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307 2005 1.4 1.6 2.0 B D E PDF
307 2005 1.4 1.6 2.0 B D E PDF
e1
Thermo Top C Additional heating 00 0002
e1
Thermo Top P Additional heating 00 0104
Installation instructions
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.
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.
Table of Contents
Validity 2 Moving the cable harness 18
Heater Unit / Installation Kit 3 Water Connection 19
Foreword 3 Only for 1.4l and 1.6l gasoline 19
General Instructions 3 2.0l Gasoline only 23
Special Tools 3 1.6l Diesel only 27
Explanatory Notes on the Document 4 2.0l Diesel only 31
Preliminary work 5 Combustion Air 36
Heater unit installation location 5 Exhaust System 37
Preparing the electronics for the automatic air Fuel Connection 38
conditioning 6 Fuel take-off for gasoline engine 40
Electrical Connections 7 Fuel take-off for diesel engine 41
Manual air conditioning blower control 8 Final Work 43
Automatic air conditioning blower control 10 Operating instructions for the end customer 44
Remote Start Option 13 Template for bracket 45
Thermo Call Option 14 Gasoline tank extracting device template 46
Preparing the Installation Location 15 Diesel tank extracting device template 47
Installing the Heater Unit 16
Validity
Manufacturer Model Type EG-BE No. / ABE
Peugeot 307 3... e2 * 2001 / 116 * ...
Vehicle and engine types as well as equipment variants, 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.
2
Peugeot 307/ 307Break/ 307SW
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 307/ 307Break/ 307SW with Gasoline and
diesel engines.
– Re. validity, see page 2 – from model year 2005 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 for example bore holes, with anti-corrosion wax (Tectyl 100K,
Order No. 111329)!
Special Tools
- Torque spanner for 2.0 - 10 Nm
- Vice-grip wrench
- Riveting nut tool
- Stage drill to Ø 42mm
3
Peugeot 307/ 307Break/ 307SW
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.
Mechanical work
Electrics
Water connection
Fuel connection
Exhaust system
Combustion air
4
Peugeot 307/ 307Break/ 307SW
Preliminary work
WARNING!
1 Heater unit
Installation
location
1
5
Peugeot 307/ 307Break/ 307SW
300
4
br 1,0mm²
300
5 Enclosed
br 4,0mm²
wires
1500
6
rt 4,0mm²
Reconnect according to the circuit diagram.
Insert wires 5 and 6 in enclosed insulating
1500 hose.
HG
X1 F3
4
rt/ws
rt
gn/ws
rt
86 87 87a 3
Pre-
assem-
K3 bling the
85 30 cable
sw Harness
rt
6
4 86 30
K3.1
85 87 87a
br
2
br br br
5
6
Peugeot 307/ 307Break/ 307SW
Electrical Connections
Cable harness feed-through Cable harness feed-through
1 1
2 3
br
bl
sw rt br rt Cable
Wait to install the metering pump harness
cable harness until later together installation
with fuel line along the original diagram
vehicle fuel lines.
Wires shown grey are only used
for automatic air conditioning.
1 2 1 2
3
4 5
Fuse holder, K3 relay, K3.1 relay Time switch, summer / winter switch option
1 K3.1 relay, Ø 5mm bore hole; M5x12 bolt, 1 Summer / winter switch, bore hole Ø 12 mm.
washer, flanged nut (only for automatic air 2 Time switch, drilling template
conditioning)
