 0,75mm²...
  • Page 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: IPCU Duty cycle: 75% Frequency: 2000Hz Voltage: Premount- Function: Low-side ing IPCU The settings are to be checked during start- up of heater, and adjusted if necessary.

  • Page 9: Electrical System

    Peugeot 207 / 207 SW / 207 CC Electrical system Wiring harness pass through Summer/winter switch option 1 18 mm dia. hole, included protective rubber plug 1 Summer/winter switch, drilled hole 12 mm dia. Wait until later to route wiring harness of metering pump to- gether with fuel line in corrugat- ed tube along original vehicle...

  • Page 10: Fan Control For Manual Air Conditioning

    Peugeot 207 / 207 SW / 207 CC Fan control for manual air condi- tioning Fasten additional relay K3.1 1 with 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.
  • Page 11 4² 4² 1,5² K3.1 1² 2V NR 4V NR 8046 8050 4² 1,5² 4² Webasto components Vehicle components Colours and symbols TT-C/E Heater 8050 Fan motor 6-pin connector 8025 Fan switch/A/C control white panel 25 A fuse black Fan relay...

  • Page 12: Automatic Air-Conditioning Fan Control

    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. Connect- ing fan mo- 1 Black (sw) wire from K3/30 2 White (ws) wire of connector IC 26, Pin 3 4 White (ws) wire of PSF 1 connector 2V NR Pin 2...
  • Page 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. 1 Gray (gr) wire of terminal 15 2 Red (rt) wire to K3.1/86 Connect- 3 Gray (gr) wire to connector 18V NR ing termi- nal 15 for...
  • Page 14 K3.1 2V VE 8045 6V VE 18V NR 8080 40V BE IPCU 2V NR 8050 K3.2 Webasto components Vehicle components Colours and symbols TT-C/E Heater 8050 Fan motor 6-pin connector PSF1 Main power supply white Fuse 8045 Fan controller...
  • Page 15 Wiring dia- gram K3.1 8045 6V NR 18V NR 8080 40V BE IPCU 2V NR 8050 K3.2 Webasto components Vehicle components Colours and symbols TT-C/E Heater 8050 Fan motor 6-pin connector PSF1 Main power supply white Fuse 8045 Fan controller...

  • Page 16: Remote Option (Telestart)

    Peugeot 207 / 207 SW / 207 CC Remote option (Telestart) 1 Bracket, drill out hole to 7 mm dia. 2 Original vehicle bolt 3 Receiver Mounting receiver 1 Antenna Mounting antenna Temperature sensor for HTM100 only 1 Temperature sensor 2 Installation strap Mounting tempera-...
  • Page 17 Peugeot 207 / 207 SW / 207 CC Preparing heater KFU/NFU 1 Fuel line 2 Hose section, 10 mm dia. hose clamp [2x] Mounting fuel line 5FW/X/Y The premounting of the strut differs according to the vehicle-specific routing of the coolant hose.

  • Page 18: Preparing Installation Location

    Peugeot 207 / 207 SW / 207 CC Preparing installation location 1 Remove original vehicle strut Removing strut Copy hole pattern as shown and drill 9.1 mm 235mm dia. holes [2x] in strut at pos. 1 . 90mm Copying 25mm hole pat- tern 1 M6 rivet nut [2x]...

  • Page 19: Installing Heater

    Peugeot 207 / 207 SW / 207 CC 1 Loosely mount bracket 2 M6x16 bolt [2x], spring lockwasher [2x] Premount- ing bracket 1 Tighten M6x16 bolt with spring lockwasher [2x] 2 Original vehicle bolt [2x] Mounting bracket Installing heater Petrol Tighten EJOT screws to 10 Nm.
  • Page 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. 1 M6x20 bolt, flanged nut on prepared strut Mounting 2 52 mm dia. rubber-coated p-clamp heater Diesel Tighten EJOT screws to 10 Nm.

  • Page 21: Petrol Coolant Circuit

    Peugeot 207 / 207 SW / 207 CC Petrol coolant circuit WARNING! Any coolant running off should be collected in an appropriate container. Install hoses so that they are kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that other hos- es cannot be damaged.
  • Page 22 Peugeot 207 / 207 SW / 207 CC KFU/NFU a = 640 mm b = 530mm Discard section X Cutting hoses to length 1 Cutting point Cutting point 1 Black (sw) rubber profile fastened on trans- mission mount with cable tie 2 Engine outlet hose section Connect- ing engine...
  • Page 23 Peugeot 207 / 207 SW / 207 CC Install coolant hose B with 90° elbow on heat- er outlet. Connect- ing heater Before connecting, fill the coolant hoses with coolant. 1 Hose section of heat exchanger inlet 2 Cable tie Connect- ing heat exchanger...
  • Page 24 Peugeot 207 / 207 SW / 207 CC 5FW/X/Y a = 640 mm b = 530mm Discard section X Cutting hoses to length 1 Cutting point Cutting point 1 Engine outlet hose section 2 Black (sw) rubber profile fastened on trans- mission mount with cable tie Connect- ing engine...
  • Page 25 Peugeot 207 / 207 SW / 207 CC Install coolant hose B with 90° elbow on heat- er outlet. Connect- ing heater Before connecting, fill the coolant hoses with coolant. 1 Hose section of heat exchanger inlet Connect- ing heat exchanger inlet 1 Black (sw) rubber profile...

