Webasto Thermo Top E Bedienerhandbuch

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 Fee Euro 10.00 © Webasto AG

Feel the drive

Peugeot 207 / 207 SW / 207 CC

Petrol and Diesel

from Model Year 2006

Left-hand drive vehicle

Manual transmission

Water Heater

Thermo Top E Parking Heater

Thermo Top C Parking Heater

Installation documentation

00 0003

00 0002

Peugeot 207 / 207 SW / 207 CC

Validity

Vehicle and engine types, equipment variants and national specifications not listed in this installation

documentationhavenot beentested. However,installationaccordingtothis installationdocumentation

may be possible.

The installation location of a digital timer 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 model Output in kW Displacement in cm³

KFU Petrol 65 1360

NFU Petrol 80 1587

5FW Petrol 88 1598

5FX Petrol 110 1598

5FY Petrol 128 1598

9HV Diesel 66 1560

9HX Diesel 66 1560

9HY Diesel 80 1560

9 Hz Diesel 80 1560

Validity 2

Heater/Installation Kit 3

Foreword 3

General Instructions 3

Special Tools 3

Explanatory Notes on Document 4

Preliminary Work 5

Heater installation location 5

Automatic air-conditioning 6

Electrical system 9

Fan control for manual air conditioning 10

Automatic air-conditioning fan control 12

Remote option (Telestart) 16

Preparing heater 17

Preparing installation location 18

Installing heater 19

Petrol coolant circuit 21

Diesel coolant circuit 26

Combustion air 29

Fuel 30

Exhaust gas 33

Final Work 35

Operating Instructions for End Customer 37

Table of Contents

Peugeot 207 / 207 SW / 207 CC

Heater/Installation Kit

Also required with manual air conditioning:

Also required with automatic air-conditioning:

Heater recommended for the respective vehicle class:

The selection of the heater is based on the passenger compartment size of the vehicle and the level of

comfort required by the customer.

Foreword

This installation documentation appliesto the vehicles Peugeot 207 / 207 SW / 207 CC with Petrol and

Diesel engine - for validity, see page 2 - from model year 2006 and later, assuming technical modifica-

tions 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 this instal-

lation documentation.

However, the stipulations in this "installation documentation", the "operating instructions" and the "in-

stallation instructions" for the Thermo Top C/E must always be observed.

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 spec-

ified otherwise, fasten hoses, lines and wiring harnesses to original vehicle lines and wiring harnesses

using cable ties.

Sharp edges must be provided with rub protection (cut-open fuel hose).

Spray unfinished body areas, e.g. drilled holes, with anti-corrosion wax (Tectyl 100K, Order No. 111329).

While installing an IPCU, the corresponding settings must be checked or adjusted before the installa-

tion.

Special Tools

- Torque wrench for 2.0 - 10 Nm

- Hose clamping pliers

- Metric thread-setter kit

Quantity Designation Order No.:

1 Retail accessories of Thermo Top C / E See price list

1 Heater control See price list

Quantity Designation Order No.:

Installation kit for Peugeot 207 / 207 SW / 207 CC

Petrol and Diesel

with manual air conditioning 1311147C

Quantity Designation Order No.:

Installation kit for Peugeot 207 / 207 SW / 207 CC

Petrol and Diesel

Automatic air-conditioning 1311169D

Vehicle Heater

Compact car Thermo Top E

Mid-size car, estate car Thermo Top C

Special features are highlighted using the following symbols:

Mechanical system

Electrical system

Coolant circuit

Fuel

Exhaust gas

Combustion air

The arrow in the vehicle icon indicates the position on

the vehicle and the viewing angle.

Peugeot 207 / 207 SW / 207 CC

Specific risk of injury or fatal accidents.

Specific risk of damage to components.

Specific risk of fire or explosion.

Referenceto generalinstallationinstructions ofWebas-

tocomponentsortothemanufacturer'svehicle-specific

documents.

Reference to a special technical feature.

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.

Peugeot 207 / 207 SW / 207 CC

Heater installation location

1Heater

Installa-

tion loca-

tion

Preliminary Work

WARNING!

- Disconnect the battery.

-Depressurisethe 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.