2 Fuse holder retaining plate, Ø 5mm hole,
M5x12 bolt, washers, nuts
4 K3.1 relay, Ø 5mm hole, M5x12 bolt, washers,
flanged nuts
3 Positive wire to positive terminal.
5 Ground wire to ground point
7
Peugeot 307/ 307Break/ 307SW
1 6
5 4 3 7
8
Peugeot 307/ 307Break/ 307SW
HG
X1 F3 PSF1
4
gn/ rt/ws
ws BE
rt Circuit
A1 A5 A4 A3 A2 diagram
without
86 87 87a ws bl gn ge automatic
rt air condi-
tioning
K3
85 30 sw
rt
+ gn
A1 B1 A2 B3 A3
M GM
-
WG
br sw
31
9
Peugeot 307/ 307Break/ 307SW
Positive
triggering
of the
blower
motor
3 10
4 3 11
10
Peugeot 307/ 307Break/ 307SW
1 Diode
2 White (ws) wire from the air conditioning Diode
control. connection
3 White (ws) wire to blower motor controller
3 12
11
Peugeot 307/ 307Break/ 307SW
Peugeot 307 i
Webasto
Klimaautomatik
30
15
PSF1 KB
HG 1 St 2
X1 F3
4 3 St 1 ws
rt/ws rt
rt
gn/ws
86 87 87a sw
rt rt
K3 +
Automatic
85 30 M GM air condi-
tioning
-
br rt circuit
4 3 sw diagram
rt 6
86 30
K3.1
85 87 87a
D1
br 5
br
br
sw ws
2
R1 1 3 4 2
GR
br
1
31
12
Peugeot 307/ 307Break/ 307SW
Assem-
bling the
receiver
3 13
1 1 Antenna
Assem-
bling the
antenna
14
Assem-
bling the
temperature
sensor
15
13
Peugeot 307/ 307Break/ 307SW
Assem-
bling the
receiver
16
1 1 Antenna
Assem-
bling the
antenna
17
1 1 Tip switch
Assem-
bling the
tip switch
18
14
Peugeot 307/ 307Break/ 307SW
2 19
1 Bracket
2 M6x20 bolt, washer [2x]
3 M6x20 bolt, washer
1 Assem-
bling the
bracket
2 2
3 20
1 Cross rail
2 Bolt20/2, flanged nuts [2x]
3 3 Cable harness
Assem-
bling the
bracket
21
2 Assem-
bling the
bracket
4 22
15
Peugeot 307/ 307Break/ 307SW
Replacing
the
circulation
pump
cover
1
23
1 heater unit
2 Ejot screw bolt [2x]
3 Ejot screw bolt, 2 washers
Assem-
bling the
heater unit
3 24
1 Insert the
cable
harness
1 1 25
1 Cross rail
4 Strut
3 2 Ejot screw bolt [2x]
3 Copying the hole image [2x]
Hole image
on the
3 cross rail
Inserting
the rivet
nut
27
Inserting
the rivet
nut
28
1 4 29
17
Peugeot 307/ 307Break/ 307SW
30
Moving the
cable
1 harness
31
18
Peugeot 307/ 307Break/ 307SW
Water Connection
WARNING!
Tighten all hose clamps to 2.0 + 0.5 Nm.
Any cold water 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:
Heat
Wärme-
exchanger
tauscher
Water
installation
diagram
A
Motor
19
Peugeot 307/ 307Break/ 307SW
a = 1,300mm
Dispose of section X
A X
Cutting
water
hoses into
sections
b = 1400
Dispose of sections X
B
X
Cutting
water
hoses into
sections
b
X
3 4 3 32
2 33
20
Peugeot 307/ 307Break/ 307SW
Splitting
point
3 34
Engine
A outlet
connection
3 35
2 36
Hose
placement
A
1 37
21
Peugeot 307/ 307Break/ 307SW
Hose
placement
A 38
39
2 Connecting
the heater
unit outlet
40
22
Peugeot 307/ 307Break/ 307SW
Water connection
WARNING!
Tighten all hose clamps to 2.0 + 0.5 Nm.
Any cold water 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:
Wärme-
Heat
exchanger
tauscher
Water
installation
diagram
Motor B
23
Peugeot 307/ 307Break/ 307SW
b = 1,420mm
B Cutting
X Dispose of sections X
water
hoses into
sections
b
X
c = 1,450mm
Dispose of sections X
C
X
Cutting
water
hoses into
sections
c
X
3 41
4 3 42
24
Peugeot 307/ 307Break/ 307SW
Splitting
point
43
Engine
outlet
connection
44
Connect
hose A and
A B
1 45
Connecting
B the heat
exchanger
inlet
2 C 46
25
Peugeot 307/ 307Break/ 307SW
Hose
placement
1 C 47
Hose
placement
B 1 48
Connecting
to the
heater unit
B 49
26
Peugeot 307/ 307Break/ 307SW
Water connection
WARNING!
Tighten all hose clamps to 2.0 + 0.5 Nm.
Any cold water 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:
Heat
Wärme-
exchanger
tauscher
Water
installation
diagram
Motor B
27
Peugeot 307/ 307Break/ 307SW
b = 1,150mm
B Cutting
X Dispose of sections X
water
hoses into
sections
b
X
c = 1,200mm
Dispose of sections X
C
X
Cutting
water
hoses into
sections
c
X
3 50
2 51
28
Peugeot 307/ 307Break/ 307SW
Splitting
point
52
Engine
outlet
connection
1 53
Connect
hose A and
B
1 54
Connecting
B the heat
exchanger
inlet
C 1 55
29
Peugeot 307/ 307Break/ 307SW
Hose
placement
C 1 56
57
2 Connecting
the heater
unit outlet
58
30
Peugeot 307/ 307Break/ 307SW
Water connection
WARNING!
