Water Heater Unit

e1

Auxiliary heating Thermo Top C00 0002

Installation Instructions
Peugeot 407
Peugeot 407 SW
Gasoline and diesel
1 2 3

6
from the 2004 model
For left-hand drive vehicles only

Legend for Figure 1:

1 Combustion air intake silencer
2 Exhaust silencer
3 Thermo Top C heater unit
4 Blade-type fuse holder
5 Time switch
6 Metering pump

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.

Ident. No.: 1303097EEN

Fee 10.- Euro

Webasto AG

Peugeot 407
Table of Contents
Validity
Heater Unit / Installation Kit
Foreword
Special Tools
Explanatory Notes on the Document
Preliminary Work
Heater Unit Installation Location
Preparing the electrics
Connection of electrics
Remote start option
Thermo Call option
Automatic air conditioning blower control
Circuit diagram
Pre-assembling heater unit
Preparing the installation location
Installing the heater unit

2
3
3
3
4
5
5
6
7
8
9
10
11
12
13
14

Water connection
Only gasoline vehicles
Only diesel vehicles
For all vehicles
Fuel connection
Metering pump
Fuel Take-Off
Gasoline Vehicles Only
Diesel Vehicles Only
For all vehicles
Exhaust Connection
Combustion air connection
Final work
Operating instructions for the end customer
Tank extracting device template

15
16
18
22
23
23
24
25
25
26
27
28
29
30

Validity
Manufacturer

Model

Type

EG-BE No. / ABE

Peugeot

407

e2*2001 / 116*029
e2*2001 / 116*0331
e2*2001 / 116*0346

Engine type

Engine type

Power in kW

Engine capacity in cm

6FZ
RFN
RFJ
3FZ
9 Hz
RHR
4HT

Gasoline
Gasoline
Gasoline
Gasoline
Diesel
Diesel
Diesel

85
100
100
116
80
100
125

1749
1997
1997
2230
1560
1997
2179

Vehicle types, engine types, equipment variants as well as national specifications 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.

Peugeot 407
Heater Unit / Installation Kit
Amount
1
1

Description
Commercial supply of required control
Installation kit for Peugeot 407 Gasoline and diesel

Order no.:
See price list
1303094C

Recommended heater unit for the relevant vehicle class:

Vehicle
Compact car
Mid-class, station wagon
Luxury, van, off-roader

Heater unit
Thermo Top E
Thermo Top C
Thermo Top P

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 Peugeot 407 vehicles with gasoline and diesel engines re.
validity, see page 2 from model year 2004 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, where this is the case the stipulations in the "installation instructions" and "operating and
maintenance instructions" for the Thermo Top C/E should 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
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
- Vice-grip wrench

Peugeot 407
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.

Mechanics

Electrics

Water connection

Fuel connection

Exhaust system

Combustion air

Special features are highlighted using the following symbols:

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 vehiclespecific documents.
Reference to a special technical feature.

The arrow in the vehicle icon indicates the position on

the vehicle and the viewing angle

Peugeot 407
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.
- Remove the central electronics covers in the engine compartment.
- Completely remove the air filter with intake hose.
- Open the tank cap, ventilate the tank.
- Close the tank cap again.
- Remove the right underbody underride protection (diesel vehicles only).
- Remove the left underbody underride protection.
- Remove the underride protection.
- Remove the left wheel-house panel
- Remove the bumper.
- Remove the left underride protection
- Open right tank mounting service lid (only gasoline vehicles).
- Remove tank mounting according to manufacturer's instructions (only gasoline vehicles).
- Remove the left dashboard panel.
- Remove air conditioning control according to manufacturer's instructions.

Heater unit installation location

(1) Heater unit

Installation location
1

Peugeot 407
Preparing the electrics
Only for automatic air conditioning
Insert wire sections 2 and 4 in enclosed
insulating hose.
1

rt 0,75mm
2500

500

rt

1
86

rt

2
87

30

1 = Red (rt) wire 500 mm

2 = Red (rt) wire 2,500mm
3 = Black (sw) wire 2,500 mm
4 = Brown (br) wire 900 mm
Connect with enclosed blade receptacles.
Connect brown (br) wire 4 from K3.1/85 to
K3/85 according to the circuit diagram.
Insert wires 2 and 3 in enclosed insulating
hose.

