installation instructions peugeot 307/ 307break/...

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


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.


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.


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
5


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


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


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


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


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


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


84

1 2

3

9

1

10

4

3

1

2

11

1

3

2

4

5

10


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


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


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


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


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


1 Bolt20/3, body washer, flanged nuts 2 Plastic traverse3 Bracket4 Cross rail


19

4

2

2

2

4

4

31

20

1

3

22

21

3

221

22

2

1

4

3

15


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
16


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


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


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


a = 1,300mm

Dispose of section X

Cutting water hoses into sections

b = 1400

Dispose of sections X


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


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


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


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


Water connection


2.0l Gasoline only


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


A = Enclosed 180° bend Ø 18mm

b = 1,420mm

Dispose of sections X Cutting water hoses into sections

c = 1,450mm



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


Pull the hose 1 off the engine outlet.

1 Engine outlet hose to the heat exchanger inlet.

Splitting point


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
25



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


1 Heater unit outlet2 Heater unit inlet

Connecting to the heater unit


47C

B

1

1

48

C 1

B 1

49

C1 2

B

26


Water connection


1.6l Diesel only



Wärme-tauscher

Motor

A

B

C

Heat exchanger

27


A = Enclosed 180° bend Ø 18mm

b = 1,150mm


c = 1,200mm




1 Original vehicle double bolt4 Angle bracket3 Rubberized tube clamp Ø 29 mm [2x]2 M6x20 bolt, flanged nut

Preassem-bling the hose mounting


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


Pull the hose 1 off the engine outlet.

1 Engine outlet hose to the heat exchanger inlet.

Splitting point




Connect hose A and B



52

1

53

A

1

54

A

B

1

55

B

A

1C
29



Hose placement

Cut the enclosed 1500 mm heat protection hose in the middle and slide it onto hoses C and C.


1 Heater unit inletConnecting the heater unit inlet



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


Water connection


2.0l Diesel only



Wärme-tauscher

A

B

Motor

Heat exchanger

31


a = 1,250mm

Dispose of section X Cutting water hoses into sections

b = 1,300mm


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


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.


61

21

62

1 2

63

A1

B 1 11

2

1

64A

1

2
33


2 Reinsert heat exchanger inlet hose section.

1 Black rubber profile positioned according to figure.


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


Hose placement

65A

2B 1

66A

B 1 2

67

1

A

B

1

2

68

B1 1

A
34


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


1 Heater unit outlet2 Heater unit inlet



69

B 1

A 1

70

B1 2

A

35


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


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
37


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


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


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

78

2 31

79

1 2 3

4567

i

39


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.


80

1

3

2

81

1

224 3

i

82

1

21

3

83

1 2 3

40


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


Only for HDI-FAP.

Run the tank extracting device according to figure along the return line.

1 Return line2 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

84

1

3

2

2

85

3

4 4

21 i

86

1

2

87

1

3

2

41


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.


88

1 2 3

42


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.

i

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


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


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


0

100mm

100mm

Scale 1:1



Gasoline tank extracting device template

47


0

100mm

100mm

Scale 1:1



Diesel tank extracting device template

installation instructions peugeot 307/ 307break/...

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