  • Page 26: Diesel Coolant Circuit

    Peugeot 207 / 207 SW / 207 CC Diesel coolant circuit WARNING! Any coolant running off should be collected in an appropriate container. Install hoses so that they are kink-free. Unless specified otherwise, always fasten using cable ties. Position clamps so that other hos- es cannot be damaged.
  • Page 27 Peugeot 207 / 207 SW / 207 CC b = 480 mm c = 390 mm Discard section X Cutting hoses to length Disconnect coolant hose 1 from engine out- let. Hose clamp will be reused. Cutting point 1 Original vehicle hose clamp Connect- ing engine outlet...
  • Page 28 Peugeot 207 / 207 SW / 207 CC Install coolant hose C with 90° elbow on heat- er outlet. 1 Black (sw) rubber profile Connect- ing heater Before connecting, fill the coolant hoses with coolant. 1 Hose on heat exchanger inlet 2 Black (sw) rubber profile Connect- ing heat...

  • Page 29: Combustion Air

    Peugeot 207 / 207 SW / 207 CC Combustion air 1 Original vehicle bolt 2 Angle bracket 3 Intake silencer 4 Cable tie Installing intake si- lencer 1 Intake pipe 2 27 mm dia. hose clamp Mounting intake pipe...

  • Page 30: Fuel

    Peugeot 207 / 207 SW / 207 CC Fuel CAUTION! Open the vehicle's fuel tank cap, ventilate the tank and then re-close the tank lock. Catch any fuel running off in an appropriate container. Install fuel line and metering pump wiring harness so that they are protected against stone impact. Un- less specified otherwise, always fasten using cable ties.
  • Page 31 Peugeot 207 / 207 SW / 207 CC Shape fuel standpipe 1 according to tem- plate, cut to length and install, see "installa- tion instructions". Installing fuel stand- pipe Install fuel-tank sending unit 1 in accordance with manufacturer's instructions. 2 Hose section, 10 mm dia. hose clamps [2x]. 3 Mecanyl fuel line Connect- ing fuel...
  • Page 32 Peugeot 207 / 207 SW / 207 CC Shape fuel standpipe 1 according to tem- plate, cut to length and install, see "installa- tion instructions". Installing fuel stand- pipe Install fuel-tank sending unit 1 in accordance with manufacturer's instructions. 2 Hose section, 10 mm dia. hose clamps [2x]. 3 Mecanyl fuel line Connect- ing fuel...

  • Page 33: Exhaust Gas

    Peugeot 207 / 207 SW / 207 CC Exhaust gas Petrol 1 Exhaust pipe a =230mm Preparing 2 Exhaust end section exhaust b = 100mm pipe Discard section X 1 Silencer 2 M6x55 bolt, flanged nut 3 40 mm spacer Mounting silencer 1 Exhaust end section...
  • Page 34 Peugeot 207 / 207 SW / 207 CC Diesel 1 Exhaust pipe a =170mm 2 Exhaust end section b = 100mm Preparing Discard section X exhaust pipe 1 Silencer 2 M6x55 bolt, flanged nut 3 40 mm spacer Mounting exhaust end sec- tion Ensure sufficient distance from neighbouring...

  • Page 35: Final Work

    - Place the "Switch off parking heater before refuelling" signboard near the filler neck. - For initial start-up and function check, see installation instructions Feel the drive Webasto AG Postfach 80 D-82132 Stockdorf / Germany National Hotline: 01805 93 22 78...
  • Page 36 Peugeot 207 / 207 SW / 207 CC Template for petrol fuel standpipe Template for diesel fuel standpipe 100mm Scale 1:1 Compare size of the printed version with dimension lines. Allowed tolerance 2%. Set the printer settings to “no margin” or “minimise margins” and 100% of the normal size.

  • Page 37: Operating Instructions For End Customer

    Peugeot 207 / 207 SW / 207 CC Operating Instructions for End Customer Please remove page and add to the vehicle operating instructions. Note: We recommend matching the heating time to the driving time. Heating time = driving time Example: For a driving time of approx.
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This manual is also suitable for:

Thermo top c

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