87a

85
br

Cutting
wire into
sections

K3.1

Pre-assembling
the K3.1
relay

sw

Peugeot 407
Electrical Connection

fuse holder, K3 relay

(1) K3 relay, M5x12 bolt, flanged
nut
(2) Fuse holder, M4x12 bolt,
washers, nuts
(3) K3.1 relay, M5x12 bolt,
flanged nut
(4) Fuse holder on existing bolt
1 2 3

Option. summer / winter

switch
(1) Summer / winter switch, bore
hole 12 mm.
(2) Center console

Time switch
(1) Time switch
(2) Center console

rt

Don't install the metering

pump cable harness until
later together with fuel pipe
along the original vehicle fuel
lines on the underbody.

sw

Electrics
diagram

bl
br
rt

sw

1
2

2
1
2

5
Ground connection
(1) Original vehicle chassis
ground point
(2) Ground wire

6
Installing the cable harness/
positive connection
(1) Blower controller cable
harness, clock cable harness
(2) Positive line to the original
vehicle positive base.

7
Cable harness feed-through
(1) Protective rubber sleeve in
left wheel housing
(2) Cable feed-through from the
engine compartment

Peugeot 407
1

Remote Start T80 Option

(1) Receiver
(2) Bracket
(3) 5.5 mm bore hole; M5x12 bolt, washer, M5
flanged nut [2x each]
Assembling the
receiver

8
(1) Antenna

Assembling the
antenna

Peugeot 407
Thermo Call TC 1.1 option

(1) Receiver
(2) Self-tapping screws 5.5x13 [4x]
(3) Glove compartment
2

Assembling the
receiver
3
10
(1) Antenna

Assembling the
antenna

11
(1) Tip switch

Assembling the
tip switch

12

Peugeot 407
Automatic air conditioning blower
control

Connect with enclosed 3-way splitter

according to the circuit diagram.

3
6

13

5
1

(1) Red (rt) wire from original vehicle fuse

Blower
(2) Black (sw) wire from K3/30
motor
(3) Red (rt) wire from K3/87a, insulate and tie
controller
back
(4) 3-way splitter
(5) Red (rt) wire from blower motor connector
(6) 2-pin blower motor connector

Connect with enclosed red butt connectors

according to the circuit diagram.

(1) White (ws) wire (code XC2B)

(2) Red (rt) wire 2 from K3.1/87
(3) Black (sw) wire 3 from K3.1/30
(4) 6-pin connector pin 1
(5) Air conditioning control

14

4
1

Blower
motor
control
unit

Measure the directly switched terminal 15

without turn-off delay.
Pin assignment and cable colors may vary
depending on vehicle equipment.

Connect with enclosed blue butt connector

according to the circuit diagram.
1
3

(1) Terminal 15 wire pin 3 [blue or pink]

(2) Red (rt) wire 1 from K3.1/86
(3) Central electrics connector

Connecting to central
electrics

15

10

Peugeot 407

Webasto

Peugeot 407
30
15

HG
rt

X1

F3

4
gn/
ws

rt/ws

ws

rt
86

87

85

FG

87a

30

GR

K3

Circuit Diagram
rt

sw
2

4
86

85

87

87a

30

rt
sw

K3.1

+
ws

3
br

M GM

1
-

KB

br

31
Webasto components
HG
Heater unit TT-C/E
F3
Fuse 25A
K3
Blower relay
K3.1 Supplementary relay

Peugeot components
GM
Blower motor
GR
Blower relay
KB
Air conditioning control
FG
Blower fuse
F
Fuse 10A

Colors and symbols

rt
red
ws
white
sw
black
br
brown
gn
green
Legend

Insulate and tie back

wire ends
Splitting point

11

Peugeot 407
1

Pre-assemble the Heater Unit

Note the installation position of the air intake

silencer, see the Installation Instructions.
(1) Combustion air intake pipe
(2) 27 mm hose clamp
(3) Heater unit

