installation instructions peugeot 307/ 307break/...
TRANSCRIPT
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 307/ 307Break/ 307SWGasoline and dieselFrom model year 2005For left-hand drive vehicles onlyAutomatic gear not tested!
Ident. No.: 1310346BEN Fee 10.- Euro © Webasto AG
Water heater unit
Thermo Top E Additional heating
Thermo Top C Additional heating
Thermo Top P Additional heating
Installation instructions
e100 0003
e100 0002
e100 0104
22
Peugeot 307/ 307Break/ 307SW
Validity
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.
Manufacturer Model Type EG-BE No. / ABEPeugeot 307 3... e2 * 2001 / 116 * ...
Engine type Engine model Power in kW Engine capacity in cm³KFU Gasoline 65 1360NFU Gasoline 80 1587RFJ Gasoline 103 19979HV Diesel 66 15609 Hz Diesel 80 1560RHR Diesel 100 1997
Validity 2Heater Unit / Installation Kit 3Foreword 3General Instructions 3Special Tools 3Explanatory Notes on the Document 4Preliminary work 5Heater unit installation location 5Preparing the electronics for the automatic air
conditioning 6Electrical Connections 7Manual air conditioning blower control 8Automatic air conditioning blower control 10Remote Start Option 13Thermo Call Option 14Preparing the Installation Location 15Installing the Heater Unit 16
Moving the cable harness 18Water Connection 19
Only for 1.4l and 1.6l gasoline 192.0l Gasoline only 231.6l Diesel only 272.0l Diesel only 31
Combustion Air 36Exhaust System 37Fuel Connection 38
Fuel take-off for gasoline engine 40Fuel take-off for diesel engine 41
Final Work 43Operating instructions for the end customer 44Template for bracket 45Gasoline tank extracting device template 46Diesel tank extracting device template 47
Table of Contents
33
Peugeot 307/ 307Break/ 307SW
Heater Unit / Installation Kit
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.
ForewordThese 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 InstructionsInstallation 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
Amount Description Order no.:1 Commercial supply of required control See price list1 Installation kit Peugeot 307/ 307Break/ 307SW Gasoline
and diesel from model year 051310342A
Amount Description Order no.:1 Peugeot 307/406 climate kit 66299A
Vehicle Heater unitCompact car Thermo Top EMid-class, station wagon Thermo Top CLuxury, van, off-roader Thermo Top P
44
Special features are highlighted using the following symbols:
Mechanical work
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 307/ 307Break/ 307SW
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.
i
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 307/ 307Break/ 307SW
Preliminary work
WARNING!
- Open the tank cap, ventilate the tank.- Close the tank cap again.- 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.- Disconnect the battery and remove it!- Let off pressure in the cooling system.- Completely remove the air filter.- Remove the bumper.- Remove the underride protection- Open right tank mounting service lid.- Remove the footwell panel on the driver’s side.
Heater unit installation location
1 Heater unit
Installation location
1
1
5Peugeot 307/ 307Break/ 307SW
Preparing the electronics for the automatic air conditioning
Wire section 1 will be needed later forconnecting the resistor.
Cutting enclosed wires into sections
Reconnect according to the circuit diagram.Insert wires 5 and 6 in enclosed insulating hose.
Enclosed wires
Pre-assem-bling the cable Harness
br 2,5mm²
400
21
100
rt 0,75mm²3
300
br 4,0mm²
1500
5
br 1,0mm²
300
4
rt 4,0mm²
1500
6
gn/ws
sw
br
rt/wsrt
F3
rt
rt
br br
br
4
HGX1
K3.1
87a8785
86 30
K3
87a8786
85 30
6
5
3
4
2
6
Peugeot 307/ 307Break/ 307SW
Electrical Connections
Cable harness feed-through
1 Protective rubber sleeve
Cable harness feed-through
1 Secure cable harnesses with cable ties.
Cable harness installation diagram
Fuse holder, K3 relay, K3.1 relay1 K3.1 relay, Ø 5mm bore hole; M5x12 bolt,
washer, flanged nut (only for automatic air 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
Time switch, summer / winter switch option1 Summer / winter switch, bore hole Ø 12 mm.2 Time switch, drilling template
2
1
3
1
br
blrtsw rtbr
Wait to install the metering pump cable harness until later together with fuel line along the original vehicle fuel lines.Wires shown grey are only used for automatic air conditioning.
i
4
5
23
4
1
5
1 2
7
Peugeot 307/ 307Break/ 307SW
Manual air conditioning blower control
Connection to 6-pin connector in resistor group pin B3.