- Remove the battery completely.

- Remove the air filter together with the intake hose.

- Open the fuel tank cap, ventilate the tank.

- Close the fuel tank cap again.

- Remove the underride protection on the left.

- Remove the rear bench seat and backrest.

- Open the tank-fitting service lid

- Remove the fuel-tank sending unit in accordance with manufacturer's instructions.

- Remove the trim of the centre tunnel in the left-hand footwell

- Remove the lower instrument panel trim on the left.

- Remove the A/C control panel.

Please remove page 35 “Operating instructions for the end customer” and add this to the vehicle op-

erating instructions.

Peugeot 207 / 207 SW / 207 CC

Preparing electrical system

Manual air conditioning

Wire sections 1 - 5 for connection K3.1 relay.

Cutting

wires to

length

Produce connections as shown in wiring dia-

gram.

Premount-

ing K3 re-

lay

Pull wire section 4 into protective sleeving C,

wire section 1 into protective sleeving A and

wire section 2, 3, 5 into protective sleeving B.

Cutting

protective

sleeving to

length

Automatic air-conditioning

Wire sections 1, 3, and 4 for connection K3.1

relay.

Wire section 2for connecting K3.2 relay.

Cutting

wires to

length

600

4²

600

4²

200

1²

600

2br

1,5²

85 30

87a87

K3.1

5br

3swbr 1

2br

550mm550mm 150mm

BA C

300

rt 0,5mm²

300

3 4

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.

Wire section 9for connection K3.

Cutting

wires to

length

Produce connections as shown in wiring dia-

gram.

Install wire section 9in protective sleeving

provided.

Premount-

ing K3 re-

lay

Produce connections as shown in wiring dia-

gram.

Premount-

ing K3.1 re-

lay

Produce connections as shown in wiring dia-

gram.

Premount-

ing K3.2 re-

lay

300

sw 0,5mm²

br 0,5mm²

3000

gn/ws 0,75mm²

5 6

7 8

200 200

85 30

87a87

br sw

rt/ws

gn/ws

85 30

87a87

K3.1

3rt

5swbr 7

85 30

87a87

K3.2

2rt

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:

Duty cycle: 75%

Frequency: 2000Hz

Voltage: 10V

Function: Low-side

The settings are to be checked during start-

up of heater, and adjusted if necessary.

Premount-

ing IPCU

86 85

IPCU

86 85

Peugeot 207 / 207 SW / 207 CC

Electrical system

Wiring harness pass through

18 mm dia. hole, included protective rubber plug

Summer/winter switch option

1Summer/winter switch, drilled hole 12 mm dia.

Wiring har-

ness rout-

ing

diagram

Fuse holder, K3 relay

1K3 relay, 5.5x13 bolt, hole 4.5 mm dia.

2Retaining plate of fuse holder, 5.5x13 bolt,

4.5 mm dia. hole

3Fuse holder

Digital timer

1Digital timer

gr/ws

Wait until later to route wiring

harness of metering pump to-

gether with fuel line in corrugat-

ed tube along original vehicle

brake lines on underbody

Peugeot 207 / 207 SW / 207 CC

Fan control for manual air condi-

tioning

Fasten additional relay K3.1 1with 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.

1White (ws) wire of connector IC 26

3White (ws) wire of PSF 1 connector 2V NR

Pin 2

4Red (rt) wire to K3.1/86

5Red (rt) wire from K3/87a

6Black (sw) wire from K3/30

Connect-

ing fan mo-

tor

Make connection with the help of attached 6

mm dia. cable lug.

1Original vehicle earth point

2Brown (br) wire K3.1/85

Earth con-

nection of

K3.1

Connection on connector 8V NR 3from fan

switch/A/C control panel. Produce connec-

tions as shown in wiring diagram.

1Violet (vi) wire of connector 4V NR, Pin 3

2Violet (vi) wire of connector 8V NR, Pin 3

4Black (sw) wire of connector 8V NR, Pin 1

5Brown (br) wire of K3.1/87a

6Brown (br) wire K3.1/87

7Black (sw) wire K3.1/30

8Black (sw) wire of earth point

Connect-

ing A/C

control

panel

2 3

1 2

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