Pre-assembling
the Combustion
Air

16
Ejot screw bolt tightening torque 10 Nm!

(1) Heater unit

(2) Ejot screw bolt
(3) Fastening strap with holes
(4) M6x20 bolt, M6 flanged nut
(5) Exhaust silencer
2
3

Pre-assembling
the exhaust silencer

17

12

Peugeot 407
1

Preparing the installation location

Loosely assemble the bracket on the existing

bore hole position 1. Transfer hole image to
position A and drill 7 mm bore holes [2x].

(1) M6x30 bolt, spacer nut, M6 flanged nut

[2x]
(2) Bracket

1
1

Preparing
the Installation Location

18
Insert one 20 mm spacer each between the
bracket and the vehicle at position 2.

(1) Bracket
(2) M6x30 bolt, 20 mm spacer, M6 flanged nut
[2x]
Assembling the
bracket

19
1

Run the heater unit cable harness to the

installation location.

(1) Heater unit cable harness

(2) Bracket
(3) Edge protection 100 long
Preparing
the Installation Location

20

13

Peugeot 407
1

Installing the Heater Unit

Ejot screw bolts tightening torque 10 Nm!

Insert two washers between the heater unit
and the bracket in position 4.
2
3
4

(1) Heater unit

(2) Ejot screw bolt [2x]
(3) Bracket
(4) Ejot screw bolt, washer [2x]

Assembling the
heater unit

21
1

Ejot screw bolts tightening torque 10 Nm!

(1) Ejot screw bolt

(2) Heater unit
(3) Bracket
3
Assembling the
heater unit

22

14

Peugeot 407
Water connection for all vehicles
WARNING!
Tighten all hose clamps to 2.0 + 0.5 Nm.
Any coolant running off should be collected using an appropriatecontainer.
Route 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
Wrmeexchanger
tauscher
Water diagram

*
20x20

C
Motor

All undesignated clamps = 20-27 mm hose clamps.

*! Connecting pipe for 1.6 l HDI = 17 x 20 mm, for all other vehicles = 18 x 20 mm [2x each]!

15

Peugeot 407
Gasoline vehicle water connection

b = 910mm
c = 1,030mm

Dispose of section X
Cutting
water hoses to
length

Slide the braided protective hoses onto hose

B and hose C.
(1) Cut shrink fit hoses in the middle, slide on,
shrink-fit

Preparing
the water

23
(1) Remove the original vehicle engine outlet
hose to the heat exchanger inlet.

Preparing
the water

24
(1) Heat exchanger inlet hose
(2) Engine outlet hose

Splitting
point

25

16

Peugeot 407
(1) Original vehicle hose to the heat
exchanger inlet
(2) Enclosed moulded hose A 180
(3) Original vehicle hose from the engine
outlet

Preparing
the water
hoses
2

26
Place pre-assembled hose 26/2, 3 on the
connecting piece for the engine outlet and
fasten with spring band clamp.

Engine
outlet connection

27
Slide pre-assembled hose 26/1 on heat
exchanger inlet with quick coupling.

(1) Heat exchanger inlet hose

Connecting to the
heat exchanger
inlet

28

17

Peugeot 407
Diesel vehicle water connection
RHR diesel vehicles only.
B

b = 1,000mm
c = 1,100mm
Dispose of section X

Cutting
water hoses to
length

Slide the braided protective hoses onto hose

B and hose C.

(1) Cut shrink fit hoses in the middle, slide on,

shrink-fit

Preparing
the water

29

(1) Remove the original vehicle engine outlet

hose to the heat exchanger inlet.