1 Plug for resistor groupPlug for resistor group
Connect with enclosed blade receptacles according to the circuit diagram.
5 Plug for resistor group, pulled1 Green (gn) line from blower switch level 22 Red (rt) wire from K3/87a3 Black (sw) wire from K3/304 Green (gn) wire to connector in resistor
group pin B3. Connect cables
61
7
1
5
2
34
8
Peugeot 307/ 307Break/ 307SW
Circuit diagram without automatic air condi-tioning
Webasto components Peugeot components Colours and symbols
Legend
HG heater unit TT-C/E PSF1 central electrics rt redF3 blower fuse BE Control unit with blower
switch ws white
K3 blower relay sw blackWG resistor group br brownGM blower motor gn green
bl bluege yellow
Insulate and tie back wire ends
X splitting point
gn/ws
sw
br
rt/ws
Webasto
31
3015
Peugeot 307 ohneKlimaautomatik
rt
4
HGX1 F3
M
+
-
GM
rt
K3
87a8786
85 30
WG
A3B3A2B1A1
A2A3A4A5
BE
A1
rt
sw
gegn
gn
blws
PSF1
i
9
Peugeot 307/ 307Break/ 307SW
Automatic air conditioning blower control
Ensure sufficient distance of the resistor from adjacent components. This will be hot!Reconnect according to the circuit diagram.
4 Bracket (short limb), M6x16 bolt, spring washer, 5 mm spacer on original vehicle ground point.
1 Resistance, M5x20 pan head screw, washer, flanged nut
2 Wire from K3/87a3 Wire section 1to ground point
Assembly of resistor
The positive triggering is between the 6 pin plug connection on Pin 3 and the two pin plug for the blower motor, pin 2.
1 6-pin plug connection
Positive triggering of the blower motor
Connect with enclosed flat connectors according to the circuit diagram.
1 Red (rt) wire to blower motor and blower controller
2 Black (sw) wire from K3/303 Red (rt) wire from K3/87a4 Red (rt) wire from PSF1 central electronics
Positive triggering of the blower motor
The ground triggering is between the 2 pin plug connection on the blower motor, pin 1, and the 4 pin plug on the blower controller, pin 3.Connect with enclosed flat connectors according to the circuit diagram.
1 Blower motor connector2 Black (bk) wire from blower motor
connector5 Red (rt) wire from K3.1/303 Black (bk) wire to blower motor controller4 Brown (br) wire from K3.1/87
Positive triggering of the blower motor
84
1 2
3
9
1
10
4
3
1
2
11
1
3
2
4
5
10
Peugeot 307/ 307Break/ 307SW
The diode connection is between the 6 pin plug connection on the air conditioner, pin 1, and the 4 pin plug on the blower controller, pin 2.Connect with enclosed flat connectors according to the circuit diagram.