Tighten all hose clamps to 2.0 + 0.5 Nm.
Any cold water 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:
Wärme-
Heat
tauscher
exchanger
Water
installation
diagram
Motor
A
31
Peugeot 307/ 307Break/ 307SW
A X a = 1,250mm
Dispose of section X
Cutting
water
hoses into
sections
B b = 1,300mm
X
Dispose of sections X
Cutting
water
hoses into
sections
b
X
4 4 59
4 3 60
32
Peugeot 307/ 307Break/ 307SW
Remove
the bracket
and hose
61
Splitting
point
Pre-
assem-
bling the
2 hoses
1 B 1 1 63
Engine
outlet
connection
2 A 64
33
Peugeot 307/ 307Break/ 307SW
Connecting
the heat
exchanger
inlet
A 65
Hose
placement
A 66
Hose
placement
2 A 67
Hose
placement
A 68
34
Peugeot 307/ 307Break/ 307SW
Hose
placement
A 1 69
Connecting
to the
heater unit
A 70
35
Peugeot 307/ 307Break/ 307SW
3 Combustion Air
Fasten the fuel pipe and silencer with cable i
clips according to the figure.
2 1 71
36
Peugeot 307/ 307Break/ 307SW
1 2 Exhaust System
1 Exhaust pipe
a = 190mm
2 Exhaust end section
b = 120mm Preparing
the
Dispose of section X exhaust
pipe
a b
Bore holes
5 4 72
1 2 3 4 2 5 Exhaust silencer
3 30mm spacer sleeve [2x], M6x70 bolt,
flanged nut.
2 Hose clamps [3x]
4 Exhaust pipe
1 Exhaust end section
Assem-
bling the
exhaust
system
5 2 73
74
37
Peugeot 307/ 307Break/ 307SW
Fuel Connection
CAUTION!
Open the vehicle's tank-cap lock, ventilate the tank and then re-close the tank lock.
Install fuel line and metering pump cable harness so that they are protected against stone impact.
Unless specified otherwise, always fasten using cable clips!
Fit the fuel line and cable harness with edge protectors around sharp edges.
WARNING!
The fuel line and cable harness to the metering pump should be installed based on the cable harness
installation diagram.
Connecting
to the
heater unit
3 75
Installing
lines
76
3 Installing
lines
77
38
Peugeot 307/ 307Break/ 307SW
Installing
lines
78
39
Peugeot 307/ 307Break/ 307SW
80
4 3 2 2 81
3 Tank mounting
2 Universal clip Ø 10 mm
1 1 Residual section of Mecanyl fuel line
Connecting
3
and
disconnecti
ng the fuel
line
82
83
40
Peugeot 307/ 307Break/ 307SW
2 84
4 4 85
1 Return line
2 Tank extracting device
2 Inserting
tank
extracting
device
1
86
1 Tank mounting
3 Universal clip Ø 10 mm
2 Residual section of Mecanyl fuel line
Connecting
and
disconnecti
ng the fuel
line
3 87
41
Peugeot 307/ 307Break/ 307SW
88
42
Peugeot 307/ 307Break/ 307SW
Final Work
WARNING!
Reassemble disassembled components in reverse order.
Check that all hose lines, hose, spring band clamps and universal clips, and all electrical connections
are securely fastened.
Secure all loose cables using cable clips.
Spray heating unit components with anti-corrosion wax (Tectyl 100K, Order No. 111329).
- Connect battery
- Start engine, bleed water circuit according to the vehicle manufacturer's specifications, top up with
cold water.
- Set the time switch.
- Set the vehicle heating with automatic air conditioning or without automatic air conditioning
according to the "operating instructions for the end customer".
- Check that the auxiliary heating operates properly, see operating instructions / installation
instructions. i
- Attach the "Switch off auxiliary heating before re-fuelling" sticker onto the left side of the B-pillar.
For
vehicles
without
automatic
air condi-
tioning
89
For
vehicles
with
automatic
air condi-
tioning
2 90
44
Peugeot 307/ 307Break/ 307SW
Template
for bracket
100mm
Scale 1:1
100mm
0 45
Peugeot 307/ 307Break/ 307SW
100mm
Scale 1:1
100mm
0 46
Peugeot 307/ 307Break/ 307SW
100mm
Scale 1:1
100mm
0 47