Preparing
the water

30
(2) Heat exchanger inlet hose section
(1) Engine exhaust hose section

Splitting
point

31

18

Peugeot 407
(1) Original vehicle hose to the heat
exchanger inlet
(2) Enclosed moulded hose A 180
(3) Original vehicle hose from the engine
outlet

Preparing
the water
hoses

32

3
A

(1) Heat exchanger inlet hose

(2) Engine exhaust hose

Preparing
the water
hoses

33

Slide pre-assembled hose 32/2 on engine

exhaust connecting piece with quick
coupling.
Slide pre-assembled hose 32/1 on heat
exchanger inlet with quick coupling.

(1) Heat exchanger inlet hose

B

Connecting the engine outlet

to the heat
exchanger inlet

34

19

Peugeot 407
9 Hz diesel vehicles only.

b = 720mm
c = 760mm

Dispose of section X
Cutting
water hoses to
length

Slide the braided protective hoses onto hose

B and hose C.

(1) Cut shrink fit hoses in the middle, slide on,

shrink-fit

Preparing
the water

29

(1) Remove the original vehicle engine outlet

hose to the heat exchanger inlet.

Preparing
the water

30
Remove protective hose and cut off 70 mm,
parts will be used again.

(2) Heat exchanger inlet hose section

(1) Engine exhaust hose section

Splitting
point

31

20

Peugeot 407
(1) Original vehicle hose to the heat
exchanger inlet, protective hose remnant
(A) Enclosed moulded hose A 180
(2) Original vehicle hose from the engine
exhaust, 70 mm protective hose remnant

Preparing
the water
hoses

32

2
C

(1) Heat exchanger inlet hose section

(2) Engine exhaust hose section

Preparing
the water
hoses

B
B

33
(1) Engine exhaust hose section
(2) Heat exchanger inlet hose section

Connecting the engine outlet

to the heat
exchanger inlet

34

21

Peugeot 407
4 HT diesel vehicles only.

b = 640mm
c = 800mm

Dispose of section X
Cutting
water hoses to
length

Slide the braided protective hoses onto hose

B and hose C.

(1) Cut shrink fit hoses in the middle, slide on,

shrink-fit

Preparing
the water

35

(1) Remove the original vehicle engine outlet

hose to the heat exchanger inlet.

Preparing
the water

36
(1) Engine exhaust hose section
(2) Heat exchanger inlet hose section
(3) Dispose of remnant

Splitting
point

37

22

Peugeot 407
(1) Original vehicle hose to the heat
exchanger inlet
( A) Enclosed moulded hose A 180
(2) Original vehicle hose from the engine
outlet

Preparing
the water
hoses

38

2
A

(1) Heat exchanger inlet hose section

(2) Engine exhaust hose section

Preparing
the water
hoses

39
(1) Heat exchanger inlet hose

Connecting to the
heat exchanger
inlet

40

C
C

(1) Engine exhaust hose section

Engine
outlet connection

41

23

Peugeot 407
1

For all vehicles.

Assemble hose B with 90 bend on the heater

unit inlet and hose C with 90 bend on the
heater unit outlet.
2

3
1

(1) Circulation pump

(2) Cable clip
(3) Hose clamps 20-27 mm

Connecting to the
heater unit

42
Align hoses B and C in the engine
compartment.

(1) cable clip

Installing
in the engine compartment

43

24

Peugeot 407
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.

For all vehicles.

(1) Mecanyl fuel pipe

(2) Hose section, 10 mm hose clamps [2x]
2
Connecting to the
heater unit

44
(1) Install the Mecanyl fuel pipe and the
metering pump cable harness on the
original vehicle fuel lines to the metering
pump installation location.

Installing
lines

45
1

Note the installation position of the metering

pump, see the Installation Instructions.
The installation location is on the left next to
the vehicle tank.

4
5

(1) Original vehicle bolt

(2) Angle bracket
(3) Silent block, spring washer [2x] nuts
M6 [2x]
(4) Metering pump
(5) Rubberized tube clamp

Assembling the
metering
pump

46

25

Peugeot 407
Fuel line from the heater unit on the pressure
side of the metering pump [side with
connector].