1 Diode2 White (ws) wire from the air conditioning
control.3 White (ws) wire to blower motor controller
Diode connection
123
21
11
Peugeot 307/ 307Break/ 307SW
Automatic air condi-tioning circuit diagram
Webasto components Peugeot components Colours and symbols
Legend
HG heater unit TT-C/E PSF1 central electrics rt redF3 blower fuse KB Air conditioning control ws whiteK3 blower relay St 1 6-pin plug connection sw blackK3.1 Supplementary
relaySt 2 6-pin connector br brown
R1 Resistor GM blower motor gn greenD1 Diode GR Blower controller
Insulate and tie back wire ends
X splitting point
gn/ws
sw
br
rt/ws rt
F3
rt
rt
br
br
br
4
HGX1
K3.1
87a8785
86 30
K3
87a8786
85 30
6
5
34
2
Webasto
31
3015
Peugeot 307Klimaautomatik
PSF1
St 1
M
+
-
GM
GR
2431
KB1 St 2
R1
br1
sw
sw
rt rt
3
rt
D1
ws
ws
i
12
Peugeot 307/ 307Break/ 307SW
Remote Start Option
1 Bolt M5x12, washer, flanged nut in previously drilled hole
2 Bracket3 Receiver
Assem-bling the receiver
1 Antenna
Assem-bling the antenna
only for HTM 100
1 Temperature sensor, self-adhesive Velcro strip
2 Air duct
Assem-bling the temperature sensor
3
1
13
2
i
1
14
1
15
2
13
Peugeot 307/ 307Break/ 307SW
Thermo Call Option
1 Receiver, self-adhesive Velcro tape [2x]
Assem-bling the receiver
1 Antenna
Assem-bling the antenna
1 Tip switch
Assem-bling the tip switch
1
16
i
1
17
1
18
14
Peugeot 307/ 307Break/ 307SW
Preparing the Installation Location
1 Place template on the middle of the cross rail.
3 Cross rail4 Existing openings [3x]2 Copy the hole image, Ø 7 mm bore hole
[3x]Copying the hole image
Position the bracket according to the figure 20, 21 and 22.
1 Bracket2 M6x20 bolt, washer [2x]3 M6x20 bolt, washer
Assem-bling the bracket
The cable harness depends on vehicle equipment.
1 Cross rail2 Bolt20/2, flanged nuts [2x]3 Cable harness
Assem-bling the bracket
1 Bolt20/3, body washer, flanged nuts 2 Plastic traverse3 Bracket4 Cross rail
Assem-bling the bracket
19
4
2
2
2
4
4
31
20
1
3
22
21
3
221
22
2
1
4
3
15
Peugeot 307/ 307Break/ 307SW
Installing the Heater Unit
1 Circulation pump cover 193°
Replacing the circulation pump cover
Ejot screw bolts tightening torque 10 Nm!Insert two washers between the heater unit and the bracket in position 3.
1 heater unit2 Ejot screw bolt [2x]3 Ejot screw bolt, 2 washers
Assem-bling the heater unit
Run the heater unit cable harness along the original vehicle cable harnesses and fasten with cable clips.
1 Heater unit cable harness
Insert the cable harness
Only loosely assemble the Ejot screw bolts.
1 Cross rail4 Strut2 Ejot screw bolt [2x]3 Copying the hole image [2x]
Disassemble the strut again.
Hole image on the cross rail
23
1
24
1 2
3
2
25
1
1
11
26
3
1 22
3
4
16Peugeot 307/ 307Break/ 307SW
1 Ø 9mm bore hole, rivet nut
Inserting the rivet nut
1 Ø 9mm bore hole, rivet nut
Inserting the rivet nut
Ejot screw bolts tightening torque 10 Nm!
1 M6x20 bolt, spring washer [2x]2 Strut3 Protective sheet4 Ejot screw bolt [2x]
Assem-bling the strut and protective sheet
27
1
28
1
29
1
41
2
3
17
Peugeot 307/ 307Break/ 307SW
Moving the cable harness
The cable harness design depends on the equipment according to image 30 or 31. Secure cable harness with cable ties.
1 Original vehicle cable harness2 Cable mount in the heater unit bore hole. Moving the
cable harness
The cable harness design depends on the equipment according to image 30 or 31. Secure cable harness with cable ties.
1 Original vehicle cable harness
Moving the cable harness
30
1
2
1
31
1
1
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:
Only for 1.4l and 1.6l gasoline
Water installation diagram
All undesignated clamps are Ø 20-27mm hose clamps.All connecting pipes are Ø 17x20.
Wärme-tauscher
MotorA
B
Heat exchanger
19
Peugeot 307/ 307Break/ 307SW
a = 1,300mm
Dispose of section X
Cutting water hoses into sections
b = 1400
Dispose of sections X
Cutting water hoses into sections
Only loosely assemble the bolt 4.
1 Original vehicle bolt2 Angle bracket drilled open to Ø 8.5mm on
the short end.3 Rubberized tube clamp Ø 29 mm [2x]4 M6x20 bolt, flanged nut Preassem-
bling the hose mounting
Only loosely pre-assemble the bolt 3.
1 15mm spacer disc2 Rubberized tube clamp Ø 34mm [2x]3 M6x30 bolt, body washer, flanged nut on
existing holePreassem-bling the hose mounting
a
A X
b
X
X
B
32
1 2
33 4
33
21
2
3
20
Peugeot 307/ 307Break/ 307SW
The design of the cable harnesses 1depends on the equipment.
1 Original vehicle cable harnesses [2x]2 Heat exchanger inlet hose section3 Engine outlet hose section
Splitting point
2 Engine outlet hose section1 Black rubber profile3 Fasten hose A to the grounding wires with
cable clips.
Engine outlet connection
The design of the cable harnesses depends on the equipment.
1 Heat exchanger inlet hose2 Fasten hose B to the cable harness
bracket with cable clips.Connecting the heat exchanger inlet
1 Preassembled rubberized tube clamp Ø 29 mm [2x]
Hose placement
34
21
3
1
35
2
A
1A
3
36
A
1
B
2
37
A1
1
A
B
21
Peugeot 307/ 307Break/ 307SW
Hose placement
Cut the enclosed 1500 mm heat protection hose in the middle and slide it onto hoses A and B.
2 Preassembled rubberized tube clamp Ø 34mm
1 Heater unit inletConnecting the heater unit inlet
Before connecting, fill the water hoses with coolant water
2 Preassembled rubberized tube clamp Ø 34mm
1 Heater unit outlet
Connecting the heater unit outlet
Check the placement of water hoses A and B along the entire length as well as the placement of the black (sw) rubber profile and correct if necessary.Secure hoses with cable ties.Tighten rubberised tube clamps [4x].
38A
B
39
2
1 A
40
B
2
1
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:
2.0l Gasoline only
Water installation diagram
All undesignated hose clamps are Ø 20-27 mm hose clamps.Original vehicle spring band clamp will be used again. All connecting pipes are Ø 18x20.
Wärme-tauscher
Motor
A
B
C
Heat exchanger
23
Peugeot 307/ 307Break/ 307SW
A = Enclosed 180° bend Ø 18mm
b = 1,420mm
Dispose of sections X Cutting water hoses into sections
c = 1,450mm
Dispose of sections X
Cutting water hoses into sections
Only loosely pre-assemble the bolt 2.-{}-
1 Original vehicle double bolt4 Angle bracket3 Rubberized tube clamp Ø 29 mm [2x]2 M6x20 bolt, flanged nut
Preassembling the hose mounting
Bend the fastening strip 4 according to pictureOnly loosely pre-assemble the bolt 2.-{}-
4 Fastening strap with holes1 M6x20 bolt, body washer, flanged nut on
existing hole3 Rubberized tube clamp Ø 34mm [2x]2 M6x20 bolt, flanged nut
Preassembling the hose mounting
A
b
X
X
B
c
X
X
C
41
2
3
31
4
42
31
34
2
24
Peugeot 307/ 307Break/ 307SW
Pull the hose 1 off the engine outlet.
1 Engine outlet hose to the heat exchanger inlet.
Splitting point
Engine outlet connection
1 Heat exchanger inlet hose
Connect hose A and B
1 Heat exchanger inlet hose2 Black rubber profile
Connecting the heat exchanger inlet
43
1
44
A
45
A
B
1
46
B
1
C2
25Peugeot 307/ 307Break/ 307SW
1 Preassembled rubberized tube clamp Ø 29 mm [2x]
Hose placement
Cut the enclosed 1500 mm heat protection hose in the middle and slide it onto hoses C and C.
1 Preassembled rubberized tube clamp Ø 34mm [2x]
Hose placement
Before connecting, fill the water hoses with coolant water
1 Heater unit outlet2 Heater unit inlet
Connecting to the heater unit
Check the placement of water hoses A and B along the entire length as well as the placement of the black (sw) rubber profile and correct if necessary.Secure hoses with cable ties.Tighten rubberised tube clamps [4x].
47C
B
1
1
48
C 1
B 1
49
C1 2
B
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:
1.6l Diesel only
Water installation diagram
All undesignated hose clamps are Ø 20-27 mm hose clamps.Original vehicle spring band clamp will be used again. All connecting pipes are Ø 18x20.
Wärme-tauscher
Motor
A
B
C
Heat exchanger
27
Peugeot 307/ 307Break/ 307SW
A = Enclosed 180° bend Ø 18mm
b = 1,150mm
Dispose of sections X Cutting water hoses into sections
c = 1,200mm
Dispose of sections X
Cutting water hoses into sections
Only loosely pre-assemble the bolt 2.-{}-
1 Original vehicle double bolt4 Angle bracket3 Rubberized tube clamp Ø 29 mm [2x]2 M6x20 bolt, flanged nut
Preassem-bling the hose mounting
Only loosely pre-assemble the bolt 3.-{}-
1 15mm spacer disc2 Rubberized tube clamp Ø 34mm [2x]3 M6x30 bolt, body washer, flanged nut on
existing holePreassem-bling the hose mounting
A
b
X
X
B
c
X
X
C
50
2
3
31
4
51
21
2
3
28
Peugeot 307/ 307Break/ 307SW
Pull the hose 1 off the engine outlet.
1 Engine outlet hose to the heat exchanger inlet.
Splitting point
1 Heat exchanger inlet hose
Engine outlet connection
1 Heat exchanger inlet hose
Connect hose A and B
1 Heat exchanger inlet hose
Connecting the heat exchanger inlet
52
1
53
A
1
54
A
B
1
55
B
A
1C
29Peugeot 307/ 307Break/ 307SW
2 Preassembled rubberized tube clamp Ø 29 mm [2x]
Hose placement
Cut the enclosed 1500 mm heat protection hose in the middle and slide it onto hoses C and C.
2 Preassembled rubberized tube clamp Ø 34mm
1 Heater unit inletConnecting the heater unit inlet
Before connecting, fill the water hoses with coolant water
2 Preassembled rubberized tube clamp Ø 34mm
1 Heater unit outlet
Connecting the heater unit outlet
Check the placement of hoses A and B along the entire length and correct if necessary.Secure hoses with cable ties.Tighten rubberised tube clamps [4x].
56C
B 1
1
57
2
1 B
58
C
2
1
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:
2.0l Diesel only
Water installation diagram
All undesignated hose clamps are Ø 20-27 mm hose clamps.Original vehicle spring band clamp will be used again. All connecting pipes are Ø 20x20.
Wärme-tauscher
A
B
Motor
Heat exchanger
31
Peugeot 307/ 307Break/ 307SW
a = 1,250mm
Dispose of section X Cutting water hoses into sections
b = 1,300mm
Dispose of sections X Cutting water hoses into sections
Only loosely pre-assemble the bolt 3.-{}-Drill angle bracket open to Ø 8.5mm on the short end.
1 Original vehicle bolt2 Angle bracket4 Rubberized tube clamp Ø 29 mm [2x]3 M6x20 bolt, flanged nut Preassem-
bling the hose mounting
Bend the fastening strip 4 according to pictureOnly loosely pre-assemble the bolt 2.
4 Fastening strap with holes1 M6x20 bolt, body washer, flanged nut on
existing hole3 Rubberized tube clamp Ø 34mm [2x]2 M6x20 bolt, flanged nut
Preassem-bling the hose mounting
a
A X
b
X
X
B
59
1
4
3
4
2
60
31
34
2
32
Peugeot 307/ 307Break/ 307SW
1 Remove the bracket2 Remove the engine outlet hose to the heat
exchanger inlet.
Remove the bracket and hose
1 Engine outlet hose section2 Heat exchanger inlet hose section
Replace the heat exchanger inlet hose section 2.
Splitting point
1 Black rubber profile [5x]2 Engine outlet hose section
Pre-assem-bling the hoses
1 Reinsert engine outlet hose section.2 Fasten black rubber profile with cable clips
to the strut.