(1) Metering pump

(2) Hose section, 10 mm hose clamps [2x]
(3) Mecanyl fuel pipe from the heater unit
(4) Metering pump cable harness, protective
rubber sleeve, flat connector, connector
housing

Connecting to the
metering
pump

47

For gasoline vehicles only.

Remove the tank mounting according to the

manufacturer's instructions and take it apart.
(1) Tank mounting
(2) M6 nut from the tank extracting device,
copy the hole image, 6 mm bore hole
Preparing
the Tank
Mounting

48

Cut the tank extracting device into sections

based on the template, see the Installation
Instructions.

(1) Tank mounting

(2) tank extracting device
Inserting
tank extracting
device

49
Install the tank mounting according to
manufacturer's instructions.

(1) tank mounting

(2) remaining Mecanyl fuel line
(3) Hose section, 10 mm hose clamps [2x]
(4) tank extracting device

Connecting and
disconnecting
the fuel
line

50

26

Peugeot 407
1

For diesel vehicles only.

Run the Mecanyl fuel pipe to the metering

pump installation location by using the heat
protection hose.

(1) remaining Mecanyl fuel line

(2) leading fuel line
(3) Fuel tank extractor, 10mm hose clamps
[2x]
(4) Hose section, 10 mm hose clamps [2x]
(5) Heat protection hose
4
1

Inserting
the fuel
tank extractor

51

For All Vehicles

(1) Remaining Mecanyl fuel line

(2) Metering pump
(3) Hose section, 10 mm hose clamps [2x]
Connecting to the
metering
pump

52

27

Peugeot 407
1

Exhaust connection

(1) Exhaust pipe

a = 200mm
(2) Exhaust end section
b = 310mm
Dispose of section X
a

Preparing
the exhaust pipe

X
(3) Exhaust silencer
(2) Exhaust pipe
(1) Hose clamp [2x]

Assembling the
exhaust
pipe.

53

3
4

(1) Exhaust end section

(2) Hose clamp
(3) Exhaust silencer
(4) Red (rt) rubber profile with groove
Assembling the
exhaust
end section

54

28

Peugeot 407
1

Combustion Air Connection

Install the combustion air intake line to the air

intake silencer.
3
(1) Heater unit
(2) Combustion air intake pipe
(3) Combustion air intake silencer

Assembling the
combustion air

55
1

Note the installation position of the air intake

silencer, see the Installation Instructions.

(1) Combustion air intake silencer

(2) Heater unit
(3) Combustion air intake pipe
(4) Tube clamp 48 mm without rubber
(5) M6x20 bolt, M6 flanged nut on existing
hole
3

Assembling the
combustion air

56

29

Peugeot 407
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.
Only use manufacturer-approved coolant.
Spray heating unit components with anti-corrosion wax (Tectyl 100K, Order No. 111329).
-

Connect battery
Fill and bleed the coolant circuit according to the vehicle manufacturers specifications.
Set the time switch.
Set the manual air conditioning or 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.
1

(1) Underride protection

(2) 42 mm bore hole, cut out on perforation

Cut out
the underride protection

57
1

(1) Underride protection

(2) Red (rt) rubber profile with groove
(3) Exhaust end section

Inserting
rubber
profile

58

Webasto AG
Postfach 80 - 82132 Stockdorf - Hotline 0 18 05 / 93 22 78
Hotfax (0395) 55 92-353 - http://www.webasto.de

Printed in Germany

10/06

Printed by: Steffen

Peugeot 407
Operating instructions for the end customer
Please remove page and add to the vehicle operating instructions.

Before parking the vehicle, make the following settings:

After making the setting, wait about 60
seconds until the engine stops.

(1) Air outlet to windscreen

(2) Left and right temperature to "max."
For vehicles with
automatic
air conditioning

59
When the ignition is activated, the air
conditioning control will start in automatic
mode.

For vehicles with

automatic
air conditioning

60

31

Peugeot 407

Tank extracting device template

100mm

Scale 1:1
Compare the size of the printed version with dimension lines.
Permitted tolerance a maximum of 2%.
Set the printer settings to no margin or minimize margins
and 100% of the normal size.

100mm
0

32