Engine outlet connection
61
21
62
1 2
63
A1
B 1 11
2
1
64A
1
2
33Peugeot 307/ 307Break/ 307SW
2 Reinsert heat exchanger inlet hose section.
1 Black rubber profile positioned according to figure.
Connecting the heat exchanger inlet
1 Black rubber profile positioned under cable harness according to figure.
2 Black rubber profile 65/1
Hose placement
1 Secure black rubber profile to the original vehicle line with cable clips [2x]
2 Original vehicle line.
Hose placement
1 Preassembled rubberized tube clamp Ø 29 mm [2x]
Hose placement
65A
2B 1
66A
B 1 2
67
1
A
B
1
2
68
B1 1
A
34Peugeot 307/ 307Break/ 307SW
Cut the enclosed 1500 mm heat protection hose in the middle and slide it onto hoses A and B.
1 Preassembled rubberized tube clamp Ø 34mm [2x]
Hose placement
Before connecting, fill the water hoses with coolant water
1 Heater unit outlet2 Heater unit inlet
Connecting to the heater unit
Check the placement of water hoses A and B along the entire length as well as the placement of the black (sw) rubber profile and correct if necessary.Secure hoses with cable ties.Tighten rubberised tube clamps [4x].
69
B 1
A 1
70
B1 2
A
35
Peugeot 307/ 307Break/ 307SW
Combustion AirFasten the fuel pipe and silencer with cable clips according to the figure.
1 Combustion air intake silencer2 Combustion air intake pipe3 Ø 27 mm hose clamp
combustion air
3
12 71
i
36
Peugeot 307/ 307Break/ 307SW
Exhaust System
1 Exhaust pipe a = 190mm2 Exhaust end section b = 120mm
Dispose of section X
Preparing the exhaust pipe
Figure shows 1.6l diesel.
1 Original vehicle bolt4 Crossarm2 Ø 6.5mm bore hole3 Underride protection5 Ø 42 mm bore hole
Bore holes
5 Exhaust silencer3 30mm spacer sleeve [2x], M6x70 bolt,
flanged nut.2 Hose clamps [3x]4 Exhaust pipe1 Exhaust end section Assem-
bling the exhaust system
First position the red (rt) rubber profile (1) from below onto the exhaust end section (2), then insert with groove in the underride protection (2). Align the end cap from the exhaust end section (2) flush with the red rubber profile (1) according to the figure.
3 Underride protection1 Red (rt) rubber profile with groove2 Exhaust end section
Inserting rubber profile
a b
1 2
X
72
2
5
3
230mm
1
4
5 2
43
73
221
1
2
3
74
37Peugeot 307/ 307Break/ 307SW
Fuel Connection
CAUTION!Open the vehicle's tank-cap lock, ventilate the tank and then re-close the tank lock.
Catch any fuel running off with an appropriate container.
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.
2 Mecanyl fuel line1 Ø 10 mm hose clamps [2x]; Ø 4.5 mm
hose section,3 Protective hose
Connecting to the heater unit
1 Mecanyl fuel line
Installing lines
1 Mecanyl fuel line2 Metering pump cable harness3 Original vehicle cable channel 78/1
Installing lines
75
1
3
2
76
1 1 1
77
3
1 2
38
Peugeot 307/ 307Break/ 307SW
1 Original vehicle cable channel 77/32 Metering pump cable harness3 Mecanyl fuel line
Installing lines
The installation location is in the middle behind the vehicle tank.Fuel line to the heater unit on the pressure side of the metering pump [side with connector].
2 Bracket fastened with oblong hole onto tank mounting
1 Metering pump7 Flanged nut [2x]; silent block, 6 Rubberized tube clamp3 Cable harness; completed connector
housing4 Fuel line to the heater unit5 Hose clamp Ø 10 mm [2x]; hose section,
Connecting to the metering pump
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2 31
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4567
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39
Peugeot 307/ 307Break/ 307SW
Fuel take-off for gasoline engine
Remove tank mounting according to manufacturer's instructions.
2 Tank mounting1 Washer, external Ø =17.6mm3 Copy the hole image, Ø 6 mm bore hole.
Fuel take-off
Shape, cut into sections, and insert the tank extracting device according to the template, see the Installation Instructions.Shorten the Ø 3.5 mm moulded hose to Ø 4.5mm with the Ø 3.5 mm end on the tank extracting device.
1 Tank mounting2 Tank extracting device4 Moulded hose Ø 3.5 mm on Ø 4.5 mm 3 Universal clip Ø 9mm
Inserting tank extracting device
Install the tank mounting according to manufacturer's instructions.
3 Tank mounting2 Universal clip Ø 10 mm1 Residual section of Mecanyl fuel line
Connecting and disconnecting the fuel line
Fuel line from the tank extracting device on the intake side of the metering pump [side without connector].
1 Fuel line from the tank extracting device2 Hose clamp Ø 10 mm [2x]; hose section,3 Metering pump
Check the placement of fuel lines and the metering pump cable harness along the entire length and correct if necessary. Secure wires and cable harness with cable ties.
Connecting to the metering pump
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3
2
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1
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82
1
21
3
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1 2 3
40
Peugeot 307/ 307Break/ 307SW
Fuel take-off for diesel engine
Remove tank mounting according to manufacturer's instructions.The design of the type label 2 depends on the equipment. Remove the type label if necessary.
1 Tank mounting2 Type label.4 Washer, external Ø =17.6mm3 Copy the hole image, Ø 6 mm bore hole.
Fuel take-off
Shape, cut into sections, and insert the tank extracting device according to the template, see the Installation Instructions.Shorten the Ø 3.5 mm moulded hose to Ø 4.5mm with the Ø 3.5 mm end on the tank extracting device.
1 Tank mounting4 Tank extracting device3 Moulded hose Ø 3.5 mm on Ø 4.5 mm 2 Universal clip Ø 9mm
Inserting tank extracting device
Only for HDI-FAP.
Run the tank extracting device according to figure along the return line.
1 Return line2 Tank extracting device
Inserting tank extracting device
Install the tank mounting according to manufacturer's instructions.
1 Tank mounting3 Universal clip Ø 10 mm2 Residual section of Mecanyl fuel line
Connecting and disconnecting the fuel line
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1
3
2
2
85
3
4 4
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86
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2
87
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3
2
41
Peugeot 307/ 307Break/ 307SW
Fuel line from the tank extracting device on the intake side of the metering pump [side without connector].
1 Fuel line from the tank extracting device2 Hose clamp Ø 10 mm [2x]; hose section,3 Metering pump
Check the placement of fuel lines and the metering pump cable harness along the entire length and correct if necessary. Secure wires and cable harness with cable ties.
Connecting to the metering pump
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1 2 3
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.- Attach the "Switch off auxiliary heating before re-fuelling" sticker onto the left side of the B-pillar.
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Webasto AGPostfach 80 - 82132 Stockdorf - Hotline 0 18 05 / 93 22 78Hotfax (0395) 55 92-353 - http://www.webasto.de
Feel the drive
Printed in Germany 08/06Printed by: Steffen
Peugeot 307/ 307Break/ 307SW
Operating instructions for the end customerPlease remove page and add to the vehicle operating instructions.
Before parking the vehicle, make the following settings:
1 Air outlet to windscreen2 Temperature to "max."
For vehicles without automatic air condi-tioning
1 Temperature to "max." [2x]2 Air outlet to windscreen
For vehicles with automatic air condi-tioning
89
1 2
902
21 1
4444
45
Peugeot 307/ 307Break/ 307SW
0
100mm
100mm
Scale 1:1
Compare the size of the printed version with dimension lines.Permitted tolerance a maximum of 2%.
In case of bigger differences, correct the printer setting accordingly or request an original printed copy.
Template for bracket
46
Peugeot 307/ 307Break/ 307SW
0
100mm
100mm
Scale 1:1
Compare the size of the printed version with dimension lines.Permitted tolerance a maximum of 2%.
In case of bigger differences, correct the printer setting accordingly or request an original printed copy.
Gasoline tank extracting device template
47
Peugeot 307/ 307Break/ 307SW
0
100mm
100mm
Scale 1:1
Compare the size of the printed version with dimension lines.Permitted tolerance a maximum of 2%.
In case of bigger differences, correct the printer setting accordingly or request an original printed copy.
Diesel tank